XPR300™
Replacement Part Procedures
Field Service Bulletin
809970 | Revision 1 | January 2019
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
return.materials@hypertherm.com (RMA email)
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Soporte.Tecnico@hypertherm.com (Technical Service Email)
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)
technicalservice.emea@hypertherm.com (Technical Service Email)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
Marketing.asia@hypertherm.com (Marketing Email)
TechSupportAPAC@hypertherm.com (Technical Service Email)
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
HTJapan.info@hypertherm.com (Main Office Email)
TechSupportAPAC@hypertherm.com (Technical Service Email)
Hypertherm Europe B.V.
Vaartveld 9, 4704 SE
Roosendaal, 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)
technicalservice.emea@hypertherm.com
(Technical Service Email)
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)
techsupport.china@hypertherm.com
(Technical Service Email)
South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
tecnico.sa@hypertherm.com (Technical Service Email)
Hypertherm Korea Branch
#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
Marketing.korea@hypertherm.com (Marketing Email)
TechSupportAPAC@hypertherm.com
(Technical Service Email)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
au.sales@Hypertherm.com (Main Office Email)
TechSupportAPAC@hypertherm.com
(Technical Service Email)
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
HTIndia.info@hypertherm.com (Main Office Email)
TechSupportAPAC@hypertherm.com
(Technical Service Email)
1/28/16
© 2019 Hypertherm, Inc. All rights reserved.
XPR, EasyConnect, OptiMix, VWI, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries. All other
trademarks are the property of their respective holders.
One of Hypertherm’s long-standing core values is a focus on minimizing our impact on the environment. Doing so is critical to our, and our customers’, success. We are
always striving to become better environmental stewards; it is a process we care deeply about.
ENGLISH
WARNING! Before operating any Hypertherm equipment, read the safety
instructions in your product’s manual and in the Safety and Compliance Manual
(80669C). Failure to follow safety instructions can result in personal injury or in
damage to equipment.
Copies of the manuals may accompany the product in electronic and printed
formats. You can also obtain copies of the manuals, in all languages available
for each manual, from the “Documents library” at www.hypertherm.com.
DANSK / DANIS H
ADVARSEL! Inden Hypertherm udstyr tages i brug skal
sikkerhedsinstruktionerne i produktets manual og i Manual om sikkerhed og
overholdelse af krav (80669C), gennemlæses. Følges sikkerhedsvejledningen
ikke kan det resultere i personskade eller beskadigelse af udstyret.
Kopier af manualerne kan ledsage produktet i elektroniske og trykte formater.
Du kan også få kopier af manualer, på alle sprog der er til rådighed for hver
manuel, fra “Dokumentbiblioteket” på www.hypertherm.com.
DEUTSCH / GERMAN
WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen
Sie bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung sowie im
Handbuch für Sicherheit und Übereinstimmung (80669C). Das Nichtbefolgen
der Sicherheitsanweisungen kann zu Verletzungen von Personen oder
Schäden am Gerät führen.
Bedienungsanleitungen und Handbücher können dem Gerät in
elektronischer Form oder als Druckversion beiliegen. Alle Handbücher
und Anleitungen können in den jeweils verfügbaren Sprachen auch in der
„Dokumente-Bibliothek“ unter www.hypertherm.com heruntergeladen werden.
FRANÇAIS / FRENCH
AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les
consignes de sécurité importantes dans le manuel de votre produit et dans
le Manuel de sécurité et de conformité (80669C). Le non-respect des
consignes de sécurité peut engendrer des blessures physiques ou des
dommages à l’équipement.
Des copies de ces manuels peuvent accompagner le produit en format
électronique et papier. Vous pouvez également obtenir des copies de chaque
manuel dans toutes les langues disponibles à partir de la «Bibliothèque
de documents» sur www.hypertherm.com.
ESPAÑOL / SPANISH
¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, leer las
instrucciones de seguridad del manual de su producto y del Manual de
Seguridad y Cumplimiento (80669C). No cumplir las instrucciones
de seguridad podría dar lugar a lesiones personales o daño a los equipos.
Pueden venir copias de los manuales en formato electrónico e impreso
junto con el producto. También se pueden obtener copias de los manuales,
en todos los idiomas disponibles para cada manual, de la “Biblioteca
de documentos” en www.hypertherm.com.
ITALIANO / ITALIAN
AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni
sulla sicurezza nel manuale del prodotto e nel Manuale sulla sicurezza e
la conformità (80669C). Il mancato rispetto delle istruzioni sulla sicurezza può
causare lesioni personali o danni all’attrezzatura.
Il prodotto può essere accompagnato da copie elettroniche e cartacee
del manuale. È anche possibile ottenere copie del manuale, in tutte le lingue
disponibili per ogni manuale, dall’“Archivio documenti” all’indirizzo
www.hypertherm.com.
NEDERLANDS / DUTCH
WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
de veiligheidsinstructies in de producthandleiding en in de Veiligheids- en
nalevingshandleiding (80669C). Het niet volgen van de veiligheidsinstructies
kan resulteren in persoonlijk letsel of schade aan apparatuur.
De handleidingen kunnen in elektronische en gedrukte vorm met het
product worden meegeleverd. De handleidingen, elke handleiding
beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek”
op www.hypertherm.com.
PORTUGUÊS / PORTUGUESE
ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as
instruções de segurança no manual do seu produto e no Manual de Segurança
e de Conformidade (80669C). Não seguir as instruções de segurança pode
resultar em lesões corporais ou danos ao equipamento.
Cópias dos manuais podem acompanhar os produtos nos formatos eletrônico
e impresso. Também é possível obter cópias dos manuais em todos os idiomas
disponíveis para cada manual na “Biblioteca de documentos” em
www.hypertherm.com.
日本語 / JAPANESE
警告 ! Hypertherm 機器を操作する前に、安全に関する重要な情報につい
て、この製品説明書にある安全情報、および製品に同梱されている別冊の
「安全とコンプライアンスマニュアル」 (80669C) をお読みください。安全
情報に従わないと怪我や装置の損傷を招くことがあります。
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。各説明書は、 www.hypertherm.com の「ドキュメントライブラ
リ」から各言語で入手できます。
简体中文 / CHINESE (SIMPLIFIED)
警告！ 在操作任何海宝设备之前，请阅读产品手册和 《安全和法规遵守手
册》 (80669C) 中的安全操作说明。若未能遵循安全操作说明，可能会造成
人员受伤或设备损坏。
随产品提供的手册可能提供电子版和印刷版两种格式。您也可从
“Documents library” （文档资料库）中获取每本手册所有可用语言的副本，
网址为 www.hypertherm.com.
NORSK / NORWEGIAN
ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese
sikkerhetsinstruksjonene i produktets håndbok og i Håndboken om sikkerhet
og samsvar (80669C). Unnlatelse av å følge sikkerhetsinstruksjoner kan føre
til personskade eller skade på utstyr.
Eksemplarer av håndbøkene kan medfølge produktet i elektroniske og trykte
utgaver. Du kan også få eksemplarer av håndbøkene i alle tilgjengelige språk
for hver håndbok fra dokumentbiblioteket på www.hypertherm.com.
SVENSKA / SWEDISH
VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och
efterlevnadsmanual (80669C) för viktig säkerhetsinformation innan du
använder eller underhåller Hypertherm-utrustning. Underlåtenhet att följa
dessa säkerhetsinstruktionerkan resultera i personskador eller skador
på utrustningen.
Kopior av manualen kan medfölja produkten i elektronisk och tryckform.
Du hittar även kopior av manualerna i alla tillgängliga språk
i dokumentbiblioteket (Documents library) på www.hypertherm.com.
한국어 / KOREAN
경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정
준수 설명서 (80669C)에 나와 있는 안전 지침을 읽으십시오. 안전 지침을
준수하지 않으면 신체 부상이나 장비 손상을 초래할 수 있습니다.
전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될
수 있습니다. www.hypertherm.com 의 'Documents library (문서라이브러리)'
에서도모든언어로이용할수있는설명서사본을얻을수있습니다.
ČESKY / CZECH
VAROVÁNÍ! Před uvedením jakéhokoliv zařízení Hypertherm do provozu
si přečtěte bezpečnostní pokyny v příručce k produktu a v Manuálu pro
bezpečnost a dodržování předpisů (80669C). Nedodržování bezpečnostních
pokynů může mít za následek zranění osob nebo poškození majetku.
Kopie příruček a manuálů mohou být součástí dodávky produktu, a to
v elektronické i tištěné formě. Kopie příruček a manuálů ve všech jazykových
verzích, v nichž byly dané příručky a manuály vytvořeny, naleznete v „Knihovně
dokumentů“ na webových stránkách www.hypertherm.com
.
TÜRKÇE / TURKISH
UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürün kullanım
kılavuzunda ve Güvenlik ve Uyumluluk Kılavuzu’nda (80669C) yer alan
güvenlik talimatlarını okuyun. Güvenlik talimatlarına uyulmaması durumunda
kişisel yaralanmalar veya ekipman hasarı meydana gelebilir.
Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir.
Her biri tüm dillerde yayınlanan kılavuzların kopyalarını www.hypertherm.com
adresindeki “Documents library” (Dosyalar kitaplığı) başlığından da elde
edebilirsiniz.
POLSKI / POLISH
OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy
Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa
zamieszczonymi w podręczniku produktu oraz w Podręczniku bezpieczeństwa
i zgodności (80669C). Nieprzestrzeganie instrukcji bezpieczeństwa może
skutkować obrażeniami ciała i uszkodzeniem sprzętu.
Do produktu mogą być dołączone kopie podręczników w formacie
elektronicznym i drukowanym. Kopie podręczników, wkażdym udostępnionym
języku, można również znaleźć w„Bibliotece dokumentów” pod adresem
www.hypertherm.com.
PУССКИЙ / RUSSIAN
БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm
ознакомьтесь с инструкциями по безопасности, представленными
в руководстве, которое поставляется вместе с продуктом, а также
в Руководстве по безопасности и соответствию (80669J). Невыполнение
инструкций по безопасности может привести к телесным повреждениям
или повреждению оборудования.
Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Копии руководств на всех
языках, на которые переведено то или иное руководство, можно также
загрузить в разделе «Библиотека документов» на веб-сайте
www.hypertherm.com.
SUOMI / FINNISH
VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen
käyttöoppaassa olevat turvallisuusohjeet ja turvallisuus- ja
vaatimustenmukaisuusohje (80669C). Turvallisuusohjeiden laiminlyönti
voi aiheuttaa henkilökohtaisen loukkaantumisen tai laitevahingon.
Käyttöoppaiden kopiot voivat olla tuotteen mukana elektronisessa ja
tulostetussa muodossa. Voit saada käyttöoppaiden kopiot kaikilla kielillä
”latauskirjastosta”, joka on osoitteessa www.hypertherm.com.
БЪЛГAPCКИ / BULGARIAN
ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване
Hypertherm, прочетете инструкциите за безопасност в ръководството на
вашия продукт и „Инструкция за безопасност и съответствие“ (80669C).
Неспазването на инструкциите за безопасност би могло да доведе
до телесно нараняване или до повреда на оборудването.
Копия на ръководствата може да придружават продукта в електронен и в
печатен формат. Можете да получите копия на ръководствата, предлагани
на всички езици, от „Documents library“ (Библиотека за документи)
на адрес www.hypertherm.com.
ROMÂNĂ / ROMANIAN
AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți
instrucțiunile de siguranță din cadrul manualului produsului și din cadrul
Manualului de siguranță și conformitate (80669C). Nerespectarea
instrucțiunilor de siguranță pot rezulta în vătămare personală sau în avarierea
echipamentului.
Produsul poate fi însoțit de copii ale manualului în format tipărit și electronic.
De asemenea, dumneavoastră puteţi obţine copii ale manualelor, în toate limbile
disponibile pentru fiecare manual, din cadrul secţiunii „Bibliotecă documente”
aflată pe site-ul www.hypertherm.com.
MAGYAR / HUNGARIAN
VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa
el a biztonsági információkat a termék kézikönyvében és a Biztonsági és
szabálykövetési kézikönyvben (80669C). A biztonági utasítások betartásának
elmulasztása személyi sérüléshez vagy a berendezés károsodásához vezethet.
A termékhez a kézikönyv példányai elektronikus és nyomtatott formában
is mellékelve lehetnek. A kézikönyvek példányai (minden nyelven) a
www.hypertherm.com weboldalon a „Documents library” (Dokumentum
könyvtár) részben is beszerezhetők.
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). Η μη τήρηση
των οδηγιών ασφαλείας μπορεί να επιφέρει σωματική βλάβη ή ζημιά στον
εξοπλισμό.
Αντίγραφα των εγχειριδίων μπορεί να συνοδεύουν το προϊόν σε ηλεκτρονική
και έντυπη μορφή. Μπορείτε, επίσης, να λάβετε αντίγραφα των εγχειριδίων σε
όλες τις γλώσσες που διατίθενται για κάθε εγχειρίδιο από την ψηφιακή
βιβλιοθήκη εγγράφων (Documents library) στη διαδικτυακή τοποθεσία
www.hypertherm.com.
繁體中文 / CHINESE (TRADITIONAL)
警告！ 在操作任何 Hypertherm 設備前，請閱讀您產品手冊和 《安全和法務
遵從手冊》(80669C) 內的安全指示。不遵守安全指示可能會導致人身傷害
或設備損壞。
手冊複本可能以電子和印刷格式隨附產品提供。您也可以在
www.hypertherm.com 的 「文檔資料庫」內獲取所有手冊的多語種複本。
SLOVENŠČINA / SLOVENIAN
OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite
varnostna navodila v priročniku vašega izdelka ter v Priročniku za varnost
in skladnost (80669C). Neupoštevanje navodil za uporabo lahko povzroči
telesne poškodbe ali materialno škodo.
Izdelku so lahko priloženi izvodi priročnikov v elektronski ali tiskani obliki. Izvode
priročnikov v vseh razpoložljivih jezikih si lahko prenesete tudi iz knjižnice
dokumentov “Documents library” na naslovu www.hypertherm.com.
SRPSKI / SERBIAN
UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom
pročitajte uputstva o bezbednosti u svom priručniku za proizvod i u Priručniku
o bezbednosti i usaglašenosti (80669C). Oglušavanje o praćenje uputstava
o bezbednosti može da ima za posledicu ličnu povredu ili oštećenje opreme.
Može se dogoditi da kopije priručnika prate proizvod u elektronskom
i štampanom formatu. Takođe možete da pronađete kopije priručnika, na svim
jezicima koji su dostupni za svaki od priručnika, u “Biblioteci dokumenata”
(“Documents library”) na www.hypertherm.com.
SLOVENČINA / SLOVAK
VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm
si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia
avManuáli o bezpečnosti a súlade s normami (80669C). V prípade
nedodržania bezpečnostných pokynov môže dôjsť k ujme na zdraví alebo
poškodeniu zariadenia.
Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú
alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch,
sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.
Contents
1 Plasma Power Supply .............................................................................................................. 11
How to use push-to-connect fittings.............................................................................................................. 12
Front parts............................................................................................................................................................. 13
Replace the magnetics fans ................................................................................................................. 13
Remove the magnetics fans...................................................................................................... 13
Install the magnetics fans.......................................................................................................... 14
Right-side (liquid-cooling-side) parts............................................................................................................. 15
Replace the flow meter.......................................................................................................................... 15
Replace the coolant level sensor......................................................................................................... 17
Replace a heat-exchanger fan ............................................................................................................. 18
Remove a heat-exchanger fan.................................................................................................. 18
Install a heat-exchanger fan...................................................................................................... 20
Replace the heat-exchanger assembly.............................................................................................. 21
Remove the heat-exchanger assembly .................................................................................. 21
Install the heat-exchanger assembly....................................................................................... 22
Replace the coolant thermistor............................................................................................................ 24
Replace the solid state relay ................................................................................................................ 25
Replace the fan power distribution PCB........................................................................................... 26
Replace the coolant pump and motor assembly ............................................................................. 27
Remove the coolant pump and motor assembly.................................................................. 27
Install the coolant pump and motor assembly...................................................................... 28
Left-side (control-side) parts............................................................................................................................ 30
Replace the chopper.............................................................................................................................. 30
Remove the chopper .................................................................................................................. 30
XPR300 Field Service Bulletin 809970 5
Contents
Install the chopper....................................................................................................................... 33
Replace the control-side fans .............................................................................................................. 34
Remove the control-side fans .................................................................................................. 34
Install the control-side fans....................................................................................................... 36
Replace the 48 V power source.......................................................................................................... 37
Remove the 48 V power source.............................................................................................. 37
Install the 48 V power source .................................................................................................. 38
Replace the 24 V power source.......................................................................................................... 40
Replace the control transformer .......................................................................................................... 41
Remove the control transformer .............................................................................................. 41
Install the control transformer................................................................................................... 42
Replace the power distribution PCB.................................................................................................. 43
Replace the control PCB ...................................................................................................................... 44
Replace the I/O PCB............................................................................................................................. 46
Replace the pilot arc relay..................................................................................................................... 47
Replace start circuit assembly ............................................................................................................. 48
Bottom-compartment parts .............................................................................................................................. 49
Replace an inductor ............................................................................................................................... 49
Remove an inductor.................................................................................................................... 49
Install an inductor ........................................................................................................................ 53
Rear-compartment parts ................................................................................................................................... 54
Replace the main contactor.................................................................................................................. 54
Replace the inrush contactor ............................................................................................................... 56
Replace the inrush resistor assembly................................................................................................. 57
Plasma power supply panels............................................................................................................................ 59
Remove the front panel.......................................................................................................................... 59
Remove the right-side (liquid-cooling-side) panel .......................................................................... 60
Remove the left-side (control-side) panel......................................................................................... 61
Remove the rear panel........................................................................................................................... 62
Remove the top panel ............................................................................................................................ 63
2 Gas Connect Consoles ............................................................................................................ 65
How to use push-to-connect fittings.............................................................................................................. 66
Replace the high-frequency, high-voltage transformer.............................................................................. 67
Replace the high-frequency, high-voltage PCB.......................................................................................... 69
Replace the coil assembly ................................................................................................................................ 71
Remove the coil assembly..................................................................................................................... 71
Install the coil assembly......................................................................................................................... 73
Replace the EMI filter......................................................................................................................................... 74
Replace the control PCB .................................................................................................................................. 75
Replace the 24 V power source...................................................................................................................... 76
6 809970 Field Service Bulletin XPR300
Contents
Replace the air filter assembly ......................................................................................................................... 77
Replace a pressure transducer........................................................................................................................ 78
Replace a proportional valve ............................................................................................................................ 80
Remove a proportional valve ................................................................................................................ 80
Install a proportional valve..................................................................................................................... 81
Replace a regulator ............................................................................................................................................ 82
Remove a regulator................................................................................................................................. 82
Install a regulator ..................................................................................................................................... 84
How to set the regulators...................................................................................................................... 85
Set the N
Set the Ar regulator .................................................................................................................... 86
Gas connect console panels............................................................................................................................ 87
regulator.................................................................................................................... 85
2
3 Torch Connect Console .......................................................................................................... 89
How to use push-to-connect fittings.............................................................................................................. 90
Replace the ohmic PCB.................................................................................................................................... 91
Replace the ohmic relay and bracket ............................................................................................................. 93
Remove the ohmic relay and bracket ................................................................................................. 93
Install the ohmic relay and bracket...................................................................................................... 94
Replace a pressure transducer........................................................................................................................ 95
Replace a solenoid valve (V4-V10, V12) ....................................................................................................... 97
Replace the solenoid valve (V11).................................................................................................................... 99
Remove the solenoid valve (V11)........................................................................................................ 99
Install the solenoid valve (V11) .......................................................................................................... 101
Replace the control PCB ................................................................................................................................ 103
Remove the control PCB .................................................................................................................... 103
Install the control PCB........................................................................................................................ 104
Replace a proportional valve ......................................................................................................................... 106
Remove a proportional valve ............................................................................................................. 106
Install a proportional valve................................................................................................................... 107
Replace the manifold assembly .................................................................................................................... 108
Remove the manifold assembly ........................................................................................................ 108
Install the manifold assembly............................................................................................................. 109
Replace the bottom manifold assembly...................................................................................................... 111
Remove the bottom manifold assembly .......................................................................................... 111
Install the bottom manifold assembly .............................................................................................. 113
Torch connect console top panel and side panels................................................................................... 114
4 Torch.......................................................................................................................................... 115
Replace the solenoid valve ............................................................................................................................ 116
XPR300 Field Service Bulletin 809970 7
Contents
5 Parts List.................................................................................................................................. 119
Plasma power supply ...................................................................................................................................... 119
Outer panels.......................................................................................................................................... 120
Fans......................................................................................................................................................... 121
Coolant system..................................................................................................................................... 122
Coolant adapters in the rear compartment .................................................................................... 123
Other adapters not shown................................................................................................................. 124
Transformers and inductors ............................................................................................................... 125
Control side – view 1.......................................................................................................................... 126
Control side – view 2.......................................................................................................................... 127
Rear compartment of the plasma power supply ........................................................................... 128
Gas connect consoles.................................................................................................................................... 129
Gas connect console high-voltage side parts .............................................................................. 130
Gas connect console manifold side parts...................................................................................... 131
Core, VWI, and OptiMix gas connect console manifold side........................................ 131
Core gas connect console manifolds and adapters ........................................................ 132
VWI gas connect console input and output manifolds and adapters.......................... 134
OptiMix gas connect console input and output manifolds and adapters.................... 136
VWI and OptiMix gas connect console mixer, transducers, and valves...................... 138
Gas connect console wire harness, hose kit, and CAN cables................................................ 139
Torch connect console.................................................................................................................................... 139
Torch connect console Easy Connect side.................................................................................... 140
Torch connect console – top............................................................................................................. 140
Torch connect console manifold side – view 1............................................................................. 141
Torch connect console manifold side – view 2............................................................................. 142
Front adapters and valves.................................................................................................................. 143
Torch assembly ................................................................................................................................................. 144
Torch bracket..................................................................................................................................................... 144
Consumable starter kits.................................................................................................................................. 145
Mild steel consumable starter kit (428616)................................................................................... 145
Stainless steel and aluminum consumable starter kit (428617)............................................... 146
Mild steel consumable starter kit with torch (428618)............................................................... 147
Stainless steel and aluminum consumable starter kit with torch (428619) ........................... 148
Other consumable and torch parts.............................................................................................................. 149
Plasma power supply to gas connect console connections.................................................................. 150
Pilot arc lead with strain relief ........................................................................................................... 150
Negative lead with strain relief .......................................................................................................... 150
Power cable........................................................................................................................................... 151
Coolant hose set.................................................................................................................................. 151
CAN cable ............................................................................................................................................. 152
Gas connect console to torch connect console connections............................................................... 152
8 809970 Field Service Bulletin XPR300
Contents
Pilot arc and coolant hose set assembly (Core)........................................................................... 152
Power, CAN, and 3-gas assembly (Core)...................................................................................... 152
Pilot arc, coolant hose set, and shield water assembly (VWI or OptiMix) .............................. 153
Power, CAN, and 5-gas assembly (VWI or OptiMix)................................................................... 153
Plasma power supply to CNC connections .............................................................................................. 154
EtherCAT CNC interface cable ........................................................................................................ 154
Discrete CNC interface cable........................................................................................................... 154
Serial CNC interface cable................................................................................................................ 155
Plasma power supply to cutting table connection ................................................................................... 155
Work lead............................................................................................................................................... 155
Torch connect console to torch receptacle connection.......................................................................... 156
Torch lead............................................................................................................................................... 156
Bevel torch lead.................................................................................................................................... 156
Supply hoses..................................................................................................................................................... 157
Oxygen hose (blue).............................................................................................................................. 157
Nitrogen or Argon hose (black)......................................................................................................... 157
Air hose (black)..................................................................................................................................... 157
Hydrogen or nitrogen-hydrogen (F5) (red) .................................................................................... 158
Water (optional shield fluid) (blue)................................................................................................... 158
Preventive maintenance kits .......................................................................................................................... 158
Tools.................................................................................................................................................................... 159
Recommended spare parts ........................................................................................................................... 159
Plasma power supply – recommended spare parts .................................................................... 159
Gas connect consoles – recommended spare parts.................................................................. 160
Torch connect console – recommended spare parts.................................................................. 160
Torch – recommended spare parts.................................................................................................. 160
Descriptions of warning label icons................................................................................................. 161
XPR300 Field Service Bulletin 809970 9
Contents
10 809970 Field Service Bulletin XPR300
Plasma Power Supply
WARNING
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before doing any installation or maintenance.
All work requiring removal of the plasma power supply outer cover or panels
must be done by a qualified technician.
See the Safety and Compliance Manual (80669C) for more safety
precautions.
XPR300 Field Service Bulletin 809970 11
Plasma Power Supply
1
1
2
3
1 Tu be 2 Collet 3 O-ring
How to use push-to-connect fittings
Some replacement procedures in the plasma power supply require you to use push-to-connect
fittings. This procedure explains how to use push-to-connect fittings without causing damage to the
tubing or fitting.
Push-to-Connect
• To connect, push the tube into the fitting until it stops. Pull on the tube lightly to make sure that the connection
is tight.
• To release, push the fitting collet and tube toward the fitting. Then, continue to push the fitting collet toward the
fitting, and pull the tube away from the fitting.
Replace any tubing that is damaged. If you reuse damaged tubing, it can
result in leaks.
Used tubing can have an indentation on the end that can cause leaks. To
prevent leaks, trim the tubing to remove the indentation.
12 809970 Field Service Bulletin XPR300
1
Front parts
Replace the magnetics fans
See Fans on page 121 for location and part number.
Remove the magnetics fans
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the front panel on page 59.
Keep all nuts and screws that you remove.
2. Use a 10 mm, hexagonal-socket wrench to remove the nut from the top of the fan bracket.
Plasma Power Supply
3. Tilt the top of the bracket towards you until you can get to the fan wire connector.
4. Disconnect the fan wire connector.
5. Remove the fan and bracket assembly.
6. Use a 4 mm, hexagonal-socket wrench to remove the 3 nuts from the fan.
7. Remove the fan from the bracket.
XPR300 Field Service Bulletin 809970 13
Plasma Power Supply
1
Install the magnetics fans
1. Put the fan on the bracket as shown.
2. Use a 4 mm, hexagonal-socket wrench to install the 3 nuts
to attach the new magnetics fan to the bracket.
3. Put the bottom of the fan and bracket assembly into the
sheet metal tab.
4. Connect the fan wire connector.
5. Use a 10 mm, hexagonal-socket wrench to install the nut.
6. Install the front panel.
14 809970 Field Service Bulletin XPR300
1
Right-side (liquid-cooling-side) parts
2
1
2
3
4
1
2
3
4
Replace the flow meter
See Coolant system on page 122 for location and part number.
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the right-side (liquid-cooling-side) panel on page 60.
c. To make removing the flow meter easier, you can remove the top panel. See Remove the top
panel on page 63.
d. Drain the coolant until the level is below the coolant tank fitting .
Keep all nuts and screws that you remove.
2. Disconnect the tube from the
push-to-connect fitting in the
flow meter. See How to use
push-to-connect fittings on
page 12.
Plasma Power Supply
3. Hold the coolant tank fitting
with a 9/16-inch, open-ended
wrench.
4. Turn the flow meter
counter-clockwise to remove the
flow meter and outside fitting
from the coolant tank fitting.
5. Use a 13/16-inch, open-ended wrench to remove the fitting from the flow meter.
6. Apply liquid thread sealant to the fitting threads.
NOTICE
Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread
ends.
XPR300 Field Service Bulletin 809970 15
Plasma Power Supply
1
7. Use a 13/16-inch, open-ended wrench to install the fitting on the new flow meter. Tighten to
2.8 N∙m (25 in∙lb).
Do not overtighten.
8. Hold the coolant tank fitting with a 9/16-inch, open-ended wrench.
9. Install the flow meter on the coolant tank fitting. Tighten to finger-tight, plus one turn, plus point
the larger part of the flow meter up, as shown.
10. Connect the tube to the push-to-connect fitting in the flow meter. See How to use
push-to-connect fittings on page 12.
11 . Install all of the panels.
12. Add coolant to fill the tank.
16 809970 Field Service Bulletin XPR300
1
Replace the coolant level sensor
See Coolant system on page 122 for location and part number.
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the right-side
(liquid-cooling-side) panel on page 60.
c. See Remove the left-side (control-side) panel
on page 61.
Keep all nuts and screws that you remove.
2. Use a 3 mm, hexagonal-key wrench to remove the
3 screws.
3. Remove J5 from the control PCB.
Plasma Power Supply
4. Remove the wire from the wire clips.
Note where the wire is routed.
5. Use the 3 screws to install the coolant level
sensor. Tighten to 6.9 kg∙cm (6 in∙lb).
6. Route the wire in the same path that you removed
the wire.
7. Connect J1.5 to J5 on the control PCB.
8. Install all of the panels.
9. Use the XPR web interface to make sure that the coolant sensor operates correctly.
For more information on the XPR web interface, see the Connect for
Communication in the XPR300 Instruction Manual (809480).
XPR300 Field Service Bulletin 809970 17
Plasma Power Supply
1
Replace a heat-exchanger fan
See Fans on page 121 for location and part number.
Remove a heat-exchanger fan
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the right-side (liquid-cooling-side) panel on page 60.
c. See Remove the top panel on page 63.
Keep all nuts and screws that you remove.
2. Use tape to attach protective material, such as cardboard, onto the rear of the heat-exchanger
assembly to protect the cooling fins.
CAUTION
Sharp cooling fins can cause cuts. Use caution when you work near the cooling fins.
3. Remove the push-to-connect fittings from the inlet and the outlet of the heat-exchanger
assembly, and immediately put the ends of the hoses in a container.
4. Disconnect the wire connector for the coolant
thermistor.
18 809970 Field Service Bulletin XPR300
1
5. Use a 10 mm, hexagonal-socket wrench
to remove the 7 nuts that attach the
heat-exchanger panel.
6. Disconnect the connectors for the fan
wires from the fan power distribution
PCB:
Plasma Power Supply
J3 for the top fan
J4 for the bottom fan
7. Pull the heat-exchanger panel away from
the center panel.
8. Remove the 4 screws that connect the
fan to the heat-exchanger assembly.
Repeat this step for both fans, if
applicable.
9. Remove the fan.
XPR300 Field Service Bulletin 809970 19
Plasma Power Supply
1
Install a heat-exchanger fan
1. Use the 4 screws to install the new fan so that the wires
point to the lower left (as shown) and the flow of air is
towards the heat-exchanger assembly.
2. Push the heat-exchanger panel back into position.
3. Connect the wires for the fans to the fan power
distribution PCB:
J3 for the top fan
J4 for the bottom fan
4. Use a 10 mm, hexagonal-socket wrench to install the 7
nuts that attach the heat-exchanger panel to the center
panel and bottom panel.
5. Connect the coolant hose fittings to the heat-exchanger
assembly.
6. Pull back on the fittings to make sure the connection is
tight.
7. Remove the tape and protective material from the rear
panel of the heat-exchanger assembly.
8. Add coolant to fill the tank.
9. Install all of the panels.
20 809970 Field Service Bulletin XPR300
1
Replace the heat-exchanger assembly
See Fans on page 121 for location and part number.
Remove the heat-exchanger assembly
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the right-side (liquid-cooling-side) panel on page 60.
c. See Remove the top panel on page 63.
Keep all nuts and screws that you remove.
CAUTION
Sharp cooling fins can cause cuts. Use caution when you work near the cooling fins.
Plasma Power Supply
2. Remove the push-to-connect fittings from the inlet and the outlet of the heat-exchanger
assembly, and immediately put the ends of the hoses in a container.
3. Carefully remove the
copper clip and thermistor
from the pipe.
Do not deform the
copper clip.
XPR300 Field Service Bulletin 809970 21
Plasma Power Supply
1
4. Use a 10 mm, hexagonal-socket wrench
to remove the 7 nuts that attach the
heat-exchanger panel.
5. Disconnect the connectors for the fan
wires from the fan power distribution
PCB:
J3 for the top fan
J4 for the bottom fan
6. Pull the heat-exchanger panel away from
the center panel.
7. Use a 10 mm, hexagonal-socket wrench
to remove the nuts that connect the
heat-exchanger assembly to the
heat-exchanger panel.
8. Remove the heat-exchanger assembly
and fans from the plasma power supply.
9. Remove the 4 screws from each fan to remove the fans from the heat-exchanger assembly.
Install the heat-exchanger assembly
1. Use tape to attach protective material, such as cardboard, onto the rear of the new
heat-exchanger assembly to protect the cooling fins.
2. Use 4 screws to install each fan onto the new heat-exchanger assembly.
3. Use the nuts to install the new heat-exchanger assembly onto the heat-exchanger panel in the
plasma power supply.
4. Push the heat-exchanger panel back into position.
22 809970 Field Service Bulletin XPR300
Plasma Power Supply
1
5. Connect the connectors for the fan wires to the fan power distribution PCB:
J3 for the top fan
J4 for the bottom fan
6. Use a 10 mm, hexagonal-socket wrench to install the 7 nuts that attach the heat-exchanger
panel to the center panel and bottom panel.
7. Install the coolant thermistor. See Replace the coolant thermistor, step 5 on page 24.
8. Connect the coolant hose fittings to the heat-exchanger assembly.
9. Remove the tape and protective material from the rear panel of the heat-exchanger assembly.
10. Add coolant to fill the tank.
11 . Install all of the panels.
XPR300 Field Service Bulletin 809970 23
Plasma Power Supply
1
Replace the coolant thermistor
See Coolant system on page 122 for location and part number.
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the right-side (liquid-cooling-side) panel on page 60.
c. To make removing the thermistor easier, you can remove the top panel. See Remove the top
panel on page 63.
Keep all nuts and screws that you remove.
2. Disconnect the thermistor
wire connector (J5).
3. Remove the wires from the
wire clip.
4. Carefully remove the
copper clip from the pipe.
5. Use the new copper clip to
install the coolant
thermistor onto the straight
part of the pipe with the
wires going toward the
heat-exchanger panel.
Make sure that
the copper clip
fits tightly around the pipe.
Make sure that the concave side of the coolant
thermistor is toward the pipe.
Do not put the coolant thermistor on the fittings of the
heat-exchanger assembly.
6. Connect the thermistor wire connector (J5).
7. Install the liquid-cooling side panel.
8. Use the XPR web interface to make sure that there are no coolant temperature errors.
For more information on the XPR web interface, see the Connect for
Communication in the XPR300 Instruction Manual (809480).
24 809970 Field Service Bulletin XPR300
1
Replace the solid state relay
1
T1
2
L1
1
A1 (+)
3
A2 (-)
4
3
4
2
1
White
Black
Red
Black
1
22
Output or load side Input or control side
2
See Fans on page 121 for location and part number.
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the right-side (liquid-cooling-side) panel on page 60.
Keep all nuts and screws that you remove.
2. Loosen the wire screws and remove the wires.
Plasma Power Supply
3. Remove the 2 mounting screws .
4. Remove the solid state relay.
5. Use the 2 mounting screws to install the solid state relay with T1, 2 in the upper-left corner, as
shown.
6. Install the wires as shown and tighten the wire screws.
7. Install the right side panel.
XPR300 Field Service Bulletin 809970 25
Plasma Power Supply
1
Replace the fan power distribution PCB
See Fans on page 121 for location and part number.
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the right-side (liquid-cooling-side) panel on page 60.
Keep all nuts and screws that you remove.
2. Disconnect all of the wire connectors.
3. Remove 2 screws from the bottom of the PCB.
4. Pull the PCB off of the 2 push connectors.
5. Align the new PCB with the studs and push it in until you
hear a click.
6. Install the 2 screws.
7. Connect the wires:
J1 for the 48 V power source
J2 for the control PCB
J3 for the top heat-exchanger fan
J4 for the bottom heat-exchanger fan
J5 for the magnetics fan
J6 for the control PCB
J7 for the top control-side fan
J8 for the bottom control-side fan
8. Install the right-side (liquid-cooling-side) panel.
26 809970 Field Service Bulletin XPR300
1
Replace the coolant pump and motor assembly
1
2
3
4
123
4
See Coolant system on page 122 for location and part number.
Remove the coolant pump and motor assembly
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the right-side (liquid-cooling-side) panel on page 60.
c. Drain the coolant. See Remove old coolant from the coolant system in the Maintenance
section in the XPR300 Instruction Manual (809480).
Keep all nuts and screws that you remove.
2. Disconnect the power connector (J21) from the
wire harness.
Plasma Power Supply
3. Disconnect the solenoid valve connector (J7) from
the motor.
4. Use a 1-1/2 inch, open-ended wrench to remove
the 1 inch hose from the pump.
5. Disconnect the tube from the push-to-connect
fitting on the solenoid valve . See How to use
push-to-connect fittings on page 12.
6. Disconnect the tube from the push-to-connect
fitting on the coolant bypass check valve .
7. Use a 10 mm, hexagonal-socket wrench to
remove the 2 screws from the pump-motor
bracket.
8. Pull the pump out from the tabs in the sheet metal.
CAUTION
This equipment is heavy.
Use a two person lift.
XPR300 Field Service Bulletin 809970 27
Plasma Power Supply
1
1inch
7/8 inch
5
6
5
6
9. Use 2 open-ended wrenches to remove the
coolant bypass valve .
10. Hold the solenoid valve, and remove the
fitting from the solenoid valve.
Install the coolant pump and motor assembly
This equipment is heavy.
Use a two person lift.
CAUTION
1. Put thread sealant on the threads of the coolant bypass valve.
NOTICE
Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread
ends.
2. Use a 1 inch and 7/8 inch, open-ended wrench to install the coolant bypass valve onto the new
coolant pump. Tighten to 14.7 N∙m (130 in∙lb).
3. Install the fitting for the solenoid valve onto the new pump. Tighten to 14.7 N∙m (130 in∙lb).
4. Slide the new coolant pump and motor assembly into the plasma power supply.
Make sure that the bracket goes under the tabs in the sheet metal.
5. Align the holes in the pump-motor bracket with the holes in the sheet metal.
6. Install the 2 screws.
7. Connect the tube to the push-to-connect fitting on the bypass check valve. See How to use
push-to-connect fittings on page 12.
8. Connect the tube to the push-to-connect fitting on the solenoid valve.
9. Use a 1-1/2 inch, open-ended wrench to install the 1 inch hose to the pump fitting. Tighten the
fitting to 47 N∙m (416 in∙lb).
10. Connect the solenoid valve connector (J7) to the wire harness.
28 809970 Field Service Bulletin XPR300
Plasma Power Supply
1
11 . Connect the power connector (J21) to the motor.
12. Install the liquid-cooling-side panel.
13. Install the coolant. See the Coolant Installation section in the XPR300 Instruction Manual
(809480).
14. Use the XPR web interface to make sure that the coolant pump and motor assembly operates
correctly.
For more information on the XPR web interface, see the Connect for
Communication in the XPR300 Instruction Manual (809480).
XPR300 Field Service Bulletin 809970 29
Plasma Power Supply
1
Left-side (control-side) parts
Replace the chopper
See Control side – view 2 on page 127 for locations and part numbers.
Remove the chopper
1. Complete the following procedures:
a. Remove the power from the cutting system.
b. See Remove the right-side (liquid-cooling-side) panel on page 60.
c. See Remove the left-side (control-side) panel on page 61.
d. Drain the coolant. See Remove old coolant from the coolant system in the Maintenance
section in the XPR300 Instruction Manual (809480).
Keep all nuts and screws that you remove.
2. Use tape to attach protective material, such as cardboard, onto the rear of the heat-exchanger
assembly to protect the cooling fins.
30 809970 Field Service Bulletin XPR300
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