Hypertherm Mechanized Family Instruction Manual (IM)

XPR170™

Instruction Manual

810060 – REVISION 7

LISH

ENG

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XPR, HyDefinition, True Hole, Sensor THC, EasyConnect, TorchConnect, TrueBevel, ProNest, LongLife, Arc Response
Technology, Core, CorePlus, OptiMix, VWI, X-Definition, and Hypertherm are trademarks of Hypertherm, Inc. and may be
registered in the United States and other countries. All other trademarks are the property of their respective holders.

Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We
are striving to reduce the environmental impact of everything we do. For more information:www.hypertherm.com/environment.

© 2019–2022 Hypertherm, Inc.

XPR1

70

Instruction Manual

810060

REVISION 7

ENGLISH

Original instructions

December 2022

Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm, Inc.

21 Great Hollow Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[e-mail] (Main Office)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel
52 55 5681 7978 Tel
[e-mail] (Technical Service)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail] (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164
164 Kallang Way #03-13
Singapore 349248, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[e-mail] (Marketing)
[e-mail] (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm Europe B.V.

Laan van Kopenhagen 100
3317 DM Dordrecht
Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail] (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

[e-mail] (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[e-mail] (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[e-mail] (Marketing)
[e-mail] (Technical Service)

Hypertherm Pty Limited

GPO Box 4836
Sydney NSW 2001, Australia
61 7 3103 1695 Tel
61 7 3219 9010 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at

www.hypertherm.com/hci.

ENGLISH

WARNING! Before operating any Hypertherm equipment, read the safety
instructions in your product’s manual, the Safety and Compliance Manual (80669C),

Waterjet Safety and Compliance Manual (80943C), and Radio Frequency Warning
Manual (80945C). Failure to follow safety instructions can result in personal injury

or in damage to equipment.
Copies of the manuals can come with the product in electronic and printed formats.

Electronic copies are also on our website. Many manuals are available in multiple
languages at www.hypertherm.com/docs.

FR (FRANÇAIS/FRENCH)

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes
de sécurité dumanuel de votre produit, duManuel de sécurité et de conformité
(80669C), du Manuel de sécurité et de conformité du jet d’eau (80943C)
et du Manuel d'avertissement relatif aux radiofréqunces (80945C).

Les exemplaires des manuels qui accompagnent le produit peuvent être sous forme
électronique ou papier. Les manuels sous forme électronique se trouvent également
sur notre site Internet. Plusieurs manuels sont offerts en plusieurs langues
à www.hypertherm.com/docs.

BG (БЪЛГAPCКИ/BULGARIAN)

ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване
Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия
продукт, „Инструкция за безопасност и съответствие“ (80669C), „Инструкция
за безопасност и съответствие на Waterjet“ (80943С) и „Инструкция
за предупреждение за радиочестота“ (80945С).

Продуктът може да е съпроводен от копия на ръководствата в електронен
и в печатен формат. Тези в електронен формат са достъпни също на уебсайта
ни. Много ръководства са налице на няколко езика
на адрес www.hypertherm.com/docs.

CS (ČESKY/CZECH)

VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu si přečtěte
bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost

a dodržování předpisů (80669C), Manuálu pro bezpečnost a dodržování
předpisů při řezání vodním paprskem (80943C) a Manuálu varování ohledně
rádiových frekvencí (80945C).

Kopie příruček mohou být součástí dodávky produktu, a to v elektronické i tištěné
formě. Elektronické kopie jsou k dispozici i na našich webových stránkách. Mnoho
příruček je k dispozici v různých jazycích na stránce www.hypertherm.com/docs.

DA (DANSK/DANISH)

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne
i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C),
Manual om sikkerhed og overholdelse af krav for vandstråleskæring (80943C),
og Manual om radiofrekvensadvarsel (80945C), gennemlæses.

Kopier af manualerne kan leveres med produktet i elektronisk og trykt format.
Elektroniske kopier findes også på vores hjemmeside. Mange manualer
er tilgængelige på flere sprog på www.hypertherm.com/docs.

DE (DEUTSCH/GERMAN)

WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die
Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit

und Übereinstimmung (80669C), das Handbuch für Sicherheit und Compliance bei
Wasserstrahl-Schneidanlagen (80943C) und das Handbuch für Hochfrequenz­Warnung (80945C).

Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form
oder als Druckversion beiliegen. In elektronischer Form liegen sie auch auf unserer
Website vor. Viele Handbücher stehen in verschiedenen Sprachen auf

www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH)

¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea las
instrucciones de seguridad del manual de su producto, del Manual de seguridad

y cumplimiento (80669C), del Manual de seguridad y cumplimiento en corte con
chorro de agua (80943C) y del Manual de advertencias de radiofrecuencia

(80945C).
El producto puede incluir copias de los manuales en formato digital e impreso.

Las copias digitales también están en nuestra página web. Hay diversos manuales
disponibles en varios idiomas en www.hypertherm.com/docs.

ET (EESTI/ESTONIAN)

HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote
kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend (80669C),
Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse hoiatusjuhend
(80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada
seadmeid.

Juhiste koopiad võivad tootega kaasas olla elektrooniliselt või trükituna.
Elektroonilised koopiad on saadaval ka meie veebilehel. Paljud kasutusjuhendid
on erinevates keeltes saadaval veebilehel www.hypertherm.com/docs.

FI (SUOMI/FINNISH)

VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen
käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden ja vaatimustenmukaisuuden

käsikirja (80669C), vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden
käsikirja (80943C) ja radiotaajuusvaroitusten käsikirja (80945C).

Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa
muodossa. Sähköiset kopiot ovat myös verkkosivustollamme. Monet käyttöoppaat
ovat myös saatavissa useilla kielillä www.hypertherm.com/docs.

GR (ΕΛΛΗΝΙΚΆ/GREEK)

ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο

εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο ασφάλειας και
συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο προειδοποιήσεων για τις
ραδιοσυχνότητες (80945C).

Το προϊόν μπορεί να συνοδεύεται από αντίγραφα των εγχειριδίων σε ηλεκτρονική
και έντυπη μορφή. Τα ηλεκτρονικά αντίγραφα υπάρχουν επίσης στον ιστότοπό μας.
Πολλά εγχειρίδια είναι διαθέσιμα σε διάφορες γλώσσες στο

www.hypertherm.com/docs.

HU (MAGYAR/HUNGARIAN)

VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne,
olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági

és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági
és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás
figyelmeztetéseket tartalmazó kézikönyvben (80945C).

A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve
lehetnek. Az elektronikus példányok webhelyünkön is megtalálhatók. Számos
kézikönyv áll rendelkezésre több nyelven a www.hypertherm.com/docs weboldalon.

ID (BAHASA INDONESIA/INDONESIAN)

PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah petunjuk
keselamatan dalam manual produk Anda, Manual Keselamatan dan Kepatuhan
(80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C), dan Manual
Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti petunjuk keselamatan
dapat menyebabkan cedera pribadi atau kerusakan pada peralatan.

Produk mungkin disertai salinan manual atau petunjuk dalam format elektronik
maupun cetak. Salinan elektronik juga tersedia di situs web kami. Berbagai manual
tersedia dalam beberapa bahasa di www.hypertherm.com/docs.

IT (ITALIANO/ITALIAN)

AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla
sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la conformità
(80669C), nel Manuale sulla sicurezza e la conformità Waterjet (80943C) e nel
Manuale di avvertenze sulla radiofrequenza(80945C).

Copie del manuale possono accompagnare il prodotto in formato cartaceo
o elettronico. Le copie elettroniche sono disponibili anche sul nostro sito web. Molti
manuali sono disponibili in diverse lingue all’indirizzo www.hypertherm.com/docs.

JA (日本語/JAPANESE)

警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報、「安全
とコンプライアンスマニュアル」 (80669C) 、「ウォータージェットの安全とコ
ンプライアンス」 (80943C)、「高周波警告」 (80945C) をお読みください。

説明書のコピーは、電子フォーマット、または印刷物として製品に同梱されて
います。電子コピーは当社ウェブサイトにも掲載されています。説明書の多く
は www.hypertherm.com/docs にて複数の言語でご用意しています。

KO (뼑뼑霢꽩 KOREAN)

陲隕+\SHUWKHUP녚ꟹꌱꩡ끞뼍韥놹꾅뇑븽꫙ꐺ꫑꿵껽놹ꗄ鞑뇊늵ꯍ
꫙ꐺ꫑&낁뫥뇤껽놹ꗄ鞑뇊늵ꯍ꫙ꐺ꫑&鞭ꍡ隕ꓩ꫕늱볁ꯍ
陲隕꫙ꐺ꫑&꾅驍꿵넽鱉껽놹덵렝냹넲냱겢겑꿙

놹녅뿊겒隱넭ꭹ鷑뿊겒냱ꈑ꫙ꐺ꫑ꩡꚭ넩뇑븽隱뼝颍뇑險鷕ꯍ넽걪鱽鲙
놹녅ꩡꚭ鵹+\SHUWKHUP낮ꩡ넩뱭꾅꫑ꚩ겙ꯍ넽냱ꐥ꫙ꐺ꫑ꩡꚭ냵

www.hypertherm.com/docs 꾅꫑꾡ꆡ꽭꽩ꈑ뇑險鷞鱽鲙

NE (NEDERLANDS/DUTCH)

WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
de veiligheidsinstructies in de producthandleiding, in de Veiligheids-

en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding
voor waterstralen (80943C) en in de Waarschuwingshandleiding radiofrequentie

(80945C).
De handleidingen kunnen in elektronische en gedrukte vorm met het product worden

meegeleverd. Elektronische versies zijn ook beschikbaar op onze website. Veel
handleidingen zijn in meerdere talen beschikbaar via www.hypertherm.com/docs.

NO (NORSK/NORWEGIAN)

ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese
sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og
samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C),
og håndboken om radiofrekvensadvarsler (80945C).

Eksemplarer av håndbøkene kan følge med produktet i elektronisk og trykt form.
Elektroniske eksemplarer finnes også på nettstedet vårt. Mange håndbøker
er tilgjengelig i flere språk på www.hypertherm.com/docs.

SV (SVENSKA/SWEDISH)

VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och
efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet

(80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig
säkerhetsinformation innan du använder eller underhåller Hypertherm-utrustning.

Kopior av manualerna kan medfölja produkten i elektroniskt och tryckt format.
Elektroniska kopior finns också på vår webbplats. Många manualer finns på flera
språk på www.hypertherm.com/docs.

PL (POLSKI/POLISH)

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu
firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi
w podręczniku produktu, w podręczniku bezpieczeństwa i zgodności (80669C),
podręczniku bezpieczeństwa i zgodności systemów strumienia wody (80943C)
oraz podręczniku z ostrzeżeniem o częstotliwości radiowej (80945C).

Do produktu mogą być dołączone podręczniki użytkownika wformie elektronicznej
idrukowanej. Kopie elektroniczne znajdują się również wnaszej witrynie internetowej.
Wiele podręczników jest dostępnych wróżnych językach pod adresem

www.hypertherm.com/docs.

PT (PORTUGUÊS/PORTUGUESE)

ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm,
leia as instruções de segurança no manual do seu produto, no Manual

de Segurança e de Conformidade (80669C), no Manual de Segurança
e de Conformidade do Waterjet (80943C) e no Manual de Advertência
de radiofrequência (80945C).

Cópias dos manuais podem vir com o produto nos formatos eletrônico e impresso.
Cópias eletrônicas também são encontradas em nosso website. Muitos manuais
estão disponíveis em vários idiomas em www.hypertherm.com/docs.

RO (ROMÂNĂ/ROMANIAN)

AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți
instrucțiunile de siguranță din manualul produsului, manualul de siguranță
și conformitate (80669C), manualul de siguranță și conformitate Waterjet (80943C)
și din manualul de avertizare privind radiofrecvența (80945C).

Produsul poate fi însoțit de copii ale manualelor în format tipărit și electronic.
Exemplarele electronice sunt disponibile și pe site-ul nostru web.
Numeroase manuale sunt disponibile în mai mult limbi la adresa:

www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь
с инструкциями по безопасности, представленными в руководстве, которое
поставляется вместе с продуктом, в Руководстве по безопасности и

соответствию (80669С), в Руководстве по безопасности и соответствию для
водоструйной резки (80943C) и Руководстве по предупреждению о
радиочастотном излучении (80945С).

Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Электронные копии также
доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких
языках по ссылке www.hypertherm.com/docs.

SK (S LOVENČINA/SLOVAK)

VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si
prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia a v Manuáli

o bezpečnosti a súlade s normami (80669C), Manuáli o bezpečnosti a súlade
snormami pre systém rezania vodou (80943C) avManuáli sinformáciami
orádiofrekvencii (80945C).

Návod na obsluhu sa dodáva spolu sproduktom velektronickej atlačenej podobe.
Jeho elektronický formát je dostupný aj na našej webovej stránke. Mnohé znávodov
na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke

www.hypertherm.com/docs.

THࡗࡩࡠࡩࡷࡎ࡙THAI

࠻ࢀࡩࡳࡌ࡮ࡤࡐ࠸ᕍࡤࡐ࠸ࡩ࡚ࡶࡁᕎ࠾ࡩࡐࡤ࡯ࡒ࠸࡚ࡊᕑ࠹ࡤ࠾+\SHUWKHUPࡎࡨࡼ࠾ࡢࡘࡋࡵࡒ࡚ࡋࡤᕍࡩࡐ࠻ࢀࡩࡴࡐࡧࡐࢀࡩࡋᕎࡩࡐ࠻࡞ࡩࡘ
ࡒ࡜ࡤࡋࡗࡨ࡙ࡶࡐ࠻ࡰᕍࡘ࡮ࡤ࠸ࡩ࡚ࡶࡁᕎࡡ࡫ࡐ࠻ᕎࡩ࠻ࡰᕍࡘ࡮ࡤࡋᕎࡩࡐ࠻࡞ࡩࡘࡒ࡜ࡤࡋࡗࡨ࡙ࡴ࡜ࡧ࠸ࡩ࡚ࡒࡆ࡫ࡑࡨࡌ࡫ࡌࡩࡘ&࠻ࡰᕍࡘ࡮ࡤ
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TR (TÜRKÇE/TUR KIS H)

UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürününüzün kullanım
kılavuzunda, Güvenlik ve Uyumluluk Kılavuzu’nda (80669C), Su Jeti Güvenlik
ve Uyumluluk Kılavuzu’nda (80943C) ve Radyo Frekansı Uyarısı Kılavuzu’nda
(80945C) yer alan güvenlik talimatlarını okuyun.

Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir. Elektronik
kopyalar web sitemizde de yer alır. Kılavuzların birçoğu www.hypertherm.com/docs
adresinde birçok dilde mevcuttur.

VI7,୰1*9, ୸79,(71$0(6(

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ZH-CN (ㆰ փѝ᮷/CHINESE SIMPLIFIED)

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(80669C)ǃlj≤ሴ⍱ᆹޘ઼⌅㿴䚥ᆸ᡻޼NJ (80943C) ԕ৺ ljሴ仁䆖᡻޼NJ
(80945C) ѝⲴᆹޘ󰪞֌䈤᰾DŽ

䲿ӗ૱ᨀ׋Ⲵ᡻޼ᨀ׋⭥ᆀ⡸઼ঠࡧ⡸є⿽ṬᔿDŽ⭥ᆀ⡸ᵜᰦҏ൘ᡁԜⲴ㖁
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SL (S LOVENŠČINA/SLOVEN IAN)

OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna
navodila v priročniku vašega izdelka, v Priročniku za varnost in skladnost (80669C),
v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom (80943C)
in v Priročniku Opozorilo o radijskih frekvencah (80945C).

Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki. Elektronski
izvodi so na voljo tudi na našem spletnem mestu. Številni priročniki so na voljo
v različnih jezikih na naslovu www.hypertherm.com/docs.

SR (SRPSKI/SERBIAN)

UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte
uputstva o bezbednosti u svom priručniku za proizvod, Priručniku o bezbednosti

i usaglašenosti (80669C), Priručniku o bezbednosti i usaglašenosti Waterjet
tehnologije (80943C) i Priručniku sa upozorenjem o radio-frekvenciji (80945C).

Уз производ се испоручују копије приручника у електронском или штампаном
формату. Електронске копије су такође доступне на нашем веб-сајту. Многи
приручници су доступни на више језика на адреси www.hypertherm.com/docs.

Contents

List of Tables.............................................................................................................................. 19

Electromagnetic Compatibility (EMC)................................................................................. 21

Introduction........................................................................................................................................................... 21

Installation and use ............................................................................................................................................. 21

Assessment of area ............................................................................................................................................ 21

Methods of reducing emissions....................................................................................................................... 21

Mains supply............................................................................................................................................. 21

Maintenance of cutting equipment.................................................................................................................. 21

Cutting cables...................................................................................................................................................... 21

Equipotential bonding ............................................................................................................................ 21

Earthing of the workpiece ..................................................................................................................... 22

Screening and shielding.................................................................................................................................... 22

Warranty..................................................................................................................................... 23

Attention................................................................................................................................................................ 23

General.................................................................................................................................................................. 23

Patent indemnity.................................................................................................................................................. 23

Limitation of liability............................................................................................................................................. 23

National and local codes................................................................................................................................... 23

Liability cap........................................................................................................................................................... 24

Insurance............................................................................................................................................................... 24

Transfer of rights.................................................................................................................................................. 24

XPR170 Instruction Manual 810060 7

Contents

Waterjet product warranty coverage .............................................................................................................. 24

Product...................................................................................................................................................... 24

Parts coverage......................................................................................................................................... 24

1 Specifications........................................................................................................................... 25

Terminology........................................................................................................................................................... 25

XPR cutting system description ...................................................................................................................... 26

General...................................................................................................................................................... 26

Plasma power supply ............................................................................................................................. 26

Gas connect consoles........................................................................................................................... 26

TorchConnect console........................................................................................................................... 26

Torch........................................................................................................................................................... 27

Plasma power supply (part number varies)................................................................................................... 27

Ecodesign requirements (CE models) ............................................................................................... 29

Gas connect console (part number varies)................................................................................................... 30

TorchConnect console (078618).................................................................................................................... 31

Torch (part number varies) ................................................................................................................................ 32

Critical raw materials.......................................................................................................................................... 33

Symbols and marks ............................................................................................................................................ 34

Safety and EMC symbols and marks ................................................................................................. 34

IEC symbols ............................................................................................................................................. 35

2 Qualifications and Requirements........................................................................................... 37

Document requirements .................................................................................................................................... 37

Operator qualifications....................................................................................................................................... 38

Qualifications of service personnel................................................................................................................. 39

System electrical requirements........................................................................................................................ 40

Code conformity...................................................................................................................................... 40

Input power requirements ..................................................................................................................... 40

General input power requirements ......................................................................................... 40

Plasma power supply ................................................................................................................. 41

Line-disconnect switch requirements..................................................................................... 41

Circuit breaker and fuse requirements................................................................................... 42

Main power cord requirements ................................................................................................ 42

Input power requirements for CE units.............................................................................................. 43

Remote on-off switch............................................................................................................................. 43

Process gas requirements (Core, CorePlus, VWI, and OptiMix gas connect consoles) .................. 45

Code conformity...................................................................................................................................... 46

Plumbing for supply gases.................................................................................................................... 47

Regulators for supply gases................................................................................................................. 49

8 810060 Instruction Manual XPR170

Contents

Shield water requirements (VWI and OptiMix) ............................................................................................ 51

Plumbing and hose requirements for shield water.......................................................................... 52

Additional regulator requirement for shield water (optional)......................................................... 52

Torque requirements for gas or water plumbing and hose connections.................................... 52

Requirements for shield water removal for freezing-ambient temperatures.............................. 53

Coolant requirements......................................................................................................................................... 54

Coolant requirements for operation between -10°C – 40°C (14°F – 104°F) .......................... 55

Coolant requirements for operation in temperatures above 40°C (104°F) ............................... 55

Flow requirements for coolant.............................................................................................................. 56

Purity requirements for coolant water................................................................................................. 56

Requirements to position system components............................................................................................ 57

Recommended configuration with the Core gas connect console............................................. 58

Recommended configuration with the CorePlus gas connect console..................................... 59

Recommended configuration with the VWI or OptiMix gas connect console.......................... 60

Site requirements.................................................................................................................................... 61

Length requirements for hoses, cables, and leads.......................................................................... 61

Bend radius requirements for hoses, cables, and leads................................................................ 62

Maximum diameters for console-to-console lead sets................................................................... 62

Distance requirements between high-frequency leads and control cables .............................. 63

Distance requirements for ventilation and access........................................................................... 63

Distance requirements for communications ..................................................................................... 64

Wireless compliance.............................................................................................................................. 64

Torch mounting bracket requirements............................................................................................................ 65

Torch lifter requirements .................................................................................................................................... 65

CNC requirements ............................................................................................................................................. 65

Remote on-off switch............................................................................................................................. 65

Adjustable settings ................................................................................................................................. 65

Display settings ....................................................................................................................................... 66

Diagnostics and troubleshooting......................................................................................................... 66

Recommended grounding and shielding....................................................................................................... 67

Introduction............................................................................................................................................... 67

Types of grounding ................................................................................................................................. 67

Grounding practices............................................................................................................................... 68

Example grounding diagram with an XPR cutting system............................................................. 71

XPR170 Instruction Manual 810060 9

Contents

3 Installation................................................................................................................................. 73

Before you begin................................................................................................................................................. 73

Installation checklist............................................................................................................................................ 74

System requirements.............................................................................................................................. 74

Installation steps...................................................................................................................................... 77

Safety instructions related to installation....................................................................................................... 80

Configuration with Core gas connect console ................................................................................ 83

Configuration with CorePlus gas connect console ........................................................................ 84

Configuration with VWI or OptiMix gas connect console ............................................................. 85

Installation steps.................................................................................................................................................. 86

Position the system components......................................................................................................... 86

Plasma power supply ................................................................................................................. 86

Gas connect console ................................................................................................................. 87

TorchConnect console............................................................................................................... 89

Ground the system components ......................................................................................................... 92

Remove the external panels from the system components........................................................... 94

Prepare the hoses, cables, and leads ................................................................................................ 98

Coolant hose set ......................................................................................................................... 98

Negative lead with strain relief ................................................................................................. 98

Pilot arc lead with strain relief .................................................................................................. 98

Power cable.................................................................................................................................. 98

CAN cable .................................................................................................................................... 98

Work lead...................................................................................................................................... 98

Pilot arc and coolant hose set assembly ............................................................................... 99

Power, CAN, 3-gas assembly (only for Core) ...................................................................... 99

Power, CAN, 4-gas assembly (only for CorePlus) .............................................................. 99

Pilot arc, coolant hose set, and shield water assembly (only for VWI and OptiMix) ... 99

Power, CAN, and 5-gas assembly (only for VWI and OptiMix)...................................... 100

Oxygen hose (blue)................................................................................................................... 100

Nitrogen hose (black)............................................................................................................... 100

Air hose (black).......................................................................................................................... 100

Hydrogen (OptiMix only) (red)................................................................................................ 100

Argon (CorePlus, VWI, or OptiMix only) (black) ................................................................ 100

F5 (VWI or OptiMix only) (red)............................................................................................... 100

Shield water (VWI or OptiMix only) (blue)........................................................................... 101

Connect the plasma power supply and gas connect console (Core, CorePlus, VWI, or

OptiMix)................................................................................................................................................... 102

Connect the coolant hose set................................................................................................ 103

Connect the power cable........................................................................................................ 105

Connect the CAN cable......................................................................................................... 106

10 810060 Instruction Manual XPR170

Contents

Connect the work lead to the plasma power supply and cutting table.................................... 107

Connect the negative lead with strain relief....................................................................... 108

Connect the pilot arc lead with strain relief ........................................................................ 110

Connect the gas connect console (Core or CorePlus) to the TorchConnect console ....... 112

Connect the pilot arc and coolant hose set assembly (Core or CorePlus)................ 112

Connect the power, CAN, and 3-gas assembly (Core).................................................. 115

Connect the power, CAN, and 4-gas assembly (CorePlus).......................................... 116

Connect the gas connect console (VWI or OptiMix) to the TorchConnect console ........... 117

Connect the pilot arc, coolant hose set, and shield water assembly

(VWI or OptiMix) ...................................................................................................................... 117

Connect the power, CAN, and 5-gas assembly (VWI or OptiMix)............................... 120

Install and connect the supply gases .......................................................................................................... 121

Install gas regulators ........................................................................................................................... 122

Connect supply gases to the gas connect console (Core or CorePlus)................................ 123

Connect supply gases and shield water to the gas connect console (VWI or OptiMix) .... 127

Connect the supply gases ..................................................................................................... 130

Connect optional shield water to the gas connect console (VWI or OptiMix)...................... 131

Connect the torch receptacle to the TorchConnect console .................................................... 131

Connect the EasyConnect™ torch lead assembly to the TorchConnect console................. 135

Install the torch in the torch mounting bracket.............................................................................. 137

Install the consumables ...................................................................................................................... 138

Install the torch into the torch receptacle....................................................................................... 140

Connect electric power to the cutting system .............................................................................. 142

Example configurations for consumables................................................................................................... 144

Ferrous (mild steel) example configurations .................................................................................. 144

Mild steel – 30 A – O

Mild steel – 50 A – O

Mild steel – 80 A, 130 A, 170 A – O

..................................................................................................... 144

2/O2

/Air ..................................................................................................... 144

2

/Air.......................................................................... 145

2

Non-ferrous (stainless steel and aluminum) example configurations....................................... 146

Non-ferrous – 40 A – N

Non-ferrous – 60 A – F5/N

Non-ferrous – 80 A – F5/N

Non-ferrous – 130 A – N

Non-ferrous – 170 A – N

and Air/Air............................................................................. 146

2/N2

**, N2/N2, N2/H2O**, and Air/Air........................................ 147

2

**, N2/N2, N2/H2O**, Air/Air................................................ 148

2

, H2-Ar-N2/N2**, N2/H2O***.............................................. 149

2/N2

, H2-Ar-N2/N2**, N2/H2O***, Air/Air ................................ 150

2/N2

XPR170 Instruction Manual 810060 11

Contents

4 Connect for Communication ................................................................................................. 151

How to connect to the plasma power supply with EtherCAT................................................................ 153

How to connect to the plasma power supply with serial RS-422 ....................................................... 155

How to connect to the plasma power supply with discrete................................................................... 158

VDC3 board installation (for AVC with RS-422 and discrete-only) .................................................... 162

Diagram of board, cable, and wire connections ........................................................................... 163

How to install the VDC3 board (141511) ..................................................................................... 164

How to connect the VDC3 board (141511)................................................................................. 167

How to connect to the plasma power supply with the XPR web interface........................................ 170

Web interface support information................................................................................................... 170

Use AP mode to connect................................................................................................................... 171

Use network mode to connect.......................................................................................................... 173

Select an existing network ..................................................................................................... 175

Set up manually ........................................................................................................................ 178

Access the XPR web interface after setup in network mode ........................................ 181

Change the limited AP settings ............................................................................................ 182

Reset the wireless module................................................................................................................. 183

How to disable the wireless connection......................................................................................... 186

Web interface screen information .................................................................................................... 188

Plasma power supply .............................................................................................................. 189

Gas system................................................................................................................................ 190

Log............................................................................................................................................... 193

Operate....................................................................................................................................... 194

Other ........................................................................................................................................... 195

How to change the device that has control............................................................................................... 196

How to use ohmic contact sense................................................................................................................. 197

Ohmic relay overview .......................................................................................................................... 197

Internal ohmic contact sense ............................................................................................................ 197

External ohmic contact sense ........................................................................................................... 198

How to install a remote on-off switch.......................................................................................................... 200

Examples of output circuits............................................................................................................................ 201

Examples of input circuits .............................................................................................................................. 202

5 Coolant Installation ............................................................................................................... 203

Overview ............................................................................................................................................................ 203

How to fill the cutting system with coolant ................................................................................................ 204

12 810060 Instruction Manual XPR170

Contents

6 Operation................................................................................................................................. 207

Overview ............................................................................................................................................................ 207

Controls and indicators .................................................................................................................................. 208

Controls.................................................................................................................................................. 208

CNC ............................................................................................................................................ 208

Wireless device ........................................................................................................................ 208

Indicators................................................................................................................................................ 209

Power-indicator LEDs............................................................................................................. 209

CNC display............................................................................................................................... 210

Sequence of operation ................................................................................................................................... 211

States of operation for the XPR cutting system ........................................................................... 211

Powerup State (1).................................................................................................................... 211

Initial checks State (2)............................................................................................................. 212

Gas purge/pump on State (3)............................................................................................... 213

Wait for start State (5) ............................................................................................................ 214

Preflow/charge DC State (7) ................................................................................................ 214

Ignite State (8).......................................................................................................................... 215

Pilot arc State (9)..................................................................................................................... 216

Rampup State (11).................................................................................................................. 217

Steady State (12)..................................................................................................................... 217

Rampdown State (13) ............................................................................................................ 218

End of cycle State (14)........................................................................................................... 218

High-voltage relay stages (closed or opened) in the ohmic circuit.......................................... 218

Automatic purges................................................................................................................................. 219

Gas-change purges for OptiMix or VWI XPR cutting systems..................................... 219

Process-setup purges for all XPR cutting systems ......................................................... 220

How to choose the torch positions and process settings you need.................................................... 221

Perpendicular-position cutting, marking, and piercing................................................................ 221

Cutting........................................................................................................................................ 221

Marking ....................................................................................................................................... 221

Piercing....................................................................................................................................... 221

Bevel cutting.......................................................................................................................................... 222

Bevel compensation tables.................................................................................................... 223

Ferrous (mild steel) processes.......................................................................................................... 223

Non-ferrous (stainless steel and aluminum) processes .............................................................. 224

Stainless steel........................................................................................................................... 225

Aluminum.................................................................................................................................... 225

Processes for special applications .................................................................................................. 226

Underwater cutting .................................................................................................................. 226

Mirror cutting............................................................................................................................. 227

XPR170 Instruction Manual 810060 13

Contents

Process selection............................................................................................................................................. 228

How to use process IDs to access optimal settings ................................................................... 228

Process ID offsets / overrides............................................................................................... 229

How to use cut charts..................................................................................................................................... 230

Process core thickness (PCT).......................................................................................................... 230

Process categories.............................................................................................................................. 230

How to select consumables .......................................................................................................................... 233

Factors of cut quality....................................................................................................................................... 233

Dross....................................................................................................................................................... 233

How to get the results you want....................................................................................................... 233

General recommendations for all processes..................................................................... 234

Recommendations for perpendicular-position cutting processes................................ 234

Recommendations for piercing processes......................................................................... 235

Recommendations for marking processes......................................................................... 236

Recommendations for bevel-cutting processes ............................................................... 236

How to maximize the life of consumable parts.............................................................................. 237

Arc Response Technology ............................................................................................................................. 237

Automatic torch protection ................................................................................................................ 237

Automatic rampdown error protection ............................................................................................ 238

7 Maintenance........................................................................................................................... 239

Overview ............................................................................................................................................................ 239

How to do daily inspections .......................................................................................................................... 241

Remove the power from the cutting system .................................................................................. 242

Examine the gas regulators................................................................................................................ 243

Examine the shield water regulator (if applicable)........................................................................ 243

Examine the connections and fittings.............................................................................................. 243

Examine the consumable parts, torch, and torch receptacle..................................................... 244

Remove the torch and consumable parts........................................................................... 244

Examine the consumable parts ............................................................................................. 245

Examine the torch..................................................................................................................... 247

Examine the torch receptacle................................................................................................ 248

Examine the torch lead........................................................................................................................ 249

How to replace the water tube ..................................................................................................................... 250

How to identify emitter wear.......................................................................................................................... 251

How to measure the pit depth of an electrode ......................................................................................... 254

How to do coolant maintenance................................................................................................................... 255

Estimate the total coolant volume for your cutting system......................................................... 256

Replace all of the coolant................................................................................................................... 256

Remove old coolant from the coolant system.................................................................... 257

14 810060 Instruction Manual XPR170

Contents

8 Diagnostics and Troubleshooting........................................................................................ 261

Overview ............................................................................................................................................................ 261

Safety considerations.......................................................................................................................... 262

Initial inspection steps..................................................................................................................................... 263

Remove the power from the cutting system .................................................................................. 263

Examine the PCBs............................................................................................................................... 265

Measure the line voltage between the terminals inside the plasma power supply............... 267

Diagnostic codes ............................................................................................................................................. 269

How to diagnose and troubleshoot diagnostic codes ................................................................ 269

CAN codes (500 – 503, 510 – 513 for gas connect console, 504, 514 for

CAN cable and jumper block, 507 – 508 for CAN network and bus,

600 – 602 for no CAN communication) ............................................................................ 307

Low shield water pressure code (532)............................................................................... 313

Low shield gas pressure code (534) .................................................................................. 314

Low coolant flow codes (540 – 542) ................................................................................. 315

High coolant flow codes (543 – 544) ................................................................................ 317

Over temp diagnostic codes – Chopper (560) and Coolant (587) ............................ 318

Start switch diagnostic codes (570 – 577)....................................................................... 321

Over temp diagnostic codes – Inductor (580 – 581), Transformers (586)............... 323

Current sensor diagnostic codes (631) ............................................................................. 326

Low inlet pressure for H

(695 – 697, 700, 701) ............................................................................................................ 327

Shield gas inlet pressure in the torch connect console diagnostic codes

(702 – 705) ............................................................................................................................... 328

Process-gas inlet pressure in the torch connect console diagnostic codes

(702, 705, 769, 770) for OptiMix-equipped cutting systems........................................ 330

Pressure transducer diagnostic codes (706 – 715) ....................................................... 332

Gas inlet pressure codes (768 – 771)............................................................................... 333

How to do a gas leak test .................................................................................................................. 334

How to measure coolant flow............................................................................................................ 337

Use the CNC or XPR web interface ................................................................................... 337

Do a container test .................................................................................................................. 337

How to test continuity between the nozzle and workpiece........................................................ 339

How to measure resistance from thermistors................................................................................ 342

How to do an ohmic-contact test .................................................................................................... 344

Identify fan diagnostic codes............................................................................................................. 347

PCB information............................................................................................................................................... 348

Plasma power supply power distribution PCB (141425) .......................................................... 348

Plasma power supply control PCB (141322)............................................................................... 349

DIP switch positions................................................................................................................ 351

Plasma power supply chopper PCB (141319)............................................................................ 352

Plasma power supply start circuit PCB (141360) ...................................................................... 353

, Ar, N2, and H2O diagnostic codes

2

XPR170 Instruction Manual 810060 15

Contents

Plasma power supply I/O PCB (141371) ..................................................................................... 353

Plasma power supply fan power distribution PCB (141384)................................................... 354

Gas connect console control PCB (141375)............................................................................... 355

Gas connect console high frequency PCB (141563)................................................................ 356

Torch connect console ohmic PCB (141368).............................................................................. 357

Torch connect console control PCB (141334)............................................................................ 358

9 Parts List................................................................................................................................. 359

Plasma power supply ...................................................................................................................................... 359

Outer panels.......................................................................................................................................... 360

Fans......................................................................................................................................................... 361

Coolant system..................................................................................................................................... 362

Coolant adapters in the rear compartment .................................................................................... 363

Other adapters not shown................................................................................................................. 364

Transformer and inductor ................................................................................................................... 365

Control side – view 1.......................................................................................................................... 366

Control side – view 2.......................................................................................................................... 367

Rear compartment of the plasma power supply ........................................................................... 368

Gas connect consoles.................................................................................................................................... 369

Gas connect console high-voltage side parts .............................................................................. 370

Gas connect console manifold side parts...................................................................................... 371

Core, CorePlus, VWI, and OptiMix gas connect console manifold side .................... 371

Core gas connect console manifolds and adapters ........................................................ 373

CorePlus gas connect console manifolds and adapters ................................................. 374

VWI gas connect console input and output manifolds and adapters.......................... 375

OptiMix gas connect console input and output manifolds and adapters.................... 377

VWI and OptiMix gas connect console mixer, transducers, and valves...................... 379

Gas connect console wire harness, hose kit, and CAN cables................................................ 380

Torch connect console.................................................................................................................................... 380

Torch connect console Easy Connect side.................................................................................... 381

Torch connect console – top............................................................................................................. 381

Torch connect console manifold side – view 1............................................................................. 382

Torch connect console manifold side – view 2............................................................................. 383

Front adapters and valves.................................................................................................................. 384

Torch assembly ................................................................................................................................................. 385

Torch bracket..................................................................................................................................................... 386

Consumable starter kits.................................................................................................................................. 386

Mild steel consumable starter kit (428840) .................................................................................. 386

Stainless steel and aluminum consumable starter kit (428843) .............................................. 387

Mild steel consumable starter kit with torch (428842)............................................................... 388

Stainless steel and aluminum consumable starter kit with torch (428841) ........................... 389

16 810060 Instruction Manual XPR170

Contents

Other consumable and torch parts.............................................................................................................. 390

Plasma power supply to gas connect console connections.................................................................. 391

Pilot arc lead with strain relief ........................................................................................................... 391

Negative lead with strain relief .......................................................................................................... 391

Power cable........................................................................................................................................... 392

Coolant hose set.................................................................................................................................. 392

CAN cable ............................................................................................................................................. 393

Gas connect console to torch connect console connections............................................................... 393

Pilot arc and coolant hose set assembly (Core or CorePlus) ................................................... 393

Power, CAN, and 3-gas assembly (Core)...................................................................................... 393

Power, CAN, and 4-gas assembly (CorePlus).............................................................................. 394

Pilot arc, coolant hose set, and shield water assembly (VWI or OptiMix) .............................. 394

Power, CAN, and 5-gas assembly (VWI or OptiMix)................................................................... 394

Plasma power supply to CNC connections .............................................................................................. 395

EtherCAT CNC interface cable ........................................................................................................ 395

Discrete CNC interface cable........................................................................................................... 395

Serial CNC interface cable................................................................................................................ 396

Plasma power supply to cutting table connection ................................................................................... 396

Work lead............................................................................................................................................... 396

Torch connect console to torch receptacle connection.......................................................................... 397

Torch lead............................................................................................................................................... 397

Bevel torch lead.................................................................................................................................... 397

Supply hoses..................................................................................................................................................... 398

Oxygen hose (blue).............................................................................................................................. 398

Nitrogen or Argon hose (black)......................................................................................................... 398

Air hose (black)..................................................................................................................................... 398

Hydrogen or nitrogen-hydrogen (F5) (red) .................................................................................... 399

Water (optional shield fluid) (blue)................................................................................................... 399

Preventive maintenance kits .......................................................................................................................... 399

Tools .................................................................................................................................................................... 400

Recommended spare parts ........................................................................................................................... 400

Plasma power supply – recommended spare parts .................................................................... 400

Gas connect consoles – recommended spare parts.................................................................. 401

Torch connect console – recommended spare parts.................................................................. 401

Torch – recommended spare parts.................................................................................................. 401

Descriptions of warning label icons................................................................................................. 402

XPR170 Instruction Manual 810060 17

Contents

10 Wiring Diagrams .................................................................................................................... 403

Wiring diagram symbols................................................................................................................................. 404

Valve states during operation ............................................................................................................ 406

Valve states by process ID..................................................................................................... 406

Overview (Sheet 1 of 22)................................................................................................................... 413

Plasma power supply 1 (Sheet 2 of 22)......................................................................................... 414

Plasma power supply 2 (Sheet 3 of 22)......................................................................................... 415

Plasma power supply 3 (Sheet 4 of 22)......................................................................................... 416

Plasma power supply 4 (Sheet 5 of 22)......................................................................................... 417

Plasma power supply 5 (Sheet 6 of 22)......................................................................................... 418

Plasma power supply 6 (Sheet 7 of 22)......................................................................................... 419

Plasma power supply 7 (Sheet 8 of 22)......................................................................................... 420

Gas connect console 1 (Sheet 9 of 22)......................................................................................... 421

Gas connect console 2 (Sheet 10 of 22)....................................................................................... 422

Torch connect console (Sheet 11 of 22) ....................................................................................... 423

Coolant system (Sheet 12 of 22)..................................................................................................... 424

Gas system 1 (Sheet 13 of 22)........................................................................................................ 425

Gas system 2 (Sheet 14 of 22)........................................................................................................ 426

Gas system 3 (Sheet 15 of 22)........................................................................................................ 427

EtherCAT multi-drop (multi-system) interface (Sheet 16 of 22) ............................................... 428

Serial RS-422 and discrete multi-drop (multi-system) interface (Sheet 17 of 22).............. 429

Discrete multi-drop (multi-system) interface (Sheet 18 of 22) ................................................. 430

EtherCAT connection to EDGE Connect/TC (Sheet 19 of 22) ............................................... 431

Discrete and serial RS-422 CNC connections (Sheet 20 of 22)............................................ 432

Discrete CNC connections (Sheet 21 of 22) ............................................................................... 433

Wireless subsystem block diagram (Sheet 22 of 22) ................................................................. 434

18 810060 Instruction Manual XPR170

List of Tables

Table 1 – Plasma power supply general specifications..............................................................................28

Table 2 – Plasma power supply part numbers and specifications...........................................................28

Table 3 – Ecodesign requirements and data ................................................................................................29

Table 4 – Gas connect console part numbers and dimensions...............................................................30

Table 5 – Length and weight by sleeve type.................................................................................................32

Table 6 – General torch specifications...........................................................................................................32

Table 7 – Input power requirements ...............................................................................................................41

Table 8 – Gas quality, pressure, and flow requirements ............................................................................45

Table 9 – Recommended sizes for gas fittings.............................................................................................48

Table 10 – Quality, pressure, and flow requirements for shield water....................................................51

Table 11 – Purity requirements for shield water...........................................................................................51

Table 12 – Torque specifications.....................................................................................................................52

Table 13 – Purity measurement methods for coolant water......................................................................56

Table 14 – Recommendations for where to position system components............................................61

Table 15 – Length ranges for interconnect hoses, cables, and leads ....................................................61

Table 16 – Maximum distance between the plasma power supply and controlling device ...............64

Table 17 – Equipment to lift or move the plasma power supply...............................................................86

Table 18 – Definitions of symbols on the label inside the plasma power supply .............................. 102

Table 19 – Torque specifications..................................................................................................................122

Table 20 – Torque specifications..................................................................................................................122

Table 21 – Recommended sizes for gas fittings.......................................................................................125

Table 22 – Recommended sizes for gas fittings.......................................................................................130

Table 23 – Color codes for main power cord wires................................................................................. 143

Table 24 – Communication requirements and options............................................................................ 152

Table 25 – Pinout for serial RS-422 interface cable................................................................................ 156

XPR170 Instruction Manual 810060 19

List of Tables

Table 26 – Pinout for J14 on the discrete cable ....................................................................................... 159

Table 27 – Pinout for J19 on the discrete cable ....................................................................................... 160

Table 28 – Pinout for J2 on the VDC3 board ............................................................................................ 169

Table 29 – Available non-ferrous processes by gas connect console type and gas type.............. 224

Table 30 – Process recommendations for cut quality, based on metal thickness and type ........... 224

Table 31 – Process category options and expected quality-speed results for ferrous

(mild steel) processes......................................................................................................................................231

Table 32 – Process category options and expected quality-speed results for non-ferrous

processes ........................................................................................................................................................... 232

Table 33 – Inspection, preventive maintenance, and cleaning tasks.................................................... 240

Table 34 – Inspection tasks for consumables ........................................................................................... 245

Table 35 – PCB names and locations......................................................................................................... 266

Table 36 – Diagnostic codes in the web interface................................................................................... 270

Table 37 – Diagnostic codes.........................................................................................................................271

Table 38 – Minimum and maximum ohmic resistance values for thermistors..................................... 320

Table 39 – Minimum and maximum ohmic resistance values for thermistors..................................... 325

Table 40 – Minimum and maximum ohmic resistance values for thermistors..................................... 343

20 810060 Instruction Manual XPR170

Electromagnetic Compatibility (EMC)

Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard
EN60974-10. The equipment should be installed and used in
accordance with the information below to achieve electromagnetic
compatibility.

The limits required by EN60974-10 may not be adequate to completely
eliminate interference when the affected equipment is in close proximity
or has a high degree of sensitivity. In such cases it may be necessary to
use other measures to further reduce interference.

This cutting equipment is designed for use only in an industrial
environment.

Installation and use

The user is responsible for installing and using the plasma equipment
according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the
responsibility of the user to resolve the situation with the technical
assistance of the manufacturer. In some cases this remedial action may
be as simple as earthing the cutting circuit, see Earthing of the
workpiece. In other cases, it could involve constructing an
electromagnetic screen enclosing the power source and the work
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to
the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
supply.

Consideration should be given to shielding the supply cable of
permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the cutting mains supply so
that good electrical contact is maintained between the conduit and the
cutting power source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and
covers should be closed and properly fastened when the cutting
equipment is in operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with the
manufacturer’s written instructions. For example, the spark gaps of arc
striking and stabilizing devices should be adjusted and maintained
according to the manufacturer’s recommendations.

Cutting cables

Assessment of area

Before installing the equipment, the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The
following shall be taken into account:

a. Other supply cables, control cables, signaling and telephone

cables; above, below and adjacent to the cutting equipment.

b. Radio and television transmitters and receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example guarding of industrial

equipment.

e. Health of the people around, for example the use of

pacemakers and hearing aids.

f. Equipment used for calibration or measurement.

g. Immunity of other equipment in the environment. User shall

ensure that other equipment being used in the environment is
compatible. This may require additional protection measures.

h. Time of day that cutting or other activities are to be carried

out.

The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.

The cutting cables should be kept as short as possible and should be
positioned close together, running at or close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.

However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
same time.

The operator should be insulated from all such bonded metallic
components.

Safety and compliance 21

Electromagnetic Compatibility (EMC)

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor
connected to earth because of its size and position, for example, ship’s
hull or building steel work, a connection bonding the workpiece to earth
may reduce emissions in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct
connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable
capacitances selected according to national regulations.

Note: The cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a
person who is competent to assess whether the changes will increase
the risk of injury, for example, by allowing parallel cutting current return
paths which may damage the earth circuits of other equipment.
Further guidance is provided in IEC 60974-9, Arc Welding Equipment,
Part 9: 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.

22 Safety and compliance

Warranty

Attention

Genuine Hypertherm parts are the factory-recommended replacement
parts for your Hypertherm system. Any damage or injury caused by the
use of other than genuine Hypertherm parts may not be covered by the
Hypertherm warranty, and will constitute misuse of the Hypertherm
Product.

You are solely responsible for the safe use of the Product. Hypertherm
does not and cannot make any guarantee or warranty regarding the safe
use of the product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth
herein and as follows: if Hypertherm is notified of a defect (i) with respect
to the plasma power supply within a period of two (2) years from the date
of its delivery to you, with the exception of Powermax brand power
supplies, which shall be within a period of three (3) years from the date of
delivery to you, and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, with the exception of the
HPRXD short torch with integrated lead, which shall be within a period of
six (6) months from the date of delivery to you, and with respect to torch
lifter assemblies within a period of one (1) year from its date of delivery to
you, and with respect to Automation products one (1) year from its date
of delivery to you, with the exception of the EDGE Connect CNC,
EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC,
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which
shall be within a period of two (2) years from the date of delivery to you,
and (iii) with respect to HyIntensity fiber laser components within a
period of two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which shall be within
a period of one (1) year from its date of delivery to you.

All third-party engines, engine accessories, alternators, and alternator
accessories are covered by the respective manufacturers’ warranties and
not covered by this warranty.

This warranty shall not apply to any Powermax brand power supplies that
have been used with phase converters. In addition, Hypertherm does not
warranty systems that have been damaged as a result of poor power
quality, whether from phase converters or incoming line power. This
warranty shall not apply to any product which has been incorrectly
installed, modified, or otherwise damaged.

The warranty set forth above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise with respect to the
Products or as to the results which may be obtained therefrom, and all
implied warranties or conditions of quality or of merchantability or fitness
for a particular purpose or against infringement. The foregoing shall
constitute the sole and exclusive remedy for any breach by Hypertherm
of its warranty.

Distributors/OEMs may offer different or additional warranties, but
Distributors/OEMs are not authorized to give any additional warranty
protection to you or make any representation to you purporting to be
binding upon Hypertherm.

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or
manufactured by a person other than Hypertherm not in strict conformity
with Hypertherm’s specifications and in cases of designs, processes,
formulae, or combinations not developed or purported to be developed
by Hypertherm, Hypertherm will have the right to defend or settle, at its
own expense, any suit or proceeding brought against you alleging that
the use of the Hypertherm product, alone and not in combination with
any other product not supplied by Hypertherm, infringes any patent of
any third party. You shall notify Hypertherm promptly upon learning of any
action or threatened action in connection with any such alleged
infringement (and in any event no longer than fourteen (14) days after
learning of any action or threat of action), and Hypertherm’s obligation to
defend shall be conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the defense of the
claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for
any incidental, consequential direct, indirect, punitive or
exemplary damages (including but not limited to lost profits)
regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty, failure of
essential purpose, or otherwise, and even if advised of the
possibility of such damages. Hypertherm shall not be liable for
any losses to Distributor based on down time, lost production or
lost profits. It is the intention of the Distributor and Hypertherm
that this provision be construed by a court as being the
broadest limitation of liability consistent with applicable law.

Hypertherm provides repair, replacement or adjustment of the Product as
the sole and exclusive remedy, if and only if the warranty set forth herein
properly is invoked and applies. Hypertherm, at its sole option, shall
repair, replace, or adjust, free of charge, any defective Products covered
by this warranty which shall be returned with Hypertherm’s prior
authorization (which shall not be unreasonably withheld), properly
packed, to Hypertherm’s place of business in Hanover, New Hampshire,
or to an authorized Hypertherm repair facility, all costs, insurance and
freight pre paid by the customer. Hypertherm shall not be liable for any
repairs, replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph and with
Hypertherm’s prior written consent.

National and local codes

National and local codes governing plumbing and electrical installation
shall take precedence over any instructions contained in this manual.
In no event shall Hypertherm be liable for injury to persons or property
damage by reason of any code violation or poor work practices.

Safety and compliance 23

Warranty

Liability cap

In no event shall Hypertherm’s liability, if any, whether such
liability is based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or otherwise,
for any claim, action, suit or proceeding (whether in court,
arbitration, regulatory proceeding or otherwise) arising out of or
relating to the use of the Products exceed in the aggregate the
amount paid for the Products that gave rise to such claim.

Insurance

At all times you will have and maintain insurance in such quantities and
types, and with coverage sufficient and appropriate to defend and to hold
Hypertherm harmless in the event of any cause of action arising from the
use of the products.

Transfer of rights

You may transfer any remaining rights you may have hereunder only in
connection with the sale of all or substantially all of your assets or capital
stock to a successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty. Within thirty (30) days before any
such transfer occurs, you agree to notify in writing Hypertherm, which
reserves the right of approval. Should you fail timely to notify Hypertherm
and seek its approval as set forth herein, the Warranty set forth herein
shall be null and void and you will have no further recourse against
Hypertherm under the Warranty or otherwise.

Waterjet product warranty coverage

Product Parts coverage

HyPrecision pumps 27 months from the ship date, or 24 months

from the date of proven installation, or
4,000 hours, whichever occurs first

PowerDredge
abrasive removal
system

EcoSift abrasive
recycling system

Abrasive metering
devices

On/off valve air
actuators

Diamond orifices 600 hours of use with the use of a thimble

Consumable parts are not covered by this warranty. Consumable parts
include, but are not limited to, high-pressure water seals, check valves,
cylinders, bleed-down valves, low-pressure seals, high-pressure tubing,
low- and high-pressure water filters and abrasive collection bags. All
third-party pumps, pump accessories, hoppers, hopper accessories,
dryer boxes, dryer box accessories and plumbing accessories are
covered by the respective manufacturers’ warranties and not covered by
this warranty.

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first

filter and compliance with Hypertherm’s
water quality requirements

24 Safety and compliance

Terminology

XPR cutting system – The plasma power supply, gas connect console, torch connect console,

and torch.

Cutting system or cutting machine – The XPR cutting system, CNC, torch lifter, cutting table,

and other components.

Wet process – Any process that uses water as a shield fluid.

Specifications

Dry process – Any process that does not use water as a shield fluid.

Ferrous – Mild steel

Non-ferrous – Stainless steel and aluminum

Gases – Hydrogen (H

5% hydrogen)

Mixed-fuel gas – A mixture of H

XPR170 Instruction Manual 810060 25

), argon (Ar), nitrogen (N2), oxygen (O2), water (H2O), F5 (95% nitrogen,

2

-Ar-N2 created in the OptiMix gas connect console.

2

Specifications

1

XPR cutting system description

General

XPR cutting systems are designed for indoor use with correct ventilation to cut a wide range of
thicknesses of mild steel, stainless steel, and aluminum.

Plasma power supply

The plasma power supply is a 170 A, 210 VDC constant-current supply. It contains a heat
exchanger, fans, and a pump to cool the torch and other electronic components. The plasma power

®

supply supports EtherCAT
communicate with a CNC or wireless device.

The power-indicator LED on the plasma power supply indicates power status:

 It illuminates amber when the plasma power supply is receiving electric power and the

remote on-off switch is in the OFF position.

, wireless, RS-422 serial, and discrete communication protocols to

 It illuminates green when the plasma power supply is receiving electric power and the

remote on-off switch is in the ON position.

Gas connect consoles

There are 4 types of gas connect consoles: Core™, CorePlus™, VWI™ (vented water injection), and
OptiMix™. Each type provides a different set of gas connection capabilities, which provide selecting
and metering functions for the gas control system. The gas connect console has 2 printed circuit
boards (PCBs): a control PCB and an ignition PCB. If your XPR cutting system is equipped with an
OptiMix gas connect console, there is also a gas mixer that has its own control board. A green
power LED illuminates when power is supplied to the console.

For some cutting systems, a remote on-off switch controls the power that



goes to the console.

The CorePlus gas connect console has many of the same features as the Core console. The primary
difference is that CorePlus adds a gas line for Argon.

To use a CorePlus console, you must install revision U (or later) of the XPR firmware. Refer to the
XPR Web Interface and PCB Firmware Updates Field Service Bulletin (809820). Technical
documentation is available at www.hypertherm.com/docs.

TorchConnect console

The TorchConnect™ console has proportional valves, solenoid valves, and pressure transducers.
The TorchConnect console also has 2 PCBs, a control PCB, and an ohmic contact PCB. The
TorchConnect console provides all power, gas, and cooling connections for connection to the torch.
A power-indicator LED illuminates when power is supplied to the console.

For some cutting systems, a remote on-off switch controls the power that



goes to the console.

26 810060 Instruction Manual XPR170

1

Tor ch

81.70 cm

(32.17 in.)

127.28 cm

(50.11 in.)

124.76 cm
(49.12 in.)

454.5 kg
(1,002 lb)

The torch assembly consists of a torch mount sleeve, torch receptacle, torch, and water tube. The
torch receptacle contains a solenoid valve. Consumables are installed on the torch.

Plasma power supply (part number varies)

Specifications

The part number and specifications can differ for your plasma power



supply. Refer to Tabl e 1 on page 28 and Ta ble 2 on page 28 for part
numbers and specifications.

XPR170 Instruction Manual 810060 27

Specifications

1

Table 1 – Plasma power supply general specifications

Maximum open-circuit voltage (U

Maximum output current (I

Output voltage (U

) 50 VDC – 210 VDC

2

) 170 A

2

) 360 VDC

0

Duty cycle rating (X) 100% at 35.7 kW, 40°C (104°F)

>0°C – 40°C (>32°F – 104°F) – Applies only to
cutting systems that use water as a shield fluid.

-10 °C – 40°C (14°F – 104°F) – Applies only to

Operational ambient temperature range

cutting systems that do not use water as a shield
fluid.

Note: Only VWI- and OptiMix-equipped cutting
systems can use water as a shield fluid.

Power factor (cosθ) 0.98 at 35.7 kW

Cooling 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 680 kg (1,500 lb)

Table 2 – Plasma power supply part numbers and specifications

)

Regulatory

approval

Safety/EMC

Part number

(VAC) (U

078640 200

Voltage

Phase Frequency (Hz)

)

1

Rated input

current at 35.7 kW

output (A) (I

1

50 – 60 117 cCSAus

078641 208 60 112 cCSAus

078642 220 50 – 60 106 cCSAus

078643 240 60 97 cCSAus

078644 380 50 – 60 62 CCC

CE, RCM,

078645 400 50 – 60 59

3

EAC, UKr, and

CE, RCM,

078646 415 50 56

EAC, UKr, and

078647 440 60 53 cCSAus

078648 480 60 49 cCSAus

078649 600 60 39 cCSAus

AAA

AAA

Power (kVA)

(± 10%)

X I1 X1.73)

(U

1

40.48

28 810060 Instruction Manual XPR170

Specifications

1

Ecodesign requirements (CE models)

Table 3 – Ecodesign requirements and data

Ecodesign requirement Idle With load Description

Output current – 170.55 A Measured at the rated duty cycle for the

Output voltage – 213.57 V

Output active power – 36.41 kW

system at the highest output power.

Root mean square (RMS) of the supply
voltage

Supply active power

Total harmonic distortion of the supply
voltage (UTHD)

Idle state power consumption by the power
source

Efficiency

* External devices were disconnected during idle measurement.

401.46 V 399.31 V

31.7 W

1.41% 4.23%

31.7 W

40.49 kW

–

– 89.91%

Measured at idle state and at the rated
duty cycle for the system at the highest
output power.

Measured at idle state.*

Calculated at the rated duty cycle for the
system at the highest output power.

XPR170 Instruction Manual 810060 29

Specifications

1

1

2

3

Varies
Refer to Table 4 .

1

2

3

1

2

3

Core

VWI

OptiMix

4

4

4

CorePlus

1

2

3

4

123

4

Gas connect console (part number varies)

The part number and some specifications differ by gas connect console



type (Core, CorePlus, VWI, or OptiMix). Refer to Ta ble 4 .

Do not remove the inlet check valves from the gas connect consoles.



Gas connect
console

Core 078631

CorePlus 078662

VWI 078632

OptiMix 078633

30 810060 Instruction Manual XPR170

Part

number

Table 4 – Gas connect console part numbers and dimensions

Dimension Dimension Dimension

383.80 mm

374.65 mm
(14.75 in.)

(15.11 in.)

434.59 mm
(17.11 in.)

205.99 mm
(8.12 in.)

Dimension

(with fittings)

431.80 mm
(17.00 in.)

433.92 mm
(17.08 in.)

522.22 mm

(20.56 in.)

524.00 mm

(20.63 in.)

Weight

16.58 kg

36.55 lb

17.2 kg

37.92 lb

19.46 kg

42.9 lb

25.79 kg

56.85 lb

1

For mounting dimensions, refer to Gas connect console on page 87.

15.24 cm
(6 in.)

22.86 cm
(9 in.)

30.48 cm
(12 in.)

2.62 cm
(1.03 in.)

9.30 kg
(20.5 lb)



TorchConnect console (078618)

Specifications

The TorchConnect console (078618) goes with the 4 types of gas



connect consoles (Core, CorePlus, VWI, and OptiMix).

Do not remove the inlet check valves from the torch connect console.



The factory location for the mounting brackets is on the bottom of the torch connect console.
However, you can move the mounting brackets to either side. Console placement with the torch
lead connection on the bottom can minimize the risk of leaked water or coolant collecting inside of
the console. Water or coolant collection inside of the TorchConnect console can damage internal
electrical components.

For mounting dimensions, refer to TorchConnect console on page 89.



XPR170 Instruction Manual 810060 31

Specifications

1

Varies

Clamp-surface length

Overall sleeve length

160.8 mm (6.33 in.)

Torch (part number varies)

Table 5 – Length and weight by sleeve type

Combined weight

Sleeve type Clamp-surface length Overall sleeve length

Short 111.7 mm (4.4 in.) 155 mm (6.1 in.) 1.4 kg (3 lb) 1.5 kg (3.3 lb)

Standard 189.6 mm (4.5 in.) 233 mm (9.2 in.) 1.6 kg (3.6 lb)

Extended 268.1 mm (10.6 in.) 311 mm (12.3 in.) 1.7 kg (3.9 lb)

The part number and some specifications for your torch can change



because of torch sleeve dimensions and other features. Refer to Tor ch

assembly on page 385 of the Parts List.

Table 6 – General torch specifications

Rated arc striking voltage 15.3 kV

Maximum gas pressure at inlet 7.9 bar, 792 kPa (115 psi)

Minimum gas pressure at inlet 7.2 bar, 723 kPa (105 psi)

Maximum torch-side and torch-front force 22.5 kg (50 lb)

(torch head,
receptacle,
consumables)

Combined weight
with sleeve

32 810060 Instruction Manual XPR170

Specifications

1

Critical raw materials

Critical raw material Components that contain more than 1 gram

Borate All printed circuit boards, 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

Silicon metal Heatsinks, cold plates, transformers, inductors, IGBT

modules

Tantalum Capacitors

Tungsten Power resistors

XPR170 Instruction Manual 810060 33

Specifications

1

s

Symbols and marks

Safety and EMC symbols and marks

Your product may have one or more of the following marks on or near the data plate. Because of differences
and conflicts in national regulations, not all marks are applied to every version of a product.

S mark

The S mark indicates that the power supply and torch are suitable for operations carried out in
environments with increased hazard of electrical shock according to IEC 60974-1.

CSA mark

Products with a CSA mark meet the United States and Canadian regulations for product safety.
The products were evaluated, tested, and certified by CSA-International. Alternatively, the product
may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL)
accredited in both the United States and Canada, such as UL or TÜV.

CE mark

The CE marking signifies the manufacturer’s declaration of conformity to applicable European
directives and standards. Only those versions of products with a CE marking located on or near
the data plate comply with European Directives. 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.

Eurasian Customs Union (CU) mark

CE versions of products that include an EAC mark of conformity meet the product safety and
EMC requirements for export to Russia, Belarus, and Kazakhstan.

GOST-TR mark

CE versions of products that include a GOST-TR mark of conformity meet the product safety and
EMC requirements for export to the Russian Federation.

RCM mark

CE versions of products with an RCM mark comply with the EMC and safety regulations required
for sale in Australia and New Zealand.

CCC mark

The China Compulsory Certification (CCC) mark indicates that the product has been tested and
found compliant with product safety regulations required for sale in China.

UkrSEPRO mark

The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety
and EMC requirements for export to the Ukraine.

Serbian AAA mark

CE versions of products that include a AAA Serbian mark meet the product safety and
EMC requirements for export to Serbia.

RoHS mark

The RoHS mark indicates that the product meets the requirements of the European Restriction of
Hazardous Substances (RoHS) Directive.

34 810060 Instruction Manual XPR170

1

IEC symbols

Direct current (DC)

Alternating current (AC)

Plasma torch cutting

Gouging

AC input power
connection

The terminal for the
external protective (earth)
(PE) conductor

I Power is ON

O Power is OFF

A 1-phase or 3-phase
inverter-based power
source

Volt/amperage curve,
“drooping” characteristic

f

1

f

2

1~

The following symbols can appear on the data plate, control labels, and switches.

Specifications

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.

XPR170 Instruction Manual 810060 35

Specifications

1

36 810060 Instruction Manual XPR170

Document requirements

This manual refers to several other documents. These documents include:

 XPR Cut Charts Instruction Manual (809830)
 CNC Communication Protocol for the XPR Cutting System (809810)
 XPR Preventive Maintenance Program (PMP) Instruction Manual (809490)
 XPR Firmware Updates Field Service Bulletin (809820)

You can find these documents on the USB memory stick that came with your plasma power supply.
If you do not have these documents, technical documentation is available at

www.hypertherm.com/docs.

Qualifications and Requirements

Technical documentation is current as of the date of its release.



Subsequent revisions are possible. Refer to www.hypertherm.com/docs
for the most recent revisions of released documents.

XPR170 Instruction Manual 810060 37

Qualifications and Requirements

2

Operator qualifications

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance. You can
get a serious electric shock if electric power is not disconnected. Electric
shock can seriously injure or kill you.

All work that requires removal of the plasma power supply outer cover or
panels must be done by a qualified technician.

Refer to the Safety and Compliance Manual (80669C) for more safety
information.

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.

WARNING

For your safety and for the best results:

 Never operate the cutting system unless you are qualified to do so.
 Follow NFPA70E Section 85 in North America.
 Follow IEC 60364 series outside of North America.
 Follow OSHA Section1910.331-335 in North America for 600 volts or less.
 Follow all local and national electrical safety requirements for both operator and service

personnel.

 Always read, understand, and follow all of the safety instructions in this manual, the Safety

and Compliance Manual (80669C), and on the labels that are on the cutting system.

 Get adequate operator training from a knowledgeable source before operation. Adequate

training topics include (but are not limited to) the following:

 How to start and stop the cutting system during routine operation and in an emergency.
 Conditions and actions that can cause injuries to people or damage cutting system

equipment.

 How to operate all controls.
 How to identify and respond to fault conditions.
 How to do maintenance.
 A copy of the instruction manual.

Additional qualifications apply for personnel who do maintenance and



troubleshooting. Refer to Qualifications of service personnel on page 39.

38 810060 Instruction Manual XPR170

2

 Do not operate the cutting system if you cannot follow all of the safety instructions or if you

cannot satisfy the minimum operator qualifications. Refer to the Safety and Compliance
Manual (80669C), Radio Frequency Warning Manual (80945C), and Safety instructions

related to installation on page 80.

Additional qualifications apply for personnel who do maintenance and



troubleshooting. Refer to Qualifications of service personnel on page 39.

Qualifications of service personnel

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance. You can
get a serious electric shock if electric power is not disconnected. Electric
shock can seriously injure or kill you.

Qualifications and Requirements

WARNING

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.

It can be hazardous to do service and maintenance on industrial cutting systems and equipment.

For your safety and for the best results:

 Always read, understand, and follow all of the safety instructions in this manual, the Safety

and Compliance Manual (80669C), and on the labels that are on the cutting system.

 Get adequate training from a knowledgeable source before you do any service or

maintenance on the cutting system or equipment.

The entity responsible for workplace safety where your XPR170 cutting



system is used must do a risk assessment and establish the criteria for
service personnel training and qualifications.

 Do not do any service or maintenance on the cutting system or equipment if you cannot

follow all of the safety instructions or if you cannot satisfy the minimum service-personnel
qualifications set by workplace safety at your organization. Refer to the Safety and
Compliance Manual (80669C), Radio Frequency Warning Manual (80945C), and Safety

instructions related to installation on page 80.

 Contact a professional repair person who has a license.

XPR170 Instruction Manual 810060 39

Qualifications and Requirements

2

System electrical requirements

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance. You can
get a serious electric shock if electric power is not disconnected. Electric
shock can seriously injure or kill you.

All work that requires removal of the plasma power supply outer cover or
panels must be done by a qualified technician.

Refer to the Safety and Compliance Manual (80669C) for more safety
information.

Code conformity

WARNING

 Follow all local and national electrical safety requirements, including requirements for

correct electrical system design and installation.

 Always read, understand, and follow all of the safety instructions in this manual, the Safety

and Compliance Manual (80669C), and on the labels that are on the cutting system.

 Contact a licensed electrician for information about the codes in your location.

Input power requirements

General input power requirements

As an installer or user, you are responsible for supplying all of the switches, time-delay fuses, and
power cords necessary for cutting system installation and operation at the installation site. The
switches, fuses, and cords that you supply must satisfy all applicable national and local electrical
codes and requirements, and be installed by a licensed electrician.

General input power requirements appear in Table 7. For specific requirements for switches, fuses,
and cords, refer to Line-disconnect switch requirements on page 41, Circuit breaker and fuse

requirements on page 42, and Main power cord requirements on page 42.

40 810060 Instruction Manual XPR170

2

Table 7 – Input power requirements

Qualifications and Requirements

Input

Part number

078640 200

078641 208 112 150 70.5 (1/0)

078642 220 106 150 70.5 (1/0)

078643 240 97 125 43.2 (2)

078644 380 62 80 27.3 (4)

078645 400 59 80 27.3 (4)

078646 415 56 70 17.2 (6)

078647 440 53 70 17.2 (6)

078648 480 49 65 17.2 (6)

078649 600 39 50 10.8 (8)

voltage

(VAC)

* AWG requirements must comply with the latest version of the US National Electric Code (in North America)

or the latest electric wiring and installation requirements (based on the codes in your location). Table 7 is for
reference only; the requirements for your location can be different. Follow all local and national electrical
codes in your location.

Phase

3

Rated input

current at 35.7 kW

output

(A)

117 150 70.5 (1/0)

Recommended

time-delay fuse

size

(A)

Recommended size

for the main power

cord 90°C (194°F)

2

(mm

Power

(kVA)

[AWG*])

40.48

The strain relief for the input power cord that comes with the plasma



power supply is sized properly (refer to Ta b le 7). Contact a licensed
electrician to make sure that your main power cord size and length meet
the codes in your location.

Plasma power supply

As an installer or user, you must connect the plasma power supply to one of the branch-feed
circuits. Use a separate, primary line-disconnect switch for the plasma power supply. Refer to

Line-disconnect switch requirements on page 41.

Always follow the local and national electrical safety requirements for your location, including
requirements for correct electrical system design and installation. Contact a licensed electrician for
more information about 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. 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.

XPR170 Instruction Manual 810060 41

Qualifications and Requirements

2

Circuit breaker and fuse requirements

For main feed protection, choose a circuit breaker or fuse that is large enough to withstand all
branch-feed loads for both inrush and steady-state current. Refer to Ta ble 7 on page 41 for the
recommended time-delay fuse sizes.

As an installer or user, you must choose time-delay fuses and circuit breakers that can withstand
inrush current that is up to 30 times the rated input current for 0.01 seconds and up to 12 times the
rated input current for 0.1 seconds.

The size requirements for breakers or fuses at your site can change because of the following:

 Local line conditions (such as source and line impedance and voltage fluctuations)
 Product inrush characteristics
 Regulatory requirements

Always follow the local and national electrical safety requirements for your location, including
requirements for correct electrical system design and installation. Contact a licensed electrician for
more information about the codes in your location.

If time-delay, high-inrush fuses are not permitted at your site because of



national or local codes, use a motor-start circuit breaker or equivalent.

Main power cord requirements

As an installer or user, you must supply the main power cord for your cutting system. Refer to Ta bl e

7 on page 41 for recommended main power cord size.

The recommended main power cord sizes in Tab le 7 are based on Table 310.15 of the US National
Electric Code (2017 Handbook). Ta ble 7 shows stranded-flexible cord rates for 90°C (194°F). The
size requirement for the main power cord at your site can change because of the following
conditions:

 Wires with lower temperature ratings
 Wires with different insulation types
 Different distances between the line-disconnect switch/receptacle and the plasma power

supply

 Local codes and regulations

Always follow the local and national electrical safety requirements for your location, including
requirements for correct electrical system design and installation. Contact a licensed electrician for
more information about the codes in your location.

42 810060 Instruction Manual XPR170

2

Input power requirements for CE units

The XPR cutting system complies with IEC 6100-3-11 and IEC 61000-3-12, provided that the
short-circuit power (Ssc) between the supply and the public system for the installation site is
greater than (or equal to) 6.79 MVA. The installer or user is responsible for verifying that the
short-circuit power (Ssc) for the installation site satisfies this requirement.

If necessary, you can consult with the distribution network operator for



your site to verify the short-circuit power Ssc for your site.

The XPR cutting system is intended for use only in sites that have a service current capacity that is
greater than (or equal to) 100 A per phase and supplied from a distribution network that has a
nominal voltage of 400/230 V. The installer or user is responsible for verifying that the service
current capacity for the installation site satisfies this requirement.

Remote on-off switch

Qualifications and Requirements

WARNING

ELECTRIC SHOCK CAN KILL

The plasma power supply contains dangerous electric voltages that can seriously injure or
kill you.

Even if the plasma power supply is turned OFF, you can still get a serious electric
shock if the plasma power supply remains connected to an electric power source. When

the remote on-off switch is in the OFF position, electric power remains active to the
following components in the system:

• Control board

• Control transformer input and output

• 48 V power supply

• 24 V power supply

• 120 VAC and 220 VAC on the power distribution board

• Input side of the contactors

• Input side of the pump relay

• Power-indicator LED on the front of the plasma power supply

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. 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.

You must supply the remote on-off switch (or switches) for your cutting system.

XPR170 Instruction Manual 810060 43

Qualifications and Requirements

2

A remote on-off switch lets you supply electric power to or remove electric power from the gas
connect console, torch connect 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.

For information about how to do this, refer to How to install a remote



on-off switch on page 200.

44 810060 Instruction Manual XPR170

Qualifications and Requirements

2

Process gas requirements (Core, CorePlus, VWI, and OptiMix gas connect consoles)

As an installer or user, you must supply the process gases and supply gas plumbing for your cutting
system. Refer to Table 8 on page 45 for supply gas quality, pressure, and flow requirements.

Process gas requirements include the following:

 Nitrogen is required for all processes.
 Air is required for H
 Water can be used as a shield fluid for plasma power supplies that have a VWI or OptiMix

mix and F5 processes.

2

gas connect console. Refer to Shield water requirements (VWI and OptiMix) on page 51 for
the specifications and requirements for water that is used for shield purposes.

Table 8 – Gas quality, pressure, and flow requirements

Gas Quality System inlet pressure (during gas flow*) Flow rate

O

(oxygen) 99.5% pure, clean, dry,

2

oil-free

N

(nitrogen) 99.99% pure, clean, dry,

2

oil-free

Air** Clean, dry, oil free

consistent with
8573-1:2010 Class 1.4.2

H

(hydrogen) 99.995% pure

2

Ar (argon) 99.99% pure; clean, dry,

oil-free

Core, CorePlus, VWI: 7.5 bar ± 0.4 (110 psi ± 5)

OptiMix: 7.9 bar ± 0.4 (115 psi ± 5)

Core, CorePlus, VWI: 7.5 bar ± 0.4 (110 psi ± 5)

OptiMix: 8.3 bar ± 0.4 (120 psi ± 5)

Core, CorePlus, VWI: 7.5 bar ± 0.4 (110 psi ± 5)

OptiMix: 7.9 bar ± 0.4 (115 psi ± 5)

OptiMix: 8.3 bar ± 0.4 (120 psi ± 5)

CorePlus, VWI: 7.5 bar ± 0.4 (110 psi ± 5)

OptiMix: 8.3 bar ± 0.4 (120 psi ± 5)

71 slpm

(150 scfh)

181 slpm

(380 scfh)

118 slpm

(250 scfh)

50 slpm

(105 scfh)

118 slpm

(250 scfh)

F5 (95% nitrogen,
5% hydrogen)

* When there is no gas flow, make sure that the pressure at the gas inlet connection is less than 8.6 bar

** Any air compressors that supply air to the cutting system must remove oil prior to air delivery.

Hypertherm recommends that air compressors supply air that obey the following requirements of ISO
Standard 8573-1:2010 Class 1.4.2:

Maximum particle count in 1.0 m

Maximum water vapor pressure dew point: 3°C (37°F)
Maximum oil concentration: 0.1 mg/m

XPR170 Instruction Manual 810060 45

99.98% pure VWI: 7.5 bar ± 0.4 (110 psi ± 5)
OptiMix: 7.9 bar ± 0.4 (115 psi ± 5)

(125 psi) to avoid system alerts.

3

: • 20,000 at 0.1 microns – 0.5 microns

• 400 at 0.5 microns – 1.0 microns

• 10 at 1.0 microns – 5.0 microns

3

(for aerosol, liquid, and vapor)

40 slpm

(85 scfh)

Qualifications and Requirements

2

Speak to your air compressor manufacturer if you operate the cutting system in



temperatures colder than 3°C (37°F) or if you are unsure that the air compressor
can obey the ISO standard for air quality.

NOTICE

RUST IN GAS CYLINDERS CAN GET INTO THE GAS LINE

Rust can collect at the bottom of gas cylinders. If the rust mixes with the gas, it can get into the gas line
and decrease cut quality and performance.

When you move gas cylinders, make sure that you do not put them on their side, roll, or shake them.

Code conformity

 All installer or user-supplied equipment must meet applicable national and local codes for

supply gas and supply gas plumbing. Contact a licensed plumber for more information
about the codes in your location.

 Any installation, modification, or repair of supply gas equipment or plumbing systems must

be done by a licensed plumber.

46 810060 Instruction Manual XPR170

2

Plumbing for supply gases

OXYGEN GAS CAN CAUSE A FIRE HAZARD

If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to
the oxygen-enriched atmosphere that collects.

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. A fire can occur if oxygen is not removed.

Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).

As an installer or user, you must supply the exhaust ventilation and flashback arrestors for
your cutting system. You can get them from your cutting machine supplier.

HYDROGEN GAS CAN CAUSE AN EXPLOSION OR FIR E

Qualifications and Requirements

WARNING

Hydrogen is a flammable gas that can cause an explosion or fire. Keep flames away from
cylinders and hoses that contain hydrogen. Keep flames and sparks away from the torch
when using hydrogen as a plasma gas.

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. An explosion or fire can occur if hydrogen is not removed.

Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).

As an installer or user, you must supply the exhaust ventilation and flashback arrestors for
your cutting system. You can get them from your cutting machine supplier.

As an installer or user, you must install the supply gases and supply gas plumbing for your cutting
system.

 You can use flexible hoses that are designed to carry the appropriate gas and are rated for

the correct pressure. Other hoses can crack and leak.

 For the best results, use the recommended torque specifications for plumbing and hose

fittings. Refer to Ta ble 12 on page 52.

 You can use rigid copper pipes.
 Do not use steel or aluminum.

Supply-gas hoses are available from Hypertherm. Refer to Supply hoses



on page 398.

XPR170 Instruction Manual 810060 47

Qualifications and Requirements

2

All installer or user-supplied equipment must meet applicable national and



local codes for supply gas and supply gas plumbing. Contact a licensed
plumber for more information about the codes in your location.

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. Ta ble 9 on page 48 describes the recommended sizes for gas
fittings.

Table 9 – Recommended sizes for gas fittings

Fitting type Size

/ Ar 5/8 inch – 18 RH, internal (inert gas) “B”

N

2

Air 9/16 inch – 19, JIC #6



F5 / H

2

O

2

The location of regulators and the number of elbow fittings can have an
effect on inlet pressure. If the inlet pressure for your cutting system is not
within recommended specifications, contact your cutting machine
supplier or regional Hypertherm Technical Service team.

9/16 inch – 18, LH (fuel gas) “B”

9/16 inch – RH (oxygen)

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.

NOTICE

INCORRECT SUPPLY-GAS CONNECTIONS CAN CAUSE CUTTING SYSTEM
DAMAGE

NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that
gas type or pressure.

Incorrect connections can reduce the life of consumables and damage the torch head,
torch receptacle, torch leads, and torch connect console.

48 810060 Instruction Manual XPR170

Qualifications and Requirements

2

CAUTION

INCORRECT HOSES, CONNECTIONS, OR FITTINGS CAN CAUSE DAMAGE AND BAD
PERFORMANCE

All hoses, hose connections, and hose fittings used for supply-gas plumbing must be designed for use
with the appropriate gas and pressure rating. Incorrect hoses, hose connections, or hose fittings can
crack or leak.

NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or
pressure.

A replacement hose, connection, or fitting must meet all applicable regulations and codes.
Non-compliant hoses, hose connections, or hose fittings can crack or leak. The wrong fittings can

cause malfunctions with the internal valves because contaminants can enter the valves through
damaged or loose fittings.

NOTICE

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.

Regulators for supply gases

CAUTION

LOW-QUALITY REGULATORS CAN REDUCE PERFORMANCE AND CUT QUALITY

Do not use low-quality gas regulators. They do not provide consistent supply-gas pressure. Low-quality
gas regulators can also reduce system performance and decrease cut quality.

NOTICE

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.

The installer or user must supply the gas regulator (regulators) for the cutting system.

XPR170 Instruction Manual 810060 49

Qualifications and Requirements

2

It is important to choose the correct gas regulator (regulators) for the conditions at the installation
site. A gas regulator must be compatible with the gases used and appropriate for the environmental
conditions. For example, certain regulators are recommended for specific temperature ranges. The
type of gas (cylinder gas, line gas, or liquefied gas), and the gas-delivery pressure and flow, can also
influence regulator selection.

Single-stage gas regulation • Reduces source gas pressure to the necessary delivery pressure in

1step.

• Delivery pressure is not tightly controlled with this type of gas
regulation.

• Good choice for generic applications and where fluctuations in source
gas pressure are small.

Dual-stage gas regulations • Reduces source gas pressure to the necessary delivery pressure in

2 steps. Dual-stage regulation uses 2 single-stage regulators. The first
regulator reduces the pressure to approximately 3 times the maximum
delivery pressure. The second regulator reduces pressure to the
necessary delivery pressure.

• Good choice for applications that require consistent delivery pressure
and where fluctuations in source gas pressure are large.

Your gas supplier can recommend the best gas regulator (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

Table 9 – Recommended sizes for gas fittings on page 48.

50 810060 Instruction Manual XPR170

2

Shield water requirements (VWI and OptiMix)

If you use water as a shield fluid, refer to Tab le 10 for water pressure and flow requirements and

Tab le 1 1 for water-purity guidelines.

If using shield water, the temperature range for cutting system operation



and storage is reduced to above 0°C to 40°C (32°F to 104°F).

Table 10 – Quality, pressure, and flow requirements for shield water

Qualifications and Requirements

Quality*

Deionized water is not recommended to use as shield water.
Deionized water will react with the copper components in the

system and result in decreased life of components and
consumables.

Hypertherm recommends that you contact a water-quality
expert for guidance.

Table 11 – Purity requirements for shield water

Particulate type Purity requirement

Total dissolved solids < 61 PPM

Calcium + magnesium < 40 PPM

Silica < 5 PPM

pH 6.5 – 8.0

A TDS meter indicates the Total Dissolved Solids (TDS) of a solution.



Dissolved ionized solids (such as salts and minerals) increase the
electrical conductivity of a solution. Total dissolved solids can be tested
with a TDS meter (Hypertherm Waterjet part number 1-13897) available
from Hypertherm.

Minimum and
maximum pressure

2.76 bar (40 psi)
minimum

8.27 bar (120 psi)
maximum

Flow rate required

35 L/h (9.4 US gal/h)

* 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. Refer to Shield water

requirements (VWI and OptiMix) on page 51.

XPR170 Instruction Manual 810060 51

Qualifications and Requirements

2

Plumbing and hose requirements for shield water

The installer or user must supply the plumbing and hoses for the shield water.

 You can use flexible hoses that are designed to carry water.
 For the best results, use the recommended torque specifications for plumbing and hose

fittings. Refer to Ta ble 12 on page 52.

 You can use rigid copper pipes.
 Do not use steel or aluminum pipes.

Install the plumbing and hoses consistent with all local and national codes. After installation,
pressurize the entire system and test it for leaks.

To decrease the risk of leaks in the cutting system, make sure to tighten all connections to the
recommended torque specifications in Table 1 2 on page 52.

Hoses are available from Hypertherm. Refer to Water (optional shield



fluid) (blue) on page 399 of the Parts List.

Additional regulator requirement for shield water (optional)

Water pressure regulators are built into the VWI and OptiMix gas connect consoles. Additional
water pressure regulators are only required when the water pressure is above 7.92 bar (115 psi).

Torque requirements for gas or water plumbing and hose connections

For the best results, use the recommended torque specifications for plumbing and hose fittings.

Table 12 – Torque specifications

Torque Specifications

Gas or water hose size N∙m in∙lbf ft∙lbf

Up to 10 mm (3/8 inch) 8.5 – 9.5 75 – 84 6.25 – 7

12 mm (1/2 inch) 16.3 – 19.0 144 – 168 12 – 14

25 mm (1 inch) 54.2 – 88.1 480 – 780 40 – 65

52 810060 Instruction Manual XPR170

Qualifications and Requirements

2

Requirements for shield water removal for freezing-ambient temperatures

If your XPR cutting system uses shield water and is stored in ambient temperatures at or below
0ºC (32ºF), Hypertherm recommends shield water removal.

Follow these steps to remove shield water from the gas connect console (VWI or OptiMix):

1. Remove the shield water supply line to the gas connect console.

2. Access a source of compressed air that is clean and dry. Use a regulator to adjust the

compressed air to 5.52 bar (80 psi).

3. Connect the compressed air hose to the water inlet on the gas connect console.

The air hose needs to adapt to a JIC 6 male fitting on the gas connect



console.

4. Use the XPR web interface or CNC to select a process ID for a water process (such as 2028).

5. Select Preflow from the Plasma Process Selection menu.

During preflow, water mist will exit the torch nozzle for approximately 45 –



50 seconds.

6. Repeat step 5 until shield water mist is no longer visible exiting the torch nozzle.

It can take 7 – 10 preflow cycles for the shield water mist to stop.



XPR170 Instruction Manual 810060 53

Qualifications and Requirements

2

Coolant requirements

The cutting system ships without coolant in the reservoir. Before you operate the cutting system,
you must fill it with coolant. The capacity of the coolant system is between 22.7 liters – 45 liters
(6 US gallons – 12 US gallons).

Lead length has an effect on the total coolant volume needed. A cutting system with long leads
needs more coolant than a cutting system with short leads.

Before you fill the coolant reservoir (refer to Coolant Installation on page 203), choose the best
coolant for your operating conditions. The ambient temperature range where your cutting system
operates affects the coolant that you choose.

NOTICE

LOW COOLANT LEVELS CAN DAMAGE THE CUTTING SYSTEM AND COOLANT PUMP

Never operate the cutting system if you get a low coolant level notice. There is a risk of serious damage
to the cutting system and to the coolant pump if you operate the cutting system with no coolant or with
low coolant.

If your coolant pump is damaged, pump replacement can be necessary.

NOTICE

AUTOMOTIVE ANTIFREEZE CAN DAMAGE THE TORCH COOLANT SYSTEM

Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that can
damage the torch coolant system.

Make sure to read and follow the warning and cautions below. Refer to the Material Safety Data
Sheets (MSDS) and Safety Data Sheets (SDS) for safety data and information about how to handle
and store coolant, propylene glycol, and benzotriazole. You can find the MSDS and SDS online.
Technical documentation is available at www.hypertherm.com/docs.

WARNING

COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF
SWALLOWED

Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if
swallowed. When you come into contact, flush skin or eyes with water. If swallowed, seek
immediate medical attention.

54 810060 Instruction Manual XPR170

Qualifications and Requirements

2

Coolant requirements for operation between -10°C – 40°C (14°F – 104°F)

Use Hypertherm premixed coolant (028872) when operating in a temperature range of -10°C to
40°C (14°Fto104°F).

If using shield water, the temperature range for cutting system operation



and storage is reduced to above 0°C to 40°C (32°F to 104°F).

If it is possible for the temperature to go below -10°C (14°F) when the cutting system is not in use,
adjust coolant propylene glycol concentration to 50% to prevent damage to cooling system
components.

Operating your XPR system below -10°C (14°F) is not recommended due



to reduced consumable life and performance.

To increase the coolant propylene glycol percentage, add 100% propylene glycol (028873) to the
premixed Hypertherm coolant (028872) according to the calculation below. The maximum
percentage of propylene glycol should never exceed 50%.

Total system coolant
volume (in liters)*

Total system coolant
volume (in US gallons)*

* Refer to Estimate the total coolant volume for your cutting system on page 256.

X 0.4 = Total volume in liters of 100% propylene glycol to

add

X 1.514 = Total volume in US gallons of 100% propylene

glycol to add

Coolant requirements for operation in temperatures above 40°C (104°F)

For operating temperatures above 40°C (104°F) and that can never go at or below 0°C (32°F) use
treated water with no propylene glycol as coolant.

For operations in very warm temperatures, treated water provides the best cooling properties.

Treated water is a mixture of purified water that meets the Purity



requirements for coolant water on page 56 and 1 part benzotriazole

(128020) to 300 parts of water. Benzotriazole acts as a corrosion
inhibitor for the copper coolant system inside of the cutting system.

XPR170 Instruction Manual 810060 55

Qualifications and Requirements

2

Flow requirements for coolant

 The maximum coolant flow rate is 11.36 liters per minute (3.0 US gallons per minute).
 The minimum coolant flow rate is 3.79 liters per minute (1 US gallon per minute).

The cutting systems stops automatically if the flow rate reaches this maximum or minimum flow rate.
Automatic, low-flow shut-off protects the coolant pump from damage from low-flow or no-flow
conditions. Automatic, high-flow shut-off protects the torch and leads from damage from a blow-out
event.

For information about how to diagnose and troubleshoot coolant flow issues, refer to:

 Low coolant flow codes (540 – 542) on page 315
 High coolant flow codes (543 – 544) on page 317

Purity requirements for coolant water

Always use water that meets the specifications in Table 13 on page 56 when using a custom
coolant mix.

Water that is too pure can also cause problems. Deionized water can cause corrosion in the coolant
system. After deionization, add benzotriazole (128020).

Use water purified by any method (deionization, reverse osmosis, sand filters, water softeners, etc.)
as long as the water purity meets the specifications in the table below. Contact a water specialist for
advice in choosing a water filtration system.

Table 13 – Purity measurement methods for coolant water

Methods to measure water purity

Water purity level

Pure water
(For reference only. Do not

use.)

Maximum purity 0.5 2 0.206 0.010

Minimum purity 18 0.054 8.5 0.43

Maximum potable water
(For reference only. Do not
use.)

Conductivity S/cm

at25°C(77°F)

0.055 18.3 0 0

1000 0.001 495 25

Resistivity mcm

at25°C(77°F)

Dissolved solids

or hardness (ppm

of NaCl)

Grains per gallon

(gpg of CaCO

)

2

56 810060 Instruction Manual XPR170

2

Requirements to position system components

When you plan where to position the plasma power supply, gas connect console, torch connect
console, and torch, use the following limitations and requirements:

 Site requirements on page 61
 Length requirements for hoses, cables, and leads on page 61
 Bend radius requirements for hoses, cables, and leads on page 62
 Distance requirements between high-frequency leads and control cables on page 63
 Distance requirements for ventilation and access on page 63
 Distance requirements for communications on page 64

Qualifications and Requirements

XPR170 Instruction Manual 810060 57

Qualifications and Requirements

2

≤ 75 m (246.1 ft)

≤ 4.5 m (14.8 ft)

1

2

3

5

6

7

a

b

4

d

e

c

A B C

D

E

F

≤15 m (49.2 ft)

≤ 75 m (246.1 ft)

8

9

11

12

10

13

A Plasma power supply
B Gas connect console (Core)
C Torch connect console

D To rc h
E Cutting table
F Computerized numeric control (CNC)

1 Computerized numeric control (CNC) lead
2 Work lead
3 Controller area network (CAN) cable
4 Power cable (120 VAC)
5 Coolant hoses (1 supply, 1 return)
6 Pilot arc lead
7 Negative lead
8 Pilot arc and coolant hose set assembly

a Pilot arc lead
b Coolant hose set (1 supply, 1 return)

9 Power, CAN, 3-gas assembly

c Power cable (120 VAC)
d CAN cable
e 3 gas hoses (Core)

10 Tor c h lea d

11 Regulators

Position a gas regulator within 3 meters (10 feet)
of the gas connect console or take actions to
adjust inlet gas pressures to tolerances specified
in the process gas requirements.

12 Hoses for supply gases
13 Gases Core: O

2

, N2, and air

Recommended configuration with the Core gas connect console

58 810060 Instruction Manual XPR170

Qualifications and Requirements

2

≤ 75 m (246.1 ft)

≤ 4.5 m (14.8 ft)

1

2

3

5

6

7

a

b

4

d

e

c

A

B C

D

E

F

≤15m (49.2ft)

≤ 75 m (246.1 ft)

8

9

11

12

10

13

A Plasma power supply
B Gas connect console (CorePlus)
C Torch connect console

D To rc h
E Cutting table
F Computerized numeric control (CNC)

1 Computerized numeric control (CNC) lead
2 Work lead
3 Controller area network (CAN) cable
4 Power cable (120 VAC)
5 Coolant hoses (1 supply, 1 return)
6 Pilot arc lead
7 Negative lead
8 Pilot arc and coolant hose set assembly

a Pilot arc lead
b Coolant hose set (1 supply, 1 return)

9 Power, CAN, 4-gas assembly

c Power cable (120 VAC)
d CAN cable
e 4 gas hoses (CorePlus)

10 Tor c h lea d

11 Regulators

Position a gas regulator within 3 meters (10 feet)
of the gas connect console or take actions to
adjust inlet gas pressures to tolerances specified
in the process gas requirements.

12 Hoses for supply gases
13 Gases CorePlus: O

2

, N2, Ar, and air

Recommended configuration with the CorePlus gas connect console

XPR170 Instruction Manual 810060 59

Qualifications and Requirements

2

1

2

3

5

6

7

8

a

4

d

e

f

b

A

B

C

D

E

F

≤ 4.5 m (14.8 ft)

≤ 75 m (246.1 ft)

≤ 75 m (246.1 ft)

≤15m (49.2ft)

c

9

10

11

12

13

A Plasma power supply
B Gas connect console (VWI or OptiMix)
C Torch connect console

D To rc h
E Cutting table
F Computerized numeric control (CNC) lead

1 Computerized numeric control (CNC) lead
2 Work lead
3 Controller area network (CAN) cable
4 Power cable (120 VAC)
5 Coolant hoses (1 supply, 1 return)
6 Pilot arc lead
7 Negative lead
8 Pilot arc, coolant hose set, shield water assembly

a Pilot arc lead
b Coolant hose set (1 supply, 1 return)
c Shield water hose (VWI or OptiMix)

9 Power, CAN, 5-gas assembly

d Power cable (120 VAC)
e CAN cable

f 5 gas hoses (VWI or OptiMix)

10 Tor c h lea d

11 Regulators

Position a gas regulator within 3 meters (10 feet)
of the gas connect console or take actions to
adjust inlet gas pressures to tolerances specified
in the process gas requirements.

12 Hoses for supply gases
13 Gases and water

VWI: O

2

, air, N2, Ar, F5, and water

OptiMix: O

2

, air, N2, Ar, F5, water, H

2

Recommended configuration with the VWI or OptiMix gas connect console

60 810060 Instruction Manual XPR170

2

Site requirements

Qualifications and Requirements

Table 14 – Recommendations for where to position system components

Plasma power
supply

Gas connect
console*

Torch connect
console*

* The same recommendations are applicable for mezzanine locations.

• Level surface (less than 10° incline)

• Clean and dry area

• Able to support at least 680 kg (1,500 lb)

• Level surface (less than 10° incline)

• Clean and dry area

• Able to support the weight of your gas connect console (weight varies with type, refer to

Specifications on page 25)

• Clean and dry area

• Able to support at least 9.3 kg (20.5 lb)

Length requirements for hoses, cables, and leads

The distances between the plasma power supply, gas connect console, torch connect console,
torch, and cutting table are limited by the lengths of the interconnect hoses, cables, and leads that
connect them.

Table 15 – Length ranges for interconnect hoses, cables, and leads

From this component... to this component... ...the length can range from:

Plasma power supply Gas connect console (Core, CorePlus, VWI,

OptiMix)

Gas connect console Torch connect console 3 m (9.8 ft) – 18 m (59.1 ft)*

Torch connect console Torch or cutting table 2 m (6.6 ft) – 4.5 m (14.8 ft)*

* Refer to Recommended configuration with the Core gas connect console on page 58, Recommended

configuration with the CorePlus gas connect console on page 59, and Recommended configuration with the
VWI or OptiMix gas connect console on page 60 for visual distance requirements.

For a complete list of hoses, cables, and leads refer to Parts List on



page 359.

3 m (9.8 ft) – 75 m (246.1 ft)*

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.
 Cables and leads that are too long can cause electromagnetic interference (EMI).

EMI can have a negative effect on cut quality.



Contact your cutting machine supplier for recommendations about the best lead lengths for your
cutting system.

XPR170 Instruction Manual 810060 61

Qualifications and Requirements

2

15.25 cm
(6 in.)

Minimum bend radius

(measured inside diameter)

Bend radius requirements for hoses, cables, and leads

The following hoses, cables, and leads cannot bend beyond a
minimum bend radius of 15.25 cm (6 inches):

 Tor ch le ad
 Pilot arc lead
 Coolant hose set
 Power cable
 CAN cable
 3-gas hose bundle for the Core gas connect console
 4-gas hose bundle for the CorePlus gas connect console
 5-gas hose bundle for the VWI or OptiMix gas connect console
 Gas supply hoses

Maximum diameters for console-to-console lead sets

The connectors for the console-to-console lead sets have the following maximum diameters:

 5.6 cm (2.2 in.) for the pilot arc / coolant-hose lead set
 5.8 cm (2.3 in.) for the gas-hose set

Example OptiMix pilot arc / coolant-hose lead set*

Example OptiMix gas-hose set*

62 810060 Instruction Manual XPR170

* OptiMix assemblies shown as examples. The connectors on all console-to-console assemblies (Core,

CorePlus, VWI, and OptiMix) have the same diameter.

Qualifications and Requirements

2

The 18 meter (59.1 feet) assembly is compatible only with the 2 meter



(6.6 feet) or 2.5 meter (8.2 feet) torch lead. For lengths, refer to Gas

connect console to torch connect console connections in Parts List on

page 359.

Distance requirements between high-frequency leads and control cables

Electromagnetic interference (EMI) can occur if high-frequency leads (such as the pilot arc and
negative leads) are too close to control cables (such as the 120 VAC power, CAN, and EtherCAT
cables).

If possible, use a separate track to isolate each lead and cable.

If separate tracks are not possible, Hypertherm recommends a minimum separation distance
150 mm (6 inches) between the high-frequency leads and control cables. Separate the pilot arc
lead, negative lead, or any power cables that have a voltage higher than 120 VAC from the
following:

 CAN cable
 Power cable (120 VAC)

®

 CNC lead (EtherCAT, serial RS-422, or discrete lead)

Distance requirements for ventilation and access

 Ventilation

 Do not block the ventilation louvers on the corners or bottom panels of the front and

back of the plasma power supply. A separation distance of least 1 m (3.3 feet) is
required for ventilation.

 Do not block the ventilation louvers on the gas connect console. A separation distance

of least 1.27 cm (0.50 inch) is required for ventilation.

 Do not block the ventilation louvers on the torch connect console. You must use the

mounting brackets to allow space between the console and mounting surface.

 Service and maintenance access – 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.

XPR170 Instruction Manual 810060 63

Qualifications and Requirements

2

Distance requirements for communications

Table 16 – Maximum distance between the plasma power supply and controlling device

Communication type Distance

Wireless Unobstructed maximum radius of 30.5 m (100 ft)*

EtherCAT** Maximum 75 m (246.1 ft)

Discrete** Maximum 75 m (246.1 ft)

Serial RS-422** Maximum 75 m (246.1 ft)

* Obstructions or distances greater than 30.5 meters (100 feet) can have an effect on communication between

the plasma power supply and wireless device.

** Refer to Recommended configuration with the Core gas connect console on page 58, Recommended

configuration with the CorePlus gas connect console on page 59, and Recommended configuration with the
VWI or OptiMix gas connect console on page 60 for visual distance requirements.

Wireless compliance

Wireless devices use radio frequencies that may be regulated, but regulations differ from country to
country. Wireless devices that conform to IEEE standards 802.11a, 802.11b, 802.11g, 802.11n,

802.16e, and others, are designed for, or certified for use in, specific countries. Certificates of
Radio Frequency (RF) Compliance from wireless device manufacturers for wireless devices
integrated into Hypertherm products can be found in the “Downloads library” at

www.hypertherm.com.

The user of Hypertherm products that have integrated wireless devices is responsible for ensuring
that each wireless device has been certified for the country of use and configured with the correct
selection of frequency and channel for the country of use. Wireless devices that are integrated into
Hypertherm products are not allowed to be operated in countries where regulations for wireless
device certification have not been satisfied. Any wireless device or antennae modification or
deviation from the permissible configuration, markings, power, frequency settings, and other local
regulations on radio frequency wireless device for the country of use can be an infringement of
national law.

Refer to the XPR Wireless Compliance Manual (80992C) for more information.

64 810060 Instruction Manual XPR170

2

Torch mounting bracket requirements

You must supply the torch mounting bracket for your cutting system. Choose one that does the
following:

 Holds a torch diameter that is 57.15 mm (2.25 inches)
 Holds the torch perpendicular (at a 90° angle) to the workpiece (for non-bevel cutting)
 Does not interfere with the torch lifter

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 Tor c h bra ck et



on page 386 of the Parts List.

Torch lifter requirements

Qualifications and Requirements

Choose a lifter that has a weight capacity of at least 11.3 kg (25 lb). This includes the weight of a
torch rotational sleeve, if used.

Refer to your torch lifter instruction manual for more information.



CNC requirements

Remote on-off switch

The CNC must have a remote on-off switch

Adjustable settings

The CNC must allow the adjustment of the following settings:

 Current setpoint
 Plasma cutflow
 Shield cutflow
 Gas mixing setpoints

XPR170 Instruction Manual 810060 65

Qualifications and Requirements

2

Display settings

The CNC must show the following data:

 Plasma gas type
 Shield gas type
 Process ID selected
 System diagnostic codes
 Gas connect console firmware version
 Plasma power supply firmware version

The CNC must show the following data in real time to troubleshoot and diagnose system operation:

 Chopper current
 Work lead current
 System status codes
 Chopper temperature
 Transformer temperature
 Coolant temperature
 Coolant flow
 Process gas pressures
 Fan speeds

Diagnostics and troubleshooting

The CNC must be able to execute the following commands to diagnose and troubleshoot system
operation:

 Test preflow gases
 Test pierceflow gases
 Test cu tfl ow gas es
 Test for gas system leaks

For more information on CNC commands, refer to the CNC



Communication Protocol for the XPR Cutting System (809810).

66 810060 Instruction Manual XPR170

2

Recommended grounding and shielding

Introduction

This section describes practices for grounding and shielding a plasma cutting system to minimize its
susceptibility to electromagnetic interference (EMI) (also known as noise). It also describes the
service ground, protective earth (PE) ground, and DC power ground. The diagram at the end of this
section shows these types of grounds in a plasma cutting system.

The grounding practices in this section have been used on many



installations with excellent results, and Hypertherm recommends that
these practices be a routine part of the installation process. The actual
methods used to implement these practices may vary from system to
system, but should remain as consistent as possible. 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 local and national electrical codes to
make sure that the grounding and shielding practices that you use satisfy
the requirements for your location.

Qualifications and Requirements

Types of grounding

Service ground (also known as safety ground) is the grounding system that applies to the incoming
line voltage. It prevents a shock hazard to any personnel from any of the equipment or the cutting
table. It includes the service ground coming into the plasma system and other systems, such as the
CNC and the motor drives, as well as the supplemental ground rod connected to the cutting table.
In the plasma circuits, the ground is carried from the plasma system chassis to the chassis of each
separate console through the interconnecting cables.

Protective earth (PE) ground is the grounding system inside the electrical equipment. The PE
ground, which connects to the service ground, provides electrical continuity between the equipment
and the AC service.

DC power ground (also known as cutting current ground or work) is the grounding system that
completes the path of the cutting current from the torch back to the plasma system. It requires that
the positive lead from the plasma system be firmly connected to the cutting table ground bus with a
properly sized cable. It also requires that the slats, on which the workpiece rests, make firm contact
with the table and the workpiece.

EMI grounding and shielding is the grounding system that limits the amount of EMI emitted by the
plasma and motor drive systems. It also limits the amount of EMI that is received by the CNC and
other control and measurement circuits. The grounding practices described in this section mainly
target EMI grounding and shielding.

XPR170 Instruction Manual 810060 67

Qualifications and Requirements

2

Grounding practices

1. Unless noted, for XPR cutting systems, use cables with a minimum gauge of 21.2 mm2
(4 AWG) (047031) for the EMI ground cables shown in the Example grounding diagram with an

XPR cutting system on page 71.

2. The cutting table is used for the common, or star, EMI ground point and should have threaded
studs welded to the table with a copper bus bar mounted on them. A separate bus bar should
be mounted on the gantry as close to each motor as possible. If there are motors at each end of
the gantry, run a separate EMI ground cable from the far motor to the gantry bus bar. The gantry
bus bar should have a separate, heavy EMI ground cable 21.2 mm
table bus bar. The EMI ground cables for the torch lifter and the RHF or combined ignition/gas
connect console must each run separately to the table ground bus.

3. Inadequate grounding not only exposes operators to dangerous voltages, but inadequate
grounding also increases the risk of equipment failure and unnecessary downtime. Ideally a
ground should be zero ohms resistance, but field experience indicates under 1 ohm resistance
is satisfactory for most applications. Hypertherm recommends that you consult your local and
national electrical codes to make sure that the grounding and shielding practices that you use
satisfy the requirements for your location.

2

(4 AWG; 047031) to the

4. A ground rod (a PE ground) that meets all applicable local and national electric codes must be
installed within 6 m (20 ft) of the cutting table. For XPR cutting systems, the PE ground must be

2

connected to the cutting table ground bus bar using a minimum 21.2 mm

(4 AWG) grounding
cable (047031). Consult an electrician in your location to make sure that your grounding meets
all local and national electric codes.

5. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial
communication signals, between plasma systems in multi-drop connections, and for
interconnections between all parts of the Hypertherm system.

6. All hardware used in the ground system must be brass or copper. While you can use steel studs
welded to the cutting table for mounting the ground bus, no other aluminum or steel hardware
can be used in the ground system.

7. AC power, PE, and service grounds must be connected to all equipment according to local and
national codes.

8. For a system with a remote high frequency (RHF) console or combined ignition/gas connect
console, the positive, negative, and pilot arc leads should be bundled together for as long a
distance as possible. The torch lead, work lead, and the pilot arc (nozzle) leads may be run
parallel to other wires or cables only if they are separated by at least 150 mm (6 inches). If
possible, run power and signal cables in separate cable tracks.

9. For a system with a RHF console or combined ignition/gas connect console, Hypertherm
recommends that you mount this console as close as possible to the torch. This console also
must have a separate ground cable that connects directly to the cutting table ground bus bar.

10. Each Hypertherm component, as well as 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 system or to the cutting table.

68 810060 Instruction Manual XPR170

Qualifications and Requirements

2

1 Gantry ground bus

2 Ground rod

3 Plasma system lead (+)

4 Gas connect console

5 CNC enclosure

6 Torch holder

7 Plasma system chassis

8 Torch connect console

1 2 3

4

5 6

7 8

11 . For XPR cutting systems, the coupler on the pilot arc and coolant hose set assembly must be

connected firmly to the gas connect console and torch connect console collars. Make sure to
tighten the clamp. The collar on the torch lead must be connected firmly to the torch sleeve.
Make sure to tighten the clamp. Connect a ground lead (10 AWG) to the flat terminal on the
torch mounting sleeve.

12. The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the
part mounted to the torch – must be connected to the stationary part of the lifter with copper
braid at least 12.7 mm (0.5 inches) wide. A separate cable must run from the lifter to the gantry
ground bus bar. The valve assembly should also have a separate ground connection to the
gantry ground bus bar.

13. If the gantry runs on rails that are not welded to the table, then each rail must be connected with
a ground cable from the end of the rail to the table. The rail ground cables connect directly to
the table and do not need to connect to the table ground bus bar.

14. If you are installing a voltage divider board, mount it as closely as possible to where the arc
voltage is sampled. One recommended location is inside the plasma system enclosure. If a
Hypertherm voltage divider board is used, the output signal is isolated from all other circuits. The
processed signal should be run in twisted shielded cable (Belden 1800F or equivalent). Use a
cable with a braided shield, not a foil shield. Connect the shield to the chassis of the plasma
system and leave it unconnected at the other end.

15. All other signals (analog, digital, serial, and encoder) should run in twisted pairs inside a
shielded cable. Connectors on these cables should have a metal housing. The shield, not the
drain, should be connected to the metal housing of the connector at each end of the cable.
Never run the shield or the drain through the connector on any of the pins.

The following picture shows an example of a cutting table ground bus with an XPR cutting system.
The components shown here may differ from your system.

XPR170 Instruction Manual 810060 69

Qualifications and Requirements

2

1 Cable to the cutting table ground bus

2 Ground cables from components on the

gantry

1 2

The following picture shows an example of a gantry ground bus. It is bolted to the gantry, close to
the motor. All of the individual ground cables from the components mounted on the gantry connect
to the bus. A single heavy cable then connects the gantry ground bus to the table ground bus.

70 810060 Instruction Manual XPR170

2

Example grounding diagram with an XPR cutting system

Chassis and EMI ground

Service ground

1

2

3

4

5

6

7

8

9

10

11

PE earth ground

1 Cutting table
2 Gantry
3 Plasma system
4 Table ground bus bar
5 Gantry ground bus bar
6 Torch height control lifter
7 Torch connect console

8 CNC controller
9 Torch height control module

10 Gas connect console. Connect to table ground

bus bar.*

11 DC power ground (work)

* The ignition console is integrated into the gas connect

console for XPR cutting systems.

Qualifications and Requirements

XPR170 Instruction Manual 810060 71



This example is based on practices in North America. Other regions can
have different local or national electrical codes. Hypertherm recommends
that you consult your local and national electrical codes to make sure that
the grounding and shielding practices that you use satisfy the
requirements for your location.

Qualifications and Requirements

2

72 810060 Instruction Manual XPR170

Before you begin

Before you begin installation, make sure to:

 Read, understand, and follow all of the safety instructions that are in this manual, the Safety

and Compliance Manual (80669C), the Radio Frequency Warning Manual (80945C), and

affixed to the cutting system. Failure to follow safety instructions can result in personal injury
or equipment damage.

 Get all necessary reference documents. Refer to Document requirements on page 37.
 Consider the following requirements about where to position system components:

Installation

 Site requirements on page 61
 Length requirements for hoses, cables, and leads on page 61
 Bend radius requirements for hoses, cables, and leads on page 62
 Distance requirements between high-frequency leads and control cables on page 63
 Distance requirements for ventilation and access on page 63
 Distance requirements for communications on page 64

 Review the Installation checklist on page 74.

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 measurements taken are related to the specific environment in which the system is used.
Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C).

In addition, you can find an Acoustical Noise Data Sheet for your system at

www.hypertherm.com/docs. In the search box, enter data sheet.

XPR170 Instruction Manual 810060 73

Installation

3

Installation checklist

System requirements

Electrical

Refer to System electrical requirements on page 40.

Make sure that the electrical system conforms to all applicable codes.

Make sure that the input power meets requirements. Refer to Input power requirements on page 40.

Make sure that the circuit breaker or fuse meets requirements. Refer to Circuit breaker and fuse

requirements on page 42.

Make sure that the main power cord is the correct size and correctly installed. Refer to Main power cord

requirements on page 42.

As an installer or user, you must supply the main power cord for your cutting system.

Make sure that there is a separate line-disconnect switch for the plasma power supply. Refer to

Line-disconnect switch requirements on page 41.

As an installer or user, you must supply the line-disconnect switch for your cutting system.

Make sure that the emergency-stop switches are correctly installed.
As an installer or user, you must supply the emergency-stop switches for your cutting system.

Make sure that the remote on-off switch is correctly installed. Refer to Remote on-off switch on page 43.
As an installer or user, you must supply the remote on-off switch for your cutting system.

Process gas and plumbing

Refer to Process gas requirements (Core, CorePlus, VWI, and OptiMix gas connect consoles) on page 45. You
must supply the process gases and supply gas plumbing for your cutting system.

Make sure that the gas quality meets requirements.

Make sure that the gas pressure meets requirements.

Make sure that the gas flow meets requirements.

Make sure that the gas plumbing and hoses meet requirements. Refer to Plumbing for supply gases on
page 47.

The cutting system comes with the hoses that connect the plasma power supply components.
As an installer or user, you must supply the plumbing for the process gases.

Make sure that the plumbing is the correct type and correctly installed.
As an installer or user, you must supply flashback arrestors for your cutting system if you use

oxygen as the plasma gas.

Make sure that the hoses are the correct type and length, and that they are correctly installed.

Make sure that the regulators are the correct type, installed in the correct locations, and correctly
installed. Refer to Regulators for supply gases on page 49.

As an installer or user, you must supply the gas regulators for your cutting system.

Make sure that the plumbing conforms to all applicable codes.

74 810060 Instruction Manual XPR170

Installation

3

Shield water (VWI and OptiMix)

Refer to Shield water requirements (VWI and OptiMix) on page 51. You must supply the shield water for your
cutting system.

Make sure that the water quality meets requirements.

Make sure that the water pressure meets requirements.

Make sure that the water flow meets requirements.

Make sure that the water plumbing and hoses meet requirements. Refer to Plumbing and hose

requirements for shield water on page 52.

As an installer or user, you must supply the plumbing and hoses for shield water.

Make sure that the plumbing is the correct type and correctly installed.

Make sure that the hoses are the correct type and length, and that they are correctly installed.

Additional water pressure regulators are only required when the water pressure is above 7.92 bar
(115 psi). Refer to Additional regulator requirement for shield water (optional) on page 52.

Configuration

Refer to Requirements to position system components on page 57.

Make sure that the configuration of system components is correct. Refer to Configuration with Core gas

connect console on page 83, Configuration with CorePlus gas connect console on page 84, and
Configuration with VWI or OptiMix gas connect console on page 85.

Make sure that the spacing and ventilation for the plasma power supply meets requirements. Refer to

Distance requirements for ventilation and access on page 63.

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.

Make sure that the surfaces that hold system components are flat, dry, clean, and can support the weight.
Refer to Site requirements on page 61.

Make sure that the table ventilation meets requirements (if applicable) (check table type).

Water table

Downdraft table

Other (specify)

XPR170 Instruction Manual 810060 75

Installation

3

Hoses, cables, and leads

Do not bend the following hoses, cables, and leads beyond a minimum bend radius of 15.25 cm (6 inches):

Torch lead, pilot arc lead, coolant hose set, power cable, CAN cable, 3-gas hose bundle (for the Core gas connect
console), 4-gas hose bundle (for the CorePlus gas connect console), 5-gas hose bundle (for the VWI or OptiMix
gas connect console), and gas supply hoses.

The cutting system comes with the cables and leads that connect system components. Refer to the following
sections in the Parts List for part numbers and descriptions:

• Plasma power supply to gas connect console connections on page 391.

• Gas connect console to torch connect console connections on page 393.

• Plasma power supply to CNC connections on page 395.

• Plasma power supply to cutting table connection on page 396.

• Torch connect console to torch receptacle connection on page 397.

Make sure that the hoses, cables and leads are the correct type. Refer to Prepare the hoses, cables, and

leads on page 98.

Make sure that the hoses, cables, and leads are the correct length. Refer to Length requirements for

hoses, cables, and leads on page 61.

Grounding

Make sure that the grounding meets requirements. Refer to Recommended grounding and shielding on
page 67.

Plasma power supply

Gas connect console

Torch connect console

Cutting table

CNC

Torch lead collar

76 810060 Instruction Manual XPR170

3

Installation steps

Connections

Make sure that the connections between the plasma power supply and the gas connect console are
correctly installed. Refer to Connect the plasma power supply and gas connect console (Core, CorePlus,

VWI, or OptiMix) on page 102.

Coolant hose set

Power cable

CAN cable

Negative lead ( - )

Pilot arc lead

Make sure that the work lead ( + ) connection between the plasma power supply and the cutting table is
correctly installed. Refer to Connect the work lead to the plasma power supply and cutting table on
page 107.

Make sure that the connections between the gas connect console and torch connect console are correctly
installed. Refer to Connect the gas connect console (Core or CorePlus) to the TorchConnect console on
page 112 and Connect the gas connect console (VWI or OptiMix) to the TorchConnect console on
page 117.

Installation

Core

CorePlus

Refer to Connect the gas connect console (Core or CorePlus) to the TorchConnect

console on page 112.

Pilot arc and coolant hose set assembly. Refer to Connect the pilot arc and coolant

hose set assembly (Core or CorePlus) on page 112.

Power, CAN, and 3-gas assembly (Core only). Refer to Connect the power, CAN, and

3-gas assembly (Core) on page 115.

Refer to Connect the gas connect console (Core or CorePlus) to the TorchConnect

console on page 112.

Pilot arc and coolant hose set assembly. Refer to Connect the pilot arc and coolant

hose set assembly (Core or CorePlus) on page 112.

Power, CAN, and 4-gas assembly (CorePlus only). Refer to Connect the power, CAN,

and 4-gas assembly (CorePlus) on page 116.

XPR170 Instruction Manual 810060 77

Installation

3

Connections

VWI /
OptiMix

Make sure that the connection between the torch receptacle and torch connect console is installed
correctly. Refer to Connect the torch receptacle to the TorchConnect console on page 131.

Make sure that the hoses, cables, and leads are correctly installed.

Installation steps

Refer to Connect the gas connect console (VWI or OptiMix) to the TorchConnect

console on page 117.

Pilot arc, coolant hose set, and water assembly. Refer to Connect the pilot arc, coolant

hose set, and shield water assembly (VWI or OptiMix) on page 117.

Power, CAN, and 5-gas assembly. Refer to Connect the power, CAN, and 5-gas

assembly (VWI or OptiMix) on page 120.

Make sure that the connections are the correct type and correctly installed.

Make sure that there is no damage or kinks.

Make sure that there are no coils in the cables that can create EMI problems.

Make sure that the distance between high-frequency leads and control cables meets
requirements. Refer to Distance requirements between high-frequency leads and

control cables on page 63.

Make sure that the distance for communication meets requirements. Refer to Distance

requirements for communications on page 64.

Make sure that the consumables are the correct type and correctly installed. A loose or overtightened
electrode can cause torch damage. Hypertherm recommends between 2.3 Nm – 2.8 Nm (20 inlbf –
25 inlbf) torque to tighten an electrode. Refer to Install the consumables on page 138.

The torch head that comes with the XPR torch assembly kit (428846) has 170 A mild steel consumables
pre-installed.

Make sure that the torch is correctly installed.

Make sure that the torch mounting bracket is correctly installed. Refer to Torch mounting bracket

requirements on page 65.

As an installer or user, you must supply the torch mounting bracket for your cutting system.

Make sure that the torch is correctly installed into the torch receptacle. Refer to Install the torch

into the torch receptacle on page 140.

Make sure that the torch is correctly installed into the lifter. Refer to Torch lifter requirements on
page 65.

As an installer or user, you must supply the motorized torch lifter for your cutting system.

Electrical power – Make sure that electrical power is supplied to the cutting system. Refer to Connect

electric power to the cutting system on page 142.

78 810060 Instruction Manual XPR170

3

Installation steps

CNC interface – Make sure that the communication method is installed correctly. Refer to Connect for

Communication on page 151.

Coolant – Make sure that the coolant is installed correctly. Refer to Coolant Installation on page 203.

Installation

EtherCAT, and remote on-off must be wired discretely by the cutting system manufacturer

Wireless (XPR web interface) and discrete

Serial RS-422 and discrete

Make sure that the coolant type is correct. Refer to Coolant requirements on page 54.

Make sure that the coolant reservoir is full. Refer to How to fill the cutting system with coolant on
page 204.

XPR170 Instruction Manual 810060 79

Installation

3

Safety instructions related to installation

Before installation, make sure to read, understand, and follow all of the safety instructions that are in
this manual, the Safety and Compliance Manual (80669C), the Radio Frequency Warning Manual
(80945C), and on to the cutting system.

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect all electric power from the plasma power supply before you move
the plasma power supply or put it into position.

You can be seriously injured or killed if you move the plasma power supply
while it is connected to electric power.

Damage to the plasma power supply also can occur if you move it while it is
connected to electric power.

Refer to the Safety and Compliance Manual (80669C) for more safety
information.

WARNING

ELECTRIC SHOCK CAN KILL

The line-disconnect switch must be in the OFF position before you connect the power
cord to the cutting system. It must REMAIN in the OFF position until all installation steps
are complete.

If the line-disconnect switch is not in the OFF position you can get a serious electric
shock. Electric shock can seriously injure or kill you.

In the United States, use a “lock out/tag out” procedure until installation is complete. In
other countries, follow the appropriate national and local safety procedures.

WARNING

ELECTRIC SHOCK CAN KILL

When the line-disconnect switch is in the ON position, there is line voltage throughout the
cutting system.

Voltages in the cutting system can cause serious electric shock. Electric shock can
seriously injure or kill you.

Use extreme caution if you do diagnosis or maintenance tasks when the line-disconnect
switch is in the ON position.

80 810060 Instruction Manual XPR170

Installation

3

WARNING

ELECTRIC SHOCK CAN KILL

The plasma power supply contains dangerous electric voltages that can seriously injure or
kill you.

Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.

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.

WARNING

OXYGEN GAS CAN CAUSE A FIRE HAZARD

If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to
the oxygen-enriched atmosphere that collects.

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. A fire can occur if oxygen is not removed.

Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).

As an installer or user, you must supply the exhaust ventilation and flashback arrestors for
your cutting system. You can get them from your cutting machine supplier.

HYDROGEN GAS CAN CAUSE AN EXPLOSION OR FIR E

Hydrogen is a flammable gas that can cause an explosion or fire. Keep flames away from
cylinders and hoses that contain hydrogen. Keep flames and sparks away from the torch
when using hydrogen as a plasma gas.

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. An explosion or fire can occur if hydrogen is not removed.

Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).

As an installer or user, you must supply the exhaust ventilation and flashback arrestors for
your cutting system. You can get them from your cutting machine supplier.

XPR170 Instruction Manual 810060 81

Installation

3

WARNING

COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF
SWALLOWED

Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if
swallowed. When you come into contact, flush skin or eyes with water. If swallowed, seek
immediate medical attention.

NOTICE

AUTOMOTIVE ANTIFREEZE CAN DAMAGE THE TORCH COOLANT SYSTEM

Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that can
damage the torch coolant system.

CAUTION

INCORRECT COOLANT CAN DAMAGE THE CUTTING SYSTEM

Incorrect coolant can damage the cutting system. Refer to Coolant requirements on page 54.

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.

NOTICE

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.

NOTICE

FOR THE BEST CUT QUALITY AND CONSUMABLE LIFE USE THE CORRECT LEAD LENGTHS

The manufactured lengths of torch and console leads are critical for system performance.
Never change the lengths of leads. Cut quality and the lifespan of consumables will be decreased if you

change the lead lengths.

82 810060 Instruction Manual XPR170

3

Configuration with Core gas connect console

O2N

2

Air

7

a

b

1

2

3

4

5

6

d

10

c

Not to scale. For
position only.

8

9

e

*

11

1 Work lead
2 CNC connection cable (EtherCAT shown)
3 Controller area network (CAN) cable
4 Power cable (120 VAC)
5 Coolant hose set (1 supply, 1 return)
6 Pilot arc lead
7 Negative lead (2/0 or 4/0)
8 Pilot arc and coolant hose set assembly

a Pilot arc lead
b Coolant hose set (1 supply, 1 return)

9 Power, CAN, 3-gas assembly

c Power cable (120 VAC)
d CAN cable
e 3 gas hoses (Core)

10 Tor c h lea d

11 Hoses for supply gases

* Regulator

Position a gas regulator within 3 meters (10 feet)
of the gas connect console or take actions to
adjust inlet gas pressures to tolerances specified
in the process gas requirements.

Installation

XPR170 Instruction Manual 810060 83

Installation

3

O2N2Air

7

a

b

1

2

3

4

5

6

d

10

c

Not to scale. For
position only.

8

9

e

*

11

Ar

1 Work lead
2 CNC connection cable (EtherCAT shown)
3 Controller area network (CAN) cable
4 Power cable (120 VAC)
5 Coolant hose set (1 supply, 1 return)
6 Pilot arc lead
7 Negative lead (2/0 or 4/0)
8 Pilot arc and coolant hose set assembly

a Pilot arc lead
b Coolant hose set (1 supply, 1 return)

9 Power, CAN, 4-gas assembly

c Power cable (120 VAC)
d CAN cable
e 4 gas hoses (CorePlus)

10 Tor c h lea d

11 Hoses for supply gases

* Regulator

Position a gas regulator within 3 meters (10 feet)
of the gas connect console or take actions to
adjust inlet gas pressures to tolerances specified
in the process gas requirements.

Configuration with CorePlus gas connect console

84 810060 Instruction Manual XPR170

3

Configuration with VWI or OptiMix gas connect console

O2Air N

2

Ar

F5

H

2

H2O

H2 for OptiMix only

7

1

2

3

4

5

6

10

Not to scale. For
position only.

a

b

d

c

8

9

e

f

*

11

1 Work lead
2 CNC connection cable (EtherCAT shown)
3 CAN cable
4 Power cable (120 VAC)
5 Coolant hose set (1 supply, 1 return)
6 Pilot arc lead
7 Negative lead (2/0 or 4/0)
8 Pilot arc, coolant hose set, shield water assembly

a Pilot arc lead
b Coolant hose set (1 supply, 1 return)
c Shield water hose (VWI or OptiMix)

9 Power, CAN, 5-gas assembly

d Power cable (120 VAC)
e CAN cable

f 5 gas hoses (VWI or OptiMix)

10 Tor c h lea d

11 Hoses for supply gases/shield water

* Regulator

Position a gas regulator within 3 meters (10 feet)
of the gas connect console or take actions to
adjust inlet gas pressures to tolerances specified
in the process gas requirements.

Installation

XPR170 Instruction Manual 810060 85

Installation

3

Installation steps

Position the system components

Put all system components into position prior to making connections.

Plasma power supply

HEAVY EQUIPMENT CAN CAUSE SERIOUS INJURY IF DROPPED – LIFT
CAREFULLY

When lifting or moving the plasma power supply:

• Remove all cables, wires, and other potential obstacles that can get caught on the plasma
power supply.

• Only use lift equipment that can safely lift and support the plasma power supply.

• If you use the lift eye to lift the plasma power supply, lift only the plasma power supply. Do not
exceed the maximum lift-eye rating. See Tabl e 1 on page 28.

• If you use a lift truck, use one with forks that extend along the entire bottom of the plasma
power supply. The bottom of the plasma power supply has lift-truck slots. Make sure to use
them.

• Be gentle when you put the plasma power supply into position. Do not drop it from any height.

WARNING

The XPR170 plasma power supply weighs 454.5 kg (1,002 lbs). You must use lift equipment to put
it into position. Refer to Tabl e 17. To protect the plasma power supply from drops and damage
during lifting, make sure to balance it evenly and use slow speeds.

Table 17 – Equipment to lift or move the plasma power supply

Lift truck

Lift eye

Lift truck forks must be long enough to fully support and extend along the entire bottom of the
plasma power supply and rated to hold its weight.

The top of the plasma power supply has a lift eye. Prior to lifting, make sure that the lift equipment
can hold the weight of the plasma power supply.

86 810060 Instruction Manual XPR170

Installation

3

26.98 cm

(10.63 in.)

1.27 cm
(0.50 in.)

Gas inlet side of
gas connect
console

Gas inlet side of gas connect console (Core)

19.69 cm
(7.75 in.)

6.48 mm

(0.26 in.)

Never position the gas connect console at an angle

Gas outlet side of

gas connect

console

Gas connect console

All 4 gas connect consoles (Core, CorePlus, VWI, and OptiMix) have 3 mounting holes on the
bottom panel. For mounting dimensions, refer to Figure 1 on page 87 and Figure 2 on page 88. If
you have questions about when or how to use the mounting holes, contact your cutting machine
supplier or regional Hypertherm Technical Service team.

Figure 1 – Mounting dimensions for the Core, CorePlus, and VWI gas connect consoles

XPR170 Instruction Manual 810060 87

Installation

3

32.05 cm

(12.62 in.)

1.27 cm
(0.50 in.)

19.69 cm
(7.75 in.)

Gas inlet side of gas connect console (OptiMix)

6.48 mm
(0.26 in.)

Gas inlet side of gas
connect console

Never position the gas connect console at an angle

Gas outlet side

of gas connect

console

Figure 2 – Mounting dimensions for the OptiMix gas connect console

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Installation

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Bottom

Side

End

TorchConnect console

There are 3 mounting orientations for the TorchConnect console: 1 bottom, 1 end, and 1 side. The
factory-installed location for the mounting brackets is on the bottom. But, you can reposition them to
the end or to the side.

Make sure to consider how console orientation can have the following effects:

 Console orientation with the torch lead connection on the bottom can minimize the risk of

leaked water or coolant collection inside. Water or coolant inside the console can damage
internal electrical components.

 If the EasyConnect connection points up, it is necessary to support the torch lead so the

minimum 15.25 cm (6 in.) bend radius is maintained.

If you have questions about console orientation or about when or how to use the mounting brackets,
contact your cutting machine supplier or regional Hypertherm Technical Service team.

Figure 3 – Recommended orientations for the TorchConnect console

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339.85 mm
(13.38 in.)

135 mm

(5.31 in.)

6.35 mm
(0.25 in.)

Mounting brackets, side
orientation

Figure 4 – Side-mount orientation and mounting-bracket dimensions for the TorchConnect console

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339.85 mm
(13.38 in.)

135 mm
(5.31 in.)

6.35 mm
(0.25 in.)

101 . 60 mm

(4.00 in.)

Mounting brackets

Figure 5 – Bottom-mount orientation and mounting-bracket dimensions for the TorchConnect console

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Ground the system components

1. Prior to grounding, review all grounding and shielding recommendations. Refer to

Recommended grounding and shielding on page 67.

2. Ground system components after you position them and before you connect the hoses, cables,
and leads. Refer to Figure 6, Figure 7, Figure 8, and Figure 9 for grounding details.

Figure 6 – Plasma power supply grounding (detail)

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Figure 7 – Gas connect consoles grounding (detail)

Core and CorePlus VWI OptiMix

Ground stud

Ground stud

Installation

Figure 8 – TorchConnect console grounding (detail)

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Ground connection – Connect a ground lead
(10 AWG) to the flat terminal on the torch mounting
bracket

Figure 9 – Torch lead collar grounding (detail)

Remove the external panels from the system components

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance. You can
get a serious electric shock if electric power is not disconnected. Electric
shock can seriously injure or kill you.

All work that requires removal of the plasma power supply outer cover or
panels must be done by a qualified technician.

Refer to the Safety and Compliance Manual (80669C) for more safety
information.

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For installation usually it is necessary to remove only the rear panel.

WARNING

ELECTRIC SHOCK CAN KILL

The plasma power supply contains dangerous electric voltages that can seriously injure or
kill you.

Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.

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.

Figure 10 – Remove the rear panel from the plasma power supply

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Move the panel
horizontally to remove it.

Figure 11 – Remove panels from the gas connect console

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Figure 12 – Remove top and side panels from the TorchConnect console

Installation

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Prepare the hoses, cables, and leads

Use the following drawings to identify the correct hoses, cables, and leads prior to installation. For
part numbers and specifications, refer to the Parts List on page 359.

Coolant hose set

The coolant hose set includes 1 supply hose with green bands and



1 return hose with red bands.

Negative lead with strain relief

Pilot arc lead with strain relief

Power cable

CAN cable

Work lead

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Pilot arc and coolant hose set assembly

The coolant hose set includes 1 supply hose with green bands and



1 return hose with red bands. The 18 meter (59.1 feet) assembly is
compatible only with the 2 meter (6.6 feet) or 2.5 meter (8.2 feet) torch
lead.

Power, CAN, 3-gas assembly (only for Core)

Installation

The 18 meter (59.1 feet) assembly is compatible only with the 2 meter



(6.6 feet) or 2.5 meter (8.2 feet) torch lead.

Power, CAN, 4-gas assembly (only for CorePlus)

The 18 meter (59.1 feet) assembly is compatible only with the 2 meter



(6.6 feet) or 2.5 meter (8.2 feet) torch lead.

Pilot arc, coolant hose set, and shield water assembly (only for VWI and OptiMix)

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The coolant hose set includes 1 supply hose with green bands and



1 return hose with red bands. The 18 meter (59.1 feet) assembly is
compatible only with the 2 meter (6.6 feet) or 2.5 meter (8.2 feet) torch
lead.

Power, CAN, and 5-gas assembly (only for VWI and OptiMix)

The 18 meter (59.1 feet) assembly is compatible only with the 2 meter



(6.6 feet) or 2.5 meter (8.2 feet) torch lead.

Oxygen hose (blue)

Nitrogen hose (black)

Air hose (black)

Hydrogen (OptiMix only) (red)

Argon (CorePlus, VWI, or OptiMix only) (black)

F5 (VWI or OptiMix only) (red)

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