Hypertherm XPR Series Preventive Maintenance Program

Hypertherm
Brand
Hypertherm
Model
XPR Series
Type
Preventive Maintenance Program

This manual is also suitable for

XPR
™
plasma
Preventive maintenance program
809490 – REVISION 1
ENGLISH
XPR 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.
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.
© 2018 Hypertherm, Inc.
XPR
Instruction Manual
809490
Revision 1
English
Original instructions
October 2018
Hypertherm, Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (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)
[email protected] (RMA email)
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
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Delegación Álvaro Obregón
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Soporte.T[email protected] (Technical Service Email)
Hypertherm Plasmatechnik GmbH
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63452 Hanau
Germany
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00 800 49 73 73 29 Fax
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
[email protected] (Technical Service Email)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
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TechSupportAP[email protected] (Technical Service Email)
Hypertherm Japan Ltd.
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Osaka 550-0002 Japan
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HT[email protected] (Main Office Email)
TechSupportAP[email protected] (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)
[email protected]
(Technical Service Email)
Hypertherm (Shanghai) Trading Co., Ltd.
B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
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86-21-80231128 Tel (Technical Service)
[email protected]
(Technical Service Email)
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Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
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[email protected] (Technical Service Email)
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#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[email protected] (Marketing Email)
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(Technical Service Email)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
[email protected] (Main Office Email)
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm (India) Thermal Cutting Pvt. Ltd
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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)
TechSupportAP[email protected]
(Technical Service Email)
1/28/16
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.
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.
DANSK / DANISH
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.
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.
/ JAPANESE
! Hypertherm
(80669C)
www.hypertherm.com
/ CHINESE (SIMPLIFIED)
(80669C)
“Documents library”
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 (문서라이브러리)'
에서도모든언어로이용할수있는설명서사본을얻을수있습니다.
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
.
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, wkażdym 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.
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.
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.
XPR Instruction Manual 809490 7
Contents
Preventive Maintenance Program.......................................................................................... 11
Overview ............................................................................................................................................................... 11
Cleaning and inspection schedule.................................................................................................................. 12
Daily............................................................................................................................................................ 13
Do a test of the inlet pressures................................................................................................ 13
Examine all of the air filters........................................................................................................ 13
Do a check of the coolant level and condition...................................................................... 13
Examine and lubricate O-rings................................................................................................. 14
Examine the water tube and torch........................................................................................... 15
Weekly ....................................................................................................................................................... 15
Examine hoses, cables, and leads........................................................................................... 15
Do tests for gas leaks................................................................................................................. 16
Do a check of the coolant flow................................................................................................. 16
Monthly ...................................................................................................................................................... 17
Clean inside the plasma power supply .................................................................................. 17
Examine the contactors ............................................................................................................. 18
Examine the pilot arc relay ........................................................................................................ 18
Examine the coolant system ..................................................................................................... 19
Do the coolant flow test............................................................................................................. 19
Examine the gas line connections ........................................................................................... 20
Examine the hoses...................................................................................................................... 20
Examine the cables..................................................................................................................... 20
Examine the ground connections ............................................................................................ 20
Examine the table-to-workpiece connection ........................................................................ 20
8 809490 Instruction Manual XPR
Every 6 months ........................................................................................................................................ 21
Replace the coolant and coolant filter, and clean and examine the pump screen....... 21
Component replacement schedule................................................................................................................. 25
Cutting area and operation effects ..................................................................................................... 28
External cutting area................................................................................................................... 28
Incoming air supply quality........................................................................................................ 29
Metal dust inside the power supply cabinet ......................................................................... 29
Consumable use.......................................................................................................................... 30
Cut-cycle time.............................................................................................................................. 31
Part numbers for hoses, cables, and leads................................................................................................... 32
Plasma power supply to gas connect console connections......................................................... 32
Pilot arc lead with strain relief .................................................................................................. 32
Negative lead with strain relief (XPR170 only)..................................................................... 32
Negative lead with strain relief (XPR300 only) .................................................................... 32
Power cable.................................................................................................................................. 33
Coolant hose set ......................................................................................................................... 33
CAN cable .................................................................................................................................... 33
Gas connect console to torch connect console connections...................................................... 33
Pilot arc and coolant hose set assembly (Core).................................................................. 33
Power, CAN, and 3-gas assembly (Core)............................................................................. 34
Pilot arc, coolant hose set, and shield water assembly (VWI or OptiMix) ..................... 34
Power, CAN, and 5-gas assembly (VWI or OptiMix).......................................................... 34
Plasma power supply to CNC connections ..................................................................................... 35
EtherCAT CNC interface cable ............................................................................................... 35
Discrete CNC interface cable.................................................................................................. 35
Serial CNC interface cable....................................................................................................... 35
Plasma power supply to cutting table connection .......................................................................... 36
Work lead (XPR only)................................................................................................................. 36
Work lead (XPR300 only)......................................................................................................... 36
Torch connect console to torch receptacle connection................................................................. 36
Torch lead...................................................................................................................................... 36
Supply hoses............................................................................................................................................ 37
Oxygen hose (blue)) ................................................................................................................... 37
Nitrogen or argon hose (black) ................................................................................................ 37
Air hose (black)............................................................................................................................ 37
Hydrogen or nitrogen-hydrogen (F5) (red) ........................................................................... 37
Water (optional shield fluid) (blue).......................................................................................... 38
System information ............................................................................................................................................. 39
System voltage ........................................................................................................................................ 39
Coolant requirements............................................................................................................................. 39
XPR Instruction Manual 809490 9
Notes...................................................................................................................................................................... 40
Maintenance log for XPR cutting systems.................................................................................................... 41
10 809490 Instruction Manual XPR
XPR Instruction Manual 809490 11
Preventive Maintenance Program
Overview
Congratulations on the purchase of your Hypertherm plasma system.
Hypertherm plasma systems can operate in harsh conditions for many years. To maintain system
performance, minimize operating costs, and lengthen system life, follow the maintenance
procedures given in this Preventative Maintenance Program (PMP).
Hypertherm made this PMP specifically for your plasma system. The PMP has two parts: a cleaning
and inspection schedule and a component replacement schedule.
If you have questions about how to maintain your plasma system, contact your OEM or regional
Hypertherm Technical Service team. You can find contact information for each regional office at
www.hypertherm.com
on the “Contact us” page.
This document refers to your system’s instruction manual. If you do not have your instruction manual,
you can find it at www.hypertherm.com/docs
.
XPR170 Instruction Manual: 810060
XPR300 Instruction Manual: 809480
The graphics in this document are for reference only. The appearance and
location of your cutting system parts and web interface screens can be
different, based on the type of XPR cutting system that you have.
Preventive Maintenance Program
12 809490 Instruction Manual XPR
Cleaning and inspection schedule
This is a daily, weekly, and monthly schedule for cleaning and inspections. The PMP has instructions
for each task. These instructions help your personnel understand what to do and what to look for
during each task. In general, an operator can do the daily and weekly tasks, while maintenance
personnel usually do the monthly tasks.
A monthly maintenance log is in the back of this manual. You can make photocopies of the
maintenance log to record tasks.
Table 1
Maintenance task or activity Daily Weekly Monthly
Every
6months
Do a test of the inlet pressures X
Examine all of the air filters X
Do a check of the coolant level and condition X
Examine and lubricate O-rings X
Examine the water tube and torch X
Examine hoses, cables, and leads X
Do tests for gas leaks X
Do a check of the coolant flow X
Clean inside the plasma power supply X
Examine the contactors X
Examine the pilot arc relay X
Examine the coolant system X
Do the coolant flow test X
Examine the gas line connections X
Examine the hoses X
Examine the cables X
Examine the ground connections X
Examine the table-to-workpiece connection X
Replace the coolant and coolant filter, and clean
and examine the pump screen
X
Preventive Maintenance Program
XPR Instruction Manual 809480 13
Daily
Do a test of the inlet pressures
1. With the gas flowing in test preflow mode, make sure that the pressure at the regulator is set to
7. 5 b a r ( 1 10 p s i) .
2. Repeat the test in cutflow mode, and make sure that the regulator is set to 7.5 bar (110 psi).
3. If you are using vented water injection processes, make sure that the inlet pressure for the water
is between 40 psi and 110 psi. (2.8 bar and 7.5 bar).
Examine all of the air filters
Examine all of the air filters for contamination.
If you find moisture or oil, replace the air filter.
If you find a moderate quantity of solid
contamination, such as dust, blow air through it
or use suction to clean the filter.
If you find a large quantity of solid
contamination, replace the air filter.
Do a check of the coolant level and condition
Make sure that the tank is full to the neck with coolant:
1. Open the cover of the coolant tank on the outside of the
enclosure.
2. If the level of the coolant is below the top of the tank, add coolant
(028872) to the neck of the tank.
3. Record the number of gallons your system requires in Coolant
requirements on page 39.
Examine the coolant tank for contamination. If you find any
contamination, then replace all of the coolant. See Replace the
coolant and coolant filter, and clean and examine the pump screen
on page 21.
2
1
1
2
Preventive Maintenance Program
14 809490 Instruction Manual XPR
Examine and lubricate O-rings
1. Examine all of the O-rings on the torch and consumables for damage or excess wear.
2. If you find damage or excess wear, replace the
O-ring.
Receptacle O-rings and torch O-rings for
the torch main body are available as part
of the torch rebuild and filter kit (428639
or 428640). Other O-rings are included
with the consumables.
3. Apply a thin film of silicone lubricant (027055)
to all O-rings.
The O-rings should look shiny. Too much
lubricant can prevent gas flow.
4. Install all O-rings so they fit snugly.
5. Examine all threaded consumables, and remove
any dirt from the threads.
Preventive Maintenance Program
XPR Instruction Manual 809480 15
Examine the water tube and torch
1. Remove the used water tube from the torch.
2. Examine the water tube for bends and pitting. If you find bends or pitting,
replace the water tube.
3. If you do not find bends or pitting on the water tube, examine the O-ring
on the end of the water tube:
a. Replace the O-ring if you find damage or excess wear.
Torch rebuild kits are available from Hypertherm.
b. Apply a thin film of silicone lubricant (027055) if replacement is not
needed.
The O-ring should look shiny. Too much lubricant can restrict water tube
motion. Remove excess lubricant if found.
4. Examine the nozzle and electrode mating surfaces on the torch main body
for damage or pitting. If found, replace the torch main body.
5. If you do not find damage or pitting, use a clean paper towel or lint-free
cloth to clean the internal and external surfaces of the torch. Use a cotton
swab to clean internal surfaces that are not easy to get to.
Make sure that you do not leave any cotton fibers on the inner
surfaces of the torch main body.
6. Use compressed air to remove any remaining particles from the torch
main body.
Weekly
Examine hoses, cables, and leads
1. Examine all hoses, cables, and leads that connect system components. Look for:
Scrapes, cuts, or holes
Chemical spills or burns
Kinks or bends
2. Replace any hose, cable, or lead if you find damage.
See Part numbers for hoses, cables, and leads on page 32 for lengths
and part numbers.
1
2
1
2
Preventive Maintenance Program
16 809490 Instruction Manual XPR
3. Examine all of the fittings that connect the hoses, cables, and leads:
a. Tighten loose connections if found, but do not make the connections too tight.
b. Order a replacement hose, cable, or lead set if you find its fitting has damage or excess
wear. Replacement hoses, cables, and leads are available from Hypertherm.
Individual fittings for external hoses, cables, and leads are not
replaceable. If you find a problem with an external fitting, you must order a
replacement hose, cable, or lead set (with integrated fitting).
4. Make sure that the hoses, cables, and leads do not twist or kink during torch movement and
system operation. Adjust them if needed.
Do tests for gas leaks
1. Use the CNC screen or XPR web interface to select the command to do an automated gas leak
test. Test results and information will appear in the error log.
For information about how to do this, see the instruction manual that came
with your CNC.
2. See the test results for guidance about how to diagnose or troubleshoot a possible gas leak.
The test results affect the corrective actions that are necessary.
Do a check of the coolant flow
1. Look at the CNC or plasma power
supply screen on the XPR web interface
to identify the coolant flow rate.
2. Make sure that the coolant flow rate is
acceptable:
Between 3.79 L/min – 11.36 L/min
(1 gal/min –3.0 gal/min) for an
XPR170 cutting system.
Between 3.79 L/min – 9.46 L/min
(1 gal/min – 2.5 gal/min) for an
XPR300 cutting system.
If the flow rate is outside of the
correct range, an internal
obstruction can be the cause.
Shown for reference only.
Preventive Maintenance Program
XPR Instruction Manual 809480 17
Monthly
Clean inside the plasma power supply
1. Remove the power from the cutting system.
2. Remove the side panels of the plasma power supply and the top panel from both the gas
connect console and torch connect console.
3. Use low pressure air or a vacuum to remove any accumulation of dust and particles from:
The side panels
The fans
The heat exchanger
The inside of the gas connect console
The inside of the torch connect console
4. Remove dust and particles from circuit boards.
Be careful not to damage the circuit boards.
5. Install the side panels on the plasma power supply and top panel on both the gas connect
console and torch connect console before you supply power to the cutting system.
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.
Preventive Maintenance Program
18 809490 Instruction Manual XPR
Examine the contactors
1. Examine the contacts for black or rough surfaces:
For the XPR170 (left), examine the main contactor .
For the XPR300 (right), examine the main contactor and inrush contactor ,
2. If you find too much of this condition, replace the contactor.
Examine the pilot arc relay
1. Remove the cover of the
pilot arc relay.
Shown for
reference only.
2. Examine the contacts
inside the relay for black or
rough surfaces.
3. If you find too much of this
condition, replace the pilot
arc relay.
4. Install the cover of the pilot arc relay.
1
1
2
1
2
1
Preventive Maintenance Program
XPR Instruction Manual 809480 19
Be careful that you do not pinch the wires between the cover and the
center panel.
Examine the coolant system
Examine the coolant system for coolant leaks at all connections. Make sure you examine:
The gas connect console
The torch connect console
The torch main body
The internal connection in the plasma power supply
Do the coolant flow test
1. Look at the CNC or plasma power
supply screen on the XPR web interface
to identify the coolant flow rate.
Shown for reference only.
2. Make sure that the coolant flow rate is
acceptable:
Between 3.79 L/min – 11.36 L/min
(1 gal/min –3.0 gal/min) for an
XPR170 cutting system.
Between 3.79 L/min – 9.46 L/min
(1 gal/min – 2.5 gal/min) for an
XPR300 cutting system.
If the flow rate is outside of the
correct range, an internal
obstruction can be the cause.
3. If you find obstructions, remove them. Replace damaged parts if found.
4. If coolant flow remains slow, and it has been more than 6 months since the last coolant
replacement, replace the coolant. See Replace the coolant and coolant filter, and clean and
examine the pump screen on page 21.
Hypertherm recommends coolant replacement every 6 months.
5. If the coolant flow remains slow, see How to measure coolant flow in your system’s instruction
manual.
6. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.
Preventive Maintenance Program
20 809490 Instruction Manual XPR
Examine the gas line connections
Spray all of the gas line connections with soapy water. If bubbles appear on a gas line, tighten or
replace it as necessary. See Part numbers for hoses, cables, and leads on page 32 for lengths and
part numbers.
Examine the hoses
Examine each hose for kinks or sharp bends that can restrict gas flow or cause damage to the hose.
If the cutting table uses a power track system to support the leads that go from the power supply to
the gas console or torch, look at the position of the leads in the track. Make sure the leads do not
twist or kink. This can cause a restriction.
Examine the cables
Examine all cables for scratches or unusual wear. If the outside insulation is cut or has any other
damage, replace the cable. See Part numbers for hoses, cables, and leads on page 32 for lengths
and part numbers.
Examine the ground connections
Make sure that all components of the system are individually grounded to a driven earth ground. See
the Installation and Grounding section of your system’s instruction manual.
Examine the table-to-workpiece connection
Examine the work lead (+) connection where the work lead (+) connects to the cutting table.
Make sure that there is no paint, oil, dirt, or rust on the workpiece. This type of contamination
prevents a clean metal-to-metal contact between the work lead and the cutting table or workpiece.
It can also cause arc-transfer problems.
CAUTION
Do not clean brass connections with ammonia-based cleaners. Ammonia causes brass to crack and
become brittle.
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Hypertherm XPR Series Preventive Maintenance Program

Hypertherm
Brand
Hypertherm
Model
XPR Series
Type
Preventive Maintenance Program
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