Hypertherm XPR170 Maintenance Manual

Torch Rebuild and Filter Replacement Kit
Maintenance Guide
XPR170 / XPR300
®
READ THE SAFETY INFORMATION
Rebuild the torch
Before operating or maintaining any Hypertherm equipment, read the Safety and Compliance Manual
(80669C) for important safety information.
1. Turn OFF the power to the system.
You can find the Safety and Compliance Manual in the "Documents library" at www.hypertherm.com.
Rebuild the torch
Rebuild the torch
2. Remove the quick-disconnect torch from the quick-discon
1. Turn OFF the power to the system.
1. Turn OFF the power to the system.
2. Remove the quick-disconnect torch from the quick-disconnect receptacle.
2. Remove the quick-disconnect torch from the quick-disconnect receptacle.
3. Remove the consumables.
3. Remove the consumables.
3. Remove the consumables.
4. Replace the following parts:
•
(1) water tube
Œ
•
Insert the tube until it comes to a stop.
When correctly installed, the water tube can
seem loose. Any side-to-side looseness will
disappear after electrode installation.
•
(2) O-rings on the front of the torch

4. Replace the following parts:
4. Replace the following parts:
body
•
Apply a thin layer of silicon lubricant to each
•
(1) water tube
•
new O-ring before you install it. The O-rings should look
(1) water tube
shiny, but there should not be too much lubricant.
•
Insert the tube until it comes to a stop.
•
(3) bullet connectors
•
Insert the tube until it comes to a stop.
When correctly installed, the water tube can
coolant-in connection
seem loose. Any side-to-side looseness will
A. Use pliers to pull the old bullet connectors
When correctly installed, the water tube can
straight out.
disappear after electrode installation.
seem loose. Any side-to-side looseness will
B. Apply a thin layer of lubricant to the new
O-ring.
•
(2) O-rings
disappear after electrode installation.
C. Carefully install the O-ring onto the
body
coolant-in connector.
•
D. Install the new bullet connectors. Make sure each new
(2) O-rings
•
Apply a thin layer of silicon lubricant to each
bullet connector is fully seated and has 2 O-rings.
Apply a thin layer of lubricant to each O-ring. Do not
new O-ring before you install it. The O-rings should look
body
use tools to push the connectors into the slots. This
shiny, but there should not be too much lubricant.
can damage the connectors.
•
Apply a thin layer of silicon lubricant to each
•
O-ring on the

•
(3) bullet connectors
quick-disconnect
new O-ring before you install it. The O-rings should look
receptacle
coolant-in connection
•
Do not lubricate this O-ring.
shiny, but there should not be too much lubricant.
A. Use pliers to pull the old bullet connectors
5. Examine the consumables,
straight out.
and remove any contamination.
•
(3) bullet connectors
6. Install the consumables. Use the 429013 tool to tighten
B. Apply a thin layer of lubricant to the new
the electrode to the correct torque.
coolant-in connection
O-ring.
•
This tool is not included in the kit.
429013
C. Carefully install the O-ring onto the
A. Use pliers to pull the old bullet connectors
2.3 N·m – 2.8 N·m
(20 lbf·in – 25 lbf·in)
coolant-in connector.
straight out.
D. Install the new bullet connectors. Make sure each new
B. Apply a thin layer of lubricant to the new
bullet connector is fully seated and has 2 O-rings.
Apply a thin layer of lubricant to each O-ring. Do not O-ring.
use tools to push the connectors into the slots. This
C. Carefully install the O-ring onto the
can damage the connectors.
coolant-in connector.
7. Assemble the quick-disconnect torch and receptacle. •
O-ring

quick-disconnect
D. Install the new bullet connectors. Make sure each new
receptacle
bullet connector is fully seated and has 2 O-rings.
•
Make sure to correctly align the torch and receptacle.
•
Do not lubricate this O-ring.
Apply a thin layer of lubricant to each O-ring. Do not
•
Make sure that there is no space between the torch body
and the O-ring on the torch quick-disconnect receptacle.
5. Examine the consumables,
use tools to push the connectors into the slots. This
and remove any contamination.
can damage the connectors.
Correct
6. Install the consumables. Use the 429013 tool to tighten
•
O-ring
the electrode to the correct torque.
8. Turn ON the power to the system.
quick-disconnect
•
This tool is not included in the kit.
Replace the air filter element
receptacle
•
Do not lubricate this O-ring.
5. Examine the consumables,
and remove any contamination.
Gas connect console
1. Turn OFF the power to the system.
6. Install the consumables. Use the 429013 tool to tighten
2. Turn OFF the supply gases.
the electrode to the correct torque.
3. Remove the filter housing
4. Remove the filter
bowl .
 •
This tool is not included in the kit.
5. Remove the filter
element from the
Ž
filter bowl and from
7. Assemble the quick-disconnect torch and receptacle.
the plastic fittings .

Discard the filter
element, but set aside
the fittings.
6. Remove water and debris from the filter bowl. Make
sure that the bowl is clean.
7. Install the new filter element in the filter bowl. Use the
•
Make sure to correctly align the torch and receptacle.
plastic fittings that you removed in step 5.
•
Make sure that there is no space between the torch body
8. Apply a thin layer of silicone lubricant to the O-ring
around the top of the filter bowl.
and the O-ring on the torch quick-disconnect receptacle.
•
The O-ring should look shiny, but there should not be too
much lubricant.
9. Install the filter bowl and the filter housing.
10. Turn ON the supply gases.
11. Turn ON the power to the system.
8. Turn ON the power to the system.
7. Assemble the quick-disconnect torch and receptacle.
Replace the air filter element
•
Make sure to correctly align the torch and receptacle.
•
Make sure that there is no space between the torch body
and the O-ring on the torch quick-disconnect receptacle.
1. Turn OFF the power to the system.
2. Turn OFF the supply gases.
3. Remove the filter housing
4. Remove the filter
8. Turn ON the power to the system.
bowl .

5. Remove the filter
element
Ž
Replace the air filter element
filter bowl and from
the plastic fittings
Discard the filter
element, but set aside
the fittings.
6. Remove water and debris from the filter bowl. Make
sure that the bowl is clean.
7. Install the new filter element in the filter bowl. Use the
plastic fittings that you removed in step 5.
8. Apply a thin layer of silicone lubricant to the O-ring
around the top of the filter bowl.
•
The O-ring should look shiny, but there should not be too
1. Turn OFF the power to the system.
much lubricant.
2. Turn OFF the supply gases.
9. Install the filter bowl and the filter housing.
10. Turn ON the supply gases.
3. Remove the filter housing
11. Turn ON the power to the system.
4. Remove the filter
bowl

5. Remove the filter
element
filter bowl and from
the plastic fittings
Discard the filter
element, but set aside
the fittings.
6. Remove water and debris from the filter bowl. Make
sure that the bowl is clean.
7. Install the new filter element in the filter bowl. Use the
plastic fittings that you removed in step 5.
8. Apply a thin layer of silicone lubricant to the O-ring
around the top of the filter bowl.
•
The O-ring should look shiny, but there should not be too
much lubricant.
9. Install the filter bowl and the filter housing.
10. Turn ON the supply gases.
11. Turn ON the power to the system.
READ THE SAFETY INFORMATION
Before operating or maintaining any Hyperthe
®
(80669C) for important safety information.
You can find the Safety and Compliance Man
READ THE SAFETY INFORMATION
Before operating or maintaining any Hypertherm equipment, rea
(80669C) for important safety information.
You can find the Safety and Compliance Manual in the "Docume
Œ

Œ
Œ
and (1) O-ring on the
Ž 

on the front of the torch

on the front of the torch

and (1) O-ring
Ž
on the
Incorrect
on the

429013
Œ
2.3 N·m – 2.8 N·m
(20 lbf·in – 25 lbf·in)
.
Œ
Œ
Ž
429013

2.3 N·m – 2.8 N·m
(20 lbf·in – 25 lbf·in)
Correct
Gas connect console
Correct
Œ
from the
.

Gas connect console
.
from the
Ž

WARNING!
Replace the coolant filter element
1. Turn OFF the power to the system.
2. Remove the filter housing
Œ
Ž
3. Discard the old coolant from the housing.
4. Remove and discard the filter element
5. Remove debris from the housing.
6. Install the new filter element
7. Install the housing.
8. Turn ON the power to the system.
Replace all of the coolant
1. Turn OFF the power to the system.


2. Connect a 3/8-inch inner diameter tube to the outlet of
the valve on the bottom of the reservoir. Put the other
end of the tube into an empty container.
3. Open the valve on the bottom of the reservoir. Remove
the cap on the reservoir fill port inlet to allow the
and (1) O-ring
coolant to flow out.
Ž

4. Remove the coolant return hose (red band) from the
rear of the power supply.
5. Attach compressed air (no
more than 6.89 bar/100 psi) to
the fitting where the hose (red
band) was connected.
6. For no more than 30 seconds,
blow the coolant into the
reservoir and filter housing.
7. Close the valve at the bottom
of the reservoir and remove the
3/8-inch tube from the valve
outlet.
8. Leave the coolant return hose (red band) disconnected.
9. Put a container under the coolant pump plug.
10. Remove the plug and coolant
pump screen. Set them aside.
11. Remove the coolant supply
hose (green band) from the
rear of the plasma power
supply.
12. Attach compressed air (no
more than 3.45 bar/50 psi)
to the fitting where the hose
(green band) was connected.
13. For no more than 30 seconds,
blow all of the coolant into the
container.
14. Leave the coolant supply hose
(green band) disconnected.
15. Examine the coolant pump
screen. Rinse it with clean water if you find debris or
replace it if you find damage.
16. Install the coolant pump screen.
17. Wipe the O-ring on the plug. Make sure that the O-ring
is free of debris, cracks, and nicks. Replace it if you find
damage.
18. Install the plug on the coolant pump housing.
19. If you have not done so already, replace the coolant
filter (see "Replace the coolant filter element" in this
guide).

20. Put the disconnected end of the return hose (red band)
into an empty container.
21. Attach compressed air (no more than 6.89 bar/100 psi)
to the disconnected end of the supply hose (green
band).
22. For approximately 3 minutes, blow air into the supply
hose (green band) fitting to force coolant out of the
return hose (red band) and into the container.
23. After 3 minutes, look for coolant flow out of the return
hose (red band).
•
Repeat steps 22 and 23 until flow from the coolant return
hose (red band) stops.
24. When the flow stops, connect both hoses (red and
green bands) to the rear of the plasma power supply.
Install new coolant
1. To choose the correct coolant, see "Coolant
requirements" in the XPR170 Instruction Manual
Incorrect
(810060) or the XPR300 Instruction Manual
(809480).
2. To install the new coolant, see "Coolant installation"
in the XPR170 Instruction Manual (810060) or the
XPR300 Instruction Manual (809480).
Œ
XPR and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States
and/ or other countries. All other trademarks are the property of their respective holders.
© 2/2022 Hypertherm, Inc. 80980C Revision 2
.
Œ
Ž

Œ
.
Œ
Œ
.
2/2022
WARNING!
.
Œ
Œ

.
Ž
on the
Ž
on the



Incorrect

Ž

80980C Revision 2
Replace the
1. Turn OFF th
2. Remove the
Œ
 Ž
.

Œ

3. Discard the
4. Remove an
Ž
5. Remove de
6. Install the n
7. Install the h
Green
8. Turn ON th
Red
Replace all o
1. Turn OFF th
2. Connect a
the valve on
end of the t
3. Open the v
the cap on
coolant to fl

4. Remove the
rear of the p
5. Attach com
more than 6
the fitting w
band) was
6. For no more
blow the co
reservoir an
7. Close the v
of the reser
3/8-inch tu
outlet.
8. Leave the c
9. Put a conta
10. Remove the
pump scree
11. Remove the
hose (green
rear of the p
supply.
12. Attach com
more than 3
to the fitting
(green band
13. For no more
blow all of t
container.
14. Leave the c
(green band
15. Examine the
screen. Rin
replace it if
16. Install the c
17. Wipe the O
is free of de
damage.
18. Install the p
19. If you have
filter (see "R
guide).
20. Put the disc
into an emp
21. Attach com
to the disco
band).
22. For approxi
hose (green
return hose
23. After 3 minu
hose (red b
•
Repeat s
hose (red
24. When the fl
green band
Install new coo
1. To choose t
requiremen
(810060) o
(809480).
2. To install th

in the XPR1
XPR300 In
XPR and Hypertherm are
and/ or other countries. All
© 2/2022 Hypertherm, In