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Hypertherm
Welding System
XPR170
Hypertherm XPR170 Replacement Part Procedures
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XPR1
7
0
Field
Service
Bulletin 81
041
0
101
T
orch Connect Console
WA
R
N
I
N
G
EL
E
C
T
RI
C SH
OC
K
C
A
N
KIL
L
Disconnect electric power before doing inst
allation or maintenance. Y
ou can
get a serious electric shock if electric power is not disc
onnected. Electric
shoc
k can seriously injure or kill you.
All work that r
equires removal of the torch connect console
panels must be
done by a qualified tec
hnician.
Refer to the
Safety and C
ompliance Manual
(80669C
)
fo
r m
or
e sa
fe
ty
information.
100
102
Table of Contents
Table of Contents
5
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 Check Valve
17
Replace the Coolant Level Sensor
19
Replace a Heat-Exchanger Fan
20
Remove a Heat-Exchanger Fan
20
Install a Heat-Exchanger Fan
22
Replace the Heat-Exchanger Assembly
23
Remove the Heat-Exchanger Assembly
23
Install the Heat-Exchanger Assembly
24
Replace the Coolant Thermistor
26
Replace the Solid State Relay
27
Replace the Fan Power Distribution PCB
28
Replace the Coolant Pump, Solenoid Valve, and Motor Assembly
29
Remove the Coolant Pump, Solenoid Valve, and Motor Assembly
29
Install the Coolant Pump, Solenoid Valve, and Motor Assembly
30
Left-Side (Control-Side) Parts
32
Replace the Chopper
32
Remove the Chopper
32
Install the Chopper
34
Replace the Control-Side Fans
35
Remove the Control-Side Fans
35
Install the Control-Side Fans
37
Replace the 48 V Power Source
38
Remove the 48 V Power Source
38
Install the 48 V Power Source
39
Replace the 24 V Power Source
41
Replace the Control Transformer
42
Remove the Control Transformer
42
Install the Control Transformer
43
Replace the Power Distribution PCB
44
Replace the Control PCB
45
Replace the I/O PCB
47
Replace the Pilot Arc Relay
48
Replace Start Circuit Assembly
49
Bottom-Compartment Parts
50
Replace an Inductor
50
Remove an Inductor
50
Install an Inductor
54
Rear-Compartment Parts
55
Replace the Main Contactor
55
Remove the Main Contactor
55
Install the Siemens Main Contactor
56
Install the Allen-Bradley or ABB Main Contactor
57
Replace the Inrush Resistor Assembly
59
Plasma Power Supply Panels
61
Remove the Front Panel
61
Remove the Right-Side (Liquid-Cooling-Side) Panel
62
Remove the Left-Side (Control-Side) Panel
63
Remove the Rear Panel
64
Remove the Top Panel
65
Gas Connect Consoles
67
How to Use Push-To-Connect Fittings
68
Replace the High-Frequency, High-Voltage Transformer
69
Replace the High-Frequency, High-Voltage PCB
71
Replace the Coil Assembly
73
Remove the Coil Assembly
73
Install the Coil Assembly
75
Replace the EMI Filter
76
Replace the Control PCB
77
Replace the 24 V Power Source
78
Replace the Air Filter Assembly
79
Replace a Pressure Transducer
80
Replace a Proportional Valve
82
Remove a Proportional Valve
82
Install a Proportional Valve
83
Replace the Mixer Module
84
Remove the Mixer Module
84
Install the Mixer Module
90
Replace a Regulator
95
Remove a Regulator
95
Install a Regulator
97
How to Set the Regulators
98
Set the N Regulator
98
Set the Ar Regulator
99
Gas Connect Console Panels
100
Torch Connect Console
101
How to Use Push-To-Connect Fittings
102
Replace the Ohmic PCB
103
Replace the Ohmic Relay and Bracket
105
Remove the Ohmic Relay and Bracket
105
Install the Ohmic Relay and Bracket
106
Replace a Pressure Transducer
107
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 PCB
115
Remove the Control PCB
115
Install the Control PCB
116
Replace a Proportional Valve
118
Remove a Proportional Valve
118
Install a Proportional Valve
119
Replace the Manifold Assembly
120
Remove the Manifold Assembly
120
Install the Manifold Assembly
121
Replace the Bottom Manifold Assembly
123
Remove the Bottom Manifold Assembly
123
Install the Bottom Manifold Assembly
125
Torch Connect Console Top Panel and Side Panels
126
Torch
127
Replace the Solenoid Valve
128
Parts List
131
Plasma Power Supply
131
Outer Panels
132
Fans
133
Coolant System
134
Coolant Adapters in the Rear Compartment
135
Other Adapters Not Shown
136
Transformer and Inductor
137
Control Side - View 1
138
Control Side - View 2
139
Rear Compartment of the Plasma Power Supply
140
Gas Connect Consoles
141
Gas Connect Console High-Voltage Side Parts
142
Gas Connect Console Manifold Side Parts
143
Core, VWI, and Optimix Gas Connect Console Manifold Side
143
Core Gas Connect Console Manifolds and Adapters
144
VWI Gas Connect Console Input and Output Manifolds and Adapters
146
Optimix Gas Connect Console Input and Output Manifolds and Adapters
148
VWI and Optimix Gas Connect Console Mixer, Transducers, and Valves
150
Gas Connect Console Wire Harness, Hose Kit, and CAN Cables
151
Torch Connect Console
151
Torch Connect Console Easy Connect Side
152
Torch Connect Console - Top
152
Torch Connect Console Manifold Side - View 1
153
Torch Connect Console Manifold Side - View 2
154
Front Adapters and Valves
155
Torch Assembly
156
Torch Bracket
157
Consumable Starter Kits
158
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 Parts
162
Plasma Power Supply to Gas Connect Console Connections
163
Pilot Arc Lead with Strain Relief
163
Negative Lead with Strain Relief
163
Power Cable
164
Coolant Hose Set
164
CAN Cable
165
Gas Connect Console to Torch Connect Console Connections
165
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 Connections
167
Ethercat CNC Interface Cable
167
Discrete CNC Interface Cable
167
Serial CNC Interface Cable
168
Plasma Power Supply to Cutting Table Connection
168
Work Lead
168
Torch Connect Console to Torch Receptacle Connection
169
Torch Lead
169
Bevel Torch Lead
169
Supply Hoses
170
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 Kits
171
Tools
172
Recommended Spare Parts
173
Plasma Power Supply - Recommended Spare Parts
173
Gas Connect Consoles - Recommended Spare Parts
173
Torch Connect Console - Recommended Spare Parts
174
Torch - Recommended Spare Parts
174
Descriptions of Warning Label Icons
175
Other manuals for Hypertherm XPR170
Instruction Manual
438 pages
Preventive Maintenance Program
41 pages
4
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Hypertherm XPR170 Specifications
General
Brand
Hypertherm
Model
XPR170
Category
Welding System
Language
English
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