Hypertherm XPR170 - Replacement Part Procedures Manual

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XPR170™

Replacement Part Procedures

Field Service Bulletin

810410 | Revision 2 | April 2021

Main Page

Table of Contents5
Plasma Power Supply11
How to Use Push-To-Connect Fittings12
Front Parts13
Replace the Magnetics Fans13
Remove the Magnetics Fans13
Install the Magnetics Fans14
Right-Side (Liquid-Cooling-Side) Parts15
Replace the Flow Meter15
Replace the Coolant Check Valve17
Replace the Coolant Level Sensor19
Replace a Heat-Exchanger Fan20
Remove a Heat-Exchanger Fan20
Install a Heat-Exchanger Fan22
Replace the Heat-Exchanger Assembly23
Remove the Heat-Exchanger Assembly23
Install the Heat-Exchanger Assembly24
Replace the Coolant Thermistor26
Replace the Solid State Relay27
Replace the Fan Power Distribution PCB28
Replace the Coolant Pump, Solenoid Valve, and Motor Assembly29
Remove the Coolant Pump, Solenoid Valve, and Motor Assembly29
Install the Coolant Pump, Solenoid Valve, and Motor Assembly30
Left-Side (Control-Side) Parts32
Replace the Chopper32
Remove the Chopper32
Install the Chopper34
Replace the Control-Side Fans35
Remove the Control-Side Fans35
Install the Control-Side Fans37
Replace the 48 V Power Source38
Remove the 48 V Power Source38
Install the 48 V Power Source39
Replace the 24 V Power Source41
Replace the Control Transformer42
Remove the Control Transformer42
Install the Control Transformer43
Replace the Power Distribution PCB44
Replace the Control PCB45
Replace the I/O PCB47
Replace the Pilot Arc Relay48
Replace Start Circuit Assembly49
Bottom-Compartment Parts50
Replace an Inductor50
Remove an Inductor50
Install an Inductor54
Rear-Compartment Parts55
Replace the Main Contactor55
Remove the Main Contactor55
Install the Siemens Main Contactor56
Install the Allen-Bradley or ABB Main Contactor57
Replace the Inrush Resistor Assembly59
Plasma Power Supply Panels61
Remove the Front Panel61
Remove the Right-Side (Liquid-Cooling-Side) Panel62
Remove the Left-Side (Control-Side) Panel63
Remove the Rear Panel64
Remove the Top Panel65
Gas Connect Consoles67
How to Use Push-To-Connect Fittings68
Replace the High-Frequency, High-Voltage Transformer69
Replace the High-Frequency, High-Voltage PCB71
Replace the Coil Assembly73
Remove the Coil Assembly73
Install the Coil Assembly75
Replace the EMI Filter76
Replace the Control PCB77
Replace the 24 V Power Source78
Replace the Air Filter Assembly79
Replace a Pressure Transducer80
Replace a Proportional Valve82
Remove a Proportional Valve82
Install a Proportional Valve83
Replace the Mixer Module84
Remove the Mixer Module84
Install the Mixer Module90
Replace a Regulator95
Remove a Regulator95
Install a Regulator97
How to Set the Regulators98
Set the N Regulator98
Set the Ar Regulator99
Gas Connect Console Panels100
Torch Connect Console101
How to Use Push-To-Connect Fittings102
Replace the Ohmic PCB103
Replace the Ohmic Relay and Bracket105
Remove the Ohmic Relay and Bracket105
Install the Ohmic Relay and Bracket106
Replace a Pressure Transducer107
Replace a Solenoid Valve (V4-V10, V12)109
Replace the Solenoid Valve (V11)111
Remove the Solenoid Valve (V11)111
Install the Solenoid Valve (V11)113
Replace the Control PCB115
Remove the Control PCB115
Install the Control PCB116
Replace a Proportional Valve118
Remove a Proportional Valve118
Install a Proportional Valve119
Replace the Manifold Assembly120
Remove the Manifold Assembly120
Install the Manifold Assembly121
Replace the Bottom Manifold Assembly123
Remove the Bottom Manifold Assembly123
Install the Bottom Manifold Assembly125
Torch Connect Console Top Panel and Side Panels126
Torch127
Replace the Solenoid Valve128
Parts List131
Plasma Power Supply131
Outer Panels132
Fans133
Coolant System134
Coolant Adapters in the Rear Compartment135
Other Adapters Not Shown136
Transformer and Inductor137
Control Side - View 1138
Control Side - View 2139
Rear Compartment of the Plasma Power Supply140
Gas Connect Consoles141
Gas Connect Console High-Voltage Side Parts142
Gas Connect Console Manifold Side Parts143
Core, VWI, and Optimix Gas Connect Console Manifold Side143
Core Gas Connect Console Manifolds and Adapters144
VWI Gas Connect Console Input and Output Manifolds and Adapters146
Optimix Gas Connect Console Input and Output Manifolds and Adapters148
VWI and Optimix Gas Connect Console Mixer, Transducers, and Valves150
Gas Connect Console Wire Harness, Hose Kit, and CAN Cables151
Torch Connect Console151
Torch Connect Console Easy Connect Side152
Torch Connect Console - Top152
Torch Connect Console Manifold Side - View 1153
Torch Connect Console Manifold Side - View 2154
Front Adapters and Valves155
Torch Assembly156
Torch Bracket157
Consumable Starter Kits158
Mild Steel Consumable Starter Kit (428840)158
Stainless Steel and Aluminum Consumable Starter Kit (428843)159
Mild Steel Consumable Starter Kit with Torch (428842)160
Stainless Steel and Aluminum Consumable Starter Kit with Torch (428841)161
Other Consumable and Torch Parts162
Plasma Power Supply to Gas Connect Console Connections163
Pilot Arc Lead with Strain Relief163
Negative Lead with Strain Relief163
Power Cable164
Coolant Hose Set164
CAN Cable165
Gas Connect Console to Torch Connect Console Connections165
Pilot Arc and Coolant Hose Set Assembly (Core)165
Power, CAN, and 3-Gas Assembly (Core)165
Pilot Arc, Coolant Hose Set, and Shield Water Assembly (VWI or Optimix)166
Power, CAN, and 5-Gas Assembly (VWI or Optimix)166
Plasma Power Supply to CNC Connections167
Ethercat CNC Interface Cable167
Discrete CNC Interface Cable167
Serial CNC Interface Cable168
Plasma Power Supply to Cutting Table Connection168
Work Lead168
Torch Connect Console to Torch Receptacle Connection169
Torch Lead169
Bevel Torch Lead169
Supply Hoses170
Oxygen Hose (Blue)170
Nitrogen or Argon Hose (Black)170
Air Hose (Black)170
Hydrogen or Nitrogen-Hydrogen (F5) (Red)171
Water (Optional Shield Fluid) (Blue)171
Preventive Maintenance Kits171
Tools172
Recommended Spare Parts173
Plasma Power Supply - Recommended Spare Parts173
Gas Connect Consoles - Recommended Spare Parts173
Torch Connect Console - Recommended Spare Parts174
Torch - Recommended Spare Parts174
Descriptions of Warning Label Icons175

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