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Hypertherm XPR460 Instruction Manual

Hypertherm XPR460 Instruction Manual

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XPR460
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Instruction Manual
811530 - Revision 0
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Summary of Contents for Hypertherm XPR460

  • Page 1 XPR460 ® Instruction Manual 811530 - Revision 0 English...

  • Page 2: For Your Records

    Hypertherm Cutting Institute. ■ Confirmation of ownership: Registration can serve as proof of purchase in case of an insurance loss. Go to www.hypertherm.com/registration for easy and fast registration. If you experience any problems with the product registration process, please contact registration@hypertherm.com.
  • Page 3 XPR460 Instruction Manual 811530 Revision 0 English Original Instructions June 2024 Hypertherm, Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 31 165 596901 Fax 31 165 596908 Tel (Marketing) 31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service) technicalservice.emeia@hypertherm.com (Technical Service) For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci...

  • Page 5: Safety Information

    OptiMix, Powermax, ProNest, Sensor, TorchConnect, TrueBevel, True Hole, VWI, X-Definition, XPR, XPR170, XPR300, and XPR460 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.

  • Page 6: Table Of Contents

    TorchConnect console specifications........................ 34 Cooler specifications............................. 35 Torch specifications..............................36 Critical raw materials..............................37 Safety and EMC symbols and marks......................... 38 IEC symbols................................40 Qualifications and Requirements..........41 Document requirements............................41 Operator qualifications............................41 Qualifications of service personnel........................43 XPR460 Instruction Manual 811530...
  • Page 7 Distance requirements for ventilation and access................68 Requirements for ventilation......................68 Requirements for service and maintenance access..............69 Distance requirements for communications..................69 Wireless compliance..........................69 Torch mounting bracket requirements........................70 Torch lifter requirements............................70 CNC requirements for plasma cutting systems....................70 XPR460 Instruction Manual 811530...
  • Page 8 Connect the power, CAN, and 5-gas assembly for VWI or OptiMix.........126 Supply gas installation..........................127 Install gas regulators........................132 Connect supply gases to Core or CorePlus................132 Connect the supply gases and shield water to VWI or OptiMix........134 811530 Instruction Manual XPR460...
  • Page 9 Change the network settings......................181 Reset the wireless module........................183 Disable the wireless connection temporarily..................185 Disable the wireless connection permanently..................187 Web interface screen information......................188 Plasma power supply screen......................190 Gas system screen........................192 Log screen............................195 Operate screen..........................195 XPR460 Instruction Manual 811530...
  • Page 10 Initial Checks state (2)..........................218 Gas Purge/Pump On state (3)......................219 Wait for Start state (5)..........................221 Preflow/Charge DC state (7).........................221 Ignite state (8)............................222 Pilot Arc state (9)............................224 Ramp-up state (11)..........................226 Steady state (12)............................227 Ramp-down state (13)..........................228 811530 Instruction Manual XPR460...
  • Page 11 Remove the power from the cutting system..................249 Examine the gas regulators........................250 Examine the shield water regulator (if applicable)................250 Examine the connections and fittings....................251 Remove the torch and consumable parts....................252 Examine the consumable parts....................254 XPR460 Instruction Manual 811530...
  • Page 12 Use the CNC or XPR web interface to measure coolant flow........... 298 Do a container test to measure coolant flow................299 Do a test for continuity between the nozzle and workpiece............301 Safety consideration for the XPR460..................301 811530 Instruction Manual...
  • Page 13 Troubleshooting for gas flow process timeouts................. 322 Diagnostic codes 522 – 525..................... 322 Symptoms............................322 Corrective action........................... 322 Troubleshooting for low inlet gas pressure..................322 Diagnostic codes 530, 531, 533....................322 Symptoms............................323 Corrective action........................... 323 Verification............................323 XPR460 Instruction Manual 811530...
  • Page 14 Diagnostic codes 570, 571, 574 – 577................... 335 Symptoms............................336 Corrective action........................... 336 Troubleshooting for over-temperature faults for inductors and transformers......337 Diagnostic codes 580 – 586, 589, 793................. 337 Symptoms............................338 Corrective action........................... 338 Troubleshooting for a fan timeout......................340 811530 Instruction Manual XPR460...
  • Page 15 Diagnostic code 654........................346 Symptoms............................346 Corrective action........................... 346 Troubleshooting for current in chopper during preflow..............346 Diagnostic code 655........................346 Symptoms............................347 Corrective action........................... 347 Troubleshooting for a console reset message................... 347 Diagnostic code 691........................347 Symptoms............................347 XPR460 Instruction Manual 811530...
  • Page 16 Troubleshooting for invalid processes....................358 Diagnostic code 716........................358 Symptoms............................358 1: invalid id............................358 2: invalid user..........................358 3: invalid user source........................359 4: invalid process...........................359 5: not allowed or system not ready................... 359 6: not supported..........................360 811530 Instruction Manual XPR460...
  • Page 17 Troubleshooting for low fan speeds – HXFAN.................. 371 Diagnostic codes 748 and 749....................371 Symptoms............................372 Corrective action........................... 372 Troubleshooting for low fan speeds – CAB FAN 1................372 Diagnostic codes 747 and 750....................372 Symptoms............................373 Corrective action........................... 373 XPR460 Instruction Manual 811530...
  • Page 18 Symptoms............................376 Corrective action........................... 377 Troubleshooting for a pilot relay fault....................377 Diagnostic code 777........................377 Symptoms............................377 Safety consideration for the XPR460..................378 Corrective action........................... 378 Troubleshooting for high or low chopper voltage................379 Diagnostic codes 779, 780, 781....................379 Symptoms............................379 Corrective action...........................
  • Page 19 OptiMix gas connect console input and output manifolds and adapters........411 VWI and OptiMix gas connect console mixer, resonators, transducers, and valves....412 Gas connect console wire harness, hose kit, and CAN cables.............413 TorchConnect console parts..........................414 TorchConnect console EasyConnect side..................415 XPR460 Instruction Manual 811530...
  • Page 20 Bevel torch leads............................432 Oxygen hoses (blue)..........................432 Nitrogen or Argon hoses (black)......................432 Air hoses (black)............................433 Hydrogen or nitrogen-hydrogen (F5) hoses (red)................433 Water (optional shield fluid) hoses (blue)................... 434 Preventive maintenance kits..........................434 Tools..................................435 Recommended spare parts..........................435 811530 Instruction Manual XPR460...
  • Page 21 EtherCAT connection to EDGE Connect (Sheet 22 of 25)..............519 Discrete and serial RS-422 CNC connections (Sheet 23 of 25)............522 Discrete CNC connections (Sheet 24 of 25)....................525 Wireless subsystem block diagram (Sheet 25 of 25)................. 528 XPR460 Instruction Manual 811530...
  • Page 22 Contents 811530 Instruction Manual XPR460...

  • Page 23: Electromagnetic Compatibility (Emc)

    The surrounding area may extend beyond the boundaries of the premises. Hypertherm’s CE-marked equipment is built in compliance with Methods of reducing emissions standard EN60974-10. The equipment should be installed and used...
  • Page 24 Installation and Use. Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications. 811530 Instruction Manual XPR460...

  • Page 25: Warranty

    Distributors/OEMs may offer different or additional warranties, but herein and as follows: if Hypertherm is notified of a defect (i) with Distributors/OEMs are not authorized to give any additional warranty...

  • Page 26: National And Local Codes

    Product Parts coverage shall take precedence over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property HyPrecision 27 months from the ship date, or 24 damage by reason of any code violation or poor work practices.

  • Page 27: Specifications

    Any process that does not use water as a shield fluid. Ferrous Mild steel Non-ferrous Stainless steel and aluminum Gases and fluid Hydrogen (H ), argon (Ar), nitrogen (N ), oxygen (O ), water (H O), F5 (95% nitrogen, 5% hydrogen) XPR460 Instruction Manual 811530...

  • Page 28: Plasma Cutting System Description And Components

    The gas connect console has a control Printed Circuit Board (PCB) and an ignition PCB. If your XPR cutting system is equipped with an 811530 Instruction Manual XPR460...

  • Page 29: Torchconnect Console Description

    Never operate the cutting system if you get a low coolant level notice. Inside of the cooler are the following components: ■ Reservoir ■ Pump ■ Flow meter ■ Filter for coolant ■ Heat exchanger XPR460 Instruction Manual 811530...

  • Page 30: Torch Description

    The torch receptacle has a gas-selection valve. Consumables are installed on the torch. Plasma power supply specifications The part number and some specifications differ for each type of plasma power supply. Figure 1 - Plasma power supply dimensions 811530 Instruction Manual XPR460...
  • Page 31 Forced air (Class F) Insulation Class H EMC emissions classification (CE models only) Class A Lift points Top lift eye Bottom lift truck slots Lift eye weight rating 782 kg (1,725 lb) Weight 635 kg (1,400 lb) XPR460 Instruction Manual 811530...

  • Page 32: Ecodesign Requirements For Ce Models

    Ecodesign requirement Idle With load Description Output current – 460.86 A Measured at the rated duty cycle for the system at the highest output power. Output voltage – 222.59 VDC Output active power – 102.53 kW 811530 Instruction Manual XPR460...

  • Page 33: Gas Connect Console Specifications

    Gas connect console specifications The part number and some specifications differ for each type of gas connect console. Do not remove the inlet check valves from the gas connect console. Figure 2 - Gas connect console dimensions XPR460 Instruction Manual 811530...

  • Page 34: Torchconnect Console Specifications

    Put the gas connect console in position on page TorchConnect console specifications There is one TorchConnect console for all XPR system configurations. Use these dimensions for console mounting or placement. Do not remove the inlet check valves from the TorchConnect console. 811530 Instruction Manual XPR460...

  • Page 35: Cooler Specifications

    1 meter (3.3 feet) between the cooler and ® other system components, or between the cooler and an obstacle. The lift eye weight rating for the cooler is 91 kg (200 lb). XPR460 Instruction Manual 811530...

  • Page 36: Torch Specifications

    Figure 4 - Cooler weight and dimensions Torch specifications The dimensions and weight differ for each type of torch and torch sleeve. But the general specifications are the same for all torch configurations. Figure 5 - Torch dimensions 811530 Instruction Manual XPR460...

  • Page 37: Critical Raw Materials

    Components that contain more than 1 gram Borate Each PCB, torch, torch mounting sleeve Magnesium Heatsinks, cold plates Natural graphite Pump motor, resistors Phosphorus Sheet metal panels Rare earth elements (heavy and light) Torch breakaway, pump motor XPR460 Instruction Manual 811530...

  • Page 38: Safety And Emc Symbols And Marks

    Applicable directives may include the European Low Voltage Directive, the European Electromagnetic Compatibility (EMC) Directive, the Radio Equipment Directive (RED), and the Restriction of Hazardous Substances (RoHS) Directive. See the European CE Declaration of Conformity for details. 811530 Instruction Manual XPR460...
  • Page 39 Restriction of Hazardous Substances (RoHS) Directive. United Kingdom Conformity Assessed mark CE versions of products that include a UKCA mark of conformity meet the product safety, EMC, RF, and RoHS requirements for export to the UK. XPR460 Instruction Manual 811530...

  • Page 40: Iec Symbols

    Alternating current (AC) Plasma torch cutting Gouging AC input power connection The terminal for the external protective (earth) (PE) conductor Power is ON Power is OFF A 1-phase or 3-phase inverter-based power source Volt/amperage curve, “drooping” characteristic   811530 Instruction Manual XPR460...

  • Page 41: Qualifications And Requirements

    A person is considered qualified to operate the cutting system if he or she is trained and knowledgeable about cutting system equipment construction, operation, and work methods, and about how to recognize and avoid hazards that can be present with certain cutting system equipment or work methods. XPR460 Instruction Manual 811530...
  • Page 42 Refer to the Safety and Compliance Manual (80669C), Radio Frequency Warning Manual (80945C), and Before you begin installation on page Additional qualifications apply for personnel who do maintenance and troubleshooting. Refer to Qualifications of service personnel on page 811530 Instruction Manual XPR460...

  • Page 43: Qualifications Of Service Personnel

    Refer to the Safety and Compliance Manual (80669C), Radio Frequency Warning Manual (80945C), and Before you begin installation on page ■ Contact a professional repair person who has a license. XPR460 Instruction Manual 811530...

  • Page 44: System Electrical Requirements

    General input power requirements are in the following table. For specific requirements for switches, fuses, and cords, refer to Line-disconnect switch requirements on page Circuit breaker or fuse requirements on page 46, and Main power cord requirements on page 811530 Instruction Manual XPR460...

  • Page 45: Line-Disconnect Switch Requirements

    Speak with a licensed electrician to make sure that your main power cord size and length comply with the codes in your location. Line-disconnect switch requirements As an installer or user, you must supply a separate line-disconnect switch for the plasma power supply. XPR460 Instruction Manual 811530...

  • Page 46: Circuit Breaker Or Fuse Requirements

    A means for disconnecting the cutting system shall be provided according to the installation, safety, and emergency requirements for the local codes and regulations, taking into account the input power requirements. Hypertherm does not supply this means of disconnection. Circuit breaker or fuse requirements You must use a circuit breaker or fuse that is sufficient to support the plasma cutting system.

  • Page 47: Input Power Requirements For Ce Units

    TorchConnect console, and some parts of the plasma power supply from a location that is remote from the main power source. A convenient location for a remote on-off switch is near the CNC. As an user or installer, you must supply the remote on-off switch, or switches, for your cutting system. XPR460 Instruction Manual 811530...

  • Page 48: Process-Gas Requirements For All Gas Connect Consoles

    ■ Water can be used as a shield fluid for plasma power supplies that have a VWI or OptiMix gas connect console. Refer to Shield-water requirements (VWI and OptiMix) on page 55 for the specifications and requirements for water that is used for shield purposes. 811530 Instruction Manual XPR460...
  • Page 49 Flow rate during argon marking and argon assist and during stainless steel cutting with an OptiMix gas connect console. Table 9 - Air compressor requirements Hypertherm recommends that air compressors supply air that complies with the requirements of ISO Standard 8573-1:2010 Class 1.4.2.

  • Page 50: Plumbing Requirements For Supply Gases

    A fire can occur if oxygen is not removed. 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 51 Consult your local safety, fire, and building code requirements for the storage and use of hydrogen. Hypertherm recommends that you install an exhaust ventilation system to remove the hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas for cutting.
  • Page 52 Qualifications and Requirements 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. Table 10 - Recommended dimensions for gas fittings Fitting type Dimensions / Ar 5/8 inch – 18, RH internal (inert gas) "B"...

  • Page 53: Regulator Requirements For Supply Gases

    Regulator requirements for supply gases  NOTICE LOW-QUALITY REGULATORS CAN REDUCE PERFORMANCE AND CUT QUALITY Low-quality gas regulators do not provide consistent supply-gas pressure. They can reduce system performance and decrease cut quality. Do not use low-quality gas regulators. XPR460 Instruction Manual 811530...
  • Page 54 Your gas supplier can recommend the best gas regulator, or regulators, for the conditions at your site. Local regulations and the type of gas that is used can influence the recommended inlet gas fittings for your gas connect console. Refer to the following table. 811530 Instruction Manual XPR460...

  • Page 55: Shield-Water Requirements (Vwi And Optimix)

    Hypertherm recommends that you contact a water-quality expert for guidance. Water that does not meet minimum purity specifications can cause excessive deposits on the torch nozzle and shield. These deposits can alter the water flow and produce an unstable arc.

  • Page 56: Plumbing And Hose Requirements For Shield Water

    If your plasma cutting system uses shield water and is stored in ambient temperatures at or below 0ºC (32ºF), Hypertherm recommends that you use these steps to remove shield water. These steps are for cutting systems that have a VWI or OptiMix gas connect consoles.

  • Page 57: Torque Specifications For Gas Or Water Plumbing And Hose Connections

    Before you fill the coolant reservoir, choose the best coolant for your operating conditions. The ambient temperature range where your cutting system operates affects the coolant that you choose. XPR460 Instruction Manual 811530...

  • Page 58: Coolant Requirements For Operation Between -10°C - 40°C (14°F - 104°F)

    Coolant requirements for operation between -10°C – 40°C (14°F – 104°F) Use the Hypertherm premixed coolant for the usual operating temperature range for plasma cutting systems. Adjust the coolant mix to operate the system at temperatures that are colder than -10°C (14°F).

  • Page 59: Coolant Requirements For Operation In Temperatures Above 40°C (104°F)

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

  • Page 60: Flow Requirements For Coolant

    25°C (77°F) at 25°C (77°F) 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 1,000 0.001 reference only. Do not use.) 811530 Instruction Manual XPR460...

  • Page 61: Requirements To Put System Components In Position

    Distance requirements for communications on page 69 Configuration with the Core gas connect console Plasma power supply Cooler Gas connect console (Core) TorchConnect console Torch Cutting table CNC lead Work cables Controller Area Network (CAN) cable XPR460 Instruction Manual 811530...

  • Page 62: Configuration With The Coreplus Gas Connect Console

    Regulators – Position a gas regulator within 3 meters (10 feet) of the gas connect console or adjust inlet gas pres- sures to tolerances specified in the process gas requirements. Hoses for supply gases Gases Core: O , and air Power cable: 220 VAC Configuration with the CorePlus gas connect console Plasma power supply Cooler 811530 Instruction Manual XPR460...

  • Page 63: Configuration With Vwi Or Optimix Gas Consoles

    Regulators – Position a gas regulator within 3 meters (10 feet) of the gas connect console or adjust inlet gas pres- sures to tolerances specified in the process gas requirements. Hoses for supply gases Gases CorePlus: O , Ar, and air Power cable: 220 VAC Configuration with VWI or OptiMix gas consoles XPR460 Instruction Manual 811530...
  • Page 64 Negative cables Pilot-arc, coolant-hose, and shield-water assembly Pilot-arc cables Coolant hoses: 1 supply, 1 return Shield-water hose (VWI or OptiMix) Power, CAN, 5-gas hose assembly Power cable: 120 VAC CAN cable 5 gas hoses (VWI or OptiMix) 811530 Instruction Manual XPR460...

  • Page 65: Worksite Requirements For System Components

    Use the following recommendations to put the TorchConnect console in the best position: ■ Clean and dry area ■ Able to support at least 9.3 kg (20.5 lb) These recommendations for the gas connect console and the TorchConnect console are also applicable for mezzanine locations. XPR460 Instruction Manual 811530...

  • Page 66: Length Requirements For Hoses, Cables, And Leads

    ■ Configuration with VWI or OptiMix gas consoles on page 63 Hoses, cables, and leads for plasma equipment are available from Hypertherm. Make sure to install hoses, cables, and leads that are the correct length: ■ Hoses, cables, or leads that are too short can cause restriction of mechanical movement.

  • Page 67: Correct Sizes For Connectors On Hoses, Cables, And Leads

    ■ 58 mm (2.3 in.) for the power cable, CAN cable, and gas-hose assembly The following images show OptiMix assemblies as examples. The connectors on all console-to-console assemblies (Core, CorePlus, VWI, and OptiMix) have the same diameter. Figure 7 - Example OptiMix pilot-arc cable and coolant-hose assembly XPR460 Instruction Manual 811530...

  • Page 68: Distance Requirements Between High-Frequency Cables And Control Cables

    (such as the 120 VAC power, CAN, and EtherCAT cables). If possible, use a separate track to isolate each cable. If separate tracks are not possible, Hypertherm recommends a minimum separation distance 150 mm (6 inches) between the high-frequency cables and control cables. Separate the pilot-arc and negative cables, or any power cables that have a voltage more than 120 VAC from the following: ■...

  • Page 69: Requirements For Service And Maintenance Access

    Qualifications and Requirements Requirements for service and maintenance access Hypertherm recommends a minimum distance of 1 meter (3.3 feet) between the plasma power supply, the cooler, and other system components, or between the plasma power supply, the cooler, and an obstacle.

  • Page 70: 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 419. Torch lifter requirements Use a torch lifter that has the correct weight capacity for XPR torches.

  • Page 71: Adjustable Settings

    Diagnostics and troubleshooting The CNC must be able to run the following commands to diagnose and troubleshoot system operation: ■ Test preflow gases ■ Test pierceflow gases ■ Test cutflow gases ■ Test for gas system leaks XPR460 Instruction Manual 811530...

  • Page 72: 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 national and local electrical codes to make sure that the grounding and shielding practices that you use comply with the requirements for your location.

  • Page 73: Grounding Practices

    1 ohm resistance is satisfactory for most applications. Hypertherm recommends that you consult your national and local electrical codes to make sure that the grounding and shielding practices that you use comply with the requirements for your location.
  • Page 74 ■ Each Hypertherm component, and any other CNC or motor drive cabinet or enclosure, must have a separate ground cable to the common (star) ground on the table. This includes the ignition/gas connect console, whether it is bolted to the plasma cutting system or to the cutting table.
  • Page 75 ■ If you are installing a voltage divider PCB, mount it as closely as possible to where the arc voltage is sampled. One recommended location is inside the plasma power supply enclosure. If a Hypertherm voltage divider PCB is used, the output signal is isolated from all other circuits. The processed signal should be run in twisted shielded cable (Belden ®...

  • Page 76: Example Grounding Diagram With A Plasma Cutting System

    Figure 10 - Gantry ground bus example Cable to the cutting table ground bus Ground cables from components on the gantry Example grounding diagram with a plasma cutting system Figure 11 - Example grounding diagram with a plasma cutting system Cutting table 811530 Instruction Manual XPR460...
  • Page 77 The ignition console is integrated into the gas connect console for XPR cutting systems. This example is based on practices in North America. Other regions can have different national or local electrical codes. Hypertherm recommends that you consult your national and local electrical codes to make sure that the grounding and shielding practices that you use comply with the  ...
  • Page 78 Qualifications and Requirements 811530 Instruction Manual XPR460...

  • Page 79: Installation

    Recommended grounding and shielding on page 72 This plasma system can make more than the permitted acoustical noise levels as defined by national and local codes. Always put on correct ear protection when cutting or gouging. Any acoustical noise XPR460 Instruction Manual 811530...
  • Page 80 When the line-disconnect switch is in the ON position, there is line voltage throughout the cutting system. Use extreme caution if you do diagnosis or maintenance tasks when the line-disconnect switch is in the ON position. 811530 Instruction Manual XPR460...
  • Page 81 Consult your local safety, fire, and building code requirements for the storage and use of hydrogen. Hypertherm recommends that you install an exhaust ventilation system to remove the hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas for cutting.
  • Page 82 A fire can occur if oxygen is not removed. 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 83 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. XPR460 Instruction Manual 811530...

  • Page 84: Installation Checklist

    Before you connect hoses, cables, and leads, make sure that all system components are correctly and fully grounded. Refer to Recommended grounding and shielding on page ☐ Connect all of the hoses, cables, and leads to the plasma power supply. 811530 Instruction Manual XPR460...
  • Page 85 The number and type of gas hose connections is based on the type of gas connect console you have. ☐ Pilot-arc and coolant-hose assembly ☐ Power, CAN, and 3-gas assembly ☐ Power, CAN, and 4-gas assembly ☐ Connect the cable and lead assemblies between the VWI or OptiMix gas connect console and TorchConnect console. XPR460 Instruction Manual 811530...
  • Page 86 As an installer or user, you must supply the torch mounting bracket for your cutting system. Refer Torch mounting bracket requirements on page ☐ Install the consumables. Refer to Install the consumables on page 149. ☐ Make sure the consumables are the correct type and correctly installed. 811530 Instruction Manual XPR460...

  • Page 87: Configuration With Core Gas Connect Consoles

    Fill the cutting system with coolant on page 209. ☐ Make sure that the coolant type is correct. Refer to Coolant requirements on page ☐ Make sure that the coolant reservoir is full. Configuration with Core gas connect consoles XPR460 Instruction Manual 811530...
  • Page 88 Coolant-supply hose and coolant-return hose Pilot-arc cable Negative cables Pilot-arc and coolant assembly Pilot-arc cable Coolant-supply hose and coolant-return hose Power, CAN, 3-gas assembly Power cable, 120 VAC CAN cable Three gas hoses (Core) Torch lead Hoses for supply gases 811530 Instruction Manual XPR460...

  • Page 89: Configuration With Coreplus Gas Connect Consoles

    Configuration with CorePlus gas connect consoles Work cables CNC connection cable (EtherCAT shown) CAN cable Power cable, 120 VAC Coolant-supply hose and coolant-return hose Pilot-arc cable Negative cables Pilot-arc and coolant assembly Pilot-arc cable XPR460 Instruction Manual 811530...

  • Page 90: Configuration With Vwi Or Optimix Gas Connect Consoles

    Put a gas regulator 3 meters (10 feet) or less from the gas connect console, or adjust inlet gas pressures to be in the specified process gas tolerances. Configuration with VWI or OptiMix gas connect consoles Work cables CNC connection cable (EtherCAT shown) 811530 Instruction Manual XPR460...

  • Page 91: Installation Steps

    The plasma power supply weighs as much as 635 kg (1,400 lb), based on voltage configuration. It must be lifted and moved with care to avoid injury or damage. Before you begin: ■ Requirements to put system components in position on page 61 ■ Worksite requirements for system components on page 65 XPR460 Instruction Manual 811530...

  • Page 92: Lifting Equipment

    The cooler weighs 83.46 kg (184 lb). It must be lifted and moved with care to avoid injury or damage. Before you begin: ■ Requirements to put system components in position on page 61 ■ Worksite requirements for system components on page 65 811530 Instruction Manual XPR460...

  • Page 93: Put The Gas Connect Console In Position

    Put the gas connect console in position All gas connect consoles have three mounting holes on the bottom panel. Before you begin: ■ Requirements to put system components in position on page 61 XPR460 Instruction Manual 811530...
  • Page 94 If you have questions about when or how to use the mounting holes, speak to your cutting machine supplier or regional Hypertherm Technical Service team. 2. Use the mounting holes on the bottom panel to install the gas connect console as shown.

  • Page 95: Put The Torchconnect Console In Position

    There are three options to put the TorchConnect console in position. The factory-installed location for the mounting brackets is on the bottom panel of the console. But, you can move the brackets to the end or to the side. XPR460 Instruction Manual 811530...
  • Page 96 If you have questions about what position to use or how to install the console, speak to your cutting machine supplier or regional Hypertherm Technical Service team. 2. Use the mounting brackets on the bottom, end, or side panel of the TorchConnect console to put the console in position, as shown.
  • Page 97 Installation Figure 15 - Mounting-bracket locations and dimensions for the bottom-panel position XPR460 Instruction Manual 811530...

  • Page 98: Ground The System Components

    Ground the system components after they are in position, and before you connect the hoses, cables, and leads. Before you begin: ■ Put the system components in position. ■ Refer to Recommended grounding and shielding on page ■ Ground the plasma power supply. 811530 Instruction Manual XPR460...
  • Page 99 Installation Figure 17 - Location of the ground connection on the plasma power supply ■ Ground the cooler. XPR460 Instruction Manual 811530...
  • Page 100 Figure 18 - Location of the ground connection on the cooler ■ Ground the gas connect console. Figure 19 - Location of the ground connection on example gas connect consoles Core and CorePlus gas connect console OptiMix gas connect console VWI gas connect console 811530 Instruction Manual XPR460...

  • Page 101: Remove External Panels From The System Components

    Figure 20 - Location of the ground connection on theTorchConnect console ■ Ground the torch. Figure 21 - Location of the ground connection on the torch-lead collar Remove external panels from the system components Before you begin: XPR460 Instruction Manual 811530...
  • Page 102 ■ Control transformer (can be different on input and output) ■ Input to the relay that controls the 48 V power supply ■ 24 V power supply ■ 120 V to the input side of the contactor or contactors 811530 Instruction Manual XPR460...
  • Page 103 ■ 220 VAC to the input side of the cooler power relay ■ Remove the rear panel from the plasma power supply. For installation usually it is necessary to remove only the rear panel. ■ Remove the external panels from the gas connect console. XPR460 Instruction Manual 811530...
  • Page 104 Installation You must move the panel horizontally to remove it. ■ Remove the external panels from the TorchConnect console. 811530 Instruction Manual XPR460...

  • Page 105: Prepare The Hoses, Cables, And Leads

    If you coil a cable or lead because it is too long, EMI problems can occur. EMI problems can have a bad effect on system performance. XPR460 Instruction Manual 811530...

  • Page 106: Connect The Plasma Power Supply

    Installation 3. Examine each hose, cable, and lead for damage. Equipment damage can have a bad effect on system performance. Speak to your cutting machine supplier or regional Hypertherm Technical Service team. Connect the plasma power supply Use this information to connect the hoses, cables, and leads to the plasma power supply.
  • Page 107 (continued) EtherNet Local Area Network (LAN) port: For future applications. Do not use. Expansion PCB connectors: Necessary for redundant remote on-off feature alternate 24 VDC power input, and analog estimated arc voltage output.  1 EtherCAT-in XPR460 Instruction Manual 811530...
  • Page 108 1. Connect the coolant-hose assembly to the plasma power supply from the cooler. The coolant-hose assembly includes one coolant-supply hose with green bands and one coolant-return hose with red bands. Refer to Coolant-hose assemblies (cooler to plasma power supply) on page 425 for lengths and part numbers. 811530 Instruction Manual XPR460...
  • Page 109 Pilot-arc cables with strain relief on page 423 for lengths and part numbers. 6. Connect both negative cables to the plasma power supply from the gas connect console. Figure 23 - Negative cable with strain relief XPR460 Instruction Manual 811530...
  • Page 110 This end goes to the cutting table. At least one work cable is necessary for all cutting systems. Some cutting systems use two work cables. Refer to Work cables on page 431 for lengths and part numbers. 811530 Instruction Manual XPR460...

  • Page 111: Connect The Cooler

    Connect the cooler Use this information to connect the hoses, cables, and leads to the cooler. Before you begin: ■ Put the plasma power supply in position on page 91 ■ Ground the system components on page 98 XPR460 Instruction Manual 811530...
  • Page 112 CAN out to the gas connect console 1. Connect the coolant-hose assembly to the cooler from the plasma power supply: The coolant-hose assembly includes one coolant-supply hose with green bands and one coolant-return hose with red bands. 811530 Instruction Manual XPR460...
  • Page 113 Connect the male cable connector on one CAN cable to the cooler from the gas connect console. b. Connect the female cable connector on the other CAN cable to the cooler from the plasma power supply. XPR460 Instruction Manual 811530...

  • Page 114: Connect The Gas Connect Console

    Prepare the hoses, cables, and leads on page 105 ■ Refer to the image that shows the connections on the gas connect console. Figure 28 - Connectors for hoses, cables, and leads in the gas connect console 811530 Instruction Manual XPR460...
  • Page 115 1. Connect the coolant-hose assembly to the gas connect console from the cooler. The coolant-hose assembly includes one coolant-supply hose with green bands and one coolant-return hose with red bands. At least one coolant-hose assembly is necessary for all cutting systems. Some cutting systems use two coolant-hose assemblies. XPR460 Instruction Manual 811530...
  • Page 116 The sheet metal of the internal console panel intersects here. At least one negative cable is necessary for all cutting systems. Some cutting systems use two negative cables. a. Remove the inner nut from the strain relief assembly on each negative cable. 811530 Instruction Manual XPR460...
  • Page 117 The strain relief nut on the pilot-arc cable is not necessary for this connection. Remove the nut from the cable and tighten the strain relief to the panel on the gas connect console. Figure 30 - Connections complete for the gas connect console XPR460 Instruction Manual 811530...

  • Page 118: Connect The Gas Connect Console (Core, Coreplus) To The Torchconnect Console

    Figure 31 - Pilot-arc and coolant assembly Pilot-arc cable, yellow Coolant-return hose, red bands Coolant-supply hose, green bands Assembly coupler To the gas connect console To the TorchConnect console For lengths, refer to Pilot-arc and coolant assemblies (Core, CorePlus) on page 426. 811530 Instruction Manual XPR460...
  • Page 119 Connect the pilot-arc cable. d. Connect the coolant-return hose with the red bands to the coolant-return fitting with the red band. e. Connect the coolant-supply hose with the green bands to the coolant-supply fitting with the green band. XPR460 Instruction Manual 811530...
  • Page 120 Connect the coolant-supply hose with green bands to the coolant-supply fitting with the green band. d. Connect the pilot-arc cable in the TorchConnect console. e. Remove the hose clamp from the pilot-arc and coolant assembly, put it in the groove on the 811530 Instruction Manual XPR460...

  • Page 121: Connect The Power, Can, And 3-Gas Assembly For Core

    Figure 32 - Power, CAN, and 3-gas assembly between an example gas connect console and the TorchConnect console Power cable CAN cable Oxygen hose, blue Nitrogen hose, black Air hose, black Core gas connect console TorchConnect console XPR460 Instruction Manual 811530...

  • Page 122: Connect The Power, Can, And 4-Gas Assembly For Coreplus

    TorchConnect console Power cable CAN cable Oxygen hose, blue Air hose, black Nitrogen hose, black Argon hose, black Gas connect console TorchConnect console For lengths, refer to Power, CAN, and 4-gas assemblies (CorePlus) on page 427. 811530 Instruction Manual XPR460...

  • Page 123: Connect The Gas Connect Console (Vwi, Optimix) To The Torchconnect Console

    The images that follow show an example gas connect console. Your gas connect console could look different. 1. Connect the pilot-arc, coolant, and shield-water assembly to the gas connect console: a. Put the pilot-arc, coolant, and shield-water assembly through the console collar on the gas connect console. XPR460 Instruction Manual 811530...
  • Page 124 Connect the coolant-supply hose with the green bands to the coolant-supply fitting with the green band. Connect the shield-water hose. g. Remove the hose clamp from the pilot-arc, coolant, and shield-water assembly, put it in the groove on the console collar. 811530 Instruction Manual XPR460...
  • Page 125 Connect the coolant-return hose with the red bands to the coolant-return fitting with the red band. d. Connect the coolant supply hose with the green bands to the coolant-supply fitting with the green band. e. Connect the pilot-arc cable. XPR460 Instruction Manual 811530...

  • Page 126: Connect The Power, Can, And 5-Gas Assembly For Vwi Or Optimix

    Air hose, black Argon hose, black Nitrogen hose, black -mix or F5 hose, red To the gas connect console To the TorchConnect console For lengths, refer to Power, CAN, and 5-gas assemblies (VWI, OptiMix) on page 427. 811530 Instruction Manual XPR460...

  • Page 127: Supply Gas Installation

    For example, use flashback arrestors, release gases with an exhaust system, and tighten hoses as specified for different hose dimensions. It is very important to comply with safety requirements if you use hydrogen or oxygen. XPR460 Instruction Manual 811530...
  • Page 128 Consult your local safety, fire, and building code requirements for the storage and use of hydrogen. Hypertherm recommends that you install an exhaust ventilation system to remove the hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas for cutting.
  • Page 129 Never remove a check valve.  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. XPR460 Instruction Manual 811530...
  • Page 130 Incorrect connections can reduce the life of consumables and cause damage to the torch head, torch receptacle, torch leads, and torch connect console. NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or pressure. 811530 Instruction Manual XPR460...
  • Page 131 As an installer or user, you must supply these items for your cutting system: ■ High-quality gas regulators ■ Supply gas plumbing ■ Supply gases The items that you supply must comply with all minimum requirements and must be installed by an approved technician. XPR460 Instruction Manual 811530...

  • Page 132: Install Gas Regulators

    Before you begin: ■ Make sure that you have the correct supply gas hoses before you connect them. ■ Hypertherm recommends a minimum internal diameter of 10 mm (0.375 inch) for supply-gas hoses that are 76 m (250 feet) or less.
  • Page 133 For the best results, make sure that the cutting system is prepared to operate and the gases are flowing when you select the gas regulator settings. This is almost equivalent to doing a test for gas preflow and cutflow. XPR460 Instruction Manual 811530...

  • Page 134: Connect The Supply Gases And Shield Water To Vwi Or Optimix

    Before you begin: ■ Make sure that you have the correct supply gas hoses before you connect them. ■ Hypertherm recommends a minimum internal diameter of 10 mm (0.375 inch) for supply-gas hoses that are 76 m (250 feet) or less.
  • Page 135 □ The temperature range for cutting system operation with shield water is decreased to > 0°C to 40°C (> 32°F to 104°F). 3. After installation is complete, fully pressurize the system, and look for gas leaks. Your system installer or a licensed plumber can do this for you. XPR460 Instruction Manual 811530...

  • Page 136: Install The Torch-Lead Assembly To The Torch Receptacle

    Adjust the mounting sleeve as necessary for good access to the connector ends. 4. Align the connectors in the torch-lead assembly and the torch receptacle. Pilot arc Ohmic Coolant return Plasma valve Plasma Line A, black Coolant supply, green Shield gas, blue Plasma Line B, yellow 811530 Instruction Manual XPR460...
  • Page 137 If you fully tighten it before the coolant-return, other connections will be difficult. Use your fingers to tighten the connection, do not use tools. c. Install the coolant-return hose and use two wrenches to tighten the nut to 16.3 N∙m –19.0 N∙m (144 lbf∙in – 168 lbf∙in). XPR460 Instruction Manual 811530...
  • Page 138 Push the Plasma Line A hose in the connector until it stops, approximately 13 mm (0.5 inch). This is a push-to-connect fitting. Make sure the hose is fully inserted and the insertion mark is no longer visible. 811530 Instruction Manual XPR460...
  • Page 139 Push the Plasma Line B hose in the connector until it stops, approximately 13 mm (0.5 inch) . This is a push-to-connect fitting. Make sure the hose is fully inserted and the insertion mark is no longer visible. XPR460 Instruction Manual 811530...
  • Page 140 7. Put the collar in the correct position on the torch-end of the torch lead: a. Move the collar in the direction of the torch-end of the torch-lead assembly. 811530 Instruction Manual XPR460...

  • Page 141: Connect The Torch Lead To The Torchconnect Console

    Cut quality and the lifespan of consumables will be decreased if you change the lead lengths. The manufactured lengths of torch and console leads are critical for system performance. Never change the lengths of leads. Figure 37 - Torch-lead assembly Protective sleeve Plasma valve cable Ohmic lead XPR460 Instruction Manual 811530...
  • Page 142 2. Optional: If you use a third-party ohmic circuit, remove the plug (*) to get access to the ohmic wire. 3. Connect the torch-lead assembly to the TorchConnect console: Use your hands to tighten the coupler on the torch-lead assembly. Do not use tools. 4. Connect the plasma valve cable to its connector. 811530 Instruction Manual XPR460...

  • Page 143: Remove The Torch And Consumable Parts

    Disconnect electric power before doing installation or maintenance. The line-disconnect switch must STAY in the OFF position until all of the installation or maintenance steps are complete. Refer to the Safety and Compliance Manual (80669C) for more safety information. XPR460 Instruction Manual 811530...
  • Page 144 If you do not correctly install and tighten the electrode, torch damage can occur. A tool is necessary to correctly install and tighten the torch electrode. Do not use your hands. Hypertherm recommends tightening the electrode to a torque value of 2.3 N∙m – 2.8 N∙m (20 lbf∙in – 25 lbf∙in).

  • Page 145: Install The Torch Into The Torch Receptacle

    7. Put the consumables on a surface that is: □ Clean □ Dry □ Oil-free Install the torch into the torch receptacle Make sure that the torch is correctly installed in the torch receptacle. Figure 38 - Torch receptacle connections XPR460 Instruction Manual 811530...
  • Page 146 Use your hands to tighten the torch-coupler nut until the coupler nut cannot turn. Do not use tools. 3. Make sure that the torch body is fully installed in the torch receptacle. Make sure that there is no space between the torch body and torch receptacle. 811530 Instruction Manual XPR460...

  • Page 147: Install The Torch In The Torch Mounting Bracket

    □ Select one that complies with the requirements in Torch mounting bracket requirements on page □ Mounting brackets are available from Hypertherm. Refer to Torch bracket on page 419. ■ The XPR torch mounting sleeve is larger than the HPR torch mounting sleeve. Modification or replacement of an HPR mounting sleeve is necessary before you install an XPR torch.
  • Page 148 This position can keep vibration at the torch tip to a minimum. 5. Make sure that the torch is level (at a 0° angle) in all directions, as shown. You can use a digital level to measure alignment for standard-position cutting, marking, and piercing. 811530 Instruction Manual XPR460...

  • Page 149: Install The Consumables

    If you do not correctly install and tighten the electrode, torch damage can occur. A tool is necessary to correctly install and tighten the torch electrode. Do not use your hands. Hypertherm recommends tightening the electrode to a torque value of 2.3 N∙m – 2.8 N∙m (20 lbf∙in – 25 lbf∙in).
  • Page 150 Installation 6. Install the consumables on the torch as shown. 811530 Instruction Manual XPR460...

  • Page 151: Connect Electric Power To The Cutting System

    If your cutting system has a 200 V, 208 V, 220 V, or 240 V configuration, connect the grounding cable (PE) to the brass block near the ground terminal of TB1. To connect the PE, U, V, and W leads from the main power cord, remove the connection hardware from the TB1 XPR460 Instruction Manual 811530...
  • Page 152 White Blue Brown GND (PE) (earth Green/yellow Green/yellow ground) 3. Comply with national and local electrical codes to connect the W, V, and U power leads from the main power cord to the line-disconnect switch.   811530 Instruction Manual XPR460...

  • Page 153: Connect For Communication

    Requirements for the XPR web interface on page 168. □ Refer to Connect to the plasma power supply with discrete on page 162. For information about signals and protocols, refer to the CNC Communication Protocol for the XPR Cutting System (809810). XPR460 Instruction Manual 811530...

  • Page 154: Requirements For Ethercat

    □ Are not near the gas connect console or TorchConnect console. ■ Hypertherm recommends a minimum distance of 1 meter (3.3 feet) between the plasma power supply and other system components, or between the plasma power supply and an obstacle.

  • Page 155: Connect To The Plasma Power Supply With Ethercat

    Figure 40 - EtherCAT cable Connect to the plasma power supply with EtherCAT ■ Connect the EtherCAT cables to the plasma power supply and to the CNC as shown. Figure 41 - Connect EtherCAT cables to the plasma power supply XPR460 Instruction Manual 811530...

  • Page 156: Ethercat Cable Specifications

    This information prepares you to connect the plasma power supply to the CNC with serial RS-422 cables. ■ For an example of a system diagram, refer to Serial RS-422 and discrete multi-drop (multi-system) interface (Sheet 20 of 25) on page 513. 811530 Instruction Manual XPR460...

  • Page 157: Connect To The Plasma Power Supply With Serial Rs-422

    Serial CNC interface cables on page 430. ■ 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. Figure 42 - Serial RS-422 cable...
  • Page 158 If you want to only monitor with RS-422 serial, you are done. Connect to the plasma power supply with discrete on page 162. Figure 43 - Connect the serial RS-422 cable to the plasma power supply 811530 Instruction Manual XPR460...
  • Page 159 Connect for Communication Figure 43 - Connect the serial RS-422 cable to the plasma power supply (continued) Serial RS-422 in from the CNC XPR460 Instruction Manual 811530...

  • Page 160: Pinouts For Serial Rs-422 Interface Cables

    ■ To use AVC with a serial RS-422 cutting system, connect pin 5 and pin 6 to J4 on the expansion PCB to get access to the estimated arc voltage. For information about how to configure the arc voltage output scale through serial or EtherCAT, refer the CNC Communication Protocol for the XPR Cutting System (809810). 811530 Instruction Manual XPR460...
  • Page 161 Discrete CNC interface cables on page 429. ■ 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. Figure 44 - Discrete cable...

  • Page 162: Connect To The Plasma Power Supply With Discrete

    6. Connect End A of the discrete cable for the expansion PCB to the J4 connector on the expansion PCB. 7. Connect End B of the discrete cable for the expansion PCB to the CNC. Figure 46 - Connect the discrete cable to the plasma power supply 811530 Instruction Manual XPR460...
  • Page 163 Connect for Communication Figure 46 - Connect the discrete cable to the plasma power supply (continued) Discrete cables in from the CNC. Ethernet LAN port: For future applications. Do not use. XPR460 Instruction Manual 811530...

  • Page 164: Pinouts For The Discrete Interface Cables

    If J27 of the main control PCB has a jumper between pin 2 and pin 3, refer to Pinouts for the discrete cable for the expansion PCB on page 165, Install a redundant remote on-off switch on page 207, and Examples of output circuits on page 202. 811530 Instruction Manual XPR460...

  • Page 165: Pinouts For The Discrete Cable For The Expansion Pcb

    Use ohmic contact sense on page 198. Pinouts for the discrete cable for the expansion PCB Use this table to identify the signals, pin numbers, and wire colors in the interface cable with discrete connectors for the expansion PCB. XPR460 Instruction Manual 811530...

  • Page 166: Use The Xpr Web Interface To Change The Arc Voltage Output Scale

    A 24 VDC (500 mA) and return (GND) from the CNC or controlling device to the expansion PCB are necessary for redundant remote on-off for the expansion PCB and input to the control PCB. Hypertherm recommends the use of a separate cable between the remote on-off input and main control PCB.
  • Page 167 3. Use the dropdown menu under Setup to choose the Arc Voltage Output Scale that you want. The default voltage ratio is 30:1. 4. Choose Apply . 5. Remove the power from the cutting system. 6. Supply power to the cutting system. XPR460 Instruction Manual 811530...

  • Page 168: Requirements For The Xpr Web Interface

    Distance requirements for communications on page 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. You can use one of the following options to connect to the XPR web interface through Wi-Fi: ■...

  • Page 169: Web Interface Support Information

    ■ If you have a problem connecting and you think it is a problem with the plasma power supply, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Use AP mode to connect In AP mode, each plasma power supply has its own connection.
  • Page 170 Connect for Communication 4. Enter the password hypertherm. If you want to change the connection name, refer to Other screen on page 196. 5. Open a web browser. 6. Go to 192.168.1.1/index.html. 7. To fully operate the cutting system, you must also use discrete.

  • Page 171: Use Network Mode To Connect

    2. Choose Connect on the Other screen to open the Device Setup screen. The XPR web interface shows different fields for different models. The screen shown is for reference only. XPR460 Instruction Manual 811530...
  • Page 172 Connect for Communication 3. Use the Device Setup screen to configure wireless adapter settings as necessary. 811530 Instruction Manual XPR460...

  • Page 173: Select An Existing Wireless Network

    Connect for Communication Select an existing wireless network Use these steps to connect to an existing wireless network. XPR460 Instruction Manual 811530...
  • Page 174 When you choose this option, the plasma power supply scans for and shows the available access points. 1. On the Device Setup screen, choose QuickConnect. 2. On the WLAN Link Scan screen, choose the network that you want. 3. On the WLAN Profile screen, enter the network password, then choose Submit. 811530 Instruction Manual XPR460...

  • Page 175: Set Up The Wireless Network Manually

    Use these steps to set up a wireless network manually. 1. On the Device Setup screen, choose WLAN Profiles. 2. In the WLAN Profile Management field, enter a name for the profile you want to create, and choose Apply. XPR460 Instruction Manual 811530...
  • Page 176 Connect for Communication 3. Choose the profile you want and configure its settings, including Network Name, Security, and Passphrase. 4. Choose Submit to save the profile settings and connect to the network. 811530 Instruction Manual XPR460...
  • Page 177 Connect to the plasma power supply with discrete on page 162. ■ To access the web interface through Wi-Fi after setup, go to Access the XPR web interface after setup in network mode on page 178. XPR460 Instruction Manual 811530...

  • Page 178: Access The Xpr Web Interface After Setup In Network Mode

    Use these steps to access the XPR web interface using the IP address of the plasma power supply. Before you begin: Hypertherm recommends that you use Dynamic Host Configuration Protocol (DHCP) reservation if it is available on your router. This lets the plasma power supply keep the same IP address through power cycles without having to set up the wireless module with the static IP address.
  • Page 179 3. Use the assigned IP address to access the XPR web interface through Wi-Fi. In the example, you navigate to http://192.168.1.15/index.html. 4. If you want to assign a different IP address, use the steps in the Modify Network Settings screen. XPR460 Instruction Manual 811530...

  • Page 180: Change The Limited Ap Settings

    2. On the Configuration screen, change the settings. 3. Make sure that all of the settings are correct, then choose Submit to save and apply them. 4. Remove the power from the cutting system. 5. Supply power to the cutting system. 811530 Instruction Manual XPR460...

  • Page 181: Change The Network Settings

    The change goes into effect after you remove and then supply power to the cutting system. Change the network settings You can change the network settings on the Device Setup screen. 1. On the Device Setup screen, choose Network > wlan0 > Interface > Configuration. XPR460 Instruction Manual 811530...
  • Page 182 2. In the Interface wlan0 Configurations fields, change the settings. 3. Make sure that all of the settings are correct, then choose Submit to save and apply them. 4. Remove the power from the cutting system. 811530 Instruction Manual XPR460...

  • Page 183: Reset The Wireless Module

    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. 1. Remove the power from the cutting system: a. Set the line-disconnect switch to the OFF position. XPR460 Instruction Manual 811530...
  • Page 184 Use extreme caution if you do service or maintenance work on a plasma power supply when it is connected to an electric power source and the outer cover or panels are removed. 811530 Instruction Manual XPR460...

  • Page 185: Disable The Wireless Connection Temporarily

    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. XPR460 Instruction Manual 811530...
  • Page 186 2. Remove the control-side panel of the plasma power supply. 3. On the main control PCB, set position 4 on DIP switch S3 to the ON position. This disables the wireless. 4. Install the control-side panel of the plasma power supply. 811530 Instruction Manual XPR460...

  • Page 187: Disable The Wireless Connection Permanently

    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. XPR460 Instruction Manual 811530...

  • Page 188: Web Interface Screen Information

    Make sure that the power-indicator LED on the plasma power supply is illuminated. Web interface screen information If you replace the control PCB, the information on the PCB changes. This includes the MAC address, System ID, passwords, and network information. 811530 Instruction Manual XPR460...
  • Page 189 Operator ID shows the type of connection that sent a process, WiFi for wireless, Uart 422 for serial RS-422, or EtherCAT for EtherCAT. To change which device has control of the plasma power supply, refer to Change the device that has control on page 197. XPR460 Instruction Manual 811530...

  • Page 190: Plasma Power Supply Screen

    On this screen you can monitor the status of the plasma power supply. This screen also shows a list of inputs and outputs. When an input or output is active, the screen shows it as red or gray. 811530 Instruction Manual XPR460...
  • Page 191 Connect for Communication Figure 48 - Example of the plasma power supply screen The XPR web interface shows different fields for different XPR models. The screen shown is for reference only. XPR460 Instruction Manual 811530...

  • Page 192: Gas System Screen

    The gases on Line A, Line B, and shield align with the process ID that you selected. The gases flow for 60 seconds unless you choose the same button or choose another button that stops the test. 811530 Instruction Manual XPR460...
  • Page 193 Connect for Communication Figure 49 - Example text-view screen that shows the gas system status XPR460 Instruction Manual 811530...
  • Page 194 Connect for Communication Figure 50 - Example diagram-view screen that shows the gas system status 811530 Instruction Manual XPR460...

  • Page 195: Log Screen

    Figure 51 - Example of a log screen Operate screen On this screen, if you have the device that is in control of the plasma power supply, you can select a process ID that aligns with the material, thickness, and process type. XPR460 Instruction Manual 811530...

  • Page 196: Other Screen

    ■ You cannot use special characters in any of the fields on this screen. ■ The connection name must be less than 32 characters long. ■ Passwords must be between 8 – 20 characters long. ■ Passwords are case sensitive. 811530 Instruction Manual XPR460...

  • Page 197: Change The Device That Has Control

    The device that first sets a process controls the plasma power supply. For example, if the CNC sets the process, all other devices that connect to the plasma power supply after the CNC sets the process can only monitor the data. XPR460 Instruction Manual 811530...

  • Page 198: Use Ohmic Contact Sense

    4. Do you have a third-party ohmic circuit? If yes... Remove the plug from the sheet metal on the TorchConnect console to get access to the ohmic wire inside. The plug is below the torch lead connection, as shown. 811530 Instruction Manual XPR460...

  • Page 199: Example Of Internal Ohmic Contact Sense

    Example of internal ohmic contact sense Internal ohmic contact sense is the default installation for the torch and the TorchConnect console. No more steps are necessary. Figure 54 - Example diagram of internal ohmic contact sense XPR460 Instruction Manual 811530...

  • Page 200: Example Of External Ohmic Contact Sense

    Refer to this example diagram if it is necessary to change the wiring inside of the TorchConnect console so that you can use external ohmic contact sense. Figure 55 - Example diagram of external ohmic contact sense 811530 Instruction Manual XPR460...

  • Page 201: Install A Remote On-Off Switch

    Compliance Manual (80669C) for more safety information. 1. Remove the jumper from pin 1 and pin 2 of the J14 connector. For the pinout of J14, refer to Pinouts for the discrete interface cables on page 164. 2. Install your own interface. XPR460 Instruction Manual 811530...

  • Page 202: Examples Of Output Circuits

    There are three types of interfaces for output circuits. Be careful not to use an incorrect circuit. It is the responsibility of the system integrator to make sure that circuit designs obey all applicable national and local codes. Logic interface, active high 811530 Instruction Manual XPR460...

  • Page 203: Logic Interface, Active Low

    Connect for Communication 5 VDC – 24 VDC 10 kΩ (optional) High-impedance (≤ 10 mA) Logic interface, active low 5 VDC – 24 VDC 10 kΩ (optional) High-impedance (≤ 10 mA) Relay interface XPR460 Instruction Manual 811530...

  • Page 204: This Circuit Voids The Warranty. Do Not Use

    • ≤ 10 mA or ≥ 2400 Ω • For all relay coils it is necessary to have a freewheeling diode across the relay coil. This circuit voids the warranty. Do not use. Any voltage Power ground 811530 Instruction Manual XPR460...

  • Page 205: Examples Of Input Circuits

    The life of the external relay can be extended if you add a resistor-capacitor series in parallel with the relay contacts. A metalized-polyester capacitor – 0.022 μF 100 V or higher – is a good example. Power ground External relay (AC or DC) Output from CNC +24 VDC Optocoupler interface XPR460 Instruction Manual 811530...

  • Page 206: Amplified-Output Interface

    Connect for Communication +24 VDC Power ground Transistor-output optocoupler Amplified-output interface +24 VDC CNC ground Active-high drive CNC 12 VDC – 24 VDC 811530 Instruction Manual XPR460...

  • Page 207: Redundant Remote On-Off Example Interface

    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. XPR460 Instruction Manual 811530...
  • Page 208 ■ 120 VAC ■ 220 VAC on the power distribution PCB ■ 120 VAC to the input side of the 40 V power relay ■ 220 VAC to the input side of the cooler power relay   811530 Instruction Manual XPR460...

  • Page 209: Coolant Installation

    XPR Preventative Maintenance Program (PMP) Instruction Manual (809490). Fill the cutting system with coolant Use the correct amount and type of coolant mixture to help prevent damage to the cutting system. XPR460 Instruction Manual 811530...
  • Page 210 If you use an incorrect coolant, it can cause damage to the cutting system. Refer to the coolant requirement specifications for your plasma cutting system. Before you begin: ■ Calculate the correct percentage of propylene glycol to add in the premixed Hypertherm coolant (028872). ■ Refer to Coolant requirements on page 1.
  • Page 211 3. Look at the coolant-level view window to see if the reservoir is full. Coolant-level view window Maximum fill line 4. Add the coolant in the reservoir until the coolant is at the recommended fill level. XPR460 Instruction Manual 811530...
  • Page 212 7. Use the CNC or XPR web interface to send a process to the plasma power supply and start the coolant pump. □ When you send a process, the gases start to flow, and after a few seconds the coolant pump starts. 811530 Instruction Manual XPR460...
  • Page 213 8. If necessary, add more coolant to fill the reservoir to the recommended fill level. What to do next: After you add the coolant, use the CNC or XPR web interface to clear the process.   XPR460 Instruction Manual 811530...
  • Page 214 Coolant Installation 811530 Instruction Manual XPR460...

  • Page 215: Operation

    CNC interfaces can include these screens: ■ Main (control) screen ■ Process setup screen ■ Diagnostic screen ■ Test screen ■ Cut chart screen Refer to the instruction manual for your CNC for descriptions of CNC screens. XPR460 Instruction Manual 811530...

  • Page 216: Wireless Device Controls

    When illuminated, the green power-indicator LED on other components is an indication that: ■ Power is supplied to the XPR cutting system. ■ The line-disconnect switch or breaker for the component is set to the ON (I) position. 811530 Instruction Manual XPR460...

  • Page 217: Sequence Of Operation

    (name or number) is specified in your cutting system settings. Power-up state (1) The Power-up state (1) process starts when the operator sets the remote on-off switch for the plasma cutting system to the ON position. XPR460 Instruction Manual 811530...

  • Page 218: Initial Checks State (2)

    Initial Checks state (2) on page 218. Refer to Initial inspection steps on page 273 for troubleshooting procedures. Initial Checks state (2) During the Initial Checks state (2), the system looks for diagnostic codes and gets temperature and inlet pressure measurements. 811530 Instruction Manual XPR460...

  • Page 219: Gas Purge/Pump On State (3)

    Start the Initial Checks state (2) again. Measure temperatures at the main transformers, choppers, and coolant. Measure the temperature at the control transformer (XPR460). Measure inlet pressures at the gas connect console and torch connect console. Are the measurements in...
  • Page 220 ■ The type of operator-selected process that the CNC or wireless device sends to the cutting system ■ If this is the first process sent after the Power-up state (1) starts ■ The type of operator-selected process that was sent before 811530 Instruction Manual XPR460...

  • Page 221: Wait For Start State (5)

    Plasma Start command Refer to Initial inspection steps on page 273 for troubleshooting procedures. Preflow/Charge DC state (7) During the Preflow/Charge DC state (7), the system starts some internal components and measures the gas pressure. XPR460 Instruction Manual 811530...

  • Page 222: Ignite State (8)

    Ignite state (8) During the Ignite state (8), the system does a check for correct gas pressures, DC bus voltage, and chopper current. The Ignite state (8) must be completed in 500 milliseconds or less. 811530 Instruction Manual XPR460...
  • Page 223 Pilot Arc state (9) on page 224. ■ If one or more of these measurements is not correct, the process continues with End of Cycle state (14) on page 228: □ Coolant flow □ Gas pressure □ DC bus voltage XPR460 Instruction Manual 811530...

  • Page 224: Pilot Arc State (9)

    During the Pilot Arc state (9), the system does a check for correct coolant flow, gas pressures, temperatures, DC bus voltage, chopper current, and work cable current. The Pilot Arc state (9) must be completed in 500 milliseconds or less. 811530 Instruction Manual XPR460...
  • Page 225 Does the Pilot Arc state (9) steps to identify the complete in 500 milliseconds? problem. Continue to Ramp-up state (11). ■ If the Pilot Arc state (9) completes correctly, the process continues with Ramp-up state (11) on page 226. XPR460 Instruction Manual 811530...

  • Page 226: Ramp-Up State (11)

    Continue to Steady state (12). If the Ramp-up state (11) completes correctly, the process continues with Steady state (12) on page 227. Refer to Initial inspection steps on page 273 for troubleshooting procedures. 811530 Instruction Manual XPR460...

  • Page 227: Steady State (12)

    If the process is less ≤ 50 A, only Chopper 1 is ON. If the operator- selected process is ≥ 50 A, monitor all of the choppers. Is the Plasma Start signal removed? Continue to Ramp-down state (13). XPR460 Instruction Manual 811530...

  • Page 228: Ramp-Down State (13)

    Initial inspection steps on page 273 for troubleshooting procedures. End of Cycle state (14) The End of Cycle state (14) stops the choppers and gas flows. It also starts timers to stop the fans and the coolant pump. 811530 Instruction Manual XPR460...

  • Page 229: High-Voltage Relay Stages In The Ohmic Circuit

    During a dry process, the cutting system closes the high-voltage relay and enables the ohmic-sense circuit (except during high-frequency starts). Automatic purges Plasma cutting system purges are automatic. The system looks at these conditions to select the type of purge to do: ■ The process that is selected now XPR460 Instruction Manual 811530...

  • Page 230: Gas-Change Purges For Optimix Or Vwi Cutting Systems

    Core and CorePlus cutting systems use only process-setup purges. They do not use gas-change purges. Process-setup purges for all plasma cutting systems Process-setup purges are different for an OptiMix or VWI gas connect console than they are for a CorePlus or Core gas connect console. 811530 Instruction Manual XPR460...

  • Page 231: Process Selection

    When you select a process ID from the CNC or from the XPR web interface, you automatically get the optimized settings that Hypertherm recommends for that process. The preprogrammed settings come from extensive Hypertherm laboratory tests. Because of differences in cutting systems, metals, and consumables, it can be necessary to adjust the settings. However, in most...

  • Page 232: Process Id Offsets / Overrides

    What to do next: If an unusual cutting process is necessary, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Process ID offsets / overrides You can adjust some preprogrammed settings with an offset or override command.

  • Page 233: Process Core Thickness (Pct)

    The category number for the process that you select changes how the cut quality and the cut speed are balanced. For best results, Hypertherm recommends that you select process category number 1 when possible. Category 1 supplies an optimal thickness (or PCT) for that cut process that balances cut quality and cut speed.
  • Page 234 100% duty cycle with extended cutting intervals. 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, use a higher amperage process.
  • Page 235 100% duty cycle with extended cutting intervals. In general, Hypertherm recommends dross-free processes. Non-ferrous dross is not easy to remove. The plasma cutting system supplies these non-ferrous cutting processes, but the processes that are available are...

  • Page 236: Torch Consumables

    Use these sets of consumables to cut ferrous material. Mild steel is an example of a ferrous metal. Mild steel – 30 A – O Figure 58 - Mild steel 30 A consumables Shield retaining cap  1 Shield 811530 Instruction Manual XPR460...

  • Page 237: Mild Steel - 50 A, 80 A, 130 A, 170 A, 220 A, 300 A, And 460 A - O /Air

    The bottom part number is for mirror cutting only. Mild steel – 50 A, 80 A, 130 A, 170 A, 220 A, 300 A, and 460 A – O /Air Figure 59 - Mild steel consumables 50 A – 460 A XPR460 Instruction Manual 811530...

  • Page 238: Non-Ferrous (Stainless Steel And Aluminum) Example Configurations

    Non-ferrous – 40 A – N and Air/Air Figure 60 - Non-ferrous 40 A consumables Shield retaining cap  1 Shield Nozzle retaining cap Nozzle Swirl ring Electrode Water tube The bottom part number is for mirror cutting only. 811530 Instruction Manual XPR460...

  • Page 239: N /N , N /H

    The bottom part number is for mirror cutting only. Non-ferrous – 80 A – F5/N O, Air/Air F5/N and N O can be used only with VWI and OptiMix gas connect consoles. Figure 62 - Non-ferrous 80 A consumables XPR460 Instruction Manual 811530...

  • Page 240: Non-Ferrous - 130 A - N

    Non-ferrous – 130 A – N , Mix/N F5/N and N O can be used only with VWI and OptiMix gas connect consoles. Mix/N can be used only with OptiMix gas connect consoles. Figure 63 - Non-ferrous 130 A consumables 811530 Instruction Manual XPR460...

  • Page 241: Non-Ferrous - 170 A - N , Mix/N O, Air/Air

    Non-ferrous – 170 A – N , Mix/N O, Air/Air O can be used only with VWI and OptiMix gas connect consoles. Mix/N can be used only with OptiMix gas connect consoles. Figure 64 - Non-ferrous 170 A consumables XPR460 Instruction Manual 811530...

  • Page 242: Non-Ferrous - 300 A - N , Mix/N O

    The bottom part number is for mirror cutting only. Non-ferrous – 300 A – N , Mix/N O can be used only with VWI and OptiMix consoles. Mix/N can be used with OptiMix consoles. Figure 65 - Non-ferrous 300 A consumables 811530 Instruction Manual XPR460...

  • Page 243: Recommendations For Maximum Consumable Life

    These steps occur automatically with LongLife electrode protection: □ An automatic ramp up of the gas and current flow at the start of a cut □ An automatic ramp down of the gas and current flow at the end of a cut XPR460 Instruction Manual 811530...

  • Page 244: Arc Response Technology

    ■ When possible, do not cut metal that is magnetic or that can easily become magnetic. For example, do not cut armor plate that has a high nickel content. ■ To get the full benefits of the Hypertherm automatic ramp-down error protection, select processes that have cut speeds of 3,560 mm/min (140 in/min) or less. Refer to...

  • Page 245: Automatic Ramp-Down Error Protection

    This type of controlled stop can help very much to increase electrode life, especially when cut speeds are less than 3,560 mm/min (140 in/min).   XPR460 Instruction Manual 811530...
  • Page 246 Operation 811530 Instruction Manual XPR460...

  • Page 247: Maintenance

    Maintenance M aintenance Plasma system maintenance 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.

  • Page 248: Daily Inspections

    Examine the shield water regulator (if applicable) on page 250 ■ Examine the connections and fittings on page 251 ■ Remove the torch and consumable parts on page 143 ■ Examine the torch lead on page 259 811530 Instruction Manual XPR460...

  • Page 249: Remove The Power From The Cutting System

    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. XPR460 Instruction Manual 811530...

  • Page 250: Examine The Gas Regulators

    If your cutting system uses water as a shield fluid, examine the shield water settings before you start cutting system operation. 1. Make sure that the water pressure and flow rate is within the recommended range. 811530 Instruction Manual XPR460...

  • Page 251: Examine The Connections And Fittings

    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. If you find a problem with an external fitting, you must order a replacement hose, cable, or lead set (with integrated fitting).

  • Page 252: Remove The Torch And Consumable Parts

    If you do not correctly install and tighten the electrode, torch damage can occur. A tool is necessary to correctly install and tighten the torch electrode. Do not use your hands. Hypertherm recommends tightening the electrode to a torque value of 2.3 N∙m – 2.8 N∙m (20 lbf∙in – 25 lbf∙in).
  • Page 253 5. Use the consumable tool to turn the electrode counterclockwise. 6. Hold the tool tightly and pull straight out to correctly remove the electrode. 7. Put the consumables on a surface that is: □ Clean □ Dry □ Oil-free XPR460 Instruction Manual 811530...

  • Page 254: Examine The Consumable Parts

    (027055) to O-rings that appear dry. Nozzle retaining cap Damage Replace the nozzle retaining cap. Poor cut quality after replacing other consumables Damaged O-rings Dry O-rings Apply a thin film of silicone lubricant (027055) to O-rings that appear dry. 811530 Instruction Manual XPR460...
  • Page 255 For guidance about how to identify correctly tighten the electrode. emitter wear, refer to Indicators of emitter wear on page 259. If an electrode needs replacement because of emitter wear, always replace the nozzle at the same time as the electrode. XPR460 Instruction Manual 811530...

  • Page 256: Examine The Torch

    1. Examine the torch for: □ Damage or excess wear on the external O-rings that are on the front of the torch □ Damage or excess wear on the internal O-rings that are on the rear of the torch 811530 Instruction Manual XPR460...
  • Page 257 □ Cracks in the torch main body □ Cracks in the torch insulator 2. Replace any O-rings that have damage or excess wear. Torch rebuild kits are available from Hypertherm. Refer to Preventive maintenance kits on page 434. 3. If you find cracks in the torch main body or torch insulator, replace the entire torch main body.

  • Page 258: Examine The Torch Receptacle

    The O-ring is for dust protection only. □ Cracks in the torch receptacle body 2. 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 434.

  • Page 259: Examine The Torch Lead

    Emitter wear can cause the cut quality to degrade. Your cut quality requirements will indicate when to replace the electrode. If an electrode needs replacement because of emitter wear, always replace the nozzle at the same time as the electrode. Use the electrode torque tool (429013) to correctly tighten the electrode. XPR460 Instruction Manual 811530...
  • Page 260 ■ If the electrode pit diameter extends beyond the hafnium, as shown, replace the electrode and nozzle. ■ If you see a non-symmetrical, rough-edged pit and rough-surfaced electrode face, replace the electrode and nozzle. Always replace the nozzle at the same time as the electrode. 811530 Instruction Manual XPR460...

  • Page 261: Measure The Pit Depth Of An Electrode

    Remove the torch and consumable parts on page 143 ■ Use an electrode pit-depth gauge to measure the pit depth on the electrode. A pit-depth gauge is available from Hypertherm. Refer to Other consumable and torch parts on page 422.

  • Page 262: Coolant Maintenance

    Never operate the cutting system if you get a low coolant level notice.  NOTICE AUTOMOTIVE ANTIFREEZE CAN DAMAGE THE TORCH COOLANT SYSTEM Antifreeze contains chemicals that can damage the torch coolant system. Never use automotive antifreeze in place of Hypertherm coolant. 811530 Instruction Manual XPR460...

  • Page 263: Calculations For Total Coolant Volume Estimates

    Coolant replacement and its significance 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 264: Remove Old Coolant From The System

    Keep one end of the tube with the 3/8-inch inner diameter connected to the valve on the bottom of the reservoir and the other end of the tube in the container. b. Remove the coolant return hose from the rear of the plasma power supply. 811530 Instruction Manual XPR460...
  • Page 265 Do not keep the tube with the 3/8-inch diameter in the of the plasma power supply. Keep the coolant return hose (red band) disconnected from the rear of the plasma power supply. XPR460 Instruction Manual 811530...
  • Page 266 Make sure that the O-ring is free of debris, cracks, and dents. h. Install the plug on the coolant pump housing. 5. To remove the old coolant from the filter housing and replace the coolant filter: 811530 Instruction Manual XPR460...
  • Page 267 If you do not, the new coolant will mix with the old coolant. This will cause faster deterioration of the new coolant. a. Put the disconnected end of the coolant return hose into an empty container. XPR460 Instruction Manual 811530...
  • Page 268 Do the previous step again until coolant flow from the coolant return hose (red band) stops. When the coolant flow from the coolant return hose (red band) stops, connect the two hoses to the rear of the plasma power supply.   811530 Instruction Manual XPR460...

  • Page 269: Diagnostics And Troubleshooting

    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. XPR460 Instruction Manual 811530...
  • Page 270 When the line-disconnect switch is in the ON position, there is line voltage throughout the cutting system. Use extreme caution if you do diagnosis or maintenance tasks when the line-disconnect switch is in the ON position. 811530 Instruction Manual XPR460...
  • Page 271 Consult your local safety, fire, and building code requirements for the storage and use of hydrogen. Hypertherm recommends that you install an exhaust ventilation system to remove the hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas for cutting.
  • Page 272 A fire can occur if oxygen is not removed. 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 273: Initial Inspection Steps

    Always start with the following inspection steps: 1. Make sure that the cutting system is connected to electric power. Refer to Connect electric power to the cutting system on page 151. 2. Make sure that the line-disconnect switch is set to ON. XPR460 Instruction Manual 811530...

  • Page 274: Remove The Power From The Cutting System

    2. Remove the external panel or panels from the system component that has the PCB that you want to examine. Refer to PCB names and locations on page 277. 3. Examine the PCB for: □ Loose or disconnected PCB connectors □ Loose or disconnected PCB assemblies 811530 Instruction Manual XPR460...
  • Page 275 7. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. It is necessary for the cutting system to have electric power to measure line voltage. Use extreme caution if you do diagnosis or maintenance tasks when the plasma power supply stays plugged in and the panels on the plasma power supply are removed.

  • Page 276: Measure The Line Voltage Between The Terminals Inside The Plasma Power Supply

    Repair or replace any parts that are defective or have damage, if found. 5. Continue to do these steps until the line voltage between any two of the three lines is equal to the supply voltage. 811530 Instruction Manual XPR460...

  • Page 277: Pcb Names And Locations

    Diagnostic codes can include the following abbreviations: ■ GCC: Gas connect console ■ CAN: Controller area network ■ TCC: Torch connect console ■ t/o: Time out ■ HF: High frequency ■ IGBT: Insulated-gate bipolar transistor ■ Ch1, Ch2, Ch3: Choppers XPR460 Instruction Manual 811530...

  • Page 278: Diagnostic Codes

    If you cannot find or resolve the problem with the corrective actions in Diagnostic codes on page 278, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Diagnostic codes Use this table to identify a diagnostic code and where to find more troubleshooting information about it.
  • Page 279 CAN communications for the main control at least once per second. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team. • XPR action: Shut down • Code cancels with: Remote on-off Failure Main->GCC CAN t/o...
  • Page 280 CAN communications from the cooler at least once per second. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team. • XPR action: None • Code cancels with: Remote on-off...
  • Page 281 Description Corrective action models Failure DC exceeds limit–Ch1 All models Failure DC exceeds limit–Ch2 XPR300, Troubleshooting for high current on page 330 XPR460 Failure DC exceeds limit–Ch3 XPR460 Error Over temp–Ch1 All models Error Over temp–Ch2 XPR300, Troubleshooting for over-temperature faults for chop-...
  • Page 282 This code occurs after power is supplied and the main control does not receive CAN communications for the cooler. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Tech- nical Service team. • XPR action: None •...
  • Page 283 Alert No DC output–Ch1 All models Alert No DC output–Ch2 XPR300, Troubleshooting for consumable part failure or no XPR460 chopper current on page 341 Alert No DC output–Ch3 XPR460 Failure DC at wait-start All models Troubleshooting for current sensor faults on page...
  • Page 284 This code occurs during the ramp-up or ramp-down state if the process block time definition is more than one second. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team. • XPR action: Shut down •...
  • Page 285 XPR460 This code occurs when the state duration is less than the minimum. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team. • XPR action: End of cycle • Code cancels with: Start or set process; remote on- Error Thermistor Fault–Ind 1...
  • Page 286 No Thermistor–Ind 2 All models Use a digital multimeter to measure the resistance Error No Thermistor–Ind 3 XPR300, from the thermistor. Refer to Measure resistance from XPR460 thermistors on page 307. Error No Thermistor–Ind 4 XPR300, • XPR action: Shut down XPR460 •...
  • Page 287 No sensor P7–GCC All models (VWI or OptiMix only) Error No sensor P8–GCC All models (VWI or OptiMix only) Error No sensor P9–GCC All models Alert Process Invalid All models Troubleshooting for invalid processes on page 358 XPR460 Instruction Manual 811530...
  • Page 288 Error Bad Temp Reading–Ch3 XPR460 plier or regional Hypertherm Technical Service team. • XPR action: Ramp down • Code cancels with: Start or set process; remote on- Alert Solenoid error V1...
  • Page 289 Troubleshooting for low fan speeds – MAGFAN on Alert Low Speed–MagFan 2 All models page 371 Alert Low Speed–MagFan 3 XPR460 Alert Low Speed–CabFan 1 XPR460 Troubleshooting for low fan speeds – CAB FAN 1 on page 372 Alert Low Speed–HxFan 1 All models Troubleshooting for low fan speeds –...
  • Page 290 XPR firmware. You can log into the Xnet at to download it. If the code contin- www.hypertherm.com ues, speak to your cutting machine supplier or regional Hypertherm Technical Service team. • XPR action: End of cycle • Code cancels with: Remote on-off Alert...
  • Page 291 This code occurs when the system changes from an OptiMix system to a VWI system as a result of an error condition. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team. • XPR action: None •...
  • Page 292 This code occurs when there is an error during com- munication with the fieldbus (field bus) module. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team. • XPR action: None •...

  • Page 293: General Troubleshooting Procedures

    XPR460 This code occurs when the 24 VDC bus is less than 20 V. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Tech- nical Service team. • XPR action: None • Code cancels with: Start or set process; remote on-...

  • Page 294: The Cut Settings Are Not Correct

    Cutting faults that can occur frequently Hypertherm recommends these steps when you have one of these cutting problems. The pilot arc starts but does not transfer to the workpiece. ■ Make sure that the work cable is correctly connected to the cutting table and is fully tightened.

  • Page 295: There Is Dross On The Bottom Of The Cut

    ■ Replace consumables that are worn or have damage. Do a gas leak test Do an automated gas leak test on the CNC screen or XPR web interface if you suspect a cutting system gas leak. XPR460 Instruction Manual 811530...
  • Page 296 Consult your local safety, fire, and building code requirements for the storage and use of hydrogen. Hypertherm recommends that you install an exhaust ventilation system to remove the hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas for cutting.
  • Page 297 Line A (black) and for Line B (yellow) but not for the shield gas line (blue). The gases flow until you select the same button or select another button that interrupts the test. Figure 67 - GAS LEAK TEST in the XPR web interface XPR460 Instruction Manual 811530...

  • Page 298: Coolant Flow Measurements

    If the coolant flow rate is outside of the correct range, an internal obstruction or leak can be the cause. 1. Look at the CNC or XPR web interface to identify the coolant flow rate. 2. Make sure that the coolant flow rate is more than the minimum flow rate limit for your system. 811530 Instruction Manual XPR460...

  • Page 299: Do A Container Test To Measure Coolant Flow

    3. At the rear of the cooler, disconnect the red coolant return hose that goes to the plasma power supply from the red coolant return fitting that is on the coolant hose manifold. Use the container to collect coolant leaks if necessary. Remove the coolant from the container before you start the test. XPR460 Instruction Manual 811530...
  • Page 300 11. If you find parts that have damage, replace them. 12. If coolant flow stays slow, and it has been more than six months since the last coolant replacement, replace the coolant. Refer to Coolant replacement and its significance on page 263. 811530 Instruction Manual XPR460...

  • Page 301: Do A Test For Continuity Between The Nozzle And Workpiece

    Diagnostics and Troubleshooting Hypertherm recommends coolant replacement every six months. For complete preventive maintenance information, refer to the XPR Preventive Maintenance Program (PMP) Instruction Manual (809490). 13. If coolant flow stays slow after replacement, make sure that the bypass is operating correctly and that these components are good: □...

  • Page 302: Corrective Action

    Diagnostics and Troubleshooting Pilot-arc relay Cooler-power relay Corrective action 1. Remove the power from the cutting system. 2. Locate the start-circuit assembly (PCB 4 in the plasma power supply). 811530 Instruction Manual XPR460...
  • Page 303 3. Install a temporary jumper wire between J5 (nozzle) and J1 (work) on the start circuit PCB (PCB 4 in the plasma power supply). If you do not have a jumper wire, you can put plugs in the J7 and J8 connectors instead. XPR460 Instruction Manual 811530...
  • Page 304 Diagnostics and Troubleshooting 4. Find the pilot-arc relay (CR 1), and remove the dust cover. 811530 Instruction Manual XPR460...
  • Page 305 Diagnostics and Troubleshooting 5. Have a second person close (push in) the contact on the pilot arc relay. XPR460 Instruction Manual 811530...
  • Page 306 Look for insulation damage and short circuits to ground: □ From the plasma power supply to the gas connect console □ From the gas connect console to the TorchConnect console □ From the TorchConnect console to the torch receptacle 811530 Instruction Manual XPR460...

  • Page 307: Measure Resistance From Thermistors

    If you get this condition... Do these steps... The resistance is more than the maximum Speak to your cutting machine supplier or regional Hypertherm Techni- value. cal Service team. They can help you to identify if there is a wiring fault or if thermistor replacement is necessary.

  • Page 308: Do An Ohmic-Contact Test

    The resistance is in the permitted range. Continue cutting system operation. The resistance stays at less than the mini- Speak to your cutting machine supplier or regional Hypertherm Techni- mum ohmic value or does not change after the cal Service team.
  • Page 309 7. Examine the ohmic contact PCB. Refer to Torch connect console ohmic PCB (141368) diagram on page 389. a. If the PCB configuration is for internal ohmic, make sure that the ohmic wire from the ohmic relay is connected to J3. XPR460 Instruction Manual 811530...
  • Page 310 Replace the relay if necessary. d. If the connections are good but there is no 24 VDC, speak to your cutting machine supplier or regional Hypertherm Technical Service team. 12. If you find 24 VDC, continue with these steps: a.

  • Page 311: Troubleshooting Procedures For Diagnostic Codes

    Diagnostics and Troubleshooting 13. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting procedures for diagnostic codes CAN communication troubleshooting for gas connect consoles Diagnostic codes 500, 507, 508, 510, 602 Do these steps if you get a diagnostic code that is related to CAN communication issues with a Core, CorePlus, VWI, or OptiMix gas connect console.
  • Page 312 7. Disconnect these cables and examine them for sockets and pins that are bent: a. If you find bent pins, make the bent pins straight. b. If you find bent sockets or broken pins, get a new cable. 8. Examine D24 and D25 on the control PCB again: 811530 Instruction Manual XPR460...

  • Page 313: Can Communication Troubleshooting For Mixing Modules In Optimix Consoles

    3. If there is a shorting block, remove it and start the cutting system again. 4. If J16 is open, replace the control PCB. 9. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. CAN communication troubleshooting for mixing modules in OptiMix consoles...

  • Page 314: Corrective Action

    • There is a bad connection between the small CAN jumper cable for the gas connect console control PCB and the sheet metal panel in the gas connect console. Reconnect the CAN cable, or replace it if necessary. If no... Continue with the next step. 811530 Instruction Manual XPR460...
  • Page 315 There is a possible problem with the mixer in the OptiMix console. Speak to your per second, and the red LED is illumi- cutting machine supplier or regional Hypertherm Technical Service team. nated and not flickering. On the mixer PCB, look for a green LED, a yellow LED, and a red LED that are aligned in a row.

  • Page 316: Can Communication Troubleshooting For Torchconnect Consoles

    3. Make sure that the D43 (+5 VDC) LED and the D46 (+3.3 VDC) LED are illuminated on the control PCB (141334) in the TorchConnect console. 4. Examine D43 (+5 VDC) and D46 (+3.3 VDC) on the control PCB: 811530 Instruction Manual XPR460...

  • Page 317: Can Communication Troubleshooting For Choppers

    Replace the control PCB in the TorchConnect console. For assistance, speak to ering. your cutting machine supplier or regional Hypertherm Technical Service team. 6. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team.

  • Page 318: Symptoms

    CAN. Chopper 2 cannot receive communications (at XPR300, Shut down Remote on-off least once-per-second) from the main control PCB XPR460 through the CAN. Chopper 3 cannot receive communications (at XPR460 Shut down Remote on-off least once-per-second) from the main control PCB through the CAN.
  • Page 319 3. Do a check for 24 VDC on J2 pin 1 and pin 3 for each chopper in the system. 4. If the wiring is good and you continue to get the same diagnostic code, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Each LED is illuminated except for one Replace the chopper control PCB if necessary.

  • Page 320: Troubleshooting For An Ignition Timeout

    Make sure that the CAN cable connector is fully engaged in J7. d. If an LED is not operating correctly, speak to your cutting machine supplier or regional Hypertherm Technical Service team. 7. Make sure that the D33 LED and D34 LED are flickering.

  • Page 321: Troubleshooting For A Pilot Arc Timeout

    1. Make sure that the transfer height is correct. 2. Examine the consumables. 3. Replace consumables that have damage or excess wear. Verification Do a torch lead test. Refer to Do a test for continuity between the nozzle and workpiece on page 301. XPR460 Instruction Manual 811530...

  • Page 322: Troubleshooting For Gas Flow Process Timeouts

    3. Replace any consumables, valves, or inlet hoses that have damage or excess wear. Troubleshooting for low inlet gas pressure Diagnostic codes 530, 531, 533 Diagnostic codes 530, 531, and 533 identify low pressure with the inlet gas supply. 811530 Instruction Manual XPR460...

  • Page 323: Symptoms

    Diagnostic code 532 identifies when the shield water pressure supplied to the cutting system is less than the required range. This condition can cause system shutdown or poor cut quality. Examination of water hoses, fittings, regulators, and possibly the use of a booster water pump can be necessary. XPR460 Instruction Manual 811530...

  • Page 324: Symptoms

    7. Examine water regulators for debris that can block the flow path. 8. Adjust the inlet water pressures to a minimum of 2.77 bar (40 psi) when cutting, if necessary. The Hypertherm-supplied regulator that is connected to the gas connect console is set at the factory. Do not adjust this regulator.

  • Page 325: Symptoms

    PCB. 6. If you cannot get the recommended pressure, or if pressure is within range but the code continues, interchange B2 with B1 or B3, or interchange P14 with a different transducer. XPR460 Instruction Manual 811530...

  • Page 326: Troubleshooting For Low Coolant Flow

    3.79 L/min (1 gal/ min). XPR460: The low coolant flow rate limit is less than 2.5 L/min (0.66 gal/min) when the coolant temper- ature is ≤0°C (≤32°F) or less than 4.9 L/min (1.3 gal/min) when the coolant temperature is ≥40°C...
  • Page 327 0.5 gal/min 15 Hz 3.78 L/min 1.0 gal/min 33 Hz 5.67 L/min 1.5 gal/min 51 Hz 7. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. XPR460 Instruction Manual 811530...

  • Page 328: Troubleshooting For High Coolant Flow

    2. For diagnostic code 543, examine the coolant hoses. a. Make sure that you have Hypertherm-supplied coolant hoses. b. Replace the bad hoses with Hypertherm-supplied coolant hoses, if necessary. 3. For diagnostic code 544, do the following steps to reset the cutting system: a.

  • Page 329: Troubleshooting For Low Current

    Examine the hoses and hose fittings. Look for damage or loose connections. 4. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for low current Diagnostic codes 550, 552 – 554 Diagnostic codes 550 and 552 –...

  • Page 330: Troubleshooting For High Current

    Go to step 8 on page 330. XPR300 or XPR460 Continue with the next step. 7. Interchange the choppers, and make sure that the diagnostic code aligns with the change: a. If yes, the chopper is bad and must be replaced.

  • Page 331: Corrective Action

    Go to step 7 on page 331. XPR300 or XPR460 Continue with the next step. 6. Interchange the choppers and make sure that the diagnostic code aligns with the change: a. If yes, the chopper is bad and must be replaced.

  • Page 332: Symptoms

    Make sure that no objects cause a blockage to the cooler fan inlets. Objects that are very near the cooler can get pulled into the fan inlets. For sufficient ventilation, Hypertherm recommends a minimum separation distance of 1 meter (3.3 feet) between the cooler and other objects or equipment.
  • Page 333 561, 668, 679 Chopper 2 (cold PCB 3 (plasma power supply) J9 pin 1 J9 pin 2 plate) (XPR300 and XPR460 only) 562, 669, 680 Chopper 3 (cold PCB 8 (plasma power supply) J9 pin 1 J9 pin 2 plate) (XPR460 only)

  • Page 334: Ohmic Resistance Values For Thermistors

    The resistance value is outside of Look for a wiring fault. To make a decision on if thermistor replacement is the minimum or maximum value in necessary, speak to your cutting machine supplier or regional Hypertherm Ohmic resistance values for ther- Technical Service team.

  • Page 335: Troubleshooting For Start Switch Faults

    Diagnostic codes 570, 571, 574 – 577 Diagnostic codes 570 – 577 can identify problems with the CNC, PCB, discrete cable, or the D50 LED on the control PCB (PCB 1) in the plasma power supply. XPR460 Instruction Manual 811530...

  • Page 336: Symptoms

    2. Remove the connector from J14 on the rear of the plasma power supply. 3. Supply power to the cutting system. 4. Continue with the next step. 6. Examine D50 on PCB 1 again to find if it stays illuminated: 811530 Instruction Manual XPR460...

  • Page 337: Troubleshooting For Over-Temperature Faults For Inductors And Transformers

    CNC interface cables on page 429. 7. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for over-temperature faults for inductors and transformers Diagnostic codes 580 – 586, 589, 793 These over-temperature diagnostic codes identify when the temperature of the inductors or transformers in the plasma system is more than the permitted range.

  • Page 338: Symptoms

    Corrective action 1. Make sure that there is sufficient clearance around the plasma power supply. For sufficient ventilation, Hypertherm recommends a minimum separation distance of 1 meter (3.3 feet) between the plasma power supply and other objects or equipment. 2. Make sure that the ambient temperature at the location of the plasma power supply is in the permitted temperature range for cutting system operation.
  • Page 339 J1.4 pin 3 J1.4 pin 4 581, 661, 672 Inductor 1B PCB 1 (plasma power supply) J1.4 pin 5 J1.4 pin 6 582, 662, 673 Inductor 2A PCB 1 (plasma power supply) J1.4 pin 7 J1.4 pin 8 XPR460 Instruction Manual 811530...

  • Page 340: Troubleshooting For A Fan Timeout

    The ohmic resistance is outside of Look for a wiring fault. To make a decision on if thermistor replacement is the minimum or maximum value in necessary, speak to your cutting machine supplier or regional Hypertherm Ohmic resistance values for ther- Technical Service team.

  • Page 341: Symptoms

    Channel B Chopper 1 current signature. A catastrophic failure of a consumable part is found XPR300, on the Channel A Chopper 2 current signature. XPR460 A catastrophic failure of a consumable part is found XPR300, on the Channel B Chopper 2 current signature.

  • Page 342: Corrective Action

    Install the consumables on page 149. 3. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for a ramp-down error Diagnostic code 620 Diagnostic code 620 shows that there is a ramp-down error.

  • Page 343: Corrective Action

    Refer to General input power requirements on page 2. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for low DC bus voltage Diagnostic code 622 Diagnostic code 622 occurs when the DC bus voltage is too low.

  • Page 344: Symptoms

    11. If K1 is bad, replace either the power distribution PCB or the K1 relay (003257). 12. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. 811530 Instruction Manual...

  • Page 345: Troubleshooting For Idle Choppers With Current

    10 A. Chopper 2 is in an idle state, and the chopper cur- XPR300, rent is more than 10 A. XPR460 Chopper 3 is in an idle state, and the chopper cur- XPR460 rent is more than 10 A.

  • Page 346: Corrective Action

    3. If the connections are good and the code continues, replace the I/O PCB. 4. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for arc timeouts during the Ignite state Diagnostic code 654 Diagnostic code 654 identifies a problem related to plasma arc timeouts at the start of a cut.

  • Page 347: Symptoms

    3. If an LED is not illuminated, examine the power distribution PCB and look for: a. Loose and poorly connected connectors and CAN cables b. Signs of 120 V (the D1 LED is illuminated) 4. If D1 is illuminated, examine the plasma power supply control PCB. XPR460 Instruction Manual 811530...

  • Page 348: Troubleshooting For Low Inlet Pressure For Hydrogen, Argon, Or Nitrogen

    If necessary, set the remote on-off switch to OFF and then back to ON. 6. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Make sure that you have the record ID for the error.

  • Page 349: Permitted Inlet Pressures To Gas Connect Consoles

    8. Tighten loose connections if found. 9. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Permitted inlet pressures to gas connect consoles Permitted gas inlet pressures to the gas connect console Gas connect console 7.5 bar ±...

  • Page 350: Symptoms

    7. Replace fittings that have damage. 8. Tighten loose connections if found. 9. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for low inlet pressure for water Diagnostic code 701 Diagnostic code 701 occurs because water inlet pressure in the gas connect console is less than the permitted range.

  • Page 351: Symptoms

    5. If the pressure stays too low, examine the gas hoses and gas inlet fittings for: □ Damage or kinks that can restrict flow □ Leaks that can decrease pressure 6. Replace the hoses if you find damage or kinks. XPR460 Instruction Manual 811530...

  • Page 352: Troubleshooting For Shield Gas Inlet Pressure In The Torchconnect Console

    Refer to Shield-water requirements (VWI and OptiMix) on page 11. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for shield gas inlet pressure in the TorchConnect console Diagnostic codes 702 –...

  • Page 353: Corrective Action

    8. Tighten loose connections if found. 9. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Permitted inlet pressures to the TorchConnect console Permitted gas inlet pressures to the TorchConnect console Gas connect console 7.5 bar ±...

  • Page 354: Troubleshooting For Process-Gas Inlet Pressure Faults In The Torchconnect Console For Optimix Systems

    ) and Argon (Ar) gas regulators inside the OptiMix gas connect console are set at Hypertherm before the regulators are installed in the gas connect console. The regulators are set in a dynamic condition, when gas is flowing, with 7.9 bar – 8.6 bar (115 psi – 125 psi) on the inlet and 6.9 bar (100 psi) on the outlet.
  • Page 355 3. Remove the cover from the OptiMix gas connect console. 4. Pull up the N regulator knob until the orange indicator is visible. Nitrogen (N ) regulator knob Argon (Ar) regulator knob 5. Go to Gas System in the XPR web interface. XPR460 Instruction Manual 811530...

  • Page 356: Corrective Action To Adjust The Ar Regulator

    7. While the gas flows, adjust the regulator until the shield inlet sensor (P4) on the web interface is 6.9 bar (100 psi). Troubleshooting for pressure transducer faults Diagnostic codes 706 – 715 Diagnostic codes 706 – 715 identify a problem with a pressure sensor in the TorchConnect console or the gas connect console. 811530 Instruction Manual XPR460...

  • Page 357: Symptoms

    □ If the code shows P6-GCC, examine the P6 pressure transducer in the gas connect console. 3. Make sure that the pressure transducer is correctly connected to: □ TorchConnect console control PCB □ Gas connect console control PCB 4. Install the pressure transducer correctly if you find loose or incorrect connections. XPR460 Instruction Manual 811530...

  • Page 358: Troubleshooting For Invalid Processes

    5. If you find damage, replace the control PCB that has damage. 6. Replace the pressure transducer. 7. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for invalid processes Diagnostic code 716 Diagnostic code 716 occurs when there is a problem with the cut process sent to the CNC.

  • Page 359: 3: Invalid User Source

    1. Wait until gas purge is complete or until cutting is complete. The plasma cutting system cannot accept a new process ID during gas purge or cutting. 2. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. XPR460 Instruction Manual...

  • Page 360: 6: Not Supported

    Refer to: ■ Process selection on page 231 ■ Cut charts on page 232 Troubleshooting flowchart for diagnostic code 716 Refer to these flowcharts for an overview of the troubleshooting process for the 716 diagnostic code. 811530 Instruction Manual XPR460...
  • Page 361 5 seconds. Go to page 2. Did the 716 error go away? You have a timing error. You MUST wait for the XPR to be in the “Ready for Start” state before sending a Start command. XPR460 Instruction Manual 811530...
  • Page 362 Set the XPR back to ON, and measure 24 VDC output. Does the 24 VDC supply now measure Replace the 24 VDC power 24 VDC on the output? supply (229640). There is a 24 VDC system short. Speak to Technical Service. 811530 Instruction Manual XPR460...
  • Page 363 Send a 40 A N2/N2 process (process ID 2015) to the XPR. There is a problem with the process you are trying to select with Do you continue to get a 716 error? your XPR configuration. Speak to Technical Service. XPR460 Instruction Manual 811530...

  • Page 364: Troubleshooting For Duty Cycle Limit On Proportional Valve Supply Voltage

    You can log into the Xnet at to download it. www.hypertherm.com Troubleshooting for pressure out is greater than pressure in Diagnostic code 720 Diagnostic code 720 occurs when the output pressure is more than the input pressure on the mixer. 811530 Instruction Manual XPR460...

  • Page 365: Symptoms

    Ramp down • Set process sum. • Remote on-off There was a failure of the mixing flow calibration. There was a failure of the mixing pressure calibra- tion. There is a problem with the mixing system clock. XPR460 Instruction Manual 811530...

  • Page 366: Corrective Action

    2. Make sure that there is no damage to the ribbon cables that connect the gas mixer control PCB to the flow meters. 3. Make sure that all external panels for all system components are in position and installed correctly. 811530 Instruction Manual XPR460...

  • Page 367: Troubleshooting For Solenoid Valve V1 In The Torchconnect Console

    Troubleshooting for solenoid valves V4 – V12 in the TorchConnect console Diagnostic codes 733 – 741 Diagnostic codes 733 – 741 occur when there is an overcurrent condition for one or more of the V4 – V12 valves in the TorchConnect console. XPR460 Instruction Manual 811530...

  • Page 368: Symptoms

    4. If the code continues, examine the leads, and make sure that the continuity in the leads is good. 5. If the continuity is good and the code continues, replace the control PCB in the TorchConnect console. Fan diagnostic codes diagram Each fan is related to a different diagnostic code. 811530 Instruction Manual XPR460...
  • Page 369 Diagnostics and Troubleshooting Figure 68 - Diagnostic code for each plasma power supply fan Diagnostic code CAB FAN 1 MAGFAN 1 MAGFAN 2 MAGFAN 3 XPR460 Instruction Manual 811530...
  • Page 370 Diagnostics and Troubleshooting Figure 69 - Diagnostic code for each cooler fan Diagnostic code HXFAN 1 HXFAN 2 811530 Instruction Manual XPR460...

  • Page 371: Troubleshooting For Low Fan Speeds - Magfan

    The fan tachometer feedback for MAGFAN 2 is less All models None than the minimum acceptable value. The fan tachometer feedback for MAGFAN 3 is less XPR460 None than the minimum acceptable value. Corrective action 1. Use the Fan diagnostic codes diagram on page 368 to identify the location of the MAGFAN in the plasma power supply.

  • Page 372: Symptoms

    Diagnostics and Troubleshooting For XPR170 and XPR300, the heat exchanger fans are in the plasma power supply. For XPR460, the heat exchanger fans are in the cooler. Symptoms Code Symptoms XPR models XPR action Code cancels with... The fan tachometer feedback for HXFAN 1 is less...

  • Page 373: Symptoms

    Code Symptoms XPR models XPR action Code cancels with... The fan speed for CAB FAN 1 is less than the min- XPR460 None • Set process imum acceptable Revolutions Per Minute (RPM) • Remote on-off value. The fan speed for CAB FAN 1 is less than the mini- XPR170, mum acceptable RPM value.

  • Page 374: Corrective Action

    Power cord 6. Tighten loose connections if found. 7. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for a main contactor fault Diagnostic code 764 Diagnostic code 764 occurs when the current for the main contactor is too high.

  • Page 375: Troubleshooting For An Inrush Contactor Fault

    4. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for a pump-enable fault or remote-relay fault Diagnostic codes 766, 767 Diagnostic codes 766 and 767 occur when there is a fault that is related to the pump solid-state relay.

  • Page 376: Corrective Action

    4. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for gas inlet pressure faults Diagnostic codes 768 – 771 Diagnostic codes 768 – 771 occur when gas inlet pressure is less than the permitted pressure level.

  • Page 377: Corrective Action

    TorchConnect console for OptiMix systems on page 354. 5. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team. Troubleshooting for a pilot relay fault Diagnostic code 777 Diagnostic code 777 occurs when there is a fault related to the pilot relay.

  • Page 378: Safety Consideration For The Xpr460

    Diagnostics and Troubleshooting Safety consideration for the XPR460 For this procedure, make sure that you use the pilot-arc relay, NOT the cooler-power relay. When at least one remote on-off switch is set to OFF (disabled), 220 VAC electric power stays ON (active) to the input side of the cooler-power relay.

  • Page 379: Troubleshooting For High Or Low Chopper Voltage

    The Chopper 2 15 V bus is out of range (less than XPR300, 13 V or more than 17 V). XPR460 The Chopper 3 15 V bus is out of range (less than XPR460 13 V or more than 17 V).

  • Page 380: Symptoms

    3. 5. If there is no voltage on J1 pin 1 and pin 3, examine the red and white wires. 6. If the wires are good, replace the control PCB in the plasma power supply. 811530 Instruction Manual XPR460...

  • Page 381: Pcb Information

    Diagnostics and Troubleshooting PCB information Plasma power supply power distribution PCB (141577) diagram Signal 120 VAC XPR460 Instruction Manual 811530...

  • Page 382: Plasma Power Supply Control Pcb (141545) Diagram

    Diagnostics and Troubleshooting Plasma power supply control PCB (141545) diagram 811530 Instruction Manual XPR460...

  • Page 383: Dip Switch Positions

    RS-422 RX termination – Default is ON RS-422 TX termination – Default is OFF Not used – Default is OFF CAN termination resistor • ON = 121 ohms (Ω) Default is OFF • OFF = Open XPR460 Instruction Manual 811530...
  • Page 384 • Switch 4 = ON • Switch 5 = OFF Redundant remote on-off is set to disabled (OFF) by default, with a jumper across pin 1 and pin 2 of the J27 connector. For more information, 811530 Instruction Manual XPR460...

  • Page 385: Plasma Power Supply Chopper Pcb (141319) Diagram

    Plasma power supply chopper PCB (141319) diagram Signal Signal +15V AND -15V POWER +5 V +3.3 V STATUS OVER CURRENT CHANNEL B ACTIVITY OVER CURRENT CHANNEL A +5VB USB FLAG CAN TX +18V AND -5V POWER CAN RX XPR460 Instruction Manual 811530...

  • Page 386: Plasma Power Supply Start Circuit Pcb (141360) Diagram

    +18V AND -5V POWER Plasma power supply I/O PCB (10085206) diagram Fan power distribution PCB (141384) diagram The fan power distribution PCB is used in the plasma power supply. For the XPR460, this PCB is also used in the cooler. 811530...

  • Page 387: Gas Connect Console Control Pcb (141375) Diagram

    Diagnostics and Troubleshooting Gas connect console control PCB (141375) diagram XPR460 Instruction Manual 811530...

  • Page 388: Gas Connect Console High Frequency Pcb (141563) Diagram

    Diagnostics and Troubleshooting Signal Signal +24 V CAN RX STATUS ACTIVITY USB FLAG +3.3 V +5 V CAN TX A3.3 Gas connect console high frequency PCB (141563) diagram Signal HIGH FREQUENCY ENABLE 811530 Instruction Manual XPR460...

  • Page 389: Torch Connect Console Ohmic Pcb (141368) Diagram

    Diagnostics and Troubleshooting Torch connect console ohmic PCB (141368) diagram Signal Ohmic contact Torch connect console control PCB (141334) diagram XPR460 Instruction Manual 811530...

  • Page 390: Cooler Control Pcb (141524) Diagram

    +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 Cooler control PCB (141524) diagram 811530 Instruction Manual XPR460...

  • Page 391: Cooler Power Distribution Pcb (141573) Diagram

    COOLANT LEVEL HXFAN 1 HXFAN 2 +5 V +3.3 V SIGNAL +24 V +24 V COOLANT FLOW CAN1 RX CAN1 TX CAN2 RX CAN2 TX POWER GROUND Cooler power distribution PCB (141573) diagram Signal 220 VAC   XPR460 Instruction Manual 811530...
  • Page 392 Diagnostics and Troubleshooting 811530 Instruction Manual XPR460...

  • Page 393: Parts List

    Parts List Parts List Plasma power supply parts Part number Voltage (VAC) 078650 078651 078652 078653 078654 078655 078656 XPR460 Instruction Manual 811530...

  • Page 394: Outer Panel Parts

    Outer panel parts Part number Description Quantity 10084227 Top panel with labels 10084228 Side panel with labels and handles 10084230 Front panel with "H" (not shown) and power-indicator LED label 10084229 Rear panel with label and handles 811530 Instruction Manual XPR460...

  • Page 395: Fans

    Coolant connections manifold 015938 Elbow adapter: 3/8 inch NPT X 1/2 inch tube, 45° swivel 10082222 Adapter: 3/8 inch NPT X #6 male BRS 10083877 Green ring: 0.70 inch inner diameter 10083878 Red ring: 0.70 inch inner diameter XPR460 Instruction Manual 811530...

  • Page 396: Coolant Adapters And Manifolds In Plasma Power Supply

    Nut for chopper fitting on the back of the choppers 015815 Elbow fitting: 1/2 inch tube X 1/2 inch tube, 90° on the back of the choppers 528123 Kit: Tubing for plasma power supply Transformers and inductors 811530 Instruction Manual XPR460...

  • Page 397: Control Parts - 1

    380 V, 50 Hz 429147 400 V, 50 Hz 429148 415 V, 50 Hz 429149 440 V, 50 Hz - 60 Hz 429150 480 V, 60 Hz 429151 600 V, 60 Hz 10082243 Start circuit assembly PCB4 XPR460 Instruction Manual 811530...

  • Page 398: Control Parts - 2

    Wire harness and CAN cables in the plasma power supply Part number Description 429117 XPR460 wire harness 223399 CAN cable 0.5 m (1.6 ft) (Located between the choppers.) 223400 CAN cable 1 m (3.3 ft) (Located between the control PCB and chopper.)

  • Page 399: Rear Compartment Of The Plasma Power Supply

    Main contactor assembly (380 V, 400 V, 415 V, 440 V, 480 V, 600 V) 10083630 Strain relief (380 V, 400 V, 415 V, 440 V, 480 V, 600 V) Cooler parts Part number Description 078660 Cooler XPR460 Instruction Manual 811530...

  • Page 400: Cooler Outer Parts

    Parts List Cooler outer parts Part Number Description Quantity 10084232 Cooler top panel 10084231 Cooler side panel 229825 Power-indicator LED 127014 Coolant reservoir cap Cooler interior parts - view 1 811530 Instruction Manual XPR460...

  • Page 401: Cooler Interior Parts - View 2

    Cooler control PCB PCB2 229822 Fan: 890 cfm, 48 VDC, 254 mm (10 inch) diameter HXFAN 1, HXFAN 2 10082471 Coolant hose (1 inch) 141384 Fan power distribution PCB PCB3 Cooler interior parts - view 2 XPR460 Instruction Manual 811530...

  • Page 402: Cooler Interior Parts - View 3

    • Coolant solenoid valve assembly 015815 Elbow fitting: 1/2 inch tube X 1/2 inch tube, 90° Refer to Cooler interior parts - view 3 on page 402 for other locations. Cooler interior parts - view 3 811530 Instruction Manual XPR460...

  • Page 403: Cooler Interior Parts - View 4

    Cooler interior parts - view 2 on page 401 for other locations. Cooler interior parts - view 4 Part Number Description Designator Quantity 10082976 Power source: 48 VDC with bracket 209643 EMI filter 10082942 Coolant reservoir 127853 Cooler heat exchanger XPR460 Instruction Manual 811530...

  • Page 404: Gas Connect Console Parts

    Green ring: 0.50 inch inner diameter 015730 Red ring: 0.50 inch inner diameter Gas connect console parts Part number Description 078631 Core gas connect console 078662 CorePlus gas connect console 078632 VWI gas connect console 078633 OptiMix gas connect console 811530 Instruction Manual XPR460...

  • Page 405: Gas Connect Console High-Voltage Side Parts

    141563 High-frequency, high-voltage ignition PCB Core, CorePlus, VWI, PCB2 OptiMix 141595 Spark gap PCB Core, CorePlus, VWI, – OptiMix 075678 Socket head cap screw: M5 - 0.8 X 10 Core, CorePlus, VWI, – mm hexagonal OptiMix XPR460 Instruction Manual 811530...

  • Page 406: Gas Connect Console Manifold Side Parts

    CorePlus only – This is not a ground wire, and it is not included with the 141375 control PCB. 229825 Green power-indicator LED assembly Core, CorePlus, VWI, – OptiMix 104757 Coolant manifold Core, CorePlus, VWI, – OptiMix 811530 Instruction Manual XPR460...

  • Page 407: Core Gas Connect Console Manifolds And Adapters

    Manifold: Gas output (no adapters) 104802 Manifold: Gas input (no adapters) Push-to-connect adapters 015876 1/4 inch NPT X 1/4 inch tube 015811 1/4 inch NPT X 8 mm tube 015853 Male elbow: 1/4 inch NPT X 5/16 inch tube XPR460 Instruction Manual 811530...

  • Page 408: Coreplus Gas Connect Console Manifolds And Adapters

    3/8 inch NPT X 5/16 inch tube 015811 1/4 inch NPT X 8 mm tube 015909 Male elbow: 1/4 inch NPT X 5/16 inch tube 015907 1/4 inch NPT X 3/8 inch tube Threaded adapters with thread sealant applied 811530 Instruction Manual XPR460...

  • Page 409: Vwi Gas Connect Console Input And Output Manifolds And Adapters

    1/4 inch NPT X RH ‘B’ male (oxygen input) VWI gas connect console input and output manifolds and adapters Part number Description Quantity 229898 Manifold: Gas input (with adapters) 104843 Manifold: Gas output (no adapters) 229844 Water regulator 006157 Check valve Push-to-connect adapters XPR460 Instruction Manual 811530...
  • Page 410 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) 811530 Instruction Manual XPR460...

  • Page 411: Optimix Gas Connect Console Input And Output Manifolds And Adapters

    Check valve Push-to-connect adapters 015905 1/8 inch NPT X 1/4 inch tube 015853 Elbow: 1/4 inch NPT X 5/16 inch tube 015876 1/4 inch NPT X 1/4 inch tube 015907 1/4 inch NPT X 3/8 inch tube XPR460 Instruction Manual 811530...

  • Page 412: Vwi And Optimix Gas Connect Console Mixer, Resonators, Transducers, And Valves

    1/8 inch NPT X #5 To replace the gas input manifold with adapters in an OptiMix gas connect console, contact your cutting machine supplier or regional Hypertherm Customer Service representative. VWI and OptiMix gas connect console mixer, resonators, transducers, and valves...

  • Page 413: Gas Connect Console Wire Harness, Hose Kit, And Can Cables

    P6 - P9 006167 Proportional valve VWI and OptiMix B4, B5 Gas connect console wire harness, hose kit, and CAN cables Part number Description Console Quantity 229718 Wire harness Core, CorePlus 229719 Wire harness 229720 Wire harness OptiMix XPR460 Instruction Manual 811530...

  • Page 414: Torchconnect Console Parts

    CAN cable 0.48 m (1.6 ft) male-female Core, CorePlus, 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 TorchConnect console parts Part number Description 078618 TorchConnect console 811530 Instruction Manual XPR460...

  • Page 415: Torchconnect Console Easyconnect Side

    Torch lead connector 075544 Machine screw: M6 X 10 mm Phillips, pan head 4 (3 shown) Includes the ohmic contact PCB (141368). TorchConnect console – top Part number Description Designator Quantity 428338 Kit: Tubing 006152 Check valve XPR460 Instruction Manual 811530...

  • Page 416: Torchconnect Console Manifold Side - View 1

    141334 Control PCB PCB1 141368 Ohmic contact PCB PCB2 229825 Green power-indicator LED assembly 101366 Bracket 2 (1 shown) 229780 Valve cable 40 mm (1.6 inches) 229800 Valve cable 279.4 mm (11 inches) 229655 Wire harness 811530 Instruction Manual XPR460...

  • Page 417: Torchconnect Console Manifold Side - View 2

    Adapter: 1/4 inch NPT O-ring seal X 8 mm tube 104406 Adapter: 1/8 inch FPT X1/8 inch NPT X1-5/8 inch 006167 Proportional valve B1 - B3 044508 O-ring Use this tool to remove the solenoid valve without removing the control PCB or the pressure transducers. XPR460 Instruction Manual 811530...

  • Page 418: Torchconnect Console Front Adapters And Valves

    015226 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 811530 Instruction Manual XPR460...

  • Page 419: Torch Assembly

    Torch solenoid valve (V1) tool 10080574 XPR consumable tool 429013 XPR electrode torque tool 10083906 Torch assembly, 460 A mild steel consumables 104879 2.25 inch spanner wrench Torch bracket Part number Description 428646 Torch lifter bracket: 2.25 inch diameter sleeve XPR460 Instruction Manual 811530...

  • Page 420: Consumable Starter Kits

    Nozzle: 220 A 420273 Shield: 220 A 420406 Swirl ring: 220 A / 300 A 420276 Electrode: 300 A 420279 Nozzle: 300 A 420491 Shield: 300 A 420406 Swirl ring: 300 A 420834 Electrode: 460 A 811530 Instruction Manual XPR460...

  • Page 421: Mild Steel Consumable Starter Kit With Torch (10083905)

    420249 Electrode: 130 A 420252 Nozzle: 130 A 420255 Shield: 130 A 420261 Nozzle: 170 A 420258 Electrode: 170 A 420513 Shield: 170 A 420260 Swirl ring: 170 A 420276 Electrode: 220 A / 300 A XPR460 Instruction Manual 811530...

  • Page 422: Other Consumable And Torch Parts

    Nozzle retaining cap 104879 2.25 inch spanner wrench 10080574 XPR consumable tool 027055 Silicone lubricant, 1/4 ounce Other consumable and torch parts Part number Description 004630 Pit depth gauge 004629 Gauge point 027055 Silicone lubricant, 1/4 ounce 811530 Instruction Manual XPR460...

  • Page 423: Cable, Hose, And Lead Parts

    10082635 60 m (196.9 feet) 10083786 4.5 m (14.8 feet) 10082636 75 m (246.1 feet) 10083787 7.5 m (24.6 feet) 3 m (9.8 feet)  1 10084183 10083788 10 m (32.8 feet) 4.5 m (14.8 feet) 10084184 XPR460 Instruction Manual 811530...

  • Page 424: Power Cable, 120 Vac

    75 m (246.1 feet) 223445 20 m (65.6 feet) Power cables, 220 VAC These power cables are 7-position, male-female, 220 VAC cables. Part number Length Part number Length 10083764 3.05 m (10 feet) 10083765 4.57 m (15 feet) 811530 Instruction Manual XPR460...

  • Page 425: Coolant-Hose Assemblies (Cooler To Gas Connect Console)

    20 m (65.6 feet) Coolant-hose assemblies (cooler to plasma power supply) Part number Length Part number Length 10083243 3 m (9.8 feet) 10083794 4.5 m (14.8 feet) CAN cables CAN cables are 5-position, male-female. Two CAN cables are necessary. XPR460 Instruction Manual 811530...

  • Page 426: Pilot-Arc And Coolant Assemblies (Core, Coreplus)

    Part number Length Part number Length 428464 3 m (9.8 feet) 428468 10 m (32.8 feet) 428465 4.5 m (14.8 feet) 428469 15 m (49.2 feet) 428466 6 m (19.7 feet) 428467 7.5 m (24.6 feet) 811530 Instruction Manual XPR460...

  • Page 427: Power, Can, And 4-Gas Assemblies (Coreplus)

    3 m (9.8 feet) 428357 10 m (32.8 feet) 428354 4.5 m (14.8 feet) 428358 15 m (49.2 feet) 428355 6 m (19.7 feet) 428356 7.5 m (24.6 feet) Power, CAN, and 5-gas assemblies (VWI, OptiMix) XPR460 Instruction Manual 811530...

  • Page 428: Ethercat Cnc Interface Cables

    2.5 m (8.2 feet) 223515 30 m (98.4 feet) 223509 3 m (9.8 feet) 223516 45 m (147.6 feet) 223510 6 m (19.7 feet) 223517 60 m (196.9 feet) 223511 7.5 m (24.6 feet) 223714 75 m (246.1 feet) 811530 Instruction Manual XPR460...

  • Page 429: Discrete Cnc Interface Cables

    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) Discrete cables for the expansion PCB XPR460 Instruction Manual 811530...

  • Page 430: Serial Cnc Interface Cables

    12 m (39.4 feet) 223687 37.5 m (123 feet) 223679 13.5 m (44.3 feet) 223688 45 m (147.6 feet) 223680 15 m (49.2 feet) 223689 60 m (196.9 feet) 223681 16.5 m (54.1 feet) 223690 75 m (246.1 feet) 811530 Instruction Manual XPR460...

  • Page 431: Work Cables

    Part number Length Part number Length 428383 2 m (6.6 feet) 428386 3.5 m (11.5 feet) 428384 2.5 m (8.2 feet) 428824 4 m (13.1 feet) 428385 3 m (9.8 feet) 428387 4.5 m (14.8 feet) XPR460 Instruction Manual 811530...

  • Page 432: Bevel Torch Leads

    124007 15 m (49.2 feet) 124012 60 m (196.9 feet) 124008 20 m (65.6 feet) 124013 75 m (246.1 feet) Nitrogen or Argon hoses (black) The nitrogen or argon hose has RH type "B" male fittings. 811530 Instruction Manual XPR460...

  • Page 433: Air Hoses (Black)

    Part number Length Part number Length 124036 3 m (9.8 feet) 124042 25 m (82 feet) 124037 4.5 m (14.8 feet) 124110 30 m (98.4 feet) 124038 7.5 m (24.6 feet) 124043 35 m (114.8 feet) XPR460 Instruction Manual 811530...

  • Page 434: Water (Optional Shield Fluid) Hoses (Blue)

    Part number Description 428639 Kit: Filter, torch rebuild without coolant 428640 Kit: Filter, torch rebuild with coolant 428920 Kit: Shield-fluid treatment 10083902 Kit: Electronics (200 V - 240 V) 10083903 Kit: Electronics (380 V - 600 V) 811530 Instruction Manual XPR460...

  • Page 435: Tools

    XPR electrode torque tool 1-13897 (Hypertherm Waterjet part number) TDS meter Recommended spare parts Plasma power supply – recommended spare parts Hypertherm recommends that you keep these parts available for the plasma power supply. Part number Description Designator Quantity 428810...

  • Page 436: Cooler - Recommended Spare Parts

    Coolant  1 Refer to Calculations for total coolant volume estimates on page 263. Gas connect consoles – recommended spare parts Hypertherm recommends that you keep these parts available for the gas connect consoles. Part number Description Designator Quantity 011110 Air filter element...

  • Page 437: Torchconnect Console - Recommended Spare Parts

    Parts List TorchConnect console – recommended spare parts Hypertherm recommends that you keep these parts available for the TorchConnect console. Part number Description Designator Quantity 141368 Ohmic contact PCB PCB2 223477 Pressure transducer with wire and connector P1 - P5, P14...
  • Page 438 Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep nonquali- fied personnel and children away. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn.   811530 Instruction Manual XPR460...

  • Page 439: Wiring Diagrams

    These symbols are used in the wiring diagrams to represent elements of the plasma cutting system and torch. Battery Ground clamp Receptacle Cap, polarized Ground, chassis Relay, coil Cap, not polarized Ground, earth Relay, normally closed XPR460 Instruction Manual 811530...
  • Page 440 Zener diode throw NO/off Switch, 1 pole, 2 Transformer throw, center off Switch, tempera- Transformer, air ture, core normally closed Switch, tempera- Transformer, coil ture, normally open Terminal block Triac Time delay closed, VAC source NC/off 811530 Instruction Manual XPR460...

  • Page 441: Torch Symbols

    192. On this screen you can see which valves are active when the gas is flowing. Active valves are indicated with a gray highlight. On the Gas System screen, enable the desired mode (Test Preflow, Test Pierceflow, or Test XPR460 Instruction Manual 811530...

  • Page 442: Valve States By Process Id

    Cutflow) for the process you want to view. Valve states by process ID The table shows whether the valve is active (ON) or inactive (OFF) for different types of blocks (preflow, cutflow, piercing) and gases in certain processes. 811530 Instruction Manual XPR460...
  • Page 443 Block type Preflow /Air Cutflow /Air Piercing /Air Process IDs: 7001, 7004, 7005, 7007, 7008, 7009, 7010, 7011, 7012, 7013, 7018, 7020 Block type Preflow /Air Cutflow Piercing /Air Process IDs: 8001 Block type Preflow Cutflow Piercing Instruction Manual 811530 XPR460...
  • Page 444 Ar/Air Cutflow Ar/Air Piercing Ar/Air Process IDs: 2051, 2054, 2057, 2100, 8004, 8005, 8006 Block type Preflow Cutflow Piercing Process IDs: 2010, 2011, 2028, 2029, 2052, 2055, 2058 Block type Preflow /H2O Cutflow /H2O Piercing /H2O 811530 Instruction Manual XPR460...
  • Page 445 Mix/N Process IDs: 1201, 1203, 1206, 1251, 1252, 1253, 1254, 1255, 1281, 1282, 1283, 1284, 1285, 1286, 1287 Block type Preflow /Air Cutflow /Air Piercing /Air Process IDs: 1051, 7014, 7015 Block type Preflow Cutflow Piercing Instruction Manual 811530 XPR460...
  • Page 446 Process IDs: 1101, 1102 Block type Preflow /Air Cutflow /Air Piercing /Air Process IDs: 1103, 1104, 1105, 1106, 1107 Block type Preflow /Air Cutflow /Air Piercing /Air Process IDs: 7002, 7003, 7006 Block type Preflow /Air Cutflow Piercing /Air 811530 Instruction Manual XPR460...
  • Page 447 Process IDs: 2001, 2002, 2003, 2004, 2005 Block type Preflow Cutflow F5/N Piercing F5/N 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 Instruction Manual 811530 XPR460...
  • Page 448 Preflow /Air Cutflow Air/Air Piercing Air/Air Process IDs: 2020, 2021, 2022, 2023 Block type Preflow Cutflow F5/N Piercing F5/N Process IDs: 9004, 9005, 9006, 9014, 9015, 9016, 9017 Block type Preflow Ar/N Cutflow Ar/N Piercing Ar/N 811530 Instruction Manual XPR460...
  • Page 449 Table 36 - Valve states by process ID (continued) Process IDs: 8007, 8010 Block type Preflow /Air Cutflow /Air Piercing /Air Process IDs: 9007, 9019 Block type Preflow Ar/Air Cutflow Ar/Air Piercing Ar/Air Process IDs: 9008 Block type Preflow Ar/Air Cutflow Ar/Air Piercing Ar/N Instruction Manual 811530 XPR460...
  • Page 450 Table 36 - Valve states by process ID (continued) Process IDs: 9002, 9003, 9009 Block type Preflow Ar/N Cutflow Ar/N Piercing Ar/N Process IDs: 1202, 1204 Block type Preflow Cutflow Piercing Process IDs: 2027, 2101 Block type Preflow /Air Cutflow Air/Air Piercing Air/Air 811530 Instruction Manual XPR460...
  • Page 451 Wiring Diagrams Table 36 - Valve states by process ID (continued) Process IDs: 8002 Block type Preflow Cutflow Piercing Process IDs: 1205 Block type Preflow Cutflow Piercing Process IDs: 1207 Block type Preflow /Air Cutflow /Air Piercing Instruction Manual 811530 XPR460...
  • Page 452 Process IDs: 9011, 9012, 9013 Block type Preflow Ar/N Cutflow Ar/N Piercing Ar/N Process IDs: 1060, 1061, 7016, 7017 Block type Preflow /Air Cutflow /Air Piercing /Air Process IDs: 1157 Block type Preflow /Air Cutflow /Air Piercing 811530 Instruction Manual XPR460...
  • Page 453 Table 36 - Valve states by process ID (continued) Process IDs: 7019 Block type Preflow Cutflow Piercing /Air Process IDs: 1288 Block type Preflow /Air Cutflow /Air Piercing Process IDs: 1289 Block type Preflow /Air Cutflow Piercing Instruction Manual 811530 XPR460...
  • Page 454 Table 36 - Valve states by process ID (continued) Process IDs: 2071, 2073, 2075 Block type Preflow Cutflow Mix/N Piercing Mix/N Process IDs: 2072, 2074 Block type Preflow Cutflow Mix/N Piercing Mix/Ar Process IDs: 2076 Block type Preflow Cutflow Mix/Ar Piercing Mix/Ar 811530 Instruction Manual XPR460...
  • Page 455 Wiring Diagrams Table 36 - Valve states by process ID (continued) Process IDs: 8011 Block type Preflow Cutflow Piercing Process IDs: 9020, 9021 Block type Preflow Ar/N Cutflow Ar/N Piercing Ar/N Instruction Manual 811530 XPR460...

  • Page 456: Overview (Sheet 1 Of 25)

    Wiring Diagrams Overview (Sheet 1 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 457 Wiring Diagrams This page is blank.
  • Page 458 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 459: Plasma Power Supply 1 (Sheet 2 Of 25)

    Wiring Diagrams Plasma power supply 1 (Sheet 2 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 460 Wiring Diagrams This page is blank.
  • Page 461 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 462: Plasma Power Supply 2 (Sheet 3 Of 25)

    Wiring Diagrams Plasma power supply 2 (Sheet 3 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 463 Wiring Diagrams This page is blank.
  • Page 464 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 465: Plasma Power Supply 3 (Sheet 4 Of 25)

    Wiring Diagrams Plasma power supply 3 (Sheet 4 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 466 Wiring Diagrams This page is blank.
  • Page 467 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 468: Plasma Power Supply 4 (Sheet 5 Of 25)

    Wiring Diagrams Plasma power supply 4 (Sheet 5 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 469 Wiring Diagrams This page is blank.
  • Page 470 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 471: Plasma Power Supply 5 (Sheet 6 Of 25)

    Wiring Diagrams Plasma power supply 5 (Sheet 6 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 472 Wiring Diagrams This page is blank.
  • Page 473 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 474: Plasma Power Supply 6 (Sheet 7 Of 25)

    Wiring Diagrams Plasma power supply 6 (Sheet 7 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 475 Wiring Diagrams This page is blank.
  • Page 476 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 477: Plasma Power Supply 7 (Sheet 8 Of 25)

    Wiring Diagrams Plasma power supply 7 (Sheet 8 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 478 Wiring Diagrams This page is blank.
  • Page 479 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 480: Gas Connect Console 1 (Sheet 9 Of 25)

    Wiring Diagrams Gas connect console 1 (Sheet 9 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 481 Wiring Diagrams This page is blank.
  • Page 482 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 483: Gas Connect Console 2 (Sheet 10 Of 25)

    Wiring Diagrams Gas connect console 2 (Sheet 10 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 484 Wiring Diagrams This page is blank.
  • Page 485 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 486: Torchconnect Console (Sheet 11 Of 25)

    Wiring Diagrams TorchConnect console (Sheet 11 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 487 Wiring Diagrams This page is blank.
  • Page 488 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 489: Cooler (Sheet 12 Of 25)

    Wiring Diagrams Cooler (Sheet 12 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 490 Wiring Diagrams This page is blank.
  • Page 491 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 492: Coolant System 1 (Sheet 13 Of 25)

    Wiring Diagrams Coolant system 1 (Sheet 13 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 493 Wiring Diagrams This page is blank.
  • Page 494 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 495: Coolant System 2 (Sheet 14 Of 25)

    Wiring Diagrams Coolant system 2 (Sheet 14 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 496 Wiring Diagrams This page is blank.
  • Page 497 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 498: Gas System 1 Core (Sheet 15 Of 25)

    Wiring Diagrams Gas system 1 Core (Sheet 15 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 499 Wiring Diagrams This page is blank.
  • Page 500 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 501: Gas System 2 Coreplus (Sheet 16 Of 25)

    Wiring Diagrams Gas system 2 CorePlus (Sheet 16 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 502 Wiring Diagrams This page is blank.
  • Page 503 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 504: Gas System 3 Vwi (Sheet 17 Of 25)

    Wiring Diagrams Gas system 3 VWI (Sheet 17 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 505 Wiring Diagrams This page is blank.
  • Page 506 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 507: Gas System 4 Optimix (Sheet 18 Of 25)

    Wiring Diagrams Gas system 4 OptiMix (Sheet 18 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 508 Wiring Diagrams This page is blank.
  • Page 509 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 510: Ethercat Multi-Drop (Multi-System) Interface (Sheet 19 Of 25)

    Wiring Diagrams EtherCAT multi-drop (multi-system) interface (Sheet 19 of This page is blank. 811530 Instruction Manual XPR460...
  • Page 511 Wiring Diagrams This page is blank.
  • Page 512 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 513: Serial Rs-422 And Discrete Multi-Drop (Multi-System) Interface (Sheet 20 Of 25)

    Wiring Diagrams Serial RS-422 and discrete multi-drop (multi-system) interface (Sheet 20 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 514 Wiring Diagrams This page is blank.
  • Page 515 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 516: Discrete Multi-Drop (Multi-System) Interface (Sheet 21 Of 25)

    Wiring Diagrams Discrete multi-drop (multi-system) interface (Sheet 21 of This page is blank. 811530 Instruction Manual XPR460...
  • Page 517 Wiring Diagrams This page is blank.
  • Page 518 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 519: Ethercat Connection To Edge Connect (Sheet 22 Of 25)

    Wiring Diagrams EtherCAT connection to EDGE Connect (Sheet 22 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 520 Wiring Diagrams This page is blank.
  • Page 521 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 522: Discrete And Serial Rs-422 Cnc Connections (Sheet 23 Of 25)

    Wiring Diagrams Discrete and serial RS-422 CNC connections (Sheet 23 of This page is blank. 811530 Instruction Manual XPR460...
  • Page 523 Wiring Diagrams This page is blank.
  • Page 524 Wiring Diagrams 811530 Instruction Manual XPR460...

  • Page 525: Discrete Cnc Connections (Sheet 24 Of 25)

    Wiring Diagrams Discrete CNC connections (Sheet 24 of 25) This page is blank. XPR460 Instruction Manual 811530...
  • Page 526 Wiring Diagrams This page is blank.
  • Page 527 Wiring Diagrams XPR460 Instruction Manual 811530...

  • Page 528: Wireless Subsystem Block Diagram (Sheet 25 Of 25)

    Wiring Diagrams Wireless subsystem block diagram (Sheet 25 of 25) This page is blank. 811530 Instruction Manual XPR460...
  • Page 529 Wiring Diagrams This page is blank.
  • Page 530 Wiring Diagrams 811530 Instruction Manual XPR460...
  • Page 531 Wiring Diagrams This page is blank. XPR460 Instruction Manual 811530...
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