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Hypertherm
Welding System
XPR300
Hypertherm XPR300 Replacement Part Procedures
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T
orch Connect Console
3
XPR3
00
Field Service Bulletin
80
9
9
7
0
10
5
Ta
b
l
e
1
–
Solenoid valve connectors
T
able 2
–
Pressure transducer connectors
Va
l
v
e
Connector
V4
J11
V8
J20
V5
J12
V12
J25
V6
J14
V1
0
J23
V9
J22
V7
J18
T
ransducer
Connector
P3
J6
P1
J1
P14
J3
P4
J8
P5
J2
P2
J4
D58
D51
D41
D16
D84
D64
D35
D34
D75
D69
D87
D88
D24
D25
D
104
106
Table of Contents
Default Chapter
5
Table of Contents
5
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
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
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 Regulator
85
Set the Ar Regulator
86
Gas Connect Console Panels
87
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
5 Parts List
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
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
Other manuals for Hypertherm XPR300
Instruction Manual
438 pages
Preventive Maintenance Program
41 pages
4
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Hypertherm XPR300 Specifications
General
Brand
Hypertherm
Model
XPR300
Category
Welding System
Language
English
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