XPR300™

Instruction Manual

809480 – REVISION 3
ENGLISH
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 XPR300

Instruction Manual

809480
REVISION 3

ENGLISH
Original instructions

October 2019

Hypertherm, Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Hypertherm, Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9, 4704 SE
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For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at
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 Contents

List of Tables.............................................................................................................................. 17

1 Specifications............................................................................................................................ 19
Terminology........................................................................................................................................................... 19
XPR cutting system description ...................................................................................................................... 20
General ...................................................................................................................................................... 20
Plasma power supply ............................................................................................................................. 20
Gas connect consoles ........................................................................................................................... 20
TorchConnect console........................................................................................................................... 20
Torch........................................................................................................................................................... 20
Plasma power supply (part number varies)................................................................................................... 21
Gas connect console (part number varies)................................................................................................... 23
TorchConnect console (078618).................................................................................................................... 24
Torch (part number varies) ................................................................................................................................ 25
Symbols and marks ............................................................................................................................................ 26
Safety and EMC symbols and marks ................................................................................................. 26
IEC symbols ............................................................................................................................................. 28

2 Qualifications and Requirements.......................................................................................... 29

Document requirements .................................................................................................................................... 29
Operator qualifications....................................................................................................................................... 30
Qualifications of service personnel ................................................................................................................. 31
System electrical requirements........................................................................................................................ 32

XPR300 Instruction Manual 809480 5

 Code conformity...................................................................................................................................... 32
Input power requirements ..................................................................................................................... 32
General input power requirements ......................................................................................... 32
Plasma power supply ................................................................................................................. 33
Line-disconnect switch requirements..................................................................................... 33
Circuit breaker and fuse requirements ................................................................................... 34
Main power cord requirements ................................................................................................ 34
Input power requirements for CE units .............................................................................................. 35
Remote on-off switch ............................................................................................................................. 35
Process gas requirements (Core, VWI, and OptiMix gas connect consoles) ...................................... 36
Code conformity...................................................................................................................................... 37
Plumbing for supply gases.................................................................................................................... 38
Regulators for supply gases ................................................................................................................. 40
Shield water requirements (VWI and OptiMix) ............................................................................................ 41
Plumbing and hose requirements for shield water .......................................................................... 42
Additional regulator requirement for shield water (optional) ......................................................... 42
Torque requirements for gas or water plumbing and hose connections .................................... 42
Requirements for shield water removal for freezing-ambient temperatures .............................. 43
Coolant requirements......................................................................................................................................... 44
Coolant requirements for operation between -10°C – 40°C (14°F – 104°F) .......................... 45
Coolant requirements for operation in temperatures above 40°C (104°F) ............................... 45
Flow requirements for coolant.............................................................................................................. 46
Purity requirements for coolant water................................................................................................. 46
Requirements to position system components ............................................................................................ 47
Recommended configuration with the Core gas connect console ............................................. 48
Recommended configuration with the VWI or OptiMix gas connect console.......................... 49
Site requirements .................................................................................................................................... 50
Length requirements for hoses, cables, and leads.......................................................................... 50
Bend radius requirements for hoses, cables, and leads ................................................................ 51
Distance requirements between high-frequency leads and control cables .............................. 51
Distance requirements for ventilation and access........................................................................... 51
Distance requirements for communications ..................................................................................... 52
Wireless compliance .............................................................................................................................. 52
Torch mounting bracket requirements ............................................................................................................ 53
Torch lifter requirements .................................................................................................................................... 53
CNC requirements ............................................................................................................................................. 54
Remote on-off switch ............................................................................................................................. 54
Adjustable settings ................................................................................................................................. 54
Display settings ....................................................................................................................................... 54
Diagnostics and troubleshooting......................................................................................................... 55

6 809480 Instruction Manual XPR300

 Recommended grounding and shielding....................................................................................................... 56
Introduction............................................................................................................................................... 56
Types of grounding ................................................................................................................................. 56
Grounding practices............................................................................................................................... 57
Example grounding diagram ................................................................................................................. 60

3 Installation ................................................................................................................................ 61
Before you begin ................................................................................................................................................. 61
Upon receipt............................................................................................................................................. 61
Claims ............................................................................................................................................ 62
Acoustical noise ...................................................................................................................................... 62
Proper handling and safe use of chemicals ...................................................................................... 62
Installation requirements........................................................................................................................ 63
Installation overview............................................................................................................................................ 63
Installation checklist................................................................................................................................ 64
Verify system requirements ....................................................................................................... 64
Verify installation steps............................................................................................................... 67
Safety instructions related to installation........................................................................................... 69
Configuration with Core gas connect console ................................................................................ 73
Configuration with VWI or OptiMix gas connect console ............................................................. 74
How to position the system components ...................................................................................................... 75
Plan where to position system components ..................................................................................... 75
Position system components................................................................................................................ 76
Position the plasma power supply........................................................................................... 76
Position and mount the gas connect consoles .................................................................... 77
Position and mount the TorchConnect console ................................................................... 80
How to ground the system components ....................................................................................................... 83
How to remove the external panels from the system components.......................................................... 86
How to identify and prepare the hoses, cables, and leads ....................................................................... 90
Coolant hose set ..................................................................................................................................... 90
Negative lead with strain relief ............................................................................................................. 90
Pilot arc lead with strain relief .............................................................................................................. 90
Power cable.............................................................................................................................................. 91
CAN cable ................................................................................................................................................ 91
Work lead.................................................................................................................................................. 91
Pilot arc and coolant hose set assembly ........................................................................................... 91
Power, CAN, 3-gas assembly (only for Core) .................................................................................. 91
Pilot arc, coolant hose set, and shield water assembly (only for VWI and OptiMix) ............... 91
Power, CAN, and 5-gas assembly (only for VWI and OptiMix).................................................... 92
Oxygen hose (blue)................................................................................................................................. 92
Nitrogen hose (black)............................................................................................................................. 92

XPR300 Instruction Manual 809480 7

 Air hose (black)........................................................................................................................................ 92
Hydrogen (OptiMix only) (red).............................................................................................................. 92
Argon (VWI or OptiMix only) (black)................................................................................................... 92
F5 (VWI or OptiMix only) (red)............................................................................................................. 92
Shield water (VWI or OptiMix only) (blue) ........................................................................................ 92
How to connect the plasma power supply and gas connect console (Core, VWI, or OptiMix) ...... 93
Label in the plasma power supply....................................................................................................... 93
Connect the coolant hose set.............................................................................................................. 94
Connect the power cable...................................................................................................................... 96
Connect the CAN cable ........................................................................................................................ 97
How to connect the work lead to the plasma power supply and cutting table .................................... 98
Connect the negative lead with strain relief...................................................................................... 99
Connect the pilot arc lead with strain relief .................................................................................... 101
How to connect the gas connect console to the torch connect console............................................ 103
Connect the gas connect console (Core) to the TorchConnect console................................ 103
Connect the pilot arc and coolant hose set assembly ..................................................... 103
Connect the power, CAN, and 3-gas assembly (Core).................................................. 106
Connect the gas connect console (VWI or OptiMix) to the TorchConnect console ............ 107
Connect the pilot arc, coolant hose set, and shield water assembly............................ 107
Connect the power, CAN, and 5-gas assembly ................................................................ 110
How to install and connect the supply gases ........................................................................................... 111
Install gas regulators ........................................................................................................................... 113
Connect supply gases to the gas connect console (Core) ....................................................... 114
Connect supply gases and shield water to the gas connect console (VWI or OptiMix) .... 117
Connect shield water to the gas connect console (VWI or OptiMix).......................... 120
How to connect the torch receptacle to the TorchConnect console................................................... 121
Connect the EasyConnect torch lead assembly to the torch receptacle ............................... 121
Connect the EasyConnect™ torch lead assembly to the TorchConnect console................. 125
How to install the torch in the torch mounting bracket ........................................................................... 127
How to install the consumables.................................................................................................................... 129
How to install the torch into the torch receptacle .................................................................................... 131
How to connect electric power to the cutting system ............................................................................ 133
Sample configurations for consumables .................................................................................................... 135
Ferrous (mild steel) sample configurations .................................................................................... 135
Mild steel – 30 A – O2/O2 ..................................................................................................... 135
Mild steel – 50 A – O2/Air ..................................................................................................... 135
Mild steel – 80 A, 130 A, 170 A, and 300 A – O2/Air .................................................... 136
Non-ferrous (stainless steel and aluminum) sample configurations......................................... 137
Non-ferrous – 40 A – N2/N2 and Air/Air............................................................................. 137
Non-ferrous – 60 A – F5/N2**, N2/N2, N2/H2O**, and Air/Air........................................ 138
Non-ferrous – 80 A – F5/N2**, N2/N2, N2/H2O**, Air/Air................................................ 139

8 809480 Instruction Manual XPR300

 Non-ferrous – 130 A – N2/N2, H2-Ar-N2/N2**, N2/H2O***.............................................. 140
Non-ferrous – 170 A – N2/N2, H2-Ar-N2/N2**, N2/H2O***, Air/Air ................................ 141
Non-ferrous – 300 A – N2/N 2, H2-Ar-N2/N 2**, N2/H 2O***............................................. 142

4 Connect for Communication ................................................................................................. 143

How to connect to the plasma power supply with EtherCAT................................................................ 145
How to connect to the plasma power supply with serial RS-422 ....................................................... 147
How to connect to the plasma power supply with discrete................................................................... 150
VDC3 board installation (for AVC with RS-422 and discrete-only) .................................................... 154
Diagram of board, cable, and wire connections ........................................................................... 155
How to install the VDC3 board (141511) ..................................................................................... 156
How to connect the VDC3 board (141511)................................................................................. 159
How to connect to the plasma power supply with the XPR web interface........................................ 162
Web interface support information................................................................................................... 162
Use AP mode to connect ................................................................................................................... 163
Use network mode to connect.......................................................................................................... 165
Select an existing network ..................................................................................................... 167
Set up manually ........................................................................................................................ 170
Access the XPR web interface after setup in network mode ........................................ 173
Change the limited AP settings ............................................................................................. 174
Reset the wireless module................................................................................................................. 176
How to disable the wireless connection......................................................................................... 178
Web interface screen information .................................................................................................... 180
Plasma power supply .............................................................................................................. 181
Gas system................................................................................................................................ 182
Log............................................................................................................................................... 183
Operate....................................................................................................................................... 184
Other ........................................................................................................................................... 185
How to change the device that has control ............................................................................................... 186
How to use ohmic contact sense................................................................................................................. 187
Ohmic relay overview .......................................................................................................................... 187
Internal ohmic contact sense ............................................................................................................ 187
External ohmic contact sense ........................................................................................................... 188
How to install a remote on-off switch.......................................................................................................... 190
Examples of output circuits............................................................................................................................ 191
Examples of input circuits .............................................................................................................................. 192

5 Coolant Installation ................................................................................................................ 193

Overview ............................................................................................................................................................ 193
How to fill the cutting system with coolant ................................................................................................ 194

XPR300 Instruction Manual 809480 9

 6 Operation.................................................................................................................................. 197
Overview ............................................................................................................................................................ 197
Controls and indicators .................................................................................................................................. 198
Controls.................................................................................................................................................. 198
CNC............................................................................................................................................ 198
Wireless device ........................................................................................................................ 198
Indicators................................................................................................................................................ 199
Power-indicator LEDs ............................................................................................................. 199
CNC display.............................................................................................................................. 200
Sequence of operation ................................................................................................................................... 201
States of operation for the XPR cutting system ........................................................................... 201
Powerup State (1).................................................................................................................... 201
Initial checks State (2)............................................................................................................. 202
Gas purge/pump on State (3)............................................................................................... 203
Wait for start State (5) ............................................................................................................ 204
Preflow/charge DC State (7) ................................................................................................ 204
Ignite State (8) .......................................................................................................................... 205
Pilot arc State (9) ..................................................................................................................... 206
Rampup State (11) .................................................................................................................. 207
Steady State (12)..................................................................................................................... 207
Rampdown State (13) ............................................................................................................ 208
End of cycle State (14)........................................................................................................... 208
High-voltage relay stages (closed or opened) in the ohmic circuit.......................................... 208
Automatic purges ................................................................................................................................. 209
Gas-change purges for OptiMix or VWI XPR cutting systems..................................... 209
Process-setup purges for all XPR cutting systems .......................................................... 210
How to choose the torch positions and process settings you need.................................................... 211
Perpendicular-position cutting, marking, and piercing ................................................................ 211
Cutting ........................................................................................................................................ 211
Marking ....................................................................................................................................... 211
Piercing....................................................................................................................................... 211
Bevel cutting.......................................................................................................................................... 212
Bevel compensation tables.................................................................................................... 213
Ferrous (mild steel) processes.......................................................................................................... 213
Non-ferrous (stainless steel and aluminum) processes .............................................................. 214
Stainless steel........................................................................................................................... 215
Aluminum.................................................................................................................................... 216
Processes for special applications .................................................................................................. 217
Underwater cutting .................................................................................................................. 217
Mirror cutting ............................................................................................................................. 218

10 809480 Instruction Manual XPR300

 Process selection............................................................................................................................................. 219
How to use process IDs to access optimal settings ................................................................... 219
Process ID offsets / overrides............................................................................................... 220
How to use cut charts..................................................................................................................................... 221
Process core thickness (PCT) .......................................................................................................... 221
Process categories .............................................................................................................................. 221
How to select consumables .......................................................................................................................... 224
Factors of cut quality ....................................................................................................................................... 224
Dross....................................................................................................................................................... 224
How to get the results you want....................................................................................................... 224
General recommendations for all processes ..................................................................... 225
Recommendations for perpendicular-position cutting processes................................ 225
Recommendations for piercing processes......................................................................... 226
Recommendations for marking processes......................................................................... 227
Recommendations for bevel-cutting processes ............................................................... 227
How to maximize the life of consumable parts .............................................................................. 228
Arc Response Technology ............................................................................................................................. 228
Automatic torch protection ................................................................................................................ 228
Automatic rampdown error protection ............................................................................................ 229

7 Maintenance........................................................................................................................... 231
Overview ............................................................................................................................................................ 231
How to do daily inspections .......................................................................................................................... 233
Remove the power from the cutting system .................................................................................. 234
Examine the gas regulators................................................................................................................ 235
Examine the shield water regulator (if applicable)........................................................................ 235
Examine the connections and fittings.............................................................................................. 235
Examine the consumable parts, torch, and torch receptacle..................................................... 236
Remove the torch and consumable parts........................................................................... 236
Examine the consumable parts ............................................................................................. 237
Examine the torch..................................................................................................................... 239
Examine the torch receptacle................................................................................................ 240
Examine the torch lead........................................................................................................................ 241
How to replace the water tube ..................................................................................................................... 242
How to identify emitter wear.......................................................................................................................... 243
How to measure the pit depth of an electrode ......................................................................................... 246
How to do coolant maintenance................................................................................................................... 247
Estimate the total coolant volume for your cutting system ......................................................... 248
Replace all of the coolant................................................................................................................... 248
Remove old coolant from the coolant system.................................................................... 249

XPR300 Instruction Manual 809480 11

 8 Diagnostics and Troubleshooting........................................................................................ 253
Overview ............................................................................................................................................................ 253
Safety considerations.......................................................................................................................... 254
Initial inspection steps..................................................................................................................................... 255
Remove the power from the cutting system .................................................................................. 255
Examine the PCBs............................................................................................................................... 257
Measure the line voltage between the terminals inside the plasma power supply ............... 259
Diagnostic codes ............................................................................................................................................. 261
How to diagnose and troubleshoot diagnostic codes ................................................................ 261
CAN codes (500 – 503, 510 – 513 for gas connect console,
504 – 505, 514 – 515 for CAN cable and jumper block,
507 – 508 for CAN network and bus, 600 – 602 for no CAN communication) ..... 304
Low shield water pressure code (532) ................................................................................ 310
Low shield gas pressure code (534) .................................................................................. 311
Low coolant flow codes (540 – 542) ................................................................................. 312
High coolant flow codes (543 – 544) ................................................................................ 314
Over temp diagnostic codes – Choppers (560 – 561) and Coolant (587).............. 315
Start switch diagnostic codes (570 – 577) ....................................................................... 318
Over temp diagnostic codes – Inductors (580 – 583), Transformers (586) ............ 320
Current sensor diagnostic codes (631) ............................................................................. 323
Low inlet pressure for H2, Ar, N2, and H2O diagnostic codes
(695 – 697, 700, 701) ............................................................................................................ 324
Shield gas inlet pressure in the torch connect console diagnostic codes
(702 – 705) ............................................................................................................................... 325
Process-gas inlet pressure in the torch connect console diagnostic codes
(702, 705, 769, 770) for OptiMix-equipped cutting systems........................................ 327
Pressure transducer diagnostic codes (706 – 715) ....................................................... 329
Gas inlet pressure codes (768 – 771) ............................................................................... 330
How to do a gas leak test (VWI and OptiMix)............................................................................... 331
How to measure coolant flow............................................................................................................ 333
Use the CNC or XPR web interface ................................................................................... 333
Do a container test .................................................................................................................. 333
How to test continuity between the nozzle and workpiece ........................................................ 335
How to measure resistance from thermistors................................................................................ 338
How to do an ohmic-contact test .................................................................................................... 340
PCB information............................................................................................................................................... 343
Plasma power supply power distribution PCB (141425) ......................................................... 343
Plasma power supply control PCB (141322)............................................................................... 344
DIP switch positions................................................................................................................ 346
Plasma power supply chopper PCB (141319) ............................................................................ 347
Plasma power supply start circuit PCB (141360) ...................................................................... 348
Plasma power supply I/O PCB (141371) ..................................................................................... 348

12 809480 Instruction Manual XPR300

 Plasma power supply fan power distribution PCB (141384) ................................................... 349
Gas connect console control PCB (141375)............................................................................... 350
Gas connect console high frequency PCB (141354)................................................................ 351
Torch connect console ohmic PCB (141368).............................................................................. 351
Torch connect console control PCB (141334) ............................................................................ 352

9 Parts List ................................................................................................................................. 353

Plasma power supply ...................................................................................................................................... 353
Outer panels.......................................................................................................................................... 354
Fans......................................................................................................................................................... 355
Coolant system..................................................................................................................................... 356
Coolant adapters in the rear compartment .................................................................................... 357
Other adapters not shown ................................................................................................................. 358
Transformers and inductors ............................................................................................................... 359
Control side – view 1 .......................................................................................................................... 360
Control side – view 2 .......................................................................................................................... 361
Rear compartment of the plasma power supply ........................................................................... 362
Gas connect consoles.................................................................................................................................... 363
Gas connect console high-voltage side parts .............................................................................. 364
Gas connect console manifold side parts...................................................................................... 365
Core, VWI, and OptiMix gas connect console manifold side........................................ 365
Core gas connect console manifolds and adapters ........................................................ 366
VWI gas connect console input and output manifolds and adapters.......................... 368
OptiMix gas connect console input and output manifolds and adapters.................... 370
VWI and OptiMix gas connect console mixer, transducers, and valves...................... 372
Gas connect console wire harness, hose kit, and CAN cables ................................................ 373
Torch connect console.................................................................................................................................... 373
Torch connect console Easy Connect side..................................................................................... 374
Torch connect console – top.............................................................................................................. 374
Torch connect console manifold side – view 1 ............................................................................. 375
Torch connect console manifold side – view 2 ............................................................................. 376
Front adapters and valves .................................................................................................................. 377
Torch assembly ................................................................................................................................................. 378
Torch bracket..................................................................................................................................................... 379
Consumable starter kits.................................................................................................................................. 380
Mild steel consumable starter kit (428616)................................................................................... 380
Stainless steel and aluminum consumable starter kit (428617)............................................... 381
Mild steel consumable starter kit with torch (428618) ............................................................... 382
Stainless steel and aluminum consumable starter kit with torch (428619) ........................... 383
Other consumable and torch parts .............................................................................................................. 384

XPR300 Instruction Manual 809480 13

 Plasma power supply to gas connect console connections.................................................................. 385
Pilot arc lead with strain relief ........................................................................................................... 385
Negative lead with strain relief .......................................................................................................... 385
Power cable........................................................................................................................................... 386
Coolant hose set .................................................................................................................................. 386
CAN cable ............................................................................................................................................. 387
Gas connect console to torch connect console connections............................................................... 387
Pilot arc and coolant hose set assembly (Core)........................................................................... 387
Power, CAN, and 3-gas assembly (Core)...................................................................................... 387
Pilot arc, coolant hose set, and shield water assembly (VWI or OptiMix) .............................. 388
Power, CAN, and 5-gas assembly (VWI or OptiMix)................................................................... 388
Plasma power supply to CNC connections .............................................................................................. 389
EtherCAT CNC interface cable ........................................................................................................ 389
Discrete CNC interface cable........................................................................................................... 389
Serial CNC interface cable................................................................................................................ 390
Plasma power supply to cutting table connection ................................................................................... 390
Work lead............................................................................................................................................... 390
Torch connect console to torch receptacle connection.......................................................................... 391
Torch lead............................................................................................................................................... 391
Bevel torch lead.................................................................................................................................... 391
Supply hoses..................................................................................................................................................... 392
Oxygen hose (blue).............................................................................................................................. 392
Nitrogen or Argon hose (black)......................................................................................................... 392
Air hose (black)..................................................................................................................................... 392
Hydrogen or nitrogen-hydrogen (F5) (red) .................................................................................... 393
Water (optional shield fluid) (blue) ................................................................................................... 393
Preventive maintenance kits .......................................................................................................................... 393
Tools .................................................................................................................................................................... 394
Recommended spare parts ........................................................................................................................... 395
Plasma power supply – recommended spare parts .................................................................... 395
Gas connect consoles – recommended spare parts .................................................................. 395
Torch connect console – recommended spare parts.................................................................. 396
Torch – recommended spare parts.................................................................................................. 396
Descriptions of warning label icons................................................................................................. 397

10 Wiring Diagrams .................................................................................................................... 399

Wiring diagram symbols ................................................................................................................................. 400
Valve states during operation ............................................................................................................ 402
Valve states by process ID..................................................................................................... 402
Overview (Sheet 1 of 22)................................................................................................................... 409
Plasma power supply 1 (Sheet 2 of 22).......................................................................................... 410

14 809480 Instruction Manual XPR300

 Plasma power supply 2 (Sheet 3 of 22)......................................................................................... 411
Plasma power supply 3 (Sheet 4 of 22)......................................................................................... 412
Plasma power supply 4 (Sheet 5 of 22)......................................................................................... 413
Plasma power supply 5 (Sheet 6 of 22)......................................................................................... 414
Plasma power supply 6 (Sheet 7 of 22)......................................................................................... 415
Plasma power supply 7 (Sheet 8 of 22)......................................................................................... 416
Gas connect console 1 (Sheet 9 of 22)......................................................................................... 417
Gas connect console 2 (Sheet 10 of 22)....................................................................................... 418
Torch connect console (Sheet 11 of 22) ....................................................................................... 419
Coolant system (Sheet 12 of 22)..................................................................................................... 420
Gas system 1 (Sheet 13 of 22)........................................................................................................ 421
Gas system 2 (Sheet 14 of 22)........................................................................................................ 422
Gas system 3 (Sheet 15 of 22)........................................................................................................ 423
EtherCAT multi-system interface (Sheet 16 of 22)...................................................................... 424
Serial RS-422 and discrete multi-system interface (Sheet 17 of 22)..................................... 425
Discrete multi-system interface (Sheet 18 of 22) ........................................................................ 426
EtherCAT connection to EDGE Connect/TC (Sheet 19 of 22) ............................................... 427
Discrete and serial RS-422 CNC connections (Sheet 20 of 22)............................................ 428
Discrete CNC connections (Sheet 21 of 22) ............................................................................... 429
Wireless subsystem block diagram (Sheet 22 of 22) ................................................................. 430

XPR300 Instruction Manual 809480 15

16 809480 Instruction Manual XPR300
 List of Tables

Table 1 – Plasma power supply general specifications..............................................................................22

Table 2 – Plasma power supply part numbers and specifications...........................................................22
Table 3 – Gas connect console part numbers and dimensions ...............................................................23
Table 4 – Length and weight by sleeve type.................................................................................................25
Table 5 – General torch specifications...........................................................................................................25
Table 6 – Input power requirements ...............................................................................................................33
Table 7 – Gas quality, pressure, and flow requirements ............................................................................36
Table 8 – Recommended sizes for gas fittings.............................................................................................39
Table 9 – Quality, pressure, and flow requirements for shield water ......................................................41
Table 10 – Purity requirements for shield water...........................................................................................41
Table 11 – Torque specifications.....................................................................................................................42
Table 12 – Purity measurement methods for coolant water......................................................................46
Table 13 – Recommendations for where to position system components............................................50
Table 14 – Length ranges for interconnect hoses, cables, and leads ....................................................50
Table 15 – Maximum distance between the plasma power supply and controlling device ...............52
Table 16 – Equipment to lift or move the plasma power supply...............................................................76
Table 17 – Definitions of symbols on the label.............................................................................................93
Table 18 – Torque specifications.................................................................................................................. 112
Table 19 – Recommended sizes for gas fittings ....................................................................................... 115
Table 20 – Recommended sizes for gas fittings ....................................................................................... 118
Table 21 – Color codes for main power cord wires................................................................................. 134
Table 22 – Communication requirements and options............................................................................ 144
Table 23 – Pinout for serial RS-422 interface cable................................................................................ 148
Table 24 – Pinout for J14 on the discrete cable ....................................................................................... 151
Table 25 – Pinout for J19 on the discrete cable ....................................................................................... 152

XPR300 Instruction Manual 809480 17

 List of Tables

Table 26 – Pinout for J2 on the VDC3 board ............................................................................................ 161

Table 27 – Available non-ferrous processes by gas connect console type and gas type. ............. 214
Table 28 – Process recommendations for cut quality, based on metal thickness and type ........... 214
Table 29 – Process category options and expected quality-speed results for ferrous
(mild steel) processes...................................................................................................................................... 222
Table 30 – Process category options and expected quality-speed results for non-ferrous
processes ........................................................................................................................................................... 223
Table 31 – Inspection, preventive maintenance, and cleaning tasks.................................................... 232
Table 32 – Inspection tasks for consumables ........................................................................................... 237
Table 33 – PCB names and locations......................................................................................................... 258
Table 34 – Diagnostic codes in the web interface ................................................................................... 262
Table 35 – Diagnostic codes......................................................................................................................... 263
Table 36 – Minimum and maximum ohmic resistance values for thermistors .................................... 317
Table 37 – Minimum and maximum ohmic resistance values for thermistors .................................... 322
Table 38 – Minimum and maximum ohmic resistance values for thermistors .................................... 339

18 809480 Instruction Manual XPR300

 Specifications

Terminology

XPR cutting system – The plasma power supply, gas connect console, torch connect console,
and torch.

Cutting system or cutting machine – The XPR cutting system, CNC, torch lifter, cutting table,
and other components.

Wet process – Any process that uses water as a shield fluid.

Dry process – Any process that does not use water as a shield fluid.

Ferrous – Mild steel

Non-ferrous – Stainless steel and aluminum

Gases – Hydrogen (H2), argon (Ar), nitrogen (N2), oxygen (O2), water (H2O), F5 (95% nitrogen,
5% hydrogen)

Mixed-fuel gas – A mixture of H2-Ar-N2 created in the OptiMix gas connect console.

XPR300 Instruction Manual 809480 19

1 Specifications

XPR cutting system description

General
XPR cutting systems are designed for indoor use with correct ventilation to cut a wide range of
thicknesses of mild steel, stainless steel, and aluminum.

Plasma power supply

The plasma power supply is a 300 A, 210 VDC constant-current supply. It contains a heat
exchanger, fans, and a pump to cool the torch and other electronic components. The plasma power
supply supports EtherCAT®, wireless, RS-422 serial, and discrete communication protocols to
communicate with a CNC or wireless device.

The power-indicator LED on the plasma power supply indicates power status:
 It illuminates amber when the plasma power supply is receiving electric power and the
remote on-off switch is in the OFF position.
 It illuminates green when the plasma power supply is receiving electric power and the
remote on-off switch is in the ON position.

Gas connect consoles

There are 3 types of gas connect consoles: Core™, VWI™ (vented water injection), and OptiMix™.
Each type provides a different set of gas connection capabilities, which provide selecting and
metering functions for the gas control system. The gas connect console has 2 printed circuit boards
(PCBs): a control PCB and an ignition PCB. If your XPR cutting system is equipped with an
OptiMix gas connect console, there is also a gas mixer that has its own control board. A green
power LED illuminates when power is supplied to the console.

 For some cutting systems, a remote on-off switch controls the power that
goes to the console.

TorchConnect console
The TorchConnect™ console has proportional valves, solenoid valves, and pressure transducers.
The TorchConnect console also has 2 PCBs, a control PCB, and an ohmic contact PCB. The
TorchConnect console provides all power, gas, and cooling connections for connection to the torch.
A power-indicator LED illuminates when power is supplied to the console.

 For some cutting systems, a remote on-off switch controls the power that
goes to the console.

Torch
The torch assembly consists of a torch mount sleeve, torch receptacle, torch, and water tube. The
torch receptacle contains a solenoid valve. Consumables are installed on the torch.

20 809480 Instruction Manual XPR300

 Specifications 1

Plasma power supply (part number varies)

81.70 cm
(32.17 in.)

124.76 cm
(49.12 in.)

127.28 cm
(50.11 in.)
590 kg
(1,300 lb)

 The part number and specifications can differ for your plasma power
supply. (See Table 1 on page 22 and Table 2 on page 22 for part numbers
and specifications.)

XPR300 Instruction Manual 809480 21

1 Specifications

Table 1 – Plasma power supply general specifications

Maximum open-circuit voltage (U0) 360 VDC

Maximum output current (I2) 300 A
Output voltage (U2) 50 VDC – 210 VDC
Duty cycle rating (X) 100% at 63 kW, 40°C (104°F)
>0°C – 40°C (>32°F – 104°F) – Applies only to
cutting systems that use water as a shield fluid.
-10 °C – 40°C (14°F – 104°F) – Applies only to
Operational ambient temperature range cutting systems that do not use water as a shield
fluid.
Note: Only VWI- and OptiMix-equipped cutting
systems can use water as a shield fluid.
Power factor (cosθ) 0.98 at 63 kW
Cooling Forced air (Class F)
Insulation Class H
EMC emissions classification (CE models only) Class A
Top lift eye
Lift points
Bottom lift truck slots
Lift eye weight rating 680 kg (1,500 lb)

Table 2 – Plasma power supply part numbers and specifications

Rated input Regulatory Power (kVA)

Voltage approval (± 10%)
Part number Phase Frequency (Hz) current at 66.5 kW
(VAC) (U1)
output (A) (I1) Safety/EMC (U1 X I1 X1.73)
078620 200 50 – 60 206 cCSAus
078621 208 60 198 cCSAus
078622 220 50 – 60 188 cCSAus
078623 240 60 172 cCSAus
078624 380 50 – 60 109 CCC
CE, RCM,
078625 400 3 50 – 60 103 EAC, UKr, and 71.43
AAA
CE, RCM,
078626 415 50 99 EAC, UKr, and
AAA
078627 440 60 94 cCSAus
078628 480 60 86 cCSAus
078629 600 60 69 cCSAus

22 809480 Instruction Manual XPR300

 Specifications 1

Gas connect console (part number varies)

1 2 1 2

3
3

4
4

Core 1 2

OptiMix

Varies
See Table 3.

VWI

 The part number and some specifications differ by gas connect console
type (Core, VWI, or OptiMix). (See Table 3.)

 Do not remove the inlet check valves from the gas connect consoles.

Table 3 – Gas connect console part numbers and dimensions

Gas connect Part Dimension 4

Dimension 1 Dimension 2 Dimension 3 Weight
console number (with fittings)
431.80 mm 16.24 kg
Core 078631
383.80 mm (17.00 in.) 35.80 lb
374.65 mm (15.11 in.) 205.99 mm 522.22 mm 19.12 kg
VWI 078632
(14.75 in.) (8.12 in.) (20.56 in.) 42.15 lb
434.59 mm 524.00 mm 24.36 kg
OptiMix 078633
(17.11 in.) (20.63 in.) 53.70 lb

 For mounting dimensions, see Position and mount the gas connect
consoles on page 77.

XPR300 Instruction Manual 809480 23

1 Specifications

TorchConnect console (078618)

22.86 cm
30.48 cm (9 in.)
(12 in.)

15.24 cm
(6 in.)

9.30 kg
(20.5 lb) 2.62 cm
(1.03 in.)

 The TorchConnect console (078618) goes with the 3 types of gas

connect consoles (Core, VWI, and OptiMix).

 Do not remove the inlet check valves from the torch connect console.

The factory location for the mounting brackets is on the bottom of the torch connect console.
However, you can move the mounting brackets to either side. Console placement with the torch
lead connection on the bottom can minimize the risk of leaked water or coolant collecting inside of
the console. Water or coolant collection inside of the TorchConnect console can damage internal
electrical components.

 For mounting dimensions, see Position and mount the TorchConnect

console on page 80.

24 809480 Instruction Manual XPR300

 Specifications 1

Torch (part number varies)

Clamp-surface length 160.8 mm (6.33 in.)

Overall sleeve length

Varies

Table 4 – Length and weight by sleeve type

Combined weight
(torch head, Combined weight
Sleeve type Clamp-surface length Overall sleeve length
receptacle, with sleeve
consumables)
Short 111.7 mm (4.4 in.) 155 mm (6.1 in.) 1.4 kg (3 lb) 1.5 kg (3.3 lb)
Standard 189.6 mm (4.5 in.) 233 mm (9.2 in.) 1.6 kg (3.6 lb)
Extended 268.1 mm (10.6 in.) 311 mm (12.3 in.) 1.7 kg (3.9 lb)

 The part number and some specifications for your torch can change
because of torch sleeve dimensions and other features. (See Torch
assembly on page 378 of the Parts List.)

Table 5 – General torch specifications

Rated arc striking voltage 15.3 kV

Maximum gas pressure at inlet 7.9 bar, 792 kPa (115 psi)
Minimum gas pressure at inlet 7.2 bar, 723 kPa (105 psi)
Maximum torch-side and torch-front force 22.5 kg (50 lb)

XPR300 Instruction Manual 809480 25

1 Specifications

Symbols and marks

Safety and EMC symbols and marks

Your product may have one or more of the following marks on or near the data plate. Because of differences
and conflicts in national regulations, not all marks are applied to every version of a product.
S mark
The S mark indicates that the power supply and torch are suitable for operations carried out in
environments with increased hazard of electrical shock according to IEC 60974-1.
CSA mark
Products with a CSA mark meet the United States and Canadian regulations for product safety.
The products were evaluated, tested, and certified by CSA-International. Alternatively, the product
may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL)
accredited in both the United States and Canada, such as UL or TÜV.
CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European
directives and standards. Only those versions of products with a CE marking located on or near
the data plate comply with European Directives. Applicable directives may include the European
Low Voltage Directive, the European Electromagnetic Compatibility (EMC) Directive, the Radio
Equipment Directive (RED), and the Restriction of Hazardous Substances (RoHS) Directive.
See the European CE Declaration of Conformity for details.
Eurasian Customs Union (CU) mark
CE versions of products that include an EAC mark of conformity meet the product safety and
EMC requirements for export to Russia, Belarus, and Kazakhstan.
GOST-TR mark
CE versions of products that include a GOST-TR mark of conformity meet the product safety and
EMC requirements for export to the Russian Federation.

RCM mark
CE versions of products with a RCM mark comply with the EMC and safety regulations required
for sale in Australia and New Zealand.
CCC mark
s
The China Compulsory Certification (CCC) mark indicates that the product has been tested and
found compliant with product safety regulations required for sale in China.

UkrSEPRO mark
The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety
and EMC requirements for export to the Ukraine.

Serbian AAA mark

CE versions of products that include a AAA Serbian mark meet the product safety and
EMC requirements for export to Serbia.

26 809480 Instruction Manual XPR300

 Specifications 1
RoHS mark
The RoHS mark indicates that the product meets the requirements of the European Restriction of
Hazardous Substances (RoHS) Directive.

XPR300 Instruction Manual 809480 27

1 Specifications

IEC symbols
The following symbols can appear on the data plate, control labels, and switches.

The terminal for the

Direct current (DC) external protective (earth)
(PE) conductor

Alternating current (AC) I Power is ON

O Power is OFF
Plasma torch cutting
1~ f 1
A 1-phase or 3-phase
f2
inverter-based power
source
Gouging
Volt/amperage curve,
“drooping” characteristic
AC input power
connection

28 809480 Instruction Manual XPR300

 Qualifications and Requirements

Document requirements

This manual refers to several other documents. These documents include:

 XPR Cut Charts Instruction Manual (809830)
 CNC Communication Protocol Application Notes for the XPR Cutting System (809810)
 XPR Preventive Maintenance Program Instruction Manual (809490)
 XPR Firmware Updates Field Service Bulletin (809820)

You can find these documents on the USB memory stick that came with your plasma power supply.
If you do not have these documents, technical documentation is available at
www.hypertherm.com/docs.

 Technical documentation is current as of the date of its release.

Subsequent revisions are possible. Refer to www.hypertherm.com/docs
for the most recent revisions of released documents.

XPR300 Instruction Manual 809480 29

2 Qualifications and Requirements

Operator qualifications

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.

A person is considered qualified to operate the cutting system if he or she is trained and
knowledgeable about cutting system equipment construction, operation, and work methods, and
about how to recognize and avoid hazards that can be present with certain cutting system
equipment or work methods.

For your safety and for the best results:

 Never operate the cutting system unless you are qualified to do so.
 Follow NFPA70E Section 85 in North America.
 Follow IEC 60364 series outside of North America.
 Follow OSHA Section1910.331-335 in North America for 600 volts or less.
 Follow all local and national electrical safety requirements for both operator and service
personnel.
 Always read, understand, and follow all of the safety instructions in this manual, the Safety
and Compliance Manual (80669C), and on the labels that are on the cutting system.
 Get adequate operator training from a knowledgeable source before operation. Adequate
training topics include (but are not limited to) the following:
 How to start and stop the cutting system during routine operation and in an emergency.
 Conditions and actions that can cause injuries to people or damage cutting system
equipment.
 How to operate all controls.
 How to identify and respond to fault conditions.
 How to do maintenance.
 A copy of the instruction manual.

 Additional qualifications apply for personnel who do maintenance and

troubleshooting (Qualifications of service personnel on page 31).

30 809480 Instruction Manual XPR300

 Qualifications and Requirements 2
 Do not operate the cutting system if you cannot follow all of the safety instructions or if you
cannot satisfy the minimum operator qualifications. (See the Safety and Compliance Manual
[80669C], Radio Frequency Warning Manual [80945C], and Safety instructions related to
installation on page 69.)

 Additional qualifications apply for personnel who do maintenance and

troubleshooting (Qualifications of service personnel on page 31).

Qualifications of service personnel

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.

It can be hazardous to do service and maintenance on industrial cutting systems and equipment.

For your safety and for the best results:

 Always read, understand, and follow all of the safety instructions in this manual, the Safety
and Compliance Manual (80669C), and on the labels that are on the cutting system.
 Get adequate training from a knowledgeable source before you do any service or
maintenance on the cutting system or equipment.

 The entity responsible for workplace safety where your XPR300 cutting
system is used must do a risk assessment and establish the criteria for
service personnel training and qualifications.

 Do not do any service or maintenance on the cutting system or equipment if you cannot
follow all of the safety instructions (See the Safety and Compliance Manual [80669C],
Radio Frequency Warning Manual [80945C], and Safety instructions related to installation
on page 69.) or if you cannot satisfy the minimum service personnel qualifications set by
workplace safety at your organization.
 Contact a professional repair person who has a license.

XPR300 Instruction Manual 809480 31

2 Qualifications and Requirements

System electrical requirements

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.

Code conformity
 Follow all local and national electrical safety requirements, including requirements for
correct electrical system design and installation.
 Always read, understand, and follow all of the safety instructions in this manual, the Safety
and Compliance Manual (80669C), and on the labels that are on the cutting system.
 Contact a licensed electrician for information about the codes in your location.

Input power requirements

General input power requirements
As an installer or user, you are responsible for supplying all of the switches, time-delay fuses, and
power cords necessary for cutting system installation and operation at the installation site. The
switches, fuses, and cords that you supply must satisfy all applicable national and local electrical
codes and requirements, and be installed by a licensed electrician.

General input power requirements appear in Table 6. For specific requirements for switches, fuses,
and cords, refer to Line-disconnect switch requirements on page 33, Circuit breaker and fuse
requirements on page 34, and Main power cord requirements on page 34.

32 809480 Instruction Manual XPR300

 Qualifications and Requirements 2
Table 6 – Input power requirements

Rated input Recommended Recommended size

Input
current at 66.5 kW time-delay fuse for the main power Power
Part number voltage Phase output size cord 90°C (194°F) (kVA)
(VAC)
(A) (A) (mm2 [AWG*])
078620 200 218 250 141.3 (4/0)
078621 208 209 250 141.3 (4/0)
078622 220 198 250 141.3 (4/0)
078623 240 181 225 111.9 (3/0)
078624 380 115 150 53.5 (1/0)**
3 75.4
078625 400 109 150 70.5 (1/0)**
078626 415 105 125 43.2 (2)
078627 440 99 125 43.2 (2)
078628 480 91 110 34.3 (3)
078629 600 73 90 27.3 (4)

* AWG requirements must comply with the latest version of the US National Electric Code (in North America)
or the latest electric wiring and installation requirements (based on the codes in your location). Table 6 is for
reference only; the requirements for your location can be different. Follow all local and national electrical
codes in your location.

** Differences in cross-sectional diameters depend on the strand variations of each cable.

 The strain relief for the input power cord that comes with the plasma
power supply is sized properly (see Table 6). Contact a licensed
electrician to make sure that your main power cord size and length meet
the codes in your location.

Plasma power supply

As an installer or user, you must connect the plasma power supply to one of the branch-feed
circuits. Use a separate, primary line-disconnect switch for the plasma power supply. (See
Line-disconnect switch requirements on page 33.)

Always follow the local and national electrical safety requirements for your location, including
requirements for correct electrical system design and installation. Contact a licensed electrician for
more information about the codes in your location.

Line-disconnect switch requirements

As an installer or user, you must supply a separate, line-disconnect switch for the plasma power
supply. A means for disconnecting the cutting system shall be provided according to the installation,
safety, and emergency requirements for the local codes and regulations, taking into account the
input power requirements. Hypertherm does not supply this means of disconnection.

XPR300 Instruction Manual 809480 33

2 Qualifications and Requirements

Circuit breaker and fuse requirements

For main feed protection, choose a circuit breaker or fuse that is large enough to withstand all
branch-feed loads for both inrush and steady-state current. See Table 6 on page 33 for the
recommended time-delay fuse sizes.

As an installer or user, you must choose time-delay fuses and circuit breakers that can withstand
inrush current that is up to 15 times the rated input current for 0.01 seconds and up to 10 times the
rated input current for 0.1 seconds.

The size requirements for breakers or fuses at your site can change because of the following:
 Local line conditions (such as source and line impedance and voltage fluctuations)
 Product inrush characteristics
 Regulatory requirements

Always follow the local and national electrical safety requirements for your location, including
requirements for correct electrical system design and installation. Contact a licensed electrician for
more information about the codes in your location.

 If time-delay, high-inrush fuses are not permitted at your site because of

national or local codes, use a motor-start circuit breaker or equivalent.

Main power cord requirements

As an installer or user, you must supply the main power cord for your cutting system. See Table 6 on
page 33 for recommended main power cord size.

The recommended main power cord sizes in Table 6 are based on Table 310.15 of the US National
Electric Code (2017 Handbook). Table 6 shows stranded-flexible cord rates for 90°C (194°F). The
size requirement for the main power cord at your site can change because of the following
conditions:
 Wires with lower temperature ratings
 Wires with different insulation types
 Different distances between the line-disconnect switch/receptacle and the plasma power
supply
 Local codes and regulations

Always follow the local and national electrical safety requirements for your location, including
requirements for correct electrical system design and installation. Contact a licensed electrician for
more information about the codes in your location.

34 809480 Instruction Manual XPR300

 Qualifications and Requirements 2

Input power requirements for CE units

The XPR cutting system is intended for use only in sites that have a service current capacity that is
greater than (or equal to) 100 A per phase and supplied from a distribution network that has a
nominal voltage of 400/230 V. The installer or user is responsible for verifying that the service
current capacity for the installation site satisfies this requirement.

Remote on-off switch

WARNING
ELECTRIC SHOCK CAN KILL
When the remote on-off switch is set to OFF, power remains active to the following
components in the system:
• Control board
• Control transformer input and output
• 48 V power supply
• 24 V power supply
• 120 VAC and 220 VAC on the power distribution board
• Input side of the contactors
• Input side of the pump relay
• Power-indicator LED on the front of the plasma power supply
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.

You must supply the remote on-off switch (or switches) for your cutting system.

A remote on-off switch lets you supply electric power to or remove electric power from the gas
connect console, torch connect console, and some parts of the plasma power supply from a
location that is remote from the main power source. A convenient location for a remote on-off switch
is near the CNC.

 For information about how to do this, see How to install a remote on-off
switch on page 190.

XPR300 Instruction Manual 809480 35

2 Qualifications and Requirements

Process gas requirements (Core, VWI, and OptiMix gas connect consoles)

As an installer or user, you must supply the process gases and supply gas plumbing for your cutting
system. See Table 7 on page 36 for supply gas quality, pressure, and flow requirements.

Process gas requirements include the following:

 Nitrogen is required for all processes.
 Air is required for H2 mix and F5 processes.
 Water can be used as a shield fluid for plasma power supplies that have a VWI or OptiMix
gas connect console. See Shield water requirements (VWI and OptiMix) on page 41 for the
specifications and requirements for water that is used for shield purposes.

Table 7 – Gas quality, pressure, and flow requirements

Gas Quality System inlet pressure (during gas flow*) Flow rate
O2 (oxygen) 99.5% pure, clean, dry, Core, VWI: 7.5 bar ± 0.4 (110 psi ± 5) 71 slpm
oil-free OptiMix: 7.9 bar ± 0.4 (115 psi ± 5) (150 scfh)
N2 (nitrogen) 99.99% pure, clean, dry, Core, VWI: 7.5 bar ± 0.4 (110 psi ± 5) 181 slpm
oil-free OptiMix: 8.3 bar ± 0.4 (120 psi ± 5) (380 scfh)
Air** Clean, dry, oil free Core, VWI: 7.5 bar ± 0.4 (110 psi ± 5) 118 slpm
consistent with
8573-1:2010 Class 1.4.2 OptiMix: 7.9 bar ± 0.4 (115 psi ± 5) (250 scfh)

H2 (hydrogen) 99.995% pure 50 slpm

OptiMix: 8.3 bar ± 0.4 (120 psi ± 5)
(105 scfh)
Ar (argon) 99.99% pure; clean, dry, VWI: 7.5 bar ± 0.4 (110 psi ± 5) 118 slpm
oil-free OptiMix: 8.3 bar ± 0.4 (120 psi ± 5) (250 scfh)
F5 (95% nitrogen, 99.98% pure VWI: 7.5 bar ± 0.4 (110 psi ± 5) 40 slpm
5% hydrogen) OptiMix: 7.9 bar ± 0.4 (115 psi ± 5) (85 scfh)

* When there is no gas flow, make sure that the pressure at the gas inlet connection is less than 8.6 bar
(125 psi) to avoid system alerts.

** Any air compressors that supply air to the cutting system must remove oil prior to air delivery.
Hypertherm recommends that air compressors supply air that obey the following requirements of ISO
Standard 8573-1:2010 Class 1.4.2:
Maximum particle count in 1.0m3: • 20,000 at 0.1 microns – 0.5 microns
• 400 at 0.5 microns – 1.0 microns
• 10 at 1.0 microns – 5.0 microns
Maximum water vapor pressure dew point: 3°C (37°F)
Maximum oil concentration: 0.1 mg/m3 (for aerosol, liquid, and vapor)

 Speak to your air compressor manufacturer if you operate the cutting system in
temperatures colder than 3°C (37°F) or if you are unsure that the air compressor
can obey the ISO standard for air quality.

36 809480 Instruction Manual XPR300

 Qualifications and Requirements 2

Code conformity
 All installer or user-supplied equipment must meet applicable national and local codes for
supply gas and supply gas plumbing. Contact a licensed plumber for more information
about the codes in your location.
 Any installation, modification, or repair of supply gas equipment or plumbing systems must
be done by a licensed plumber.

XPR300 Instruction Manual 809480 37

2 Qualifications and Requirements

Plumbing for supply gases

WARNING
If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to
the oxygen-enriched atmosphere that collects.
Hypertherm recommends that you install an exhaust ventilation system to remove the
oxygen-enriched atmosphere that can collect when oxygen is used as the plasma gas for
cutting.
Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).
As an installer or user, you must supply the flashback arrestors for your cutting system. You
can get them from your cutting machine supplier.

Hydrogen is a flammable gas that presents an explosion hazard. Keep flames away from
cylinders and hoses that contain hydrogen. Keep flames and sparks away from the torch
when using hydrogen as a plasma gas.
Consult your local safety, fire, and building code requirements for the storage and use of
hydrogen.
Hypertherm recommends that you install an exhaust ventilation system to remove the
hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas
for cutting.
Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).
As an installer or user, you must supply the flashback arrestors for your cutting system. You
can get them from your cutting machine supplier.

As an installer or user, you must install the supply gases and supply gas plumbing for your cutting
system.
 You can use flexible hoses that are designed to carry the appropriate gas and are rated for
the correct pressure. Other hoses can crack and leak.
 For the best results, use the recommended torque specifications for plumbing and hose
fittings. (See Table 11 on page 42.)
 You can use rigid copper pipes.
 Do not use steel or aluminum.

 Supply-gas hoses are available from Hypertherm. (See Supply hoses on

page 392.)

 All installer or user-supplied equipment must meet applicable national and

local codes for supply gas and supply gas plumbing. Contact a licensed
plumber for more information about the codes in your location.

38 809480 Instruction Manual XPR300

 Qualifications and Requirements 2
Hypertherm recommends an internal diameter of 10 mm (0.375 inch) for supply-gas hoses that are
76 m (250 feet) or less. Table 8 on page 39 describes the recommended sizes for gas fittings.

Table 8 – Recommended sizes for gas fittings

Fitting type Size

N2 / Ar 5/8 inch – 18 RH, internal (inert gas) “B”
Air 9/16 inch – 19, JIC #6
F5 / H2 9/16 inch – 18, LH (fuel gas) “B”
O2 9/16 inch – RH (oxygen)

 The location of regulators and the number of elbow fittings can have an
effect on inlet pressure. If the inlet pressure for your cutting system is not
within recommended specifications, contact your cutting machine
supplier or regional Hypertherm Technical Service team.

NOTICE
Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread
ends.

CAUTION
All hoses, hose connections, and hose fittings used for supply gas plumbing must be designed for use
with the appropriate gas and pressure rating. Other hoses, hose connections, or hose fittings can crack
or leak.
NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or
pressure.
Any replacement hose, connection, or fitting must satisfy all applicable regulations and codes.
Non-compliant hoses, hose connections, or hose fittings can crack or leak.
If you replace any fittings on the consoles, or if you use the wrong fittings, it can cause the internal
valves to malfunction because contaminants can get into the valves.

NOTICE
Some air compressors use synthetic lubricants that contain esters. Esters will damage the
polycarbonates in the air filter bowl.

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2 Qualifications and Requirements

Regulators for supply gases

CAUTION
Do not use low-quality gas regulators. They do not provide consistent supply gas pressure. Low-quality
gas regulators can also cause problems with system performance and decrease cut quality.

NOTICE
Some air compressors use synthetic lubricants that contain esters. Esters will damage the
polycarbonates in the air filter bowl.

The installer or user must supply the gas regulator (regulators) for the cutting system.

It is important to choose the correct gas regulator (regulators) for the conditions at the installation
site. A gas regulator must be compatible with the gases used and appropriate for the environmental
conditions. For example, certain regulators are recommended for specific temperature ranges. The
type of gas (cylinder gas, line gas, or liquefied gas), and the gas-delivery pressure and flow, can also
influence regulator selection.

Single-stage gas regulation • Reduces source gas pressure to the necessary delivery pressure in
1 step.
• Delivery pressure is not tightly controlled with this type of gas
regulation.
• Good choice for generic applications and where fluctuations in source
gas pressure are small.
Dual-stage gas regulations • Reduces source gas pressure to the necessary delivery pressure in
2 steps. Dual-stage regulation uses 2 single-stage regulators. The first
regulator reduces the pressure to approximately 3 times the maximum
delivery pressure. The second regulator reduces pressure to the
necessary delivery pressure.
• Good choice for applications that require consistent delivery pressure
and where fluctuations in source gas pressure are large.

Your gas supplier can recommend the best gas regulator (regulators) for the conditions at your site.

 Local regulations and the type of gas that is used can influence the
recommended inlet gas fittings for your gas connect console. (See Table
8 – Recommended sizes for gas fittings on page 39.)

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 Qualifications and Requirements 2

Shield water requirements (VWI and OptiMix)

If you use water as a shield fluid, see Table 9 for water pressure and flow requirements and Table 10
for water-purity guidelines.

 If using shield water, the temperature range for cutting system operation
and storage is reduced to above 0°C to 40°C (32°F to 104°F).

Table 9 – Quality, pressure, and flow requirements for shield water

Minimum and
Quality* Flow rate required
maximum pressure
Deionized water is not recommended to use as shield water. 2.76 bar (40 psi) 35 L/h (9.4 US gal/h)
Deionized water will react with the copper components in the minimum
system and result in decreased life of components and 8.27 bar (120 psi)
consumables. maximum
Hypertherm recommends that you contact a water-quality
expert for guidance.
Shield water treatments are available:
• A water softener if the water has high particulate or
mineral content (see Table 10 on page 41). A
water-softener comes with the shield-fluid treatment kit
(428920) that is available from Hypertherm.
• Treatment of incoming shield water with a filter rated to 50
microns or less. A filter comes with the shield-fluid
treatment kit (428920) that is available from Hypertherm.
The filter alone (428810) is also available.

Table 10 – Purity requirements for shield water

Particulate type Purity requirement

Total dissolved solids < 61 PPM
Calcium + magnesium < 40 PPM
Silica < 5 PPM
pH 6.5 – 8.0

 A TDS meter indicates the Total Dissolved Solids (TDS) of a solution.

Dissolved ionized solids (such as salts and minerals) increase the
electrical conductivity of a solution. Total dissolved solids can be tested
with a TDS meter (Hypertherm Waterjet part number 1-13897) available
from Hypertherm.

 The following accessories are available from Hypertherm

* Water that does not meet minimum purity specifications can cause excessive deposits on the torch nozzle
and shield. These deposits can alter the water flow and produce an unstable arc. See Shield water
requirements (VWI and OptiMix) on page 41.

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2 Qualifications and Requirements

Plumbing and hose requirements for shield water

The installer or user must supply the plumbing and hoses for the shield water.
 You can use flexible hoses that are designed to carry water.
 For the best results, use the recommended torque specifications for plumbing and hose
fittings. (See Table 11 on page 42.)
 You can use rigid copper pipes.
 Do not use steel or aluminum pipes.

Install the plumbing and hoses consistent with all local and national codes. After installation,
pressurize the entire system and test it for leaks.

To decrease the risk of leaks in the cutting system, make sure to tighten all connections to the
recommended torque specifications in Table 11 on page 42.

 Hoses are available from Hypertherm. (See Water (optional shield fluid)
(blue) on page 393 of the Parts List.)

Additional regulator requirement for shield water (optional)

Water pressure regulators are built into the VWI and OptiMix gas connect consoles. Additional
water pressure regulators are only required when the water pressure is above 7.92 bar (115 psi).

Torque requirements for gas or water plumbing and hose connections

For the best results, use the recommended torque specifications for plumbing and hose fittings.

Table 11 – Torque specifications

Torque Specifications
Gas or water hose size N∙m in∙lbf ft∙lbf
Up to 10 mm (3/8 inch) 8.5 – 9.5 75 – 84 6.25 – 7
12 mm (1/2 inch) 16.3 – 19.0 144 – 168 12 – 14

25 mm (1 inch) 54.2 – 88.1 480 – 780 40 – 65

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 Qualifications and Requirements 2

Requirements for shield water removal for freezing-ambient temperatures

If your XPR cutting system uses shield water and is stored in ambient temperatures at or below 0ºC
(32ºF), Hypertherm recommends shield water removal.

Follow these steps to remove shield water from the gas connect console (VWI or OptiMix):

1. Remove the shield water supply line to the gas connect console.

2. Access a source of compressed air that is clean and dry. Use a regulator to adjust the
compressed air to 5.52 bar (80 psi).

3. Connect the compressed air hose to the water inlet on the gas connect console.

 The air hose needs to adapt to a JIC 6 male fitting on the gas connect
console.

4. Use the XPR web interface or CNC to select a process ID for a water process (such as 2028).

5. Select Preflow from the Plasma Process Selection menu.

 During preflow, water mist will exit the torch nozzle for approximately 45 –
50 seconds.

6. Repeat step 5 until shield water mist is no longer visible exiting the torch nozzle.

 It can take 7 – 10 preflow cycles for the shield water mist to stop.

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2 Qualifications and Requirements

Coolant requirements

The cutting system ships without coolant in the reservoir. Before you operate the cutting system,
you must fill it with coolant. The capacity of the coolant system is between 22.7 liters – 45 liters
(6 US gallons – 12 US gallons).

Lead length has an effect on the total coolant volume needed. A cutting system with long leads
needs more coolant than a cutting system with short leads.

Before you fill the coolant reservoir (see Coolant Installation on page 193), choose the best coolant
for your operating conditions. The ambient temperature range where your cutting system operates
affects the coolant that you choose.

NOTICE
Never operate the cutting system if you get a low coolant level notice.
There is a risk of serious damage to the cutting system and to the coolant pump if you operate the
cutting system with no coolant or with low coolant.
If your coolant pump is damaged, it may need to be replaced.

NOTICE
Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that
damage the torch coolant system.

Make sure to read and follow the warning and cautions below. See the Material Safety Data Sheets
(MSDS) and Safety Data Sheets (SDS) for safety data and information about how to handle and
store coolant, propylene glycol, and benzotriazole. You can find the MSDS and SDS online.
Technical documentation is available at www.hypertherm.com/docs.

WARNING
COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF
SWALLOWED.
Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if
swallowed. When you come into contact, flush skin or eyes with water. If swallowed, seek
immediate medical attention.

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 Qualifications and Requirements 2

Coolant requirements for operation between -10°C – 40°C (14°F – 104°F)

Use Hypertherm premixed coolant (028872) when operating in a temperature range of -10°C to
40°C (14°F to 104°F).

 If using shield water, the temperature range for cutting system operation
and storage is reduced to above 0°C to 40°C (32°F to 104°F).

If it is possible for the temperature to go below -10°C (14°F) when the cutting system is not in use,
adjust coolant propylene glycol concentration to 50% to prevent damage to cooling system
components.

 Operating your XPR system below -10°C (14°F) is not recommended due
to reduced consumable life and performance.

To increase the coolant propylene glycol percentage, add 100% propylene glycol (028873) to the
premixed Hypertherm coolant (028872) according to the calculation below. The maximum
percentage of propylene glycol should never exceed 50%.

Total system coolant X 0.4 = Total volume in liters of 100% propylene glycol to
volume (in liters)* add
Total system coolant X 1.514 = Total volume in US gallons of 100% propylene
volume (in US gallons)* glycol to add

* See Estimate the total coolant volume for your cutting system on page 248.

Coolant requirements for operation in temperatures above 40°C (104°F)

For operating temperatures above 40°C (104°F) and that can never go at or below 0°C (32°F) use
treated water with no propylene glycol as coolant.

For operations in very warm temperatures, treated water provides the best cooling properties.

 Treated water is a mixture of purified water that meets the Purity

requirements for coolant water on page 54 and 1 part benzotriazole
(128020) to 300 parts of water. Benzotriazole acts as a corrosion
inhibitor for the copper coolant system inside of the cutting system.

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2 Qualifications and Requirements

Flow requirements for coolant

 The maximum coolant flow rate is 11.36 liters per minute (3.0 US gallons per minute).
 The minimum coolant flow rate is 3.79 liters per minute (1 US gallon per minute).

The cutting systems stops automatically if the flow rate reaches this maximum or minimum flow rate.
Automatic, low-flow shut-off protects the coolant pump from damage from low-flow or no-flow
conditions. Automatic, high-flow shut-off protects the torch and leads from damage from a blow-out
event.

For information about how to diagnose and troubleshoot coolant flow issues, see:
 Low coolant flow codes (540 – 542) on page 312
 High coolant flow codes (543 – 544) on page 314

Purity requirements for coolant water

Always use water that meets the specifications in Table 12 on page 46 when using a custom
coolant mix.

Water that is too pure can also cause problems. Deionized water can cause corrosion in the coolant
system. After deionization, add benzotriazole (128020).

Use water purified by any method (deionization, reverse osmosis, sand filters, water softeners, etc.)
as long as the water purity meets the specifications in the table below. Contact a water specialist for
advice in choosing a water filtration system.

Table 12 – Purity measurement methods for coolant water

Methods to measure water purity

Dissolved solids
Conductivity μS/cm Resistivity mΩ∙cm Grains per gallon
Water purity level or hardness (ppm
at 25°C (77°F) at 25°C (77°F) (gpg of CaCO2)
of NaCl)
Pure water
(For reference only. Do not 0.055 18.3 0 0
use.)
Maximum purity 0.5 2 0.206 0.010
Minimum purity 18 0.054 8.5 0.43
Maximum potable water
(For reference only. Do not 1000 0.001 495 25
use.)

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 Qualifications and Requirements 2

Requirements to position system components

When you plan where to position the plasma power supply, gas connect console, torch connect
console, and torch, use the following limitations and requirements:
 Site requirements on page 50
 Length requirements for hoses, cables, and leads on page 50
 Bend radius requirements for hoses, cables, and leads on page 51
 Distance requirements between high-frequency leads and control cables on page 51
 Distance requirements for ventilation and access on page 51
 Distance requirements for communications on page 52

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2 Qualifications and Requirements

Recommended configuration with the Core gas connect console

≤ 75 m (246.1 ft) ≤15 m (49.2 ft)

8
3 a
4 b
A 5 B 9 C
6 c
d

≤ 4.5 m (14.8 ft)

7
e
12
≤3 m (9.8 ft)
11 10

13 D

2
E

1 F

≤ 75 m (246.1 ft)

A Plasma power supply D Torch

B Gas connect console (Core) E Cutting table
C Torch connect console F Computerized numeric control (CNC)

1 Computerized numeric control (CNC) lead 9 Power, CAN, 3-gas assembly

2 Work lead c Power cable (120 VAC)
3 Controller area network (CAN) cable d CAN cable
4 Power cable (120 VAC) e 3 gas hoses (Core)
5 Coolant hoses (1 supply, 1 return) 10 Torch lead
6 Pilot arc lead 11 Gas regulators (For the best results, position a
7 Negative lead gas regulator within 3 meters (10 feet) of the gas
connect console)
8 Pilot arc and coolant hose set assembly
12 Hoses for supply gases
a Pilot arc lead
13 Gases Core: O2, N2, and air
b Coolant hose set (1 supply, 1 return)

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 Qualifications and Requirements 2

Recommended configuration with the VWI or OptiMix gas connect console

≤ 75 m (246.1 ft) ≤15 m (49.2 ft)

8
A B a
3 b C
4 c
5 9
6 d

≤ 4.5 m (14.8 ft)

7 e
12 f
11 ≤ 3 m (9.8 ft)
10

13

2 E

1 F

≤ 75 m (246.1 ft)
A Plasma power supply D Torch
B Gas connect console (VWI or OptiMix) E Cutting table
C Torch connect console F Computerized numeric control (CNC) lead

1 Computerized numeric control (CNC) lead 9 Power, CAN, 5-gas assembly

2 Work lead d Power cable (120 VAC)
3 Controller area network (CAN) cable e CAN cable
4 Power cable (120 VAC) f 5 gas hoses (VWI or OptiMix)
5 Coolant hoses (1 supply, 1 return) 10 Torch lead
6 Pilot arc lead 11 Gas regulators (For the best results, position a gas
7 Negative lead regulator within 3 meters (10 feet) of the gas
connect console)
8 Pilot arc, coolant hose set, shield water assembly
12 Hoses for supply gases
a Pilot arc lead
13 Gases and water
b Coolant hose set (1 supply, 1 return)
VWI: O2, air, N2, Ar, F5, and water
c Shield water hose (VWI or OptiMix)
OptiMix: O2, air, N2, Ar, F5, water, H2

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2 Qualifications and Requirements

Site requirements

Table 13 – Recommendations for where to position system components

Plasma power • Level surface (less than 10° incline)

supply • Clean and dry area
• Able to support at least 680 kg (1,500 lb)
Gas connect • Level surface (less than 10° incline)
console* • Clean and dry area
• Able to support the weight of your gas connect console (weight varies with type, see
Specifications on page 19)
Torch connect • Clean and dry area
console* • Able to support at least 9.3 kg (20.5 lb)

* The same recommendations are applicable for mezzanine locations.

Length requirements for hoses, cables, and leads

The distances between the plasma power supply, gas connect console, torch connect console,
torch, and cutting table are limited by the lengths of the interconnect hoses, cables, and leads that
connect them.

Table 14 – Length ranges for interconnect hoses, cables, and leads

From this component... to this component... ...the length can range from:
Plasma power supply Gas connect console (Core, VWI, OptiMix) 3 m (9.8 ft) – 75 m (246.1 ft)*
Gas connect console Torch connect console 3 m (9.8 ft) – 15 m (49.2 ft)*
Torch connect console Torch or cutting table 2 m (6.6 ft) – 4.5 m (14.8 ft)*

* See Recommended configuration with the Core gas connect console on page 48 and Recommended
configuration with the VWI or OptiMix gas connect console on page 49 for visual distance requirements.

 For a complete list of hoses, cables, and leads see Parts List on
page 353.

Make sure to install hoses, cables, and leads that are the correct length.
 Hoses, cables, or leads that are too short can cause restriction of mechanical movement.
 Cables and leads that are too long can cause electromagnetic interference (EMI).

 EMI can have a negative effect on cut quality.

Contact your cutting machine supplier for recommendations about the best lead lengths for your
cutting system.

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 Qualifications and Requirements 2

Bend radius requirements for hoses, cables, and leads

The following hoses, cables, and leads cannot bend beyond a
minimum bend radius of 15.25 cm (6 inches):
 Torch lead Minimum bend radius
 Pilot arc lead (measured inside diameter)

 Coolant hose set

 Power cable
 CAN cable 15.25 cm
(6 in.)
 3-gas hose bundle for the Core gas connect console
 5-gas hose bundle for the VWI or OptiMix gas connect console
 Gas supply hoses

Distance requirements between high-frequency leads and control cables

Electromagnetic interference (EMI) can occur if high-frequency leads (such as the pilot arc and
negative leads) are too close to control cables (such as the 120 VAC power, CAN, and EtherCAT®
cables).

If possible, use a separate track to isolate each lead and cable.

If separate tracks are not possible, Hypertherm recommends a minimum separation distance
150 mm (6 inches) between the high-frequency leads and control cables. Separate the pilot arc
lead, negative lead, or any power cables that have a voltage higher than 120 VAC from the
following:
 CAN cable
 Power cable (120 VAC)
 CNC lead (EtherCAT, serial RS-422, or discrete lead)

Distance requirements for ventilation and access

 Ventilation
 Do not block the ventilation louvers on the corners or bottom panels of the front and
back of the plasma power supply. A separation distance of least 1 m (3.3 feet) is
required for ventilation.
 Do not block the ventilation louvers on the gas connect console. A separation distance
of least 1.27 cm (0.50 inch) is required for ventilation.
 Do not block the ventilation louvers on the torch connect console. You must use the
mounting brackets to allow space between the console and mounting surface.
 Service and maintenance access – Hypertherm recommends a minimum distance of
1 meter (3.3 feet) between the plasma power supply and other system components, or
between the plasma power supply and an obstacle.

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2 Qualifications and Requirements

Distance requirements for communications

Table 15 – Maximum distance between the plasma power supply and controlling device

Communication type Distance

Wireless Unobstructed maximum radius of 30.5 m (100 ft)*
EtherCAT** Maximum 75 m (246.1 ft)
Discrete** Maximum 75 m (246.1 ft)
Serial RS-422** Maximum 75 m (246.1 ft)

* Obstructions or distances greater than 30.5 meters (100 feet) can have an effect on communication between
the plasma power supply and wireless device.

** See Recommended configuration with the Core gas connect console on page 48 and Recommended
configuration with the VWI or OptiMix gas connect console on page 49 for visual distance requirements.

Wireless compliance
Wireless devices use radio frequencies that may be regulated, but regulations differ from country to
country. Wireless devices that conform to IEEE standards 802.11a, 802.11b, 802.11g, 802.11n,
802.16e, and others, are designed for, or certified for use in, specific countries. Certificates of
Radio Frequency (RF) Compliance from wireless device manufacturers for wireless devices
integrated into Hypertherm products can be found in the “Downloads library” at
www.hypertherm.com.

The user of Hypertherm products that have integrated wireless devices is responsible for ensuring
that each wireless device has been certified for the country of use and configured with the correct
selection of frequency and channel for the country of use. Wireless devices that are integrated into
Hypertherm products are not allowed to be operated in countries where regulations for wireless
device certification have not been satisfied. Any wireless device or antennae modification or
deviation from the permissible configuration, markings, power, frequency settings, and other local
regulations on radio frequency wireless device for the country of use can be an infringement of
national law.

See the XPR Wireless Compliance Manual (80992C) for more information.

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 Qualifications and Requirements 2

Torch mounting bracket requirements

You must supply the torch mounting bracket for your cutting system. Choose one that does the
following:
 Holds a torch diameter that is 57.15 mm (2.25 inches)
 Holds the torch perpendicular (at a 90° angle) to the workpiece (for non-bevel cutting)
 Does not interfere with the torch lifter

 The XPR torch mounting sleeve is larger than the torch mounting sleeve
for HPR torches. Modification or replacement of previous mounting
hardware is necessary for XPR torches.

 Mounting brackets are available from Hypertherm. (See Torch bracket on

page 379 of the Parts List.)

Torch lifter requirements

Choose a lifter that has a weight capacity of at least 11.3 kg (25 lb). This includes the weight of a
torch rotational sleeve, if used.

 See your torch lifter instruction manual for more information.

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2 Qualifications and Requirements

CNC requirements

Remote on-off switch

The CNC must have a remote on-off switch

Adjustable settings
The CNC must allow the adjustment of the following settings:
 Current setpoint
 Plasma cutflow
 Shield cutflow
 Gas mixing setpoints

Display settings
The CNC must show the following data:
 Plasma gas type
 Shield gas type
 Process ID selected
 System diagnostic codes
 Gas connect console firmware version
 Plasma power supply firmware version

The CNC must show the following data in real time to troubleshoot and diagnose system operation:
 Chopper current
 Work lead current
 System status codes
 Chopper temperature
 Transformer temperature
 Coolant temperature
 Coolant flow
 Process gas pressures
 Fan speeds

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 Qualifications and Requirements 2

Diagnostics and troubleshooting

The CNC must be able to execute the following commands to diagnose and troubleshoot system
operation:
 Test preflow gases
 Test pierceflow gases
 Test cutflow gases
 Test for gas system leaks

 For more information on CNC commands, see the CNC Communication

Protocol for the XPR Cutting System (809810).

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2 Qualifications and Requirements

Recommended grounding and shielding

Introduction
This section describes practices for grounding and shielding a plasma cutting system to minimize its
susceptibility to electromagnetic interference (EMI) (also known as noise). It also describes the
service ground, protective earth (PE) ground, and DC power ground. The diagram at the end of this
section shows these types of grounds in a plasma cutting system.

 The grounding practices in this section have been used on many

installations with excellent results, and Hypertherm recommends that
these practices be a routine part of the installation process. The actual
methods used to implement these practices may vary from system to
system, but should remain as consistent as possible. However, due to the
variation in equipment and installations, these grounding practices may
not succeed in every case to eliminate EMI problems. Hypertherm
recommends that you consult your local and national electrical codes to
make sure that the grounding and shielding practices that you use satisfy
the requirements for your location.

Types of grounding
Service ground (also known as safety ground) is the grounding system that applies to the incoming
line voltage. It prevents a shock hazard to any personnel from any of the equipment or the cutting
table. It includes the service ground coming into the plasma system and other systems, such as the
CNC and the motor drives, as well as the supplemental ground rod connected to the cutting table.
In the plasma circuits, the ground is carried from the plasma system chassis to the chassis of each
separate console through the interconnecting cables.

Protective earth (PE) ground is the grounding system inside the electrical equipment. The PE
ground, which connects to the service ground, provides electrical continuity between the equipment
and the AC service.

DC power ground (also known as cutting current ground or work) is the grounding system that
completes the path of the cutting current from the torch back to the plasma system. It requires that
the positive lead from the plasma system be firmly connected to the cutting table ground bus with a
properly sized cable. It also requires that the slats, on which the workpiece rests, make firm contact
with the table and the workpiece.

EMI grounding and shielding is the grounding system that limits the amount of EMI emitted by the
plasma and motor drive systems. It also limits the amount of EMI that is received by the CNC and
other control and measurement circuits. The grounding practices described in this section mainly
target EMI grounding and shielding.

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 Qualifications and Requirements 2

Grounding practices
1. Unless noted, use cables with a minimum gauge of 21.2 mm2 (4 AWG) (047031) for the EMI
ground cables shown in the Example grounding diagram on page 60.

2. The cutting table is used for the common, or star, EMI ground point and should have threaded
studs welded to the table with a copper bus bar mounted on them. A separate bus bar should
be mounted on the gantry as close to each motor as possible. If there are motors at each end of
the gantry, run a separate EMI ground cable from the far motor to the gantry bus bar. The gantry
bus bar should have a separate, heavy EMI ground cable 21.2 mm2 (4 AWG; 047031) to the
table bus bar. The EMI ground cables for the torch lifter and the RHF or combined ignition/gas
connect console must each run separately to the table ground bus.

3. Inadequate grounding not only exposes operators to dangerous voltages, but inadequate
grounding also increases the risk of equipment failure and unnecessary downtime. Ideally a
ground should be zero ohms resistance, but field experience indicates under 1 ohm resistance
is satisfactory for most applications. Hypertherm recommends that you consult your local and
national electrical codes to make sure that the grounding and shielding practices that you use
satisfy the requirements for your location.

4. A ground rod (a PE ground) that meets all applicable local and national electric codes must be
installed within 6 m (20 ft) of the cutting table. The PE ground must be connected to the cutting
table ground bus bar using a minimum 21.2 mm2 (4 AWG) grounding cable (047031). Consult
an electrician in your location to make sure that your grounding meets all local and national
electric codes.

5. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial
communication signals, between plasma systems in multi-drop connections, and for
interconnections between all parts of the Hypertherm system.

6. All hardware used in the ground system must be brass or copper. While you can use steel studs
welded to the cutting table for mounting the ground bus, no other aluminum or steel hardware
can be used in the ground system.

7. AC power, PE, and service grounds must be connected to all equipment according to local and
national codes.

8. For a system with a remote high frequency (RHF) console or combined ignition/gas connect
console, the positive, negative, and pilot arc leads should be bundled together for as long a
distance as possible. The torch lead, work lead, and the pilot arc (nozzle) leads may be run
parallel to other wires or cables only if they are separated by at least 150 mm (6 inches). If
possible, run power and signal cables in separate cable tracks.

9. For a system with a RHF console or combined ignition/gas connect console, Hypertherm
recommends that you mount this console as close as possible to the torch. This console also
must have a separate ground cable that connects directly to the cutting table ground bus bar.

10. Each Hypertherm component, as well as any other CNC or motor drive cabinet or enclosure,
must have a separate ground cable to the common (star) ground on the table. This includes the
ignition/gas connect console, whether it is bolted to the plasma system or to the cutting table.

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2 Qualifications and Requirements

11. The coupler on the pilot arc and coolant hose set assembly must be connected firmly to the gas
connect console and torch connect console collars. Make sure to tighten the clamp. The collar
on the torch lead must be connected firmly to the torch sleeve. Make sure to tighten the clamp.
Connect a ground lead (10 AWG) to the flat terminal on the torch mounting sleeve.

12. The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the
part mounted to the torch – must be connected to the stationary part of the lifter with copper
braid at least 12.7 mm (0.5 inches) wide. A separate cable must run from the lifter to the gantry
ground bus bar. The valve assembly should also have a separate ground connection to the
gantry ground bus bar.

13. If the gantry runs on rails that are not welded to the table, then each rail must be connected with
a ground cable from the end of the rail to the table. The rail ground cables connect directly to
the table and do not need to connect to the table ground bus bar.

14. If you are installing a voltage divider board, mount it as closely as possible to where the arc
voltage is sampled. One recommended location is inside the plasma system enclosure. If a
Hypertherm voltage divider board is used, the output signal is isolated from all other circuits. The
processed signal should be run in twisted shielded cable (Belden 1800F or equivalent). Use a
cable with a braided shield, not a foil shield. Connect the shield to the chassis of the plasma
system and leave it unconnected at the other end.

15. All other signals (analog, digital, serial, and encoder) should run in twisted pairs inside a
shielded cable. Connectors on these cables should have a metal housing. The shield, not the
drain, should be connected to the metal housing of the connector at each end of the cable.
Never run the shield or the drain through the connector on any of the pins.

The following picture shows an example of a cutting table ground bus. The components shown here
may differ from your system.

1 2 3 4 5 6 7 8
1 Gantry ground bus
2 Ground rod
3 Plasma system lead (+)
4 Gas connect console
5 CNC enclosure
6 Torch holder
7 Plasma system chassis
8 Torch connect console

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 Qualifications and Requirements 2
The following picture shows an example of a gantry ground bus. It is bolted to the gantry, close to
the motor. All of the individual ground cables from the components mounted on the gantry connect
to the bus. A single heavy cable then connects the gantry ground bus to the table ground bus.

1 Cable to the cutting table ground bus

2 Ground cables from components on the
gantry

1 2

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2 Qualifications and Requirements

Example grounding diagram

6 7 8

10

Chassis and EMI ground 11

Service ground
3

PE earth ground

1 Cutting table 8 CNC controller

2 Gantry 9 Torch height control module
3 Plasma system 10 Gas connect console. Connect to table ground
4 Table ground bus bar bus bar.*

5 Gantry ground bus bar 11 DC power ground (work)

* The ignition console is integrated into the gas connect
6 Torch height control lifter
console for XPR cutting systems.
7 Torch connect console

 This example is based on practices in North America. Other regions can

have different local or national electrical codes. Hypertherm recommends
that you consult your local and national electrical codes to make sure that
the grounding and shielding practices that you use satisfy the
requirements for your location.

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Before you begin

 As an installer or user, make sure to read, understand, and follow all safety instructions
related to installation before you start installation. (See Safety instructions related to
installation on page 69.)
 Make sure that you have all of the documents that you need. (See Document requirements
on page 29.)

Upon receipt
 Make sure that you received all items on your order in good condition. Contact your cutting
machine supplier if any parts are damaged or missing.
 Inspect the items for damage that may have occurred during shipment. If you find evidence
of damage, see Claims below. All communications regarding this equipment must include
the model number and serial number.
 Record your product information and register your product’s serial number at
www.hypertherm.com.
 Before you set up this equipment, read the safety information included with your equipment.
Failure to follow safety instructions can result in personal injury or in damage to equipment.

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Claims
 Claims for damage during shipment – If your equipment was damaged during shipment, file
a claim with the carrier. You can contact Hypertherm for a copy of the bill of lading. If you
need additional assistance, call the nearest Hypertherm office listed in the front of this
manual.
 Claims for defective or missing merchandise – If any component is missing or defective,
contact your Hypertherm cutting machine supplier. If you need additional assistance, call the
nearest Hypertherm office listed in the front of this manual.

Acoustical noise
This plasma system can make more than the permitted acoustical noise levels as defined by national
and local codes. Always put on correct ear protection when cutting or gouging. Any acoustical
noise measurements taken are related to the specific environment in which the system is used.
Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C).

In addition, you can find an Acoustical Noise Data Sheet for your system at
www.hypertherm.com/docs. In the search box, enter data sheet.

Proper handling and safe use of chemicals

Material Safety Data Sheets (MSDS) and Safety Data Sheets (SDS) are part of a hazard
communication plan that supplies detailed information about hazardous chemicals. The information
includes the chemical’s toxicity and reactivity, first aid for exposure, approved storage and disposal,
recommended protective equipment, and spill-handling procedures.

The Occupational Safety and Health Administration (OSHA) has presented new hazardous
chemical labeling requirements as a part of its recent revision of the Hazard Communication
Standard (29 CFR 1910.1200), to align with the United Nations’ Globally Harmonized System of
Classification and Labeling of Chemicals (GHS). The GHS is an international system for
standardizing chemical classification and labeling.

Chemical regulations in the USA, Europe, and other locations require that Material Safety Data
Sheets (MSDS) and Safety Data Sheets (SDS) be made available for chemicals that are supplied
with the product and chemicals used in or on the product. This list of chemicals is supplied by
Hypertherm.

See the MSDS and SDS online. Technical documentation is available at

www.hypertherm.com/docs.

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Installation requirements
All installation and service of the electrical systems must obey national and local electrical codes. A
qualified person must do this work.

Contact the nearest Hypertherm Technical Service team listed in the front of this manual or your
authorized Hypertherm cutting machine supplier with any technical questions.

Installation overview

These are the general steps to install the cutting system. It is important to be familiar with these
steps before installation begins.

1. Position the system components. See How to position the system components on page 75.

2. Ground the system components. See How to ground the system components on page 83.

3. Remove the rear panel of the plasma power supply. Remove the top and side panels from the
consoles. See How to remove the external panels from the system components on page 86.

4. Connect the plasma power supply to the gas connect console. See How to connect the plasma
power supply and gas connect console (Core, VWI, or OptiMix) on page 93.

5. Connect the work lead to the plasma power supply and the cutting table. See How to connect
the work lead to the plasma power supply and cutting table on page 98.

6. Connect the gas connect console to the torch connect console. See How to connect the gas
connect console to the torch connect console on page 103.

7. Install and connect the supply gas plumbing and water. See How to install and connect the
supply gases on page 111.

8. Connect the torch receptacle to the torch connect console. See How to connect the torch
receptacle to the TorchConnect console on page 121.

9. Install the torch onto a lifter. See How to install the torch in the torch mounting bracket on
page 127.

10. Install the consumables. See How to install the consumables on page 129.

11. Install the torch in the torch receptacle. See How to install the torch into the torch receptacle on
page 131.

12. Connect the cutting system to power. See How to connect electric power to the cutting system
on page 133.

You can use the included checklist to verify system requirements and the completion of major
installation steps. (See Installation checklist on page 64.)

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3 Installation

Installation checklist
Verify system requirements

Electrical
See System electrical requirements on page 32.
Make sure that the electrical system conforms to all applicable codes.
Make sure that the input power meets requirements. See Input power requirements on page 32.
Make sure that the circuit breaker or fuse meets requirements. See Circuit breaker and fuse requirements
on page 34.
Make sure that the main power cord is the correct size and correctly installed. See Main power cord
requirements on page 34.
As an installer or user, you must supply the main power cord for your cutting system.
Make sure that there is a separate line-disconnect switch for the plasma power supply. See
Line-disconnect switch requirements on page 33.
As an installer or user, you must supply the line-disconnect switch for your cutting system.
Make sure that the emergency-stop switches are correctly installed.
As an installer or user, you must supply the emergency-stop switches for your cutting system.
Make sure that the remote on-off switch is correctly installed. See Remote on-off switch on page 35.
As an installer or user, you must supply the remote on-off switch for your cutting system.

Process gas and plumbing

See Process gas requirements (Core, VWI, and OptiMix gas connect consoles) on page 36. You must supply the
process gases and supply gas plumbing for your cutting system.
Make sure that the gas quality meets requirements.
Make sure that the gas pressure meets requirements.
Make sure that the gas flow meets requirements.
Make sure that the gas plumbing and hoses meet requirements. See Plumbing for supply gases on
page 38.
The cutting system comes with the hoses that connect the plasma power supply components.
As an installer or user, you must supply the plumbing for the process gases.
Make sure that the plumbing is the correct type and correctly installed.
As an installer or user, you must supply flashback arrestors for your cutting system if you use
oxygen as the plasma gas.
Make sure that the hoses are the correct type and length, and that they are correctly installed.
Make sure that the regulators are the correct type, installed in the correct locations, and correctly
installed. See Regulators for supply gases on page 40.
As an installer or user, you must supply the gas regulators for your cutting system.
Make sure that the plumbing conforms to all applicable codes.

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 Installation 3

Shield water (VWI and OptiMix)

See Shield water requirements (VWI and OptiMix) on page 41. You must supply the shield water for your cutting
system.
Make sure that the water quality meets requirements.
Make sure that the water pressure meets requirements.
Make sure that the water flow meets requirements.
Make sure that the water plumbing and hoses meet requirements. See Plumbing and hose requirements
for shield water on page 42.
As an installer or user, you must supply the plumbing and hoses for shield water.
Make sure that the plumbing is the correct type and correctly installed.
Make sure that the hoses are the correct type and length, and that they are correctly installed.
Additional water pressure regulators are only required when the water pressure is above 7.92 bar
(115 psi). See Additional regulator requirement for shield water (optional) on page 42.

Configuration
See Requirements to position system components on page 47.
Make sure that the configuration of system components is correct. See Recommended configuration with
the Core gas connect console on page 48 and Configuration with VWI or OptiMix gas connect console
on page 74.
Make sure that the spacing and ventilation for the plasma power supply meets requirements. See Distance
requirements for ventilation and access on page 51.
Hypertherm recommends a minimum distance of 1 meter (3.3 feet) between the plasma power supply and
other system components, or between the plasma power supply and an obstacle.
Make sure that the surfaces that hold system components are flat, dry, clean, and can support the weight.
See Site requirements on page 50.
Make sure that the table ventilation meets requirements (if applicable) (check table type).
Water table
Downdraft table
Other (specify)

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3 Installation

Hoses, cables, and leads

Do not bend the following hoses, cables, and leads beyond a minimum bend radius of 15.25 cm (6 inches):
Torch lead, pilot arc lead, coolant hose set, power cable, CAN cable, 3-gas hose bundle (for the Core gas connect
console), 5-gas hose bundle (for the VWI or OptiMix gas connect console), and gas supply hoses.
The cutting system comes with the cables and leads that connect system components. See the following sections
in the Parts List for part numbers and descriptions:
• Plasma power supply to gas connect console connections on page 385.
• Gas connect console to torch connect console connections on page 387.
• Plasma power supply to CNC connections on page 389.
• Plasma power supply to cutting table connection on page 390.
• Torch connect console to torch receptacle connection on page 391.
Make sure that the hoses, cables and leads are the correct type. See How to identify and prepare the
hoses, cables, and leads on page 90.
Make sure that the hoses, cables, and leads are the correct length. See Length requirements for hoses,
cables, and leads on page 50.

Grounding
Make sure that the grounding meets requirements. See Recommended grounding and shielding on
page 56.
Plasma power supply
Gas connect console
Torch connect console
Cutting table
CNC
Torch lead collar

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 Installation 3

Verify installation steps

Connections
Make sure that the connections between the plasma power supply and the gas connect console are
correctly installed. See How to connect the plasma power supply and gas connect console (Core, VWI, or
OptiMix) on page 93.
Coolant hose set
Power cable
CAN cable
Negative lead ( - )
Pilot arc lead
Make sure that the work lead ( + ) connection between the plasma power supply and the cutting table is
correctly installed. See How to connect the work lead to the plasma power supply and cutting table on
page 98.
Make sure that the connections between the gas connect console and torch connect console are correctly
installed. See How to connect the gas connect console to the torch connect console on page 103.
See Connect the gas connect console (Core) to the TorchConnect console on
Core
page 103.
Pilot arc and coolant hose set assembly. See Connect the pilot arc and coolant hose
set assembly on page 103.
Power, CAN, and 3-gas assembly (Core only). See Connect the power, CAN, and
3-gas assembly (Core) on page 106.
VWI / See Connect the gas connect console (VWI or OptiMix) to the TorchConnect console
OptiMix on page 107.
Pilot arc, coolant hose set, and water assembly. See Connect the pilot arc, coolant hose
set, and shield water assembly on page 107.
Power, CAN, and 5-gas assembly. See Connect the power, CAN, and 5-gas assembly
on page 110.
Make sure that the connection between the torch receptacle and torch connect console is installed
correctly. See How to connect the torch receptacle to the TorchConnect console on page 121.
Make sure that the hoses, cables, and leads are correctly installed.
Make sure that the connections are the correct type and correctly installed.
Make sure that there is no damage or kinks.
Make sure that there are no coils in the cables that can create EMI problems.
Make sure that the distance between high-frequency leads and control cables meets
requirements. See Distance requirements between high-frequency leads and control
cables on page 51.
Make sure that the distance for communication meets requirements. See Distance
requirements for communications on page 52.

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3 Installation

Installation steps
Make sure that the consumables are the correct type and correctly installed. A loose or overtightened
electrode can cause torch damage. Hypertherm recommends between 2.3 N∙m – 2.8 N∙m (20 in∙lbf –
25 in∙lbf) torque to tighten an electrode. See How to install the consumables on page 129.
The torch head that comes with the XPR torch assembly kit (428488) has 300 A mild steel consumables
pre-installed.
Make sure that the torch is correctly installed.
Make sure that the torch mounting bracket is correctly installed. See Torch mounting bracket
requirements on page 53.
As an installer or user, you must supply the torch mounting bracket for your cutting system.
Make sure that the torch is correctly installed into the torch receptacle. See How to install the
torch into the torch receptacle on page 131.
Make sure that the torch is correctly installed into the lifter. See Torch lifter requirements on
page 53.
As an installer or user, you must supply the motorized torch lifter for your cutting system.
Electrical power – Make sure that electrical power is supplied to the cutting system. See How to connect
electric power to the cutting system on page 133.
CNC interface – Make sure that the communication method is installed correctly. See Connect for
Communication on page 143.
EtherCAT
Wireless (XPR web interface) and discrete
Serial RS-422 and discrete
Coolant – Make sure that the coolant is installed correctly. See Coolant Installation on page 193.
Make sure that the coolant type is correct. See Coolant requirements on page 44.
Make sure that the coolant reservoir is full. See How to fill the cutting system with coolant on
page 194.

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 Installation 3

Safety instructions related to installation

Before you start installation, make sure to read, understand, and follow all of the safety instructions
that are in this manual, the Safety and Compliance Manual (80669C) and Radio Frequency
Warning Manual (80945C), and affixed to the cutting system.

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect all electric power from the plasma power supply before you move
the plasma power supply or put it into position.
If you move or position the plasma power supply while it is connected to
electric power, you can be injured or killed and the plasma power supply can
be damaged.
See the Safety and Compliance Manual (80669C) for more safety
precautions.

WARNING
ELECTRIC SHOCK CAN KILL
The line-disconnect switch must be in the OFF position before you connect the power
cord to the cutting system.
The line-disconnect switch must REMAIN in the OFF position until all installation steps are
complete.
In the United States, use a “lock out/tag out” procedure until installation is complete. In
other countries, follow the appropriate national and local safety procedures.

WARNING

ELECTRIC SHOCK CAN KILL

When the line-disconnect switch is in the ON position, there is line voltage throughout the
cutting system.
Voltages present throughout the cutting system can cause injury or death.
Use extreme caution if you do diagnosis or maintenance tasks when the line-disconnect
switch is in the ON position.

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3 Installation

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

WARNING
If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to
the oxygen-enriched atmosphere that collects.
Hypertherm recommends that you install an exhaust ventilation system to remove the
oxygen-enriched atmosphere that can collect when oxygen is used as the plasma gas for
cutting.
Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).
As an installer or user, you must supply the flashback arrestors for your cutting system. You
can get them from your cutting machine supplier.

Hydrogen is a flammable gas that presents an explosion hazard. Keep flames away from
cylinders and hoses that contain hydrogen. Keep flames and sparks away from the torch
when using hydrogen as a plasma gas.
Consult your local safety, fire, and building code requirements for the storage and use of
hydrogen.
Hypertherm recommends that you install an exhaust ventilation system to remove the
hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas
for cutting.
Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).
As an installer or user, you must supply the flashback arrestors for your cutting system. You
can get them from your cutting machine supplier.

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 Installation 3

WARNING
COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF
SWALLOWED.
Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if
swallowed. When you come into contact, flush skin or eyes with water. If swallowed, seek
immediate medical attention.

NOTICE
Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that
damage the torch coolant system.

CAUTION
If you use the wrong coolant, it can cause damage to the cutting system. See Coolant requirements on
page 44.

NOTICE
Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread
ends.

NOTICE
Some air compressors use synthetic lubricants that contain esters. Esters will damage the
polycarbonates in the air filter bowl.

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3 Installation

CAUTION
All hoses, hose connections, and hose fittings used for supply gas plumbing must be designed for use
with the appropriate gas and pressure rating. Other hoses, hose connections, or hose fittings can crack
or leak.
NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or
pressure.
Any replacement hose, connection, or fitting must satisfy all applicable regulations and codes.
Non-compliant hoses, hose connections, or hose fittings can crack or leak.
If you replace any fittings on the consoles, or if you use the wrong fittings, it can cause the internal
valves to malfunction because contaminants can get into the valves.

NOTICE
The manufactured lengths of torch and console leads are critical for system performance.
Never alter the lengths of any leads.
Cut quality and the lifespan of consumables will be decreased if you alter the leads.

NOTICE
Gas leaks or pressure and flow rates that are outside of recommended ranges can:
• Cause problems with system performance
• Result in bad cut quality
• Shorten the life of consumables
If the quality of the gas is bad or if the pressure setting is incorrect, it can decrease:
• Cut quality
• Cut speed
• Cut thickness capabilities

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 Installation 3

Configuration with Core gas connect console

1 Not to scale. For
2 position only.

8
6 b d
c e
a

7
9
10

11
Never position the gas connect
console at an angle or on its sides

O2 N2 Air

1 Work lead 9 Power, CAN, 3-gas assembly

2 CNC connection cable (EtherCAT shown) c Power cable (120 VAC)
3 Controller area network (CAN) cable d CAN cable
4 Power cable (120 VAC) e 3 gas hoses (Core)
5 Coolant hose set (1 supply, 1 return) 10 Torch lead
6 Pilot arc lead 11 Hoses for supply gases
7 Negative lead (2/0 or 4/0) * Regulator (For the best results, position a gas
8 Pilot arc and coolant hose set assembly regulator within 3 meters (10 feet) of the gas
connect console)
a Pilot arc lead
b Coolant hose set (1 supply, 1 return)

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Configuration with VWI or OptiMix gas connect console

1
Not to scale. For
2 position only.

8
6 b c d e
a 10
f
7

*
11
Never position the gas
connect console at an angle or
H2O on its sides
O2 Air Ar N2 F5 H2

H2 for OptiMix only

1 Work lead c Shield water hose (VWI or OptiMix)

2 CNC connection cable (EtherCAT shown) 9 Power, CAN, 5-gas assembly
3 CAN cable d Power cable (120 VAC)
4 Power cable (120 VAC) e CAN cable
5 Coolant hose set (1 supply, 1 return) f 5 gas hoses (VWI or OptiMix)
6 Pilot arc lead 10 Torch lead
7 Negative lead (2/0 or 4/0) 11 Hoses for supply gases/shield water
8 Pilot arc, coolant hose set, shield water assembly * Regulator (For the best results, position a gas
a Pilot arc lead regulator within 3 meters (10 feet) of the gas
connect console)
b Coolant hose set (1 supply, 1 return)

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 Installation 3

How to position the system components

Put all system components into position prior to making connections.

Plan where to position system components

When you plan where to position system components, use the following:
 Site requirements on page 50
 Length requirements for hoses, cables, and leads on page 50
 Bend radius requirements for hoses, cables, and leads on page 51
 Distance requirements between high-frequency leads and control cables on page 51
 Distance requirements for ventilation and access on page 51
 Distance requirements for communications on page 52

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3 Installation

Position system components

Position the plasma power supply

WARNING
HEAVY EQUIPMENT CAN CAUSE SERIOUS INJURY IF DROPPED – LIFT
CAREFULLY
When lifting or moving the plasma power supply:
• Clear the area of all cables, wires, and other potential obstacles that can get caught on the
plasma power supply while you are moving it.
• Only use equipment with sufficient capability to safely lift and support the plasma power supply.
• If you use the lift eye to lift the plasma power supply, make sure that you lift only the plasma
power supply so that you do not exceed the maximum lift eye rating. See Table 1 on page 22.
• If you use a lift truck to lift the plasma power supply, use one whose forks extend along the
entire bottom of the plasma power supply. Use the lift truck slots located on the bottom of the
plasma power supply.
• Make sure that the area is clear before setting the plasma power supply down.
• Set the plasma power supply down gently. Do not drop it from any height.

The XPR300 plasma power supply weighs 590 kg (1,300 lbs). You must use a lift truck or other lift
equipment to position the plasma power supply. See Table 16.

Table 16 – Equipment to lift or move the plasma power supply

You can use a lift truck to move the plasma power supply into position. The lift truck forks must
Lift truck be: 1) long enough to fully support and extend along the entire bottom of the plasma power
supply, and 2) rated to hold the weight of the plasma power supply.
A lift eye is built into the top of the plasma power supply. Make sure that the lift equipment that
Lift eye
you use is rated to hold the weight of the plasma power supply.

 To protect the plasma power supply from drops and damage, make sure
to balance the plasma power supply evenly between the lift truck forks or
lift equipment and to use slow speeds.

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 Installation 3

Position and mount the gas connect consoles

Before you mount the gas connect console, make sure that you have done the following:
 Planned where to position the system components. (See Plan where to position system
components on page 75.)

 The gas connect console has 2 orientation options: bottom and 1 side, as
shown in Figure 1 and Figure 2.

 Followed the requirements in Requirements to position system components on page 47.

All 3 gas connect consoles (Core, VWI, and OptiMix) have 3 mounting holes on the bottom panel.
For mounting dimensions, see Figure 1 on page 78 and Figure 2 on page 79.

 If you have questions about when or how to use the mounting holes to
mount your gas connect console, contact your cutting machine supplier or
regional Hypertherm Technical Service team.

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3 Installation

Figure 1 – Mounting dimensions for the Core and VWI gas connect consoles

Never position the gas connect console at an angle

Gas inlet side of gas connect console (Core)

Gas outlet side of

gas connect console

26.98 cm
(10.63 in.)
Gas inlet side
of gas
connect
console

1.27 cm
(0.50 in.)

6.48 mm 19.69 cm
(0.26 in.) (7.75 in.)

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 Installation 3
Figure 2 – Mounting dimensions for the OptiMix gas connect console

Never position the gas connect console at an angle

Gas inlet side of gas connect console (OptiMix)

Gas outlet side

of gas connect
console

32.05 cm
(12.62 in.)

Gas inlet side of gas

connect console

1.27 cm
(0.50 in.)

6.48 mm 19.69 cm
(0.26 in.) (7.75 in.)

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3 Installation

Position and mount the TorchConnect console

Before you mount the TorchConnect console, make sure that you have done the following:
 Planned where to position the system components. (See Plan where to position system
components on page 75.)
 Followed the requirements in Requirements to position system components on page 47.

The factory location for the mounting brackets is on the bottom of the TorchConnect console.
However, you can reposition the mounting brackets from the bottom of the console to one of the
side covers. There are 3 mounting orientations, 1 bottom, 1 end, and 1 side. Console orientation
with the torch lead connection on the bottom will minimize the risk of leaked water or coolant
collecting inside of the console, which can damage internal electrical components.

For mounting dimensions, see Figure 4 on page 81.

 If you have questions about when or how to use the mounting brackets to
mount your TorchConnect console, contact your cutting machine supplier
or regional Hypertherm Technical Service team.

Figure 3 – Recommended orientations for the TorchConnect console

End
Side

Bottom

 If you position the torch connect console with the EasyConnect pointed
up, make sure to support the torch lead to maintain the
minimum 15.25 cm (6 in.) bend radius.

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 Installation 3
Figure 4 – Side mount orientation and mounting dimensions for the torch connect console

6.35 mm Mounting brackets, side

(0.25 in.) orientation

135 mm
(5.31 in.)

339.85 mm
(13.38 in.)

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3 Installation

Figure 5 – Bottom mounting for the torch connect console

Mounting brackets, bottom

orientation 6.35 mm
(0.25 in.)

135 mm
(5.31 in.)

101.60 mm 339.85 mm
(4.00 in.) (13.38 in.)

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 Installation 3

How to ground the system components

It is important to follow all grounding and shielding recommendations See Recommended

grounding and shielding on page 56.

Ground system components after you position them and before you connect the hoses, cables, and
leads.

Figure 6 – Plasma power supply grounding (detail)

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3 Installation

Figure 7 – Gas connect consoles grounding (detail)

Core VWI OptiMix

M6 ground stud

Figure 8 – Torch connect console grounding (detail)

M6 ground stud

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Figure 9 – Torch lead collar grounding (detail)

Ground connection – Connect a ground lead

(10 AWG) to the flat terminal on the torch mounting
bracket

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How to remove the external panels from the system components

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.

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

Before you remove any panels:

 Make sure that all electric power is removed from the cutting system.

 Even if power is removed from the plasma power supply, you can still get a
serious electric shock if the cutting system remains connected to an
electric power source. Make sure that all electric power is removed before
you start installation.

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Figure 10 – Remove the rear panel from the plasma power supply

 Removal of the rear panel is usually all that is necessary to complete the
installation steps.

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Figure 11 – Remove panels from the gas connect console

Move the panel

horizontally to remove
it.

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Figure 12 – Remove top and side panel from the torch connect console

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How to identify and prepare the hoses, cables, and leads

Use the following drawings of hoses, cables, and leads to confirm their appearance.
 Use a hand-over-hand motion to uncoil the hoses,
cables, and leads. As you uncoil each hose or lead,
position the flat portion on the floor. Do not pull from one
end to uncoil it. Pulling from one end to uncoil it can
damage the hose, cable, or lead.

 For more information about how to uncoil the hoses and

leads, refer to the field service bulletin that
accompanies them.

 Make sure that you have all of the necessary hoses, cables, and leads. New hoses, cables,
and leads ship with a tag or label that has a part number.

 Do not order or use cables or leads that are longer than necessary. If you
coil a cable or lead because it is too long, electrical interference or EMI
problems can occur. Electrical interference or EMI problems can have a
negative effect on system performance.

 For part numbers and specifications, see the Parts List on page 353.

Coolant hose set

 The coolant hose set includes 1 supply hose with green bands and 1
return hose with red bands.

Negative lead with strain relief

Pilot arc lead with strain relief

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Power cable

CAN cable

Work lead

Pilot arc and coolant hose set assembly

 The coolant hose set includes 1 supply hose with green bands and 1
return hose with red bands.

Power, CAN, 3-gas assembly (only for Core)

Pilot arc, coolant hose set, and shield water assembly (only for VWI and OptiMix)

 The coolant hose set includes 1 supply hose with green bands and 1
return hose with red bands.

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Power, CAN, and 5-gas assembly (only for VWI and OptiMix)

Oxygen hose (blue)

Nitrogen hose (black)

Air hose (black)

Hydrogen (OptiMix only) (red)

Argon (VWI or OptiMix only) (black)

F5 (VWI or OptiMix only) (red)

Shield water (VWI or OptiMix only) (blue)

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How to connect the plasma power supply and gas connect console (Core, VWI, or
OptiMix)

Label in the plasma power supply

EtherCAT
V
Out Power
Table 17 – Definitions of symbols on the label
EtherCAT
In

RS422
-
Negative
CAN
CAN

V Power
RS422
- Negative
+ Work
CAN
+
Work
Pilot arc

Coolant supply
CNC
Discrete Coolant return
Pilot Arc

Coolant Coolant
Supply Return
(Green) (Red)
Pilot
Arc

Negative -
Work +

Power CNC Discrete

RS422 EtherCAT
CAN

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Connect the coolant hose set

Figure 13 – Coolant hose set

1 Coolant return hose (red band) 2 Coolant supply hose (green band)

 For lengths, see Coolant hose set on page 386 of the Parts List.

Connect the coolant hose set to

the plasma power supply:

1. Connect the coolant return

hose (red) to the coolant return
fitting (red).

2. Connect the coolant supply

hose (green) to the coolant
supply fitting (green).

Green 2 1 Red

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Connect the coolant hose set to the gas Never position the gas
connect console: connect console at an
angle or on its sides
1. Connect the coolant return hose
(red) to the coolant return fitting (red,
bottom).

2. Connect the coolant supply hose

(green) to the coolant supply fitting
(green, top).
Green
2
1
Red

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Connect the power cable

Figure 14 – Power cable

To plasma power supply (male cable connector) To gas connect console (female cable connector)

 For lengths, see Power cable on page 386 of the Parts List.

Figure 15 – Connect the power cable

Gas connect console

Plasma power supply

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Connect the CAN cable

Figure 16 – CAN cable

To plasma power supply (male cable connector) To gas connect console (female cable connector)

 For lengths, see CAN cable on page 387 of the Parts List.

Figure 17 – Connect the CAN cable and finger-tighten

Gas connect console

Plasma power supply

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How to connect the work lead to the plasma power supply and cutting table

Figure 18 – Work lead

To plasma power supply To cutting table

 For lengths, see Work lead on page 390 of the Parts List.

Figure 19 – Connect the work lead to the plasma power supply (shown) and cutting table

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Connect the negative lead with strain relief

Figure 20 – Negative lead with strain relief

Sheet metal of console panel intersects

here

To plasma power supply 2 To gas connect console

1. Put the outer nut 1 and strain relief nut 2 onto the negative lead.

2. Put the negative lead and strain relief nut through the hole in the gas connect console or plasma
power supply.

3. Put the inner nut 3 over the end of the lead.

4. Connect the gas connect console end of the lead to the coolant block, or connect the plasma
power supply end of the lead to the negative (-) connector.

5. Tighten the inner nut 3 onto the strain relief nut 2 .

 For lengths, see Negative lead with strain relief on page 385 of the Parts
List.

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Figure 21 – Connect the negative lead with strain relief

Gas connect console

Plasma power supply

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Connect the pilot arc lead with strain relief

Figure 22 – Pilot arc lead with strain relief

 For lengths, see Pilot arc lead with strain relief on page 385 of the Parts
List.

Figure 23 – Connect the pilot arc lead with strain relief to the plasma power supply

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3 Installation

Figure 24 – Connect the pilot arc lead with strain relief to the gas connect console (Core, VWI, or OptiMix)

For ease of access, remove the top insulation

panel before you try to connect the pilot arc
lead. Move the panel horizontally to remove it.

 You do not need the strain relief nut. Remove the nut from the lead and
tighten the strain relief into the panel on the gas connect console.

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How to connect the gas connect console to the torch connect console

Connect the gas connect console (Core) to the TorchConnect console

 These installation steps are for the Core gas connect console.
 If you have a VWI or OptiMix gas connect console, see Connect the gas connect console
(VWI or OptiMix) to the TorchConnect console on page 107.

Connect the pilot arc and coolant hose set assembly

Figure 25 – Pilot arc and coolant hose set assembly

4 4
1
1
2 2

3 3

To gas connect console To torch connect console

1 Pilot arc lead (yellow) 3 Coolant supply hose (green band)

2 Coolant return hose (red band) 4 Lead coupler

 For lengths, see Pilot arc and coolant hose set assembly (Core) on
page 387 of the Parts List.

1. Connect the lead assembly to the gas connect console:

a. Put the hoses and lead through the hole in the
gas connect console.

 These installation steps are for the Core gas

connect console.
a

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3 Installation

b. Remove the insulator panel.

 Move the panel horizontally to remove it.

c. Connect the pilot arc lead.

d. Connect the coolant return hose (red) to the coolant return fitting (red).
e. Connect the coolant supply hose (green) to the coolant supply fitting (green).
b

f. Remove the hose clamp from the lead and

position it into the groove on the console collar.
f
g. Push the coupler into the console collar and
tighten the clamp.

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 Installation 3
2. Connect the console-to-console coolant lead to the
TorchConnect console:
a. Put the hoses and lead through the hole in the
TorchConnect console.

b. Connect the coolant return hose

(red) to the coolant return fitting (red).
d
c. Connect the coolant supply hose
(green) to the coolant supply fitting
(green).
d. Connect the pilot arc lead.

e. Remove the hose clamp from the lead

and position it into the groove on the
console collar. e

f. Push the coupler into the console

collar and tighten the clamp.

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Connect the power, CAN, and 3-gas assembly (Core)

Figure 26 – Power cable, CAN cable, and 3-gas hose assembly

3 3
4 4
5 5
1 1
2 2

To gas connect console To torch connect console

(male cable connectors) (female cable connectors)

1 Power cable 4 Nitrogen hose (black)

2 CAN cable 5 Air hose (black)
3 Oxygen hose (blue)

 For lengths, see Power, CAN, and 3-gas assembly (Core) on page 387 of
the Parts List.

Figure 27
1
2

TorchConnect console

1 Core gas connect

console
3
2

3 4
5
4

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 Installation 3

Connect the gas connect console (VWI or OptiMix) to the TorchConnect console
 These installation steps are for the VWI or OptiMix gas connect console.
 If you have a Core gas connect console, see Connect the gas connect console (Core) to
the TorchConnect console on page 103.

Connect the pilot arc, coolant hose set, and shield water assembly

Figure 28 – Pilot arc, coolant hose set, and shield water assembly
1 5 5
1
2 2

3 3

4 4

To gas connect console To torch connect console

1 Pilot arc lead (yellow) 4 Shield water hose

2 Coolant return hose (red band) 5 Lead coupler
3 Coolant supply hose (green band)

 For lengths, see Pilot arc, coolant hose set, and shield water assembly
(VWI or OptiMix) on page 388 of the Parts List.

1. Connect the lead assembly to the gas connect console:

a. Put the hoses and lead through the hole in the
gas connect console.

 These installation steps are for the VWI or

OptiMix gas connect console.
a

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3 Installation

b. Remove the insulator panel.

 Move the panel horizontally to remove it.

c. Connect the pilot arc lead.

d. Connect the coolant return hose (red) to the coolant return fitting (red).
e. Connect the coolant supply hose (green) to the coolant supply fitting (green).
f. Connect the water hose inside of the VWI or OptiMix console.

g. Remove the hose clamp from the lead and

position it into the groove on the console
collar. g

h. Push the coupler into the console collar and

tighten the clamp.

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 Installation 3
2. Connect the lead assembly to the TorchConnect
console:
a. Put the hoses and lead through the hole in the
TorchConnect console.

b. Push the water hose into the

connector until it stops, approximately
13 mm (0.5 inch). e

c. Connect the coolant return hose (red)

to the coolant return fitting (red).
d. Connect the coolant supply hose
(green) to the coolant supply fitting
(green). d
e. Connect the pilot arc lead. c

f. Remove the hose clamp from the lead

and position it into the groove on the
console collar. f

g. Push the coupler into the console collar

and tighten the clamp.

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Connect the power, CAN, and 5-gas assembly

Figure 29 – Power cable, CAN cable, and 5-gas hose assembly

3 3
5 4
6 6
7 7
4 5
1 1

2 2

To gas connect console To torch connect console

(male cable connectors) (female cable connectors)

1 Power cable 5 Argon hose (black)

2 CAN cable 6 Nitrogen hose (black)
3 Oxygen (blue) 7 H2-mix or F5 hose (red)
4 Air hose (black)

 For lengths, see Power, CAN, and 5-gas assembly (VWI or OptiMix) on
page 388 of the Parts List.

Figure 30
1
2

TorchConnect console

1
VWI or OptiMix gas connect
2
console
3
4
3
5
6 4
5
7 6
7

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How to install and connect the supply gases

WARNING
If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to
the oxygen-enriched atmosphere that collects.
Hypertherm recommends that you install an exhaust ventilation system to remove the
oxygen-enriched atmosphere that can collect when oxygen is used as the plasma gas for
cutting.
Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).
As an installer or user, you must supply the flashback arrestors for your cutting system. You
can get them from your cutting machine supplier.

Hydrogen is a flammable gas that presents an explosion hazard. Keep flames away from
cylinders and hoses that contain hydrogen. Keep flames and sparks away from the torch
when using hydrogen as a plasma gas.
Consult your local safety, fire, and building code requirements for the storage and use of
hydrogen.
Hypertherm recommends that you install an exhaust ventilation system to remove the
hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas
for cutting.
Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).
As an installer or user, you must supply the flashback arrestors for your cutting system. You
can get them from your cutting machine supplier.

CAUTION
All hoses, hose connections, and hose fittings used for supply gas plumbing must be designed for use
with the appropriate gas and pressure rating. Other hoses, hose connections, or hose fittings can crack
or leak.
NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or
pressure.
Any replacement hose, connection, or fitting must satisfy all applicable regulations and codes.
Non-compliant hoses, hose connections, or hose fittings can crack or leak.
If you replace any fittings on the consoles, or if you use the wrong fittings, it can cause the internal
valves to malfunction because contaminants can get into the valves.

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 3 Installation

You must supply the following items for your cutting system:
 High-quality gas regulators (See Regulators for supply gases on page 40 and Figure 31 on
page 116.)
 Supply gas plumbing (See Plumbing for supply gases on page 38.)
 Supply gases (See Process gas requirements (Core, VWI, and OptiMix gas connect
consoles) on page 36.)

Make sure that the gas regulators, supply gas plumbing, and supply gases that you choose satisfy
all minimum requirements. (See Process gas requirements (Core, VWI, and OptiMix gas connect
consoles) on page 36.)

Use the torque specifications in Table 18 when you tighten any gas supply fittings.

Table 18 – Torque specifications

Torque Specifications
Gas or water hose size N∙m in∙lbf ft∙lbf
Up to 10 mm (3/8 inch) 8.5 – 9.5 75 – 84 6.25 – 7
12 mm (1/2 inch) 16.3 – 19.0 144 – 168 12 – 14

25 mm (1 inch) 54.2 – 88.1 480 – 780 40 – 65

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Install gas regulators

You must install the gas regulators before the supply gas plumbing. For installation steps, see the
instruction manual that came with the gas regulator.

For the best results, position a gas regulator within 3 meters (10 feet) of the gas connect console. If
your supply gas is positioned more than 3 meters (10 feet) from the gas connect console,
Hypertherm recommends a 2-stage gas regulator configuration.

See Regulators for supply gases on page 40 for guidance about how to choose the best gas
regulator (regulators) for your cutting system.

After installation is complete, pressurize the entire system and look for gas leaks. Your system
installer or a licensed plumber can do this for you.

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Connect supply gases to the gas connect console (Core)

WARNING

Never remove a check valve.

An explosion can occur if the cutting system is operated without check valves.

NOTICE
Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread
ends.

CAUTION
All hoses, hose connections, and hose fittings used for supply gas plumbing must be designed for use
with the appropriate gas and pressure rating. Other hoses, hose connections, or hose fittings can crack
or leak.
NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or
pressure.
Any replacement hose, connection, or fitting must satisfy all applicable regulations and codes.
Non-compliant hoses, hose connections, or hose fittings can crack or leak.
If you replace any fittings on the consoles, or if you use the wrong fittings, it can cause the internal
valves to malfunction because contaminants can get into the valves.

CAUTION
Do not alter or replace the supply gas fittings on the gas connect console.
If you alter or replace the fittings, it can cause the internal valves to malfunction if particulates get into
the valves.

NOTICE
Some air compressors use synthetic lubricants that contain esters. Esters will damage the
polycarbonates in the air filter bowl.

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NOTICE
Gas leaks or pressure and flow rates that are outside of recommended ranges can:
• Cause problems with system performance
• Result in bad cut quality
• Shorten the life of consumables
If the quality of the gas is bad or if the pressure setting is incorrect, it can decrease:
• Cut quality
• Cut speed
• Cut thickness capabilities

 These installation steps are for the Core gas connect console.
 If you have a VWI or OptiMix gas connect console, see Connect supply gases and shield
water to the gas connect console (VWI or OptiMix) on page 117.

Hypertherm recommends an internal diameter of 10 mm (0.375 inch) for supply gas hoses that are
76 m (250 feet) or less. Make sure that you have the correct supply gas hoses before you connect
them. See How to identify and prepare the hoses, cables, and leads on page 90. Table 19
describes the recommended sizes for gas fittings.

Table 19 – Recommended sizes for gas fittings

Fitting type Size

N2 / Ar 5/8 inch – 18 RH, internal (inert gas) “B”
Air 9/16 inch – 19, JIC #6
F5 / H2 9/16 inch – 18, LH (fuel gas) “B”
O2 9/16 inch – RH (oxygen)

To decrease the risk of leaks in the system, make sure to tighten all connections to the torque
specifications in Table 18 on page 112.

After installation is complete, pressurize the entire system and look for gas leaks. A licensed
plumber can do this for you.

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Figure 31 – Connect the supply gas plumbing and gases to the Core gas connect console

Oxygen (O2)
Regulators*

Nitrogen (N2)

Air

Air

Nitrogen (N2)

Oxygen (O2)

* For the best results, position a gas regulator within 3 meters (10 feet) of the gas connect console. If your
supply gas is positioned more than 3 meters (10 feet) away from the gas connect console, Hypertherm
recommends a 2-stage configuration: 1) Use single-stage regulator for high pressure at the source and 2)
use a second regulator for normal pressure at the 3 meter (10 feet) location.

CAUTION
Cutting system performance can be bad if a supply gas hose is connected to the wrong port on a gas
connect console.
NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or
pressure.

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Connect supply gases and shield water to the gas connect console (VWI or OptiMix)

WARNING

Never remove a check valve.

An explosion can occur if the cutting system is operated without check valves.

NOTICE
Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread
ends.

CAUTION
All hoses, hose connections, and hose fittings used for supply gas plumbing must be designed for use
with the appropriate gas and pressure rating. Other hoses, hose connections, or hose fittings can crack
or leak.
NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or
pressure.
Any replacement hose, connection, or fitting must satisfy all applicable regulations and codes.
Non-compliant hoses, hose connections, or hose fittings can crack or leak.
If you replace any fittings on the consoles, or if you use the wrong fittings, it can cause the internal
valves to malfunction because contaminants can get into the valves.

CAUTION
Do not alter or replace the supply gas fittings on the gas connect console.
If you alter or replace the fittings, it can cause the internal valves to malfunction if particulates get into
the valves.

NOTICE
Some air compressors use synthetic lubricants that contain esters. Esters will damage the
polycarbonates in the air filter bowl.

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 3 Installation

NOTICE
Gas leaks or pressure and flow rates that are outside of recommended ranges can:
• Cause problems with system performance
• Result in bad cut quality
• Shorten the life of consumables
If the quality of the gas is bad or if the pressure setting is incorrect, it can decrease:
• Cut quality
• Cut speed
• Cut thickness capabilities

 These installation steps are for the VWI or OptiMix gas connect console.
 If you have a Core gas connect console, see Connect supply gases to the gas connect
console (Core) on page 114.

Hypertherm recommends an internal diameter of 10 mm (0.375 inch) for supply gas hoses that are
76 m (250 feet) or less. Make sure that you have the correct supply gas hoses before you connect
them. See How to identify and prepare the hoses, cables, and leads on page 90. Table 20
describes the recommended sizes for gas fittings.

Table 20 – Recommended sizes for gas fittings

Fitting type Size

N2 / Ar 5/8 inch – 18 RH, internal (inert gas) “B”
Air 9/16 inch – 19, JIC #6
F5 / H2 9/16 inch – 18, LH (fuel gas) “B”
O2 9/16 inch – RH (oxygen)

To decrease the risk of leaks in the system, make sure to tighten all connections to the torque
specifications in Table 18 on page 112.

After installation is complete, pressurize the entire system and look for gas leaks. A licensed
plumber can do this for you.

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Figure 32 – Connect the supply gas plumbing, gases, and optional shield water to the VWI or OptiMix gas connect
console
Shield water (H2O)

Shield water (H2O)

only for VWI and Oxygen (O2)
OptiMix

Air

Nitrogen (N2)
Regulators*

Argon (Ar)
Hydrogen (H2)
F5

Oxygen (O2)
Air
Nitrogen (N2)
Argon (Ar)
F5
Hydrogen (H2) only for OptiMix

* For the best results, position a gas regulator within 3 meters (10 feet) of the gas connect console. If your
supply gas is positioned more than 3 meters (10 feet) away from the gas connect console, Hypertherm
recommends a 2-stage configuration: 1) Use single-stage regulator for high pressure at the source and 2)
use a second regulator for normal pressure at the 3 meter (10 feet) location.

WARNING
An explosion can occur if a supply gas hose is connected to the wrong port
on a VWI or OptiMix gas connect console.
NEVER connect a supply gas to a hose, connection, or fitting that is not
designed for that gas type or pressure.

CAUTION
Cutting system performance can be bad if a supply gas hose is connected to the wrong port on a gas
connect console.
NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or
pressure.

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Connect shield water to the gas connect console (VWI or OptiMix)

Shield water is available with the VWI or OptiMix gas connect console.
 If you have a Core gas connect console, see Connect supply gases to the gas connect
console (Core) on page 114.
 If you have a VWI or OptiMix gas connect console, but choose to not use shield water, you
can ignore this installation step.
 Make sure to follow Shield water requirements (VWI and OptiMix) on page 41 if you do use
shield water.
 If using shield water, the temperature range for cutting system operation is reduced to above
0°C to 40°C (32°F to 104°F).

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How to connect the torch receptacle to the TorchConnect console

Connect the EasyConnect torch lead assembly to the torch receptacle

1. Uncoil approximately 2 meters (6.5 feet) of the torch-end of the torch lead assembly.

2. Position the torch collar onto the connector-end of the torch.

3. Slide the torch mounting sleeve onto the torch-end of the torch lead assembly. Make sure to
position the mounting sleeve away from the connector ends, so that the ends are not covered.
This lets you access the connector ends.

4. Align the color-coded leads in the torch lead assembly with the corresponding connectors in
the torch receptacle.

8 3

2
1
6
7

1 Coolant return (red) 5 Coolant supply (green)

2 Plasma valve 6 Shield gas (blue)
3 Pilot arc (yellow) 7 Plasma gas 2 (yellow)
4 Ohmic (orange) 8 Plasma gas 1 (black)

 Good alignment minimizes twisted leads. Twisted leads can cause gas or
coolant restrictions that shorten the life of consumables or result in bad
cut quality.

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5. Connect the torch leads and connectors in the following order:

a. Use 2 wrenches to install
the coolant return hose
(red) onto the coolant
return fitting (red) and
tighten to 16.3 N∙m –
19.0 N∙m (144 in∙lbf –
Coolant return hose (red)
168 in∙lbf).

 Do not tighten too

much.

b. Insert the plasma valve

connector and finger-tighten.

 Do not use tools.

Plasma valve connector

c. Connect the pilot arc lead

(yellow) and finger-tighten.

 Do not use tools.

Pilot arc lead (yellow)

d. Connect the ohmic lead Ohmic lead (orange)

(orange) and finger-tighten.

 Do not use tools.

e. Connect the coolant supply

hose (green). Push the hose
into the connector until it
stops, approximately 13 mm
(0.5 inch).

 This is a push-to-connect
fitting.
Coolant supply hose (green)

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f. Connect the shield gas hose Shield gas hose (blue)
(blue). Push the hose into
the connector until it stops,
approximately 13 mm
(0.5 inch).

 This is a
push-to-connect fitting.

g. Connect plasma gas hose 2 Plasma gas hose 2

(yellow). Push the hose into (yellow)
the connector until it stops,
approximately 13 mm
(0.5 inch).

 This is a push-to-connect
fitting.

h. Connect plasma gas hose 1

(black). Push the hose into
the connector until it stops,
approximately 13 mm
(0.5 inch).

 This is a push-to-connect
fitting.
Plasma gas hose 1 (black)

6. Install the torch mounting sleeve:

a. Slide the torch mounting sleeve towards the torch.
b. Hand-tighten the torch mounting sleeve.

 A spanner wrench (104879) comes with all 4 of the consumable parts kits
(428616, 428617, 428618, 428619). Do not over tighten the torch
mounting sleeve if you use the spanner wrench to stabilize the torch
during mounting sleeve installation.

7. Reposition the collar on the torch-end of the torch lead:

a. Pull the collar towards the torch-end of the torch lead assembly.

XPR300 Instruction Manual 809480 123

3 Installation

b. Tighten the hose clamp that holds the collar in position.

Tighten the clamp

Pull the collar toward the torch

124 809480 Instruction Manual XPR300

 Installation 3

Connect the EasyConnect™ torch lead assembly to the TorchConnect console

NOTICE
The manufactured lengths of torch and console leads are critical for system performance.
Never alter the lengths of any leads.
Cut quality and the lifespan of consumables will be decreased if you alter the leads.

Figure 33 – Torch lead assembly

2
2

3
1

4
5

To torch connect console To torch

6

7
8
9

1 Protective sleeve 6 Coolant supply hose (green)

2 Plasma valve cable 7 Shield gas hose
3 Ohmic lead 8 Plasma gas hose A
4 Pilot arc lead 9 Plasma gas hose B
5 Coolant return hose (red)

 For lengths, see Torch lead on page 391 of the Parts List.

XPR300 Instruction Manual 809480 125

3 Installation

1. Align the connectors in the torch lead assembly with the corresponding receptacles in the
TorchConnect console.

Remove plug to access the ohmic wire if you

use a third-party ohmic circuit.

2. Connect the torch lead assembly to the TorchConnect console:

a. Hand-tighten the coupler of the torch lead assembly.

 Do not use tools.

b. Connect the plasma valve cable to its connector, then finger-tighten.

 Do not use tools.

126 809480 Instruction Manual XPR300

 Installation 3

How to install the torch in the torch mounting bracket

Before you install the torch in the torch mounting bracket, you must attach the torch lead assembly
to the torch receptacle. (See Connect the EasyConnect torch lead assembly to the torch
receptacle on page 121.)

As the installer or user, you must supply the torch mounting bracket for your cutting system. Choose
one that meets the requirements in Torch mounting bracket requirements on page 53. Mounting
brackets are available from Hypertherm. (See Torch bracket on page 379 of the Parts List).

 The XPR torch mounting sleeve is larger than the torch mounting sleeve
for HPR torches. Modification or replacement of previous mounting
hardware is necessary for XPR torches.

1. Remove the power from the cutting system:

a. Set the line-disconnect switch to the OFF position.
b. Make sure that the power-indicator LED is not illuminated on the plasma power supply, gas
connect console, or torch connect console.

2. Install the torch mounting bracket onto the torch lifter.

 See the instruction manual that came with the torch lifter for information
about how to install the torch mounting bracket in the torch lifter.

3. Insert the torch (with attached torch lead assembly) into the torch mounting bracket. See
Figure 34.

Figure 34 – Torch in mounting bracket

4.8 mm (3/16 inch)

Lower torch sleeve

Torch mounting bracket

5.72 cm
(2.25 inches)

Torch receptacle

XPR300 Instruction Manual 809480 127

3 Installation

4. Position the torch below the torch mounting bracket. The mounting bracket:
 Must go around the lower portion of the torch sleeve
 Must not touch the torch receptacle

 To minimize vibration at the torch tip, position the torch mounting bracket
as low as possible on the torch sleeve, without touching the torch
receptacle.

5. Make sure that the torch is level (at a 0° angle) in all directions as shown in Figure 35 on
page 128.

 Remove the consumables, including the water tube, from the torch.

 You can use a digital level to measure alignment for standard-position

cutting, marking, and piercing.

 During bevel cutting, the torch is at an angle (not perpendicular) to the

workpiece. The torch position for XPR torches can range from 0° – 52°.
For information on bevel cutting, see Bevel cutting on page 212.

Figure 35 – Level the torch

6. Tighten the screws on the torch mounting bracket.

128 809480 Instruction Manual XPR300

 Installation 3

How to install the consumables

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any installation or maintenance.
The line-disconnect switch must REMAIN in the OFF position until all
installation or maintenance steps are complete.
See the Safety and Compliance Manual (80669C) for more safety
precautions.

The torch head that comes with the XPR torch assembly kit (428488) has 300 A mild steel
consumable parts pre-installed.

For guidance about how to choose the best consumables for your cutting or marking needs, see the
XPR Cut Charts Instruction Manual (809830). If you need to change the consumable parts, follow
this procedure.

 See Sample configurations for consumables on page 135.

If you need to exchange consumable parts, follow these steps.

1. Remove the power from the cutting system:

a. Set the line-disconnect switch to the OFF position.
b. Make sure that the power-indicator LED is not illuminated on the plasma power supply, gas
connect console, or torch connect console.

2. If you have not already done so, choose the best consumables for your cutting or marking
needs.

3. Apply a thin film of silicone lubricant (027055) to each O-ring on every consumable.

 The O-rings should look shiny. Too much lubricant can prevent gas flow.
Remove excess lubricant if found.

4. Use a clean, lint-free cloth to wipe the internal and external surfaces of
the torch.

XPR300 Instruction Manual 809480 129

3 Installation

5. Install the consumables on the torch as shown in Figure 36:

a. Make sure that the water tube is installed.
b. Install the electrode 1 . Use a consumable tool (104119) to tighten the electrode to
between 2.3 N∙m – 2.8 N∙m (20 in∙lbf – 25 in∙lbf) torque.

 A loose or overtightened electrode can cause torch damage. Hypertherm

recommends between 2.3 N∙m – 2.8 N∙m (20 in∙lbf – 25 in∙lbf) torque to
tighten an electrode.

 Hypertherm offers an electrode torque tool (429013) for tightening XPR

torch components. It is pre-calibrated at 2.5 N∙m (22.1 in∙lbf).

c. Install the swirl ring 2 into the nozzle.

d. Install the nozzle and swirl ring assembly 3 .
e. Install the nozzle retaining cap 4 .
f. Install the shield 5 .
g. Install the shield cap 6 .

Figure 36 – Install the consumables on the torch

1 2 3 4 5 6

6. Install the torch in the torch receptacle. (See How to install the torch into the torch receptacle
on page 131.)

7. Install the torch and attached receptacle in the torch mounting bracket. (See How to install the
torch in the torch mounting bracket on page 127.)

130 809480 Instruction Manual XPR300

 Installation 3

How to install the torch into the torch receptacle

1. Apply a thin film of silicone lubricant (027055) to each of the 4 O-rings inside of the torch body.

 Do not apply silicone to the brass electrical connectors.

 The O-rings should look shiny. Too much lubricant can prevent gas flow.
Remove excess lubricant if found.

3
2
4

5 1
1 6
2

6
3
4 5

1 Pilot arc 4 Shield gas

2 Coolant return 5 Coolant supply
3 Ohmic 6 Plasma gas

2. Put the torch body into the torch receptacle and hand-tighten:
a. Rotate the torch body with slight upward force until you feel it engage into position in the
receptacle.
b. Hand tighten the torch-coupler nut until the coupler nut no longer rotates.

 Hand tighten only. Do not use tools.

XPR300 Instruction Manual 809480 131

3 Installation

3. Make sure that the torch body is fully inserted into the torch receptacle. There should be no
space between the torch body and torch receptacle.

Incorrect Correct

132 809480 Instruction Manual XPR300

 Installation 3

How to connect electric power to the cutting system

CAUTION

Any installation, modification, or repair of electrical equipment or electrical systems must

be done by a licensed electrician.

WARNING
ELECTRIC SHOCK CAN KILL
The line-disconnect switch must be in the OFF position before you connect the power
cord to the cutting system.
The line-disconnect switch must REMAIN in the OFF position until all installation steps are
complete.
In the United States, use a “lock out/tag out” procedure until installation is complete. In
other countries, follow the appropriate national and local safety procedures.

You must supply the main power cord for your cutting system. Choose a main power cord that
satisfies local codes and regulations and that meets the input power requirements. (See Input
power requirements on page 32.) For information about the codes in your location, contact a
licensed electrician.

 The size requirements for the main power cord at your site can vary based
on the distance of the receptacle from the main box and on local codes
and regulations.

1. Make sure that the line-disconnect switch is in the OFF position and remains in the OFF
position until all installation steps are complete.

2. Connect the main power cord to the plasma power supply (Figure 37 on page 134):
a. Connect the ground lead (PE) from the main power cord to the ground terminal ( ) of
TB1.
b. Connect the W, V, and U leads from the main power cord to the corresponding TB1
terminals.

XPR300 Instruction Manual 809480 133

3 Installation

Figure 37 – Connect the main power cord to the plasma power supply

TB1

GND (PE)

3. Follow national and local electrical codes to connect the W, V, and U power leads from the main
power cord to the line-disconnect switch (Table 21 on page 134).

Table 21 – Color codes for main power cord wires

Wire color codes for Europe, Asia, and most

Wire color codes for North America
locations outside of North America
U = Black U = Black
V = White V = Blue
W = Red W = Brown
PE (earth ground) = Green/yellow PE (earth ground) = Green/yellow

134 809480 Instruction Manual XPR300

 Sample configurations for consumables

XPR300
 Worn or damaged consumables can have a negative effect on cut quality. Examine the installed consumables at

Instruction Manual
least once daily, before system operation. For information about how to do this, see Examine the consumable parts
on page 237 in the Maintenance section of this manual.

Ferrous (mild steel) sample configurations

Mild steel – 30 A – O2/O2
809480

Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube
cap cap

420200 420228 420365 420225 420407 420222 420368

420619* 420620*

* Consumables for mirror cutting only.

Mild steel – 50 A – O2/Air

Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube
cap cap

Installation
420200 420237 420365 420234 420233 420231 420368
420767* 420768*

* Consumables for mirror cutting only.

3
135
 Mild steel – 80 A, 130 A, 170 A, and 300 A – O2/Air

136

3
Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube

Installation
cap cap

80 A

420243 420242 420240

420246 420607*
420605*

420368
130 A 420365
420200
420252 420242 420249
420255 420607*
420608*

170 A

420261 420260 420258

420513 420609*
420616*

300 A
809480

420279 420406 420276

420491 420594*
420615*
Instruction Manual

* Consumables for mirror cutting only.

XPR300
 Non-ferrous (stainless steel and aluminum) sample configurations

XPR300
Non-ferrous – 40 A – N2/N2 and Air/Air

Instruction Manual
Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube
cap cap

420303
N2/N2
809480

420368
420288 420314
420200 420291 420365 420598*
420624*
420294
Air/Air

* Consumables for mirror cutting only.

Installation
3
137
 Non-ferrous – 60 A – F5/N2**, N2/N2, N2/H2O**, and Air/Air

138

3
Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube

Installation
cap cap

F5/N2**
F5/N2** N2/N2
F5/N2** N2/N2 420303
N2/N2 420297
420309
420603*
420368
420323
420365 420604*
420200

N2/H2O**
N2/H2O** 420303
N2/H2O** 420296
420300
420593*

Air/Air
809480

Air/Air 420294
Air/Air 420297
420309
Instruction Manual

* Consumables for mirror cutting only.

** F5/N2 and N2/H2O can only be used with VWI or OptiMix consoles.
XPR300
 Non-ferrous – 80 A – F5/N2**, N2/N2, N2/H2O**, Air/Air

XPR300
Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube
cap cap

Instruction Manual
F5/N2**
F5/N2**
F5/N2** N2/N2
N2/N2
N2/N2 420303
420306
420309
809480

420603*
420368
420323
420200 420365 420604*

N2/H2O**
N2/H2O** 420303
N2/H2O** 420290
420300
420593*

Air/Air
Air/Air 420294
Air/Air
420306
420309

* Consumables for mirror cutting only.

** F5/N2 and N2/H2O can only be used with VWI or OptiMix consoles.

Installation
3
139
 Non-ferrous – 130 A – N2/N2, H2-Ar-N2/N2**, N2/H2O***

140

3
Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube

Installation
cap cap

N2/N2
N2/N2 420314
420318 420598*
420597*
420356 420368
420315
420365
420200

H2-Ar-N2/N2**
H2-Ar-N2/N2** 420323
420318 420604*
420597*
809480

N2/H2O***
N2/H2O*** 420314
420469 420598*
420595*
Instruction Manual

* Consumables for mirror cutting only.

** H2-Ar-N2/N2 and N2/H2O can be used with OptiMix consoles.

*** N2/H2O can be used with VWI or OptiMix consoles.

XPR300
 Non-ferrous – 170 A – N2/N2, H2-Ar-N2/N2**, N2/H2O***, Air/Air

XPR300
Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube
cap cap

Instruction Manual
N2/N2 N2/N2 N2/N2
N2/N2 420324 420314 420356
420327 420598*
420613*
420368
809480

420200 420365

H2-Ar-N2/N2** H2-Ar-N2/N2** H2-Ar-N2/N2**

H2-Ar-N2/N2** 420324 420323 420356
420327 420604*
420613*

N2/H2O*** N2/H2O*** N2/H2O*** N2/H2O***

420324 420314 420356
420472
420598*
420611*

Air/Air Air/Air Air/Air

Air/Air 420524 420260 420258
420513

Installation
* Consumables for mirror cutting only.

** H2-Ar-N2/N2 can be used with OptiMix consoles.

3
*** N2/H2O can be used with VWI or OptiMix consoles
141
 .Non-ferrous – 300 A – N2/N2, H2-Ar-N2/N2**, N2/H2O***

142

3
Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube
cap cap

Installation
N2/N2
N2/N2 420323
420362 420604*
420601*
420356 420368
420359
420365
420200

H2-Ar-N2/N2**
H2-Ar-N2/N2** 420358
420362 420623*
420601*
809480

N2/H2O***
N2/H2O*** 420323
420475 420604*
Instruction Manual

420622*

* Consumables for mirror cutting only.

** H2-Ar-N2/N2 and N2/H2O can be used on OptiMix consoles.

*** N2/H2O can be used with VWI or OptiMix consoles.

XPR300
 Connect for Communication

Choose the communication method that is best for your cutting system. There are 3 communication
methods to fully operate the cutting system:
 EtherCAT – Use this method with an EtherCAT-compatible controller. See How to connect
to the plasma power supply with EtherCAT on page 145.

 If you use EtherCAT, do not use discrete. You can fully operate the cutting
system with EtherCAT. See Table 22 on page 144.

 Serial RS-422 and discrete – Use this method with a serial RS-422 and
discrete-compatible controller.
 See How to connect to the plasma power supply with serial RS-422 on page 147.
 See How to connect to the plasma power supply with discrete on page 150.

 If you use serial RS-422, you must also use discrete to fully operate the
cutting system. See Table 22 on page 144.

 Wireless (XPR Web Interface) and discrete – Use this method with a wireless-enabled
device and discrete-compatible controller.
 See How to connect to the plasma power supply with the XPR web interface on
page 162.
 See How to connect to the plasma power supply with discrete on page 150.

 If you use wireless, you must also use discrete to fully operate the cutting
system. See Table 22 on page 144.

For information on signals and protocols, see the CNC Communication Protocol for the XPR Cutting
System (809810).

XPR300 Instruction Manual 809480 143

4 Connect for Communication

Table 22 – Communication requirements and options

To fully operate the cutting

system... Monitor with...
XPR web
Discrete EtherCAT RS-422
Set process with...* interface
EtherCAT Can be required** Preferred Alternative Alternative
XPR web interface Required Alternative Preferred Alternative
RS-422 Required Alternative Alternative Preferred

* The device that first sets a process controls the plasma power supply. For information on how to change
the device that has control of the plasma power supply, see How to change the device that has control on
page 186.

** Discrete inputs are ignored when a process ID is set over EtherCAT to a cutting system that uses the
factory-default configuration. Contact your cutting machine supplier or Hypertherm Technical Services team
with questions.

Example: If you use EtherCAT to set the process, the preferred method to monitor is EtherCAT.
However, you can use RS-422 or the XPR web interface to monitor.

144 809480 Instruction Manual XPR300

 Connect for Communication 4

How to connect to the plasma power supply with EtherCAT

 For an example of a system diagram, see EtherCAT multi-system interface (Sheet 16 of 22)
on page 424.
 For information on signals and protocols, see EtherCAT communications and Serial
RS-422 and EtherCAT commands in the CNC Communication Protocol for the XPR Cutting
System (809810).

Figure 38 – EtherCAT cable

 Hypertherm sells EtherCAT cables that have been tested with our cutting
system. See EtherCAT CNC interface cable on page 389 in the Parts
List.

If you supply your own cables, choose EtherCAT cables that follow the Beckhoff® specification.

Type Cat5e, 2-pair, 4-wire, double-shielded (overall foil and braid shield)
Wire Construction: Stranded tinned wire
Diameter: 0.75 mm (7 X 0.25 mm), 22 AWG
Insulation: Polyethylene, 1.5 mm (0.06 inch) diameter
Core Construction: Filler as central element
Layer 1: 4 wires, 2 pair in star-quad configuration
Sequence of colors: White, yellow, blue, orange
Layer 2: Plastic tape overlapped
Inner jacket: Thermoplastic copolymer, 3.9 mm (0.04 inch) diameter
Aluminum laminated foil overlapped
Shield: Braided, tinned copper wires, 0.13 mm (0.005 inch)
diameter, coverage about 85%, 4.7 mm (0.19 inch) diameter
Jacket Material: Polyurethane
Wall thickness: 0.9 mm (0.04 inch)
Outer diameter: 6.5 mm (0.26 inch) ± 0.2 mm (0.008 inch)
Maximum length 61 m (200 ft)

Use the following recommendations to avoid electromagnetic interference (EMI) problems with your
cutting system:
 Separate the EtherCAT cable from the pilot arc lead, negative lead, or any power cables that
have a voltage higher than 120 VAC. See Distance requirements between high-frequency
leads and control cables on page 51.
 Do not route the EtherCAT cable close to the gas connect console.

XPR300 Instruction Manual 809480 145

4 Connect for Communication

Figure 39 – Connect EtherCAT cables to plasma power supply

EtherCAT out to the next plasma power supply

EtherCAT in from the CNC

146 809480 Instruction Manual XPR300

 Connect for Communication 4

How to connect to the plasma power supply with serial RS-422

 For an example of a system diagram, see Serial RS-422 and discrete multi-system interface
(Sheet 17 of 22) on page 425.
 For serial RS-422 multi-drop (multi-system) addressing, see XPR serial RS-422 multi-drop
(multi-system) addressing in the CNC Communication Protocol for the XPR Cutting System
(809810).
 For information on signals and protocols, see XPR serial RS-422 communications and
Serial RS-422 and EtherCAT commands in the CNC Communication Protocol for the XPR
Cutting System (809810).

 To use arc voltage control (AVC) with a serial RS-422 cutting system, you
must install an additional PCB inside the plasma power supply. For
information about how to install this board, see VDC3 board installation
(for AVC with RS-422 and discrete-only) on page 154.

1. Remove the rear panel of the plasma power supply. See How to remove the external panels
from the system components on page 86.

2. Put End A (Figure 40) of the serial RS-422 cable through the hole in the bottom of the rear
compartment in the plasma power supply. See Figure 41 on page 149.

3. Connect End A of the serial RS-422 cable to the correct connector on the control board in the
plasma power supply:
 For systems with multiple plasma power supplies, use the top connector (J12) for the
CNC. Use the bottom connector (J13) to connect to the next plasma power supply.
 For systems with only one plasma power supply, you can use either connector to
connect to the CNC.

4. Connect the End B (Figure 40) of the cable to the CNC.

5. If you are only monitoring with RS-422 serial, you are done. If you want to operate the cutting
system, go to step 6.

6. You must connect to the plasma power supply with discrete. See How to connect to the plasma
power supply with discrete on page 150.

XPR300 Instruction Manual 809480 147

4 Connect for Communication

Figure 40 – Serial RS-422 cable

2 3 4 5 2 3 4 5
7 7

End A End B
To the plasma power supply (top serial To the CNC
connector, J12)

 For lengths, see Serial CNC interface cable on page 390 in the Parts
List.

Table 23 – Pinout for serial RS-422 interface cable

End A End B
Wire color Wire type
Signal Pin number Pin number Signal
TxD + 4 Red 7 RxD +
Pair
TxD - 2 Black 3 RxD -
RxD + 7 White 4 TxD +
Pair
RxD - 3 Black 2 TxD -
GND 5 Green 5 GND
Pair
– Cut Black Cut –

148 809480 Instruction Manual XPR300

 Connect for Communication 4
Figure 41 – Connect the serial RS-422 cable to the plasma power supply

Serial RS-422 from the CNC

Serial RS-422 to the next plasma power supply

(if any)

XPR300 Instruction Manual 809480 149

4 Connect for Communication

How to connect to the plasma power supply with discrete

 You must use serial RS-422 or the XPR Web Interface with discrete to
operate the cutting system.

 To use arc voltage control (AVC) with a discrete cutting system, you must
install an additional PCB inside the plasma power supply. For information
about how to install this board, see VDC3 board installation (for AVC with
RS-422 and discrete-only) on page 154.

 For an example of a system diagram, see Discrete multi-system interface (Sheet 18 of 22)
on page 426.
 For information on signals and protocols, see XPR discrete communication in the CNC
Communication Protocol for the XPR Cutting System (809810).

1. Remove the rear panel of the plasma power supply. See How to remove the external panels
from the system components on page 86.

2. Put End A (Figure 42) of the discrete cable through the hole in the bottom of the rear
compartment in the plasma power supply. See Figure 43 on page 153.

3. Connect J14 and J19 to their respective connectors on the control board in the plasma power
supply.

4. Connect the End B (Figure 42) of the cable to the CNC. See Table 24 on page 151 and Table
25 on page 152 for pinouts.

Figure 42 – Discrete cable

J14 J19
End A
To the plasma power supply
1 12 1 8

End B
To the CNC

 For lengths, see Discrete CNC interface cable on page 389 in the Parts
List.

150 809480 Instruction Manual XPR300

 Connect for Communication 4
Table 24 – Pinout for J14 on the discrete cable

End A (Figure 42 on
page 150)
Input/
J14 pin Signal Function Wire color
Output
1 Remote on/off + When the input is closed, the plasma power supply Red
Input1 is enabled. When open, the power to the consoles
2 Remote on/off - and the contactors is disabled. Black

3 Plasma start + The CNC initiates preflow. If the hold input is not White
active, the CNC continues with the plasma arc. The
Input2
4 Plasma start - plasma power supply stays in preflow as long as the Black
hold input remains active.
5 Motion + Notifies the CNC that an arc transfer has occurred Green
Output2 and to begin machine motion once the CNC’s
6 Motion - pierce delay time elapses. Black

7 Hold + The CNC delays plasma arc initiation. This signal is Blue
normally used in combination with the Start signals
Input1, 3 to synchronize multiple torches. Activate this signal
8 Hold - at the same time as the Plasma Start signal. Black
Deactivate this signal to fire the torch.
9 Pierce complete + The CNC notifies the plasma system to maintain the Yellow
shield preflow until the CNC releases the signal.
Input1 Activate this signal at the same time as the Plasma
10 Pierce complete - Start signal. Deactivate this signal when the pierce Black
time is complete.
11 F+24V CNC Available 24 VDC (200 mA maximum) Brown
Output-4
12 F PWRGND Ground Black

XPR300 Instruction Manual 809480 151

4 Connect for Communication

Table 25 – Pinout for J19 on the discrete cable

End A (Figure 42 on
page 150)
Input/
J19 pin Signal Function Wire color
Output
1 Error + Notifies the CNC that an alert, error, or failure has Orange
Output2 occurred. This signal is not intended to be used to
2 Error - stop table motion. Black

3 Ready for start + Notifies the CNC that the plasma power supply is White
Output2
4 Ready for start - ready for the plasma start. Red
5 Auto pierce detect + Notifies the CNC that the plasma power supply has Green
Output2 detected that the system has pierced through the
6 Auto pierce detect - workpiece and is ready to begin motion. Red

Shield ohmic
7 Blue
contact +
Output 5 See notes below for further info.
Shield ohmic
8 Red
contact -

1 Inputs are optically isolated. They require 24 VDC at 12.5 mA or dry-contact closure at 8 mA.

2 Outputs are optically isolated, open-collector transistors. The maximum rating is 24 VDC at 10 mA.

3 Although the plasma power supply has output capability, it is normally used solely as an input.

4 CNC +24 VDC provides 24 VDC at 200 mA maximum. A jumper is required on J17 to use 24 V power.

5 Shield ohmic contact is used to interface to plasma interface boards that have their own ohmic contact
circuit. (See How to use ohmic contact sense on page 187.)

152 809480 Instruction Manual XPR300

 Connect for Communication 4
Figure 43 – Connect the discrete cable to the plasma power supply

Discrete cable to the CNC

XPR300 Instruction Manual 809480 153

4 Connect for Communication

VDC3 board installation (for AVC with RS-422 and discrete-only)

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.

CAUTION
Static electricity can damage circuit boards. Use proper precautions when
handling printed circuit boards.
Store PC boards in anti-static containers.
Wear a grounded wrist strap when handling PC boards.

154 809480 Instruction Manual XPR300

 Connect for Communication 4

Diagram of board, cable, and wire connections

See Figure 44 for an overview of the board, cable, and wire connections inside the plasma power
supply.

Figure 44 – Connections inside the plasma power supply

NE
G
4

W
OR
K
2

3
5

1 Plasma power supply 5 Male connector to VDC3 board (pre-installed

2 Board: VDC3 (141511) on the VDC3 board)

Wire harness in the plasma power supply 6 Cable and connector to the computer
numerical controller (CNC) (customer
3 Wires: VDC3 board 120 VAC supplied)
4 Wires: Arc voltage

 Part numbers are shown for parts included in the kit.

 The wire harness to connect the VDC3 board is located in a clip inside of
the plasma power supply. The wiring harness includes the arc voltage
wires and the power wires.

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4 Connect for Communication

How to install the VDC3 board (141511)

Figure 45 – VDC3 board

J3

12345678 12
J2 J1
J1 120 VAC wires connector J3 Arc voltage wires connector
J2 VDC3 board cable connector

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 Connect for Communication 4
1. Use a 10 mm hex socket wrench or nut driver to remove the rear panel of the plasma power
supply.

Figure 46

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4 Connect for Communication

2. Use a #2 Phillips screwdriver to

remove the 4 screws from the studs.

3. With J3 on top, use the 4 screws to

install the board on the studs. Tighten
the screws to 9.2 kg∙cm (8.0 in∙lb).

J3

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How to connect the VDC3 board (141511)

1. Remove the wire bundle from the wire clip in the plasma power supply.

 The wire bundle is included in the plasma power supply. The bundle
includes the arc voltage wires and power wires.

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4 Connect for Communication

2. Connect one end of the VDC3 120 VAC harness to J1 of the VDC3 board with the tab on top.
See Figure 47.

3. Connect the other end of the VDC3 120 VAC harness to the 120 VAC connector.

Figure 47

4. Attach the spade connector of the yellow wire (WORK) to the J3-WORK terminal.
See Figure 48.

5. Attach the spade connector of the yellow/black wire (NEG) to the J3-ELECTRODE terminal.

Figure 48
J3
WORK

NEG

EL
SH EC
TR
D
IEL
GN OD WOR
D E K

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 Connect for Communication 4
6. Attach the ring connector on the yellow wire (WORK)
to the work bolt in the plasma power supply.Tighten the
nut to 20 N∙m (15 ft∙lb).

7. Attach the ring connector on the yellow/black wire

(NEG) to the negative bolt in the plasma power supply.
Tighten the nut to 20 N∙m (15 ft∙lb).

NE
G
 Other wires are already attached to the bolts in
the plasma power supply. Attach the arc voltage
wires on top of the existing wires.

8. Use NCS (pin 3), NCE (pin 4), Aout+ (pin 6), and

W
OR
K
Aout- (pin 7) to connect to the CNC. See Figure 45 on
page 156 for the locations of the pins. See Table 26 for
the pinout.

 Use the interface requirements of your CNC for

additional connection requirements.

Table 26 – Pinout for J2 on the VDC3 board

J2 on the VDC3 board

Pin number Signal
1 Not connected
2 +24 VDC (out)
3 Nozzle contact sense (output)
4 Nozzle contact enable (input)
5 24 VDC common
6 + Analog out (40:1)
7 - Analog out (analog common)
8 EMI chassis ground (cable shield)

9. Install the rear panel of the plasma power supply.

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4 Connect for Communication

How to connect to the plasma power supply with the XPR web interface

CAUTION
If you use a wireless (Wi-Fi™) network to communicate with your cutting system, Hypertherm
recommends the use of a secure Wi-Fi network to minimize the risk of unauthorized cutting system
operation or misuse.
Minimum security features can include, but are not limited to, the following:
• Password protection
• WPA2 security for the plasma power supply
• A hidden SSID for the Wi-Fi network
• Operator training about network security
Unauthorized access or misuse of the Wi-Fi network can result in incorrect settings or commands. Bad
settings and commands can cause an uncontrollable or unusable system. A negative effect on system
performance, shortened consumable life, and torch damage is also possible.

 You must use discrete with the XPR web interface to operate the cutting
system.

 If you go out of range with the device, you cannot communicate with the
cutting system. The cutting system continues to operate. For more
information on distances for wireless, see Distance requirements for
communications on page 52.

You can use one of the following options to connect to the XPR web interface:
 Access point (AP) mode (See Use AP mode to connect on page 163.)
 You connect to the plasma power supply’s network.
 AP mode is the default connection option. You connect to a single plasma power supply.
 Network mode (See Use network mode to connect on page 165.)
 You connect the plasma power supply to your network.
 The advantage of network mode is that you can connect to one network and access
multiple plasma power supplies.

Web interface support information

 If you have a problem connecting and you suspect a problem with your device, router, or
local network, contact your system administrator.
 If you have a problem connecting and you suspect a problem with the plasma power supply,
contact your cutting machine supplier or Hypertherm Technical Service.

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Use AP mode to connect

In AP mode, each plasma power supply has its own connection. You can only connect to and
control one plasma power supply at a time. You must have a computer-based device with a screen,
web browser that supports the latest web standards, and wireless access.

1. Supply power to the cutting system:

a. Set the line-disconnect switch to the ON position.
b. Make sure that the power-indicator LED is illuminated on the plasma power supply.
c. Make sure that the remote on-off switch is set to ON.

2. On your device, go to the wireless connections menu.

 This menu can be different on different devices.

3. Choose the XPR connection.

 The default connection name is “xpr” +

the System ID. The System ID is the
last 4 digits of the Media Access
Control (MAC) address. For more
information on the System ID and MAC
address, see Web interface screen
information on page 180.

 If you want to change the connection

name, see Configure on page 185.

4. Enter the password, “hypertherm”.

 If you want to change your password,

see Configure on page 185.

5. Open an Internet browser.

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4 Connect for Communication

6. Go to http://192.168.1.1/index.html.
 The plasma power supply is now connected.
 The information about your plasma power supply and connection are located in the upperleft
of the XPR web interface.

 If the Client ID and the Operator ID are the same on your device, you are in control of the
plasma power supply and can set a process.
 See Web interface screen information on page 180 for more information on the interface
menus.

7. To fully operate the cutting system, you must also use discrete. See How to connect to the
plasma power supply with discrete on page 150.

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Use network mode to connect

In network mode, multiple plasma power supplies can be connected to a network. You can connect
to and control multiple plasma power supplies at the same time.You must have a computer-based
device with a screen, web browser that supports the latest web standards, and wireless access.

Before you begin:

 You must set up a router with a local network to access. Follow the router’s instructions to
do this. If you have problems setting up your router, contact your system administrator.
 You must know the SSID and passphrase for the router.

1. Follow the procedure in Use AP mode to connect on page 163 to connect the wireless set-up
device to the plasma power supply.

2. Choose Connect on the Other screen to open the Device Setup page.

 The XPR web interface shows different fields for different XPR models.
The screen shown is for reference only.

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4 Connect for Communication

3. Choose Client Settings.

4. Choose an option to connect to

wireless networks:
 Select an existing network on
page 167.
 Set up manually on page 170.

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Select an existing network

When you choose this option, the plasma power supply scans for and shows the available access
points.

1. Choose Select to connect to your router.

2. Type the required credentials for the router in Passphrase.

3. If needed, select the Advanced Options check box and select a method to get the IP address.
If not, go to step 4.
a. Dynamic Host Configuration Protocol (DHCP)

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4 Connect for Communication

b. Static IP (advanced users only.)

4. Choose Next to go to the Wireless Configuration Summary screen.

 This page shows information about the SSID, Channel, and Security
type.

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 Connect for Communication 4
5. Choose Save.

6. This page provides the option to apply the settings. Choose Apply Settings.

 The selected wireless settings are applied to connect the plasma power
supply to the new network. The plasma power supply now resets and
connects to the new network.

 To access the web interface after setup, see Access the XPR web
interface after setup in network mode on page 173.

7. If you are only monitoring with the XPR web interface, you are done. If you want to operate the
cutting system, go to step 8.

8. You must connect to the plasma power supply with discrete. See How to connect to the plasma
power supply with discrete on page 150.

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4 Connect for Communication

Set up manually
When you choose this option, you manually set up the wireless network.

1. Select or type the wireless related settings such as SSID, Channel, Security, and Passphrase.

2. If needed, select the Advanced Options check box and select a method to get the IP address.
If not, go to step 3.
a. Dynamic Host Configuration Protocol (DHCP)

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b. Static IP (advanced users only.)

3. Choose Next to go to the Wireless Configuration Summary screen.

 This page shows information about the SSID, Channel, Security type, IP
Address, Subnet Mask, Gateway, and DNS Server.

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4 Connect for Communication

4. Choose Save.

5. This page provides an option to apply the settings. Choose Apply Settings.

 The selected wireless settings are applied to connect the plasma power
supply to the new network. The plasma power supply now resets and
connects to the new network.

 To access the web interface after setup, see Access the XPR web
interface after setup in network mode on page 173.

6. If you are only monitoring with the XPR web interface, you are done. If you want to operate the
cutting system, go to step 7.

7. You must connect to the plasma power supply with discrete. See How to connect to the plasma
power supply with discrete on page 150.

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Access the XPR web interface after setup in network mode

Use the IP address of the plasma power supply.

 Hypertherm recommends that you use DHCP reservation if it is available

on your router. This allows the plasma power supply to keep the same IP
address through power cycles without having to set up the wireless
module with the static IP address.

1. Use your router’s web interface to find the DHCP client table. (See Figure 49 for an example.)

Figure 49 – Example DHCP client table

2. Find the IP address of the plasma power supply.

 Your plasma power supply name shows as “GS_” + the last 6 digits of the
MAC address.

3. Open a web browser.

4. Use the assigned IP address to access the XPR web interface. In the example in Figure 49 you
navigate to http://192.168.1.133/index.html.

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 4 Connect for Communication

Change the limited AP settings

You can change the limited AP SSID, channel, network address, and DHCP settings in the Connect
screen.

1. Choose Other > Connect > Limited AP Settings.

2. On the Limited AP Settings screen, select the AP mode settings

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 Connect for Communication 4
3. Choose Advance Options, then Next.

4. Verify that the settings are correct. Adjust if necessary, otherwise, choose Save.

5. Choose Apply Settings.

 The change takes effect after you cycle the power.

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4 Connect for Communication

6. Cycle the power to the plasma power supply.

Reset the wireless module

It is possible to make mistakes when you set up the wireless module. Use this procedure to reset
your wireless module to its default settings.

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.

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

1. Remove the power from the cutting system:

a. Set the line-disconnect switch to the OFF position.
b. Make sure that the power-indicator LED is not illuminated on the plasma power supply.

2. Remove the side panel of the plasma power supply.

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 Connect for Communication 4
3. On the main control board, set position 4 on DIP switch S3 to the ON position.

 This disables the wireless.

4. Supply power to the cutting system:

a. Set the line-disconnect switch to the ON position.
b. Make sure that the power-indicator LED is illuminated on the plasma power supply.

WARNING

ELECTRIC SHOCK CAN KILL

The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Use extreme caution if you service a plasma power supply when connected to an electric
power source and the outer cover or panels are removed.

5. Wait 30 seconds.

6. Remove the power from the cutting system:

a. Set the line-disconnect switch to the OFF position.
b. Make sure that the power-indicator LED is not illuminated on the plasma power supply.

7. Set position 4 on DIP switch S3, located on the main control board, to the OFF position.

 This enables the wireless.

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4 Connect for Communication

8. Install the side panel of the plasma power supply.

9. Supply power to the cutting system:

a. Set the line-disconnect switch to the ON position.
b. Make sure that the power-indicator LED is illuminated on the plasma power supply.

10. Wait 30 seconds.

 The wireless module is now reset to the factory default settings.

How to disable the wireless connection

If you want to completely disable the wireless connection, use this procedure.

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.

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

1. Remove the power from the cutting system:

a. Set the line-disconnect switch to the OFF position.
b. Make sure that the power-indicator LED is not illuminated on the plasma power supply.

2. Remove the side panel of the plasma power supply.

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 Connect for Communication 4

WARNING

ELECTRIC SHOCK CAN KILL

The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Use extreme caution if you service a plasma power supply when connected to an electric
power source and the outer cover or panels are removed.

3. On the main control board, set position 4 on DIP switch S3 to the ON position.

 This disables the wireless.

Figure 50 – Main control board (note DIP switch S3 location).

4. Install the side panel of the plasma power supply.

5. Supply power to the cutting system:

a. Set the line-disconnect switch to the ON position.
b. Make sure that the power-indicator LED is illuminated on the plasma power supply.

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4 Connect for Communication

Web interface screen information

If you replace the control PCB, the information stored on the PCB changes. This includes the MAC
address, System ID, passwords, and network information.
 System ID – This is the identifier for the plasma power supply. It is the last 4 digits of the
MAC address. The MAC address is printed on the wireless module on the control PCB.

 Operator ID – This is the identifier for the device or

client that has control of the plasma power supply. The
first part of the Operator ID shows the type of
connection that sent a process, WiFi for wireless, Uart
422 for serial RS-422, or EtherCAT for EtherCAT.

 To change which device has control of the plasma power supply, see How
to change the device that has control on page 186.

 Client ID – This is the identifier for a device that communicates with the plasma power
supply. This ID uses the UTC time stamp and is saved in a browser cookie.

 If the Client ID and the Operator ID are the same on your device, you are
in control of the plasma power supply.

 Connection – This is the status of the communication between the device and the plasma
power supply. (Good or Error.)

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 Connect for Communication 4

Plasma power supply

On this screen you can monitor the status of the plasma power supply. This screen also lists inputs
and outputs. When highlighted red or gray, that input or output is active.

 The XPR web interface shows different fields for different XPR models.
The screen shown is for reference only.

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4 Connect for Communication

Gas system
On this screen you can monitor the status of the torch connect console and the gas connect
console. You can also see which valves are active when the gas is flowing. Active valves are
indicated with a gray highlight.

You can do 4 tests from this screen: Test Preflow, Test Cutflow, Test Pierceflow, and Gas Leak Test.
The gas leak test is only available on XPR cutting systems equipped with a VWI or OptiMix gas
connect console. See How to do a gas leak test (VWI and OptiMix) on page 331.

The test starts when you choose the button. The button becomes active, indicated with a red
highlight. The active valves are indicated with a gray highlight. The gases shown on Line A, Line B,
and shield are different depending on the process ID that you selected. The gases flow for 60
seconds unless you choose the same button or choose another button that interrupts the test.

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Log
On this screen you can monitor active diagnostic codes and view diagnostic code history. There are
4 categories of codes: information, alert, error, and failure. See Diagnostic codes on page 261 for
definitions.

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4 Connect for Communication

Operate
On this screen, if you have the device that is in control of the plasma power supply, you can select a
process ID based on material, thickness, and process type.

You can customize some parameters by choosing the + to open the menu. The plasma power
supply keeps this customization until the remote on-off switch is set to OFF or the power is removed
from the plasma power supply. The customization is also reset when you select a new process.

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Other
On this screen you can view the software versions and monitor the status of the wireless
connection. From this screen, you can also access the Configure, Connect, and Update
commands.

 The XPR web interface shows different fields for different XPR models.
The screen shown is for reference only.

Configure – On this screen you can change the connection name, limited AP password, limited AP
IP address, or the setup password
 You cannot use special characters in any of the fields on this screen.
 The connection name must be less than 32 characters long.
 Passwords must be between 8 and 20 characters long.
 Passwords are case sensitive.

Connect – On this screen you can change your client settings and connect to other networks. For
more information on how to do this, see Use network mode to connect on page 165.

Update – On this screen you can update the web interface and firmware.

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4 Connect for Communication

How to change the device that has control

The device that first sets a process controls the plasma power supply. For example, if the CNC sets
the process, all other devices that connect to the plasma power supply after the CNC sets the
process can only monitor the data.

 If the Client ID and the Operator ID in the XPR web interface are the
same on your device, you are in control of the plasma power supply.

To change the device that has control of the plasma power supply:

1. Remove the power from the cutting system:

a. Set the line-disconnect switch to the OFF position.
b. Make sure that the power-indicator LED is not illuminated on the plasma power supply.

2. Supply power to the cutting system:

a. Set the line-disconnect switch to the ON position.
b. Make sure that the power-indicator LED is illuminated on the plasma power supply.

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How to use ohmic contact sense

Ohmic relay overview

 The relay is normally open when not powered.
 The relay is closed during operation, except during ignition or cutting with water processes.
 Ohmic contact is disabled when cutting with a water process.
 Ohmic contact is disabled when the remote on-off switch is in the OFF position.

Internal ohmic contact sense

This is the default installation for the torch and torch connect console. No action is required.

Figure 51 – Internal ohmic diagram

3
4 2
5
6

J4 J3
10 J27
9 7

8 J2

J1

11

1 Torch 7 Ohmic PCB

2 Ohmic wire, inside torch and torch lead 8 J1 to J27 wires
3 Torch connect console 9 Control PCB
4 Ohmic wire, torch receptacle to ohmic relay 10 CAN connection
5 Ohmic relay 11 2 ground connections (required)
6 Ohmic wire, ohmic relay to J3

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4 Connect for Communication

External ohmic contact sense

If you plan to use external ohmic contact sense, make the following modification to the ohmic wiring
inside of the torch connect console.

 The relay is still used to help isolate the ohmic circuit from high voltage.

1. Remove the power from the cutting system:

a. Set the line-disconnect switch to the OFF position.
b. Make sure that the power-indicator LED is not illuminated on the torch connect console.

2. Disconnect the ohmic wire from J3 on the ohmic PCB in the torch connect console.

3. Connect the ohmic wire that you removed from J3 to J4 pin1.

4. If you have a third-party ohmic circuit, remove the plug from the sheet metal on the torch
connect console to access the ohmic wire inside. Otherwise, skip to step 5.

 The plug is located below the torch lead connection (Figure 52).

Figure 52 – Remove plug to access the ohmic wire if you use a third-party ohmic circuit

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 Connect for Communication 4
5. Connect the ohmic wire 6 from the ohmic relay to J4 pin 2 on the ohmic PCB in the torch
connect console.

6. Connect the ohmic wire 9 to the PCB connection for ohmic inside the lifter.

Figure 53 – Example external ohmic diagram

3
4
5 6

8 2

10 9
J4 J3
J27
7

J2

J1

1 Torch 7 Ohmic PCB

2 Ohmic wire, inside torch and torch lead 8 Ohmic wire, J4 to lifter or third party ohmic
3 Torch connect console circuit

4 Ohmic wire, torch receptacle to ohmic relay 9 Torch lifter or third party ohmic circuit

5 Ohmic relay 10 Pin 1 and pin 2 on J4 are connected in the

ohmic PCB
6 Ohmic wire, ohmic relay to J4

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4 Connect for Communication

How to install a remote on-off switch

WARNING
ELECTRIC SHOCK CAN KILL
When the remote on-off switch is set to OFF, power remains active to the following
components in the system:
• Control board
• Control transformer input and output
• 48 V power supply
• 24 V power supply
• 120 VAC and 220 VAC on the power distribution board
• Input side of the contactors
• Input side of the pump relay
• Power-indicator LED on the front of the plasma power supply
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.

If you want to use the remote on-off feature, remove the jumper from pin 1 and pin 2 of the J14
connector and install your own interface.
 For the pinout of J14, see Table 24 on page 151.
 Use the examples in Examples of output circuits on page 191 and Examples of input
circuits on page 192 to design your circuit.

When the remote on-off switch is set to OFF (disabled), power is removed from the following parts:
 Gas connect console
 Torch connect console
 Contactor enable
 Pump relay enable
 Fan enable
 CNC outputs

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Examples of output circuits

Logic interface, active high

5 VDC – 24 VDC
XPR
C
+ CNC/PLC

-
E 10 kΩ (optional)
High-impedance (≤ 10 mA)

Logic interface, active low

5 VDC – 24 VDC

10 kΩ (optional)

CNC/PLC
XPR
C
+
- High-impedance (≤ 10 mA)
E

Relay interface
CNC +24 V
+24 V CNC +24 V
°t
Install a jumper
J17 XPR
(108056)
C CNC/PLC
+

- High-current contact closure

E inputs (AC or DC)

External relay
24 VDC low-power coil
Wire ground ≤ 10 mA or ≥ 2400 Ω
All relay coils require a freewheeling diode across the relay
coil.

This circuit VOIDS the warranty. Do NOT use.

XPR Any voltage
C
+

-
E
Power ground

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4 Connect for Communication

Examples of input circuits

Relay interface
The life of the external relay can be extended if you add a
metalized-polyester capacitor (0.022 μF 100 V or higher) in parallel with
the relay contacts.

+24 VDC

Output from XPR

CNC/PLC

External relay (AC or DC)

Power ground

Optocoupler interface
+24 VDC

CNC/PLC
XPR

Transistor-output optocoupler

Power ground

Amplified-output interface
CNC/PLC +24 VDC
12 VDC – 24 VDC
XPR

Active-high drive Power ground

Power ground

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 Coolant Installation

Overview

The cutting system ships without coolant in the reservoir. Before you operate the cutting system,
you must fill it with coolant. The coolant capacity for the XPR cutting system is between
22.7 liters – 45.4 liters (6 US gallons – 12 US gallons).

A cutting system with long leads requires more coolant than a cutting system with short leads.

 Contact your cutting machine supplier to reorder coolant. For information

about how to calculate the approximate total volume of coolant for your
cutting system, see Estimate the total coolant volume for your cutting
system on page 248.

 The plasma power supply ships with the coolant filter (027005) and
coolant pump screen (127559) installed. Additional coolant filters and
screens are available from Hypertherm. See Coolant system on
page 356.

 For information about how to install a replacement coolant filter or coolant

pump screen, see the XPR Preventive Maintenance Program Instruction
Manual (809490).

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5 Coolant Installation

How to fill the cutting system with coolant

NOTICE
Never operate the cutting system if you get a low coolant level notice.
There is a risk of serious damage to the cutting system and to the coolant pump if you operate the
cutting system with no coolant or with low coolant.
If your coolant pump is damaged, it may need to be replaced.

NOTICE
Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that
damage the torch coolant system.

NOTICE
If you use the wrong coolant, it can cause damage to the cutting system. See Coolant requirements on
page 44.

1. Get the correct coolant mixture for your cutting system.

 See Coolant requirements on page 44 to determine what percentage of

propylene glycol to add in the premixed Hypertherm coolant (028872).

2. Remove the cap from the reservoir fill

port inlet that is located on top of the
plasma power supply.

3. Look into the fill port inlet to see into

the coolant reservoir.

4. Pour the coolant into the reservoir

until the coolant level gets to the
base of the fill spout.

 You can see the coolant level

from the fill port inlet as you
pour the coolant.

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 Coolant Installation 5
5. Install the cap onto the coolant reservoir.

6. Supply the power to the cutting system:

a. Set the line-disconnect switch to the ON position.
b. Make sure that the remote on-off switch is enabled.
c. Make sure that the green power-indicator LED is illuminated
on the plasma power supply.

7. Use the CNC or XPR web interface to send a process to the

plasma power supply and start the coolant pump.

 When you send a process, the gases start to flow and after
a few seconds the coolant pump starts. If the pump stops,
it is necessary to purge the air out of the coolant loop. Use
the remote on-off switch to start and stop the coolant pump until the
pump continues to run.

8. If necessary, add more coolant to fill the reservoir to the base of the fill spout.

WARNING
WET FLOOR
The floor can become slippery when wet.
If you put too much coolant in the reservoir, coolant flows out of the front of the plasma
power supply onto the floor.

9. After installation of the coolant, use the CNC or XPR web interface to deselect the process.

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 Operation

Overview

This section of the manual describes the following items that relate to cutting system operation:
 Controls and indicators on page 198
 Sequence of operation on page 201
 How to choose the torch positions and process settings you need on page 211
 Process selection on page 219
 How to use cut charts on page 221
 How to select consumables on page 224
 Factors of cut quality on page 224

 If you have questions about how to operate your cutting system, contact
your cutting machine supplier or regional Hypertherm Technical Service
team. You can find contact information for each regional office at
www.hypertherm.com on the “Contact us” page.

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6 Operation

Controls and indicators

Controls
CNC
A computerized numeric control (CNC) controls cutting system operation. The CNC has the
following functions:
 Executes part programs from computer-aided design (CAD) and computer-aided
manufacturing (CAM) software.
 Sends commands to the cutting system through a CNC interface cable (or wireless
connection) between the CNC (or wireless device) and the plasma power supply.
 Reacts to feedback signals it receives from the cutting system and (or) operator.

Multiple cutting system commands, settings, and displays are visible and controllable from different
CNC screens.

CNC screens can include the following:

 Main (control) screen
 Process setup screen
 Diagnostic screen
 Test screen
 Cut chart screen

 See the instruction manual that came with your CNC for descriptions of
CNC screens.

For information about how to use the Hypertherm CNC to control cutting system operation, see:
 The instruction manual that came with your CNC
 CNC Communication Protocol for the XPR Cutting System (809810)

Wireless device
A wireless device can be used to setup and monitor the XPR cutting system. A wireless device with
the XPR web interface sends commands to the XPR cutting system through a wireless connection
between the wireless device and the plasma power supply.

Multiple cutting system commands, settings, and displays are visible and controllable from different
XPR web interface screens. For information on these screens, see Web interface screen
information on page 180.

For information about how to set up a wireless device with the XPR web interface, see How to
connect to the plasma power supply with the XPR web interface on page 162.

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Indicators
Power-indicator LEDs
Light emitting diodes (LEDs) illuminate to indicate power status.

The power-indicator LED on the plasma power supply (Figure 54) uses 2 colors to indicate power
status:
 The LED illuminates amber when the plasma power supply is receiving electric power and
the remote on-off switch is in the OFF position.
 The LED illuminates green when the plasma power supply is receiving electric power and
the remote on-off switch is in the ON position.
 The plasma power supply that came with early XPR300 cutting systems has a green-only
power-indicator. A power-indicator LED upgrade kit (428893) is available from Hypertherm
if you want a 2-color LED for your plasma power supply.

Figure 54 – Power-indicator LED on the plasma power supply

When illuminated, the green power-indicator LED on the gas connect console (Figure 55 on
page 200) and torch connect console (Figure 55 on page 200) indicate that:
 Power is supplied to the XPR cutting system.
 The line-disconnect switch or breaker for the unit is set to the ON (I) position.
 The unit is ready for use.

 The early XPR300 plasma power supplies use

The power-indicator LED on the plasma power supply of early XPR300 cutting systems use 1 color,
green, to indicate power status. You can upgrade your

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6 Operation

Figure 55 – Power-indicator LED on the gas connect console (left)

and on the torch connect console (right)

CNC display
Except for the power-indicator LEDs that show power status, all other visual indications of cutting
system performance appear on the CNC or XPR web interface.

 For CNC screen descriptions, see the instruction manual that came with
your CNC.

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 Operation 6

Sequence of operation

The flowcharts on the following pages show the sequence of operation for the XPR cutting system.

States of operation for the XPR cutting system

Each state of operation is assigned a unique name and number for identification purposes. The type
of name you see (name or number) depends on your cutting system settings.

Powerup State (1)

The operator supplies power to the cutting system to start the Powerup State (1).

Power is supplied to the cutting system.

Cutting system operation STARTS.

Make sure that signals are OFF for the following:

• Main contactor
• Coolant pump
• Cooling fans

Establish CAN communication.

Wait for RS-422 serial, EtherCAT, or wireless

communication between the plasma power supply
and CNC or wireless device.

Determine system configuration (number of

choppers and number and type of consoles).

No Diagnose and troubleshoot the problem. (See

Is Powerup State (1) complete and successful? Diagnostics and Troubleshooting on page 253.)
Then, start the Powerup State (1) again.
Yes

Continue to Initial checks State (2) on page 202

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6 Operation

Initial checks State (2)

Search for diagnostic codes.

Yes Diagnose and troubleshoot the problem. (See

Is there a diagnostic code? Diagnostics and Troubleshooting on page 253.)
Then, start Initial checks State (2) again.
No

Measure the following:

• Temperatures (main transformers, choppers,
coolant)
• Inlet pressures (gas connect console, torch
connect console)

Are the measurements within the acceptable No Diagnose and troubleshoot the problem. (See
range? Diagnostics and Troubleshooting on page 253.)
Yes

Wait for process selection by the operator.

Select a process ID.

Continue to Gas purge/pump on State (3) on

page 203.

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 Operation 6

Gas purge/pump on State (3)

Yes
Is a specialty purge necessary?* Do a specialty purge.

No

Stage 1: Operate preflow gases.**

Turn ON the coolant pump and start coolant flow.

Stage 2: Operate cutflow gases.**

Measure the coolant flow rate.

No Diagnose and troubleshoot the problem. (See

Is the coolant flow within the acceptable range? Diagnostics and Troubleshooting on page 253.)
Then, measure the coolant flow again.
Yes

Continue to Wait for start State (5) on page 204.

* A specialty purge (with either N2 or air) occurs automatically if the process changes from a non mixed-fuel gas
to a mixed-fuel gas or F5 process (or the reverse). If the previous process was a water (H2O) process, then a
water purge is added to the gas purge. (See Automatic purges on page 209.) If the previous process was not
H2O, or mixed-fuel gas, or F5, skip to the usual 2-stage gas purge.

** The length of time necessary to complete a purge is based on: 1) the type of operator-selected process that
the CNC or wireless device sends to the cutting system, 2) if this is the first process sent after the Powerup
State (1) starts, and 3) the type of previous operator-selected process.

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6 Operation

Wait for start State (5)

Wait for the CNC to send the Plasma Start command to the cutting system.

Wait for a command: select a new process or “Plasma

Start” (there is no limit to how long the system waits for
input).

No
Is a new process selected or “Plasma Start” selected?

Yes

For new process For a “Plasma Start”

selection, continue to command, continue to
OR
Initial checks State (2) Preflow/charge DC
on page 202. State (7) on page 204.

Preflow/charge DC State (7)

Start preflow gas flow.

Turn ON the inrush contactor and then the main

contactor.

Turn ON the chopper.

Turn ON the fans (if not already on).*

Turn ON the coolant pump (if not already on).*

Measure gas pressure.

Make sure that Hold Ignition signal is OFF.

No Diagnose and troubleshoot the problem. (See

Is the Preflow State complete and successful? Diagnostics and Troubleshooting on page 253.)
Then, start Preflow/charge DC State (7) again.
Yes

Continue to Ignite State (8) on page 205.

* To conserve energy, the coolant pump and fans stop after the time limit expires without a command.

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 Operation 6

Ignite State (8)

Is the coolant flow within the acceptable range? No

Yes

Are the gas pressures within the acceptable No

range?
Yes
Continue to End of cycle
Is the DC bus voltage within the acceptable No
State (14)
range?
Yes

Turn ON the high frequency circuit (ignition/arc

created).

Is the Chopper 1 current above the minimum No

current?
Yes

Does Ignite State (8) complete within No Diagnose and troubleshoot the problem. (See
500 milliseconds? Diagnostics and Troubleshooting on page 253.)
Yes

Continue to Pilot arc State (9) on page 206.

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6 Operation

Pilot arc State (9)

Is the coolant flow within the acceptable range? No

Yes

Are the gas pressures within the acceptable No

range?
Yes

No
Are the temperatures within the acceptable range?

Yes
Continue to End of cycle
State (14)
Is the DC bus voltage within the acceptable No
range?
Yes

Is the current for Chopper 1 within the acceptable No

range?
Yes

Is the current for the work lead within the

No
acceptable range?
Chopper 2 becomes active during this time.
Yes

Does the Pilot arc State (9) complete within 500 No Diagnose and troubleshoot the problem. (See
milliseconds? Diagnostics and Troubleshooting on page 253.)
Yes

Continue to Rampup State (11) on page 207.

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 Operation 6

Rampup State (11)

Increase current and gas flow to the setpoints for
this process.

Is the Rampup State (11) complete and No Diagnose and troubleshoot the problem. (See
successful? Diagnostics and Troubleshooting on page 253.)
Yes

Continue to Steady State (12) on page 207.

Steady State (12)

During the Steady State (12), the sent process (piercing, marking, or cutting) is active.

Does the coolant flow rate remain within the

acceptable range? No

Yes

Do the gas pressures remain within the acceptable No

range?
Yes

Do the temperatures remain within the acceptable No

range? Diagnose and troubleshoot the problem. (See
Yes Diagnostics and Troubleshooting on page 253.)

Does the current for Chopper 1 and Chopper 2

remain within the acceptable range? (If the
process is less than or equal to 30 A, only No
Chopper 1 is active).
Note: If the operator-selected process is equal to
or greater than 30 A, monitor both choppers.
Yes

Is the Plasma Start signal removed?

Yes

Continue to Rampdown State (13) on page 208.

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6 Operation

Rampdown State (13)

Rampdown State (13) begins when the CNC removes the Plasma Start command.

Decrease current to the final setpoint.

Decrease gas flow to the final setpoint.

Is Rampdown State (13) complete and No Diagnose and troubleshoot the problem. (See
successful? Diagnostics and Troubleshooting on page 253.)
Yes

Continue to End of cycle State (14) on page 208.

End of cycle State (14)

Turn OFF Chopper 1 and Chopper 2.

Turn OFF gas.

Start post-flow gas flow.

Start timer to turn OFF the contactor.

Start timer to stop the fans.

Start timer to stop the coolant pump.

Cycle ends. Continue to Wait for start State (5) on

page 204.*

* After the successful completion of an operator-selected process, the cutting system returns to the Wait for
start State (5) on page 204 to wait for the next command.

High-voltage relay stages (closed or opened) in the ohmic circuit

During a wet process (specifically, N2/H2O), water can act as a current path for the ohmic-sense
circuit. To prevent any passage of current to the ohmic board, the cutting system automatically
opens the high-voltage relay and disables the ohmic-sense circuit.

Ohmic sensing for the N2/H2O process is available in cutting systems with firmware that is
revision L or later. Stall force is required when the N2/H2O process is used underwater.

During a dry process, the cutting system closes the high-voltage relay and enables the ohmic-sense
circuit (except during high-frequency starts).

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 Operation 6

Automatic purges
XPR cutting system purges are automatic. The type of purge is based on the currently-selected
process, the previously-selected process, and on the type of gas connect console (OptiMix, VWI, or
Core).
 OptiMix and VWI XPR cutting systems do both gas-change and process-setup purges.
(See Gas-change purges for OptiMix or VWI XPR cutting systems on page 209 and
Process-setup purges for all XPR cutting systems on page 210.)
 Core XPR cutting systems do only process-setup purges. (See Process-setup purges for
all XPR cutting systems on page 210.)

 The length of time necessary to complete a purge is based on the type of

operator-selected process and if the active process is the first process
sent after the Powerup State (1). (See Sequence of operation on
page 201.)

Gas-change purges for OptiMix or VWI XPR cutting systems

If you have an XPR cutting system equipped with an OptiMix or VWI gas connect console, a
plasma-gas purge occurs automatically when the cutting system changes from a non mixed-fuel
gas process to a mixed-fuel gas (H2-mix) or F5 process or from a mixed-fuel gas (H2-mix) or F5 to a
non mixed-fuel gas process.

 Core XPR cutting systems skip gas-change purges.

The type of plasma gas used for the purge is based on the type of cutting system configuration
(OptiMix or VWI):
 OptiMix XPR cutting systems use a 2-phase gas-change purge that includes N2.
 VWI XPR cutting systems use a 2-phase gas-change purge that includes air.

Plasma-gas purge

The following steps occur automatically for a plasma-gas purge:

1. Mixed-fuel gas (H2-mix) or F5 drains from the XPR cutting system through the torch.

2. If you have an OptiMix XPR cutting system, N2 purges any residual mixed-fuel gas.

3. If you have a VWI XPR cutting system, air purges any residual F5 gas from the torch lead.

Shield-gas/shield-fluid purge

If a process changes from a wet process to a dry process, a shield-fluid purge is used. During a
shield-fluid purge, N2 purges residual water from the shield gas/fluid hose.

 A wet process uses water as a shield fluid. A dry process does not use
water as a shield fluid.

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 6 Operation

 Core XPR cutting systems skip the gas-change purge. Core XPR cutting
systems use only process-setup purges. (See Process-setup purges for
all XPR cutting systems on page 210.)

Process-setup purges for all XPR cutting systems

If you have a cutting system equipped with an OptiMix or VWI gas connect console, a
process-setup purge automatically follows the gas-change purge, and includes preflow and cutflow
purges.

If you have a Core XPR cutting system, the gas-change purge is skipped, and only the
process-setup purge occurs.

The type of process gas used for a process-setup purge is based on the operator-selected
process.

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How to choose the torch positions and process settings you need

Perpendicular-position cutting, marking, and piercing

During perpendicular-position cutting, marking, and piercing, the torch remains perpendicular (at a
90° angle) to the workpiece. Many cutting processes and all piercing and marking processes use a
perpendicular torch position.

Cutting
Cutting processes use a plasma arc that goes through the full thickness of the metal to create a
desired shape. The length and shape of a cut part is based on the path and duration of torch
movement.

Marking
Marking processes use argon (Ar) or nitrogen (N2) to make marks on metal, without piercing or
cutting through it. A typical use for marking is to mark a workpiece for secondary operations (such
as bending or drilling) or for alpha-numeric part identification.

When you use argon marking, the type of metal, its thickness, and its surface finish have an effect on
marking quality. Torch speeds and current levels also have an effect:
 Slower torch speeds and higher currents make deeper marks.
 Faster torch speeds and lower currents make shallower marks.

Make sure to mark and cut individual parts when you use the argon-marking processes. Marking the
entire nest prior to cutting can reduce the life of consumables. For better results, alternate cuts and
marks.

 Poor quality marking or burn-through can occur with metal that is less
than 1.5 mm (0.06 in. or 16 gauge).

Piercing
Piercing processes penetrate the full thickness of the metal. Piercing is also the first action involved
in cutting a part.

 Use edge starts when piercing is not possible.

If the torch moves too soon, the plasma arc cannot penetrate the metal. If the movement delays too
long, the pierce-hole size can increase, which can result in the loss of the transferred arc. If the torch
is too close to the workpiece during piercing, damage can occur to the consumables and the torch.

You can minimize unwanted results, increase the number of pierces, and maximize the life of
consumable parts when you use the piercing settings that Hypertherm recommends.

 For information about how to get the best piercing results, see
Recommendations for piercing processes on page 226.

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 6 Operation

Bevel cutting
During bevel cutting, the torch is at an angle (not perpendicular) to the workpiece. The angle of the
torch (relative to the workpiece) has an effect on the bevel cut angle of the metal.

The torch and consumable parts are designed so that the torch position can range from 0° – 52° so
that the torch tip remains the closest point to the workpiece. If you need an angle greater than 52°,
you can raise the torch to increase the clearance.

Figure 56 – Sample orientation of a torch during bevel cutting

3 4

6
90°

1 Perpendicular line: The imaginary line that is 5 Torch center line: The imaginary line along the
perpendicular (at a 90° angle) to the workpiece. central axis of the torch.
2 Bevel angle: The angle between the center line of 6 Clearance: The vertical distance from the lowest
the torch and an imaginary line that is point of the torch to the surface of the workpiece.
perpendicular to the workpiece. Make sure that the distance is at least
3 Cut height: The linear distance from the center of 2 mm – 3 mm (0.080 in. – 0.120 in.) to minimize
the torch to the workpiece surface along the torch torch contact with any slag on top of the plate.
center-line. For optimal results, select a cut height 7 Nominal thickness: The vertical thickness of a
that is based on an “effective thickness” value in workpiece. This is the thickness of the metal that
the cut charts. the plasma arc cuts, marks, or pierces.
If a specific cut height is inconsistent with a 8 Effective thickness: The distance that the plasma
clearance requirement, select a slightly higher cut arc travels through the metal while cutting. This
height to prevent torch collisions. value is equal to the nominal thickness, divided by
4 Cone angle: All XPR torches have a 76° cone the cosine of the bevel angle.
angle that makes it possible to tilt or position the
torch up to 52°. If you need an angle greater than
52°, you can raise the torch to increase the
clearance.

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 Operation 6

 Arc voltage settings for bevel cutting depend on the torch position, metal
thickness, cut speed, and effective cut height. For this reason, cut charts
only include arc voltages for perpendicular-position cutting.

Bevel compensation tables

Hypertherm’s TrueBevel™ software has specialized cut charts known as “bevel compensation
tables.” They can help you get the best results on mild steel with minimal operator intervention.

 For information about how to access and use the bevel compensation
tables, refer to the instruction manual that came with your Hypertherm
CAM software.

Hypertherm’s ProNestTM software includes bevel-compensation tables.

 For information about CNC compatibility requirements and how to use

bevel compensation tables with non-Hypertherm CNCs, contact your
cutting machine supplier or regional Hypertherm Technical Service team.

Ferrous (mild steel) processes

Ferrous (mild steel) processes are developed for cutting A36 mild steel. All mild steel processes are
available with all 3 XPR gas connect consoles (OptiMix, VWI, and Core). Mild steel processes use
O2/Air in most cases, except for the following:
 Lower-current cutting processes on thinner metals, True Hole, and internal-feature cutting
use O2/O2.
 The 300 A processes, on some thicknesses, use O2/N2.
 Argon-assist technology uses argon (Ar) in the shield to increase pierce capacity.

 See the XPR Cut Charts Instruction Manual (809830) for information
about the gases used for plasma gas and shield gas during different
processes.

All mild steel processes use Hypertherm’s enhanced LongLife® technology that works together with
Arc Response Technology™ to extend the life of consumables by detecting and reacting to
rampdown errors before they occur.

The XPR300 cutting system offers HyDefinition vented consumables for 30 A – 170 A
processes. The processes enable the operator to achieve the following results:
HyDefinition vented • High-quality cuts
processes
• Dross-free cutting (metal dependent)
• Fast cut speeds
The 300 A process is non-vented and delivers the following cutting options:
• High-quality cuts
HyDefinition 300 A
• Excellent consumable part life
process
• Dross-free cutting with most thicknesses (metal dependent)
• Consistent cut quality over the lifetime of the consumable parts

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 6 Operation

 The consumable parts for 300 A processes are non-vented and use a
liquid-cooled nozzle (in place of a vented, air-cooled nozzle).

Non-ferrous (stainless steel and aluminum) processes

Non-ferrous (stainless steel and aluminum) processes that appear in the XPR cut charts were
developed using the following metals:
 304L and 316L stainless steel
 6061 aluminum

It is possible, however, to cut other types of stainless steel and aluminum.

Non-ferrous process availability is based on the type of gas connect console that you have (Core,
VWI, or OptiMix).

Table 27 – Available non-ferrous processes by gas connect console type and gas type.

Gas connect console Available stainless steel processes Available aluminum processes
Core N2/N2 N2/N2, Air/Air
VWI N2/N2, N2/H2O, F5/N2 N2/N2, N2/H2O, Air/Air
OptiMix N2/N2, N2/H2O, H2-mix/N2, F5/N2 N2/N2, N2/H2O, H2-mix/N2, Air/Air

Table 28 – Process recommendations for cut quality, based on metal thickness and type

Metal thickness Metal type

Metric (mm) English (in) Stainless steel Aluminum
1 0.036
40 A N2/N2 40 A Air/Air
3 0.105
3.5 0.125 60 A Air/Air
60 A N2/N2
5 0.188 60 A N2/N2
6 0.250
80 A F5/N2 80 A N2/H2O
10 0.375
12 0.500 130 A H2-mix/N2 130 A N2/H2O
16 0.625 170 A H2-mix/N2
170 A N2/H2O
20 0.750
25 1.000
300 A H2-mix/N2 300 A N2/H2O
50 2.000
75 3.000 –

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 Operation 6

Stainless steel

The XPR300 cutting system offers HDi vented cutting for all processes that cut stainless
steel (up to170 A). HyDefinition vented processes produce high-quality cuts with minimal
dross and can be used with either N2, F5, or mixed-fuel gases.
HyDefinition (HDi) Specifically, HyDefinition vented processes can produce:
vented processes • A sharp top edge of the cut
• A smooth, shiny, or gray cut edge
• Excellent cut-edge angularity
• Fast cut speed
OptiMix-equipped systems let operators use mixed-fuel gas processes for stainless steel
cutting.
HyDefinition vented
mixed-fuel gas The OptiMix gas connect console has a 3-gas mixer that mixes H2, Ar, and N2 so that the
processes operator can tune the cut edge color and angle with a wide variety of gas mixtures. The
cutting system chooses an optimized combination of 3 gases or 2 gases (H2, Ar) based on
the thickness of the metal to be cut.
VWI processes use a low flow rate of water through the shield line (instead of shield gas).
HyDefinition vented A process that uses water as a shield fluid is sometimes known as a “wet” process.
water injection
processes Wet processes deliver an overall good cut quality with low operating cost and a decreased
heat-affected zone. Wet processes produce a slightly rougher edge than “dry” processes.
The 300 A processes (N2/N2, mixed-fuel gas/N2, and N2/H2O) are non-vented and deliver
the following cutting options:
• Dark-colored cut edges with N2/N2.
HyDefinition
• Yellow-orange cut edges with mixed-fuel gas/N2 on metals with 15 mm – 25 mm
non-vented
(0.59 in. – 1 in.) thicknesses.
processes
• Dark, blue-hued cut edges with mixed-fuel gas/N2 on metals with thicknesses that are
greater than 25 mm (1 in.).
• Gray cut edges with small heat-affected zone with N2/H2O.

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Aluminum

In addition to high-quality stainless steel cuts (See Stainless steel on page 215.), the N2
HyDefinition (HDi)
and mixed-fuel gas HyDefinition consumables can be used to produce high quality cuts on
vented processes
aluminum.
OptiMix-equipped systems let operators use mixed-fuel gas processes for aluminum
HyDefinition cutting.
mixed-fuel gas The OptiMix gas connect console has a 3-gas mixer that mixes H2, Ar, N2. The cutting
processes system chooses an optimized combination of 3 gases or 2 gases (H2, Ar) based on the
thickness of the metal to be cut.
VWI processes use a low flow rate of water through the shield line (instead of shield gas).
A process that uses water as a shield fluid is sometimes known as a “wet” process.
HyDefinition vented For aluminum, wet processes generally produce a smoother edge than “dry” processes.
water injection Additionally, VWI lets operators get:
processes • A sharp top edge of the cut
• A smooth cut edge
• Excellent cut-edge angularity
HyDefinition The 300 A processes (N2/N2, mixed-fuel/N2, and N2/H2O) are non-vented and deliver good
non-vented cut quality at fast cutting speeds.
processes

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Processes for special applications

Underwater cutting

WARNING

Underwater cutting with fuel gases or underwater cutting of non-ferrous alloys can create
an explosion hazard.
• Do NOT cut under water with fuel gases (H2-mix) or F5.
• Do NOT cut non-ferrous alloys under water or on a water table, unless you can prevent the
accumulation of hydrogen gas.
Doing so can result in an explosion during cutting system operation.

Underwater cutting can suppress the acoustical noise, smoke, and glare that plasma cutting
produces. Underwater cutting also decreases the heat-affected zone on the workpiece. On mild
steel, it also decreases cutting speeds and produces a rougher cut edge with increased dross.

 You can expect the acoustical noise levels to average less than 70
decibels for many processes during underwater cutting of metals that are
up to 75 mm (3 inches) below the water surface.

Make sure to satisfy the following conditions before you do underwater cutting:
 Do not cut under water with fuel gases (H2-mix) or F5. An explosion can occur.
 Do not cut non-ferrous alloys under water or on a water table, unless you have installed the
correct safety equipment from your table manufacturer or cutting machine supplier.
 Consult with your cutting machine supplier, the table manufacturer, and other experts prior
to cutting non-ferrous alloys to implement a risk assessment and mitigation plan that
eliminates the risk of detonation by preventing hydrogen accumulation.
 Do not cut a workpiece that is more than 75 mm (3 inches) below the surface of the water.
It can negatively affect cutting system performance.
 Do not use True Hole® processes underwater. True Hole processes are not compatible with
underwater cutting.

 True Hole cutting on a water table is possible only if the surface of the
water is lowered to at least 25 mm (1 inch) below the bottom surface of
the workpiece. For information about True Hole processes, contact your
cutting machine supplier or regional Hypertherm Technical Service team.

 Make sure that the torch is perpendicular (at a 90° angle) to the workpiece.

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 Make sure that preflow is turned ON during initial height sense (IHS) for all underwater
cutting.

 Use the CNC or XPR web interface to activate the IHS. For information
about how to do this, see the instruction manual that came with your
CNC.

 Make sure that ohmic contact is disabled for all underwater cutting.

 For information about how to disable ohmic contact, see the instruction
manual that came with your CNC.

Underwater cut charts are listed by amperage. They appear with the ferrous and stainless steel cut
charts. (See the XPR Cut Charts Instruction Manual (809830).)

Underwater cut chart settings are provided for:

 Ferrous processes 80 A and above
 Non-fuel gas stainless steel processes 80 A and above

Mirror cutting
Consumable parts for mirror cutting are available for all processes. They include a special swirl ring
and shield that causes the gases to swirl in the opposite direction. The opposite-direction gas swirl
makes the “good side” of the cut on the left side, relative to torch motion.

Mirror-cutting consumables are commonly used to cut a “left-handed” version of a “right-handed”

part. Mirror-cutting consumables use the same settings as standard consumables.

 For part numbers for mirror-cutting consumables, see Sample

configurations for consumables on page 135.

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Process selection

All of the XPR cutting processes have a unique identification number (process ID). Each process ID
aligns with a specific set of pre-programmed values in the cut chart database in the plasma power
supply control board.

Processes in the database can be selected by:

 Metal type and thickness
 Cutting current
 Plasma and shield gas types
 Process category (See Process categories on page 221.)

When you select a process ID from the CNC or the Operate screen in the XPR web interface, the
cutting system automatically activates the pre-programmed settings for that process based on the
values in the database.

On-screen options let you select, monitor, and control processes directly from the CNC or the
Operate screen in the XPR web interface.

Manual selection of settings is not necessary in most cases. However, you can adjust some
pre-programmed settings with override or offset commands, within limits. (See Process ID offsets /
overrides on page 220.)

How to use process IDs to access optimal settings

When you select a process ID from the CNC or XPR web interface, you automatically get the
optimized settings that Hypertherm recommends for that process.

The pre-programmed settings come from Hypertherm’s extensive laboratory tests. Because of
differences in cutting systems, metals, and consumables, it is sometimes necessary to adjust the
settings. However, in most cases, you can expect the best results when you use the default settings
that come with a process ID.

To automatically get recommended settings, select the process ID for the process that aligns with
your needs:

1. Go to the process selection screen on the CNC or the Operate screen on the XPR web
interface.

2. Select the process ID:

a. Examine the list of available processes.
b. Identify the process that best aligns with your needs. For example, choose process ID 1153
to activate the settings for 170 A, 12 mm (0.5 inch), mild steel, O2/Air.

 Process selection must occur during the Initial checks State (2) of
operation. See States of operation for the XPR cutting system on
page 201.

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3. If none of the processes are satisfactory:

a. Select the closest available process.
b. Send the necessary offset command or commands to adjust the setting or settings as
necessary. (See Process ID offsets / overrides on page 220.)

 If you have an unusual process requirement, contact your cutting machine

supplier or regional Hypertherm Technical Service team for guidance.

Process ID offsets / overrides

You can adjust some pre-programmed settings with an offset or override command. An
offset/override command is a type of serial RS-422 or EtherCAT signal that lets you change the
default value of a setting, within an allowable limit.

For example, if a pre-programmed plasma pressure value is 65, and you want to change it to 70,
send an offset command of 5 (65 + 5 = 70). You can also use the web interface to send the desired
plasma pressure value (70). See Web interface screen information on page 180.)

 Offset settings remain active until you send a new process ID to the
cutting system, or until power is removed from the cutting system.

For descriptions of offset commands and the allowable limits for each adjustable setting, see the
CNC Communication Protocol for the XPR Cutting System (809810).

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How to use cut charts

Electronic cut charts are available on the cut chart screen of your CNC or XPR web interface.

 For information about how to find electronic cut charts, see the instruction
manual that came with your CNC.

Cut charts are available in the XPR Cut Charts Instruction Manual (809830).

 The cut charts are for reference purposes. Always use the electronic cut
charts that appear on your CNC or XPR web interface for the most
complete and accurate process-selection information.

Use the cut charts for guidance about process selection, especially if the default process ID
settings are not satisfactory for your application.

 The pre-programmed settings that come with a process ID are designed

to give the best balance between quality and productivity with
consumables that are in average condition.

The results that you want from a process can influence process selection. In some cases, cut quality
is important. In other cases, speed is important. Often, the best choice balances these
requirements.

Process core thickness (PCT)

The cut chart for every cutting process contains a range of possible thicknesses. Process engineers
work to optimize a range of thicknesses (usually in the middle of the overall range of thicknesses).
This optimized range is known as the process core thickness (PCT). Thicknesses greater and less
than the PCT can have varied results relative to cut quality, cut speed, and piercing capability.

Process categories
The XPR cut charts have up to 5 process categories. Each category has a unique process category
number (1 – 5) that correlates to the performance that you can expect when you select this
process. The process category number for the process that you choose changes the quality-speed
balance.

For best results, Hypertherm recommends that you select process category number 1 whenever
possible. Category 1 represents an optimized thickness (or PCT) for that cut process with the
overall best balance of cut quality and cut speed.

Table 29 on page 222 and Table 30 on page 223 describe the results that you can expect with
different process category numbers.

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Table 29 – Process category options and expected quality-speed results for ferrous (mild steel) processes

Process
Process category
category Category description Quality Speed
condition
number
Category 1 Process Core • Best overall balance of productivity and cut Very good Very good
Thickness (PCT) quality.
• The process is optimized for this thickness.
• Expect cut speeds that range from
2,030 mm/min – 3,810 mm/min
(80 in/min – 150 in/min).
• Dross free, in most cases.
Category 2 Thicker than PCT • Good choice when edge quality is more Very Lower
important than speed. good –
• Expect cut speeds that are slower than excellent
2,030 mm/min (80 in/min).
• Expect some low-speed dross.
Category 3 Thinner than PCT • Good choice when speed is more important Lower Higher
than edge quality.
• Expect cut speeds that are faster than
3,810 mm/min (150 in/min).
• Dross-free results in most cases.
Category 4 Edge Start Only • Edge start is required. Good Low
• Thick, low-speed dross is likely.
Category 5 Severance • This is the maximum thickness for these Very low Very low
processes.
• Edge start is required.
• Expect cut speeds that are slower than
250 mm/min (10 in/min).
• Cut-edge quality can be rough.
• Expect significant dross.

 In general, Hypertherm recommends lower amperage processes for the

best cut-edge quality, and higher amperage processes for the best
dross-free cutting. When speed is more important than quality, you can
use a higher-amperage process. For guidance about process selection,
refer to Table 28 – Process recommendations for cut quality, based on
metal thickness and type on page 214 and the XPR Cut Charts
Instruction Manual (809830).

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Table 30 – Process category options and expected quality-speed results for non-ferrous processes

Process
Process category
category Category description Quality Speed
condition
number
Category 1 Process Core • Whenever possible, select Category 1 for Very Very good
Thickness (PCT) optimal edge quality and speed, with good –
minimal dross. excellent
• The process is optimized for this thickness.
• Expect cut speeds that range from
1,016 mm/min – 3,048 mm/min
(40 in/min – 120 in/min).
• Dross free, in most cases.
Category 2 Thicker than PCT • In most situations, you can expect square Good – Lower
cut edges with sharp top edges. very good
• Darker edge color is possible with stainless
steel.
• Expect cut speeds that are slower than
1,016 mm/min (40 in/min).
• Expect some dross.
Category 3 Thinner than PCT • Select Category 3 when speed is more Lower Higher
important than edge quality.
• Expect cut speeds that are faster than
3,048 mm/min (120 in/min).
• Expect some dross.
Category 4 Edge Start Only • Edge start is required. Good Low
• Darker edge color is possible with stainless
steel.
• Thick dross is likely.
Category 5 Severance • This is the maximum thickness for these Very low Very low
processes.
• Edge start is required.
• Expect cut speeds that are slower than
250 mm/min (10 in/min).
• Cut-edge quality can be rough.
• Expect significant dross.
• Thick-metal cutting techniques can be
necessary.

 In general, Hypertherm recommends dross-free processes. Non-ferrous

dross is very difficult to remove. Depending on the gas-connect console,
the XPR300 cutting system offers the following non-ferrous cutting
processes: Air/Air, N2/N2, N2/H2O, F5/N2 and mixed-fuel gas/N2. For
guidance about process selection, refer to Table 28 – Process
recommendations for cut quality, based on metal thickness and type on
page 214 and the XPR Cut Charts Instruction Manual (809830).

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How to select consumables

The XPR cutting system uses the same consumable parts for perpendicular-position (90° angle)
and bevel-cutting processes. This eliminates the need to change consumables when you switch
from a perpendicular-position process to bevel cutting or from bevel cutting to a
perpendicular-position process. This also eliminates the need to inventory two different sets of
consumables (perpendicular and bevel).

For guidance on how to select consumables (including part numbers) by process type and metal
and how to install the consumables, see the following:
 XPR Cut Charts Instruction Manual (809830)
 How to install the consumables on page 129

Factors of cut quality

Dross
 Dross is more likely to occur on a hot workpiece. The first cut in a series often produces the
least dross. You can expect more dross with more cuts.
 Changes in shield flow can dramatically influence dross formation on non-ferrous metals.

Problem Cause* Solution

On mild steel, low-speed dross is heavier, The plasma arc can move ahead of the Increase the torch speed.
but easy to remove. torch when the torch speed is too slow.
On mild steel, high-speed dross is finer, The plasma arc can lag behind the torch Decrease the torch speed.
but difficult to remove. when the torch speed is too fast.

* Worn or damaged consumables can produce intermittent dross.

How to get the results you want

This section of the manual gives general recommendations for how to get the best results for many
processes.

 For instructions on how to troubleshoot specific performance problems,

see Diagnostics and Troubleshooting on page 253.

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General recommendations for all processes

 Always start with the default settings for the process that you want to use. In most cases,
you can expect the best results when you use the default settings that come with a
process ID.
 If you decide that it is necessary to adjust a default setting, use offset or override commands
to make incremental changes to the original value (values), within limits. (See Process ID
offsets / overrides on page 220.)
 Do not allow the torch to touch the workpiece during cutting system operation. Contact with
the workpiece can damage the torch nozzle and shield. It can also damage the surface of
the workpiece.
 Make sure that the torch is perpendicular (at a 90° angle) to the workpiece for
perpendicular-position processes.
 Unsteady drive system and rail movement can make torch motion unsteady, which can
cause irregular cut patterns. Make sure to do routine service and maintenance to the drive
system and rails.

 See the instruction manual that came with your cutting machine or table
for information on how to do this.

 Do all cutting system maintenance tasks as scheduled. (See Maintenance on page 231.)

Recommendations for perpendicular-position cutting processes

 Always start with the default settings for piercing the thickness of the metal that you want to
cut.
 Avoid firing the torch into the air.

 It is acceptable to begin a cut at the edge of the workpiece.

 Avoid lead-outs that move away from the workpiece and stretch the plasma arc.
 Do the following steps to avoid the loss of a transferred plasma arc:
 End every cut with the plasma arc still attached to the workpiece. (See Automatic
rampdown error protection on page 229.)
 Decrease the cutting speed when the end of the cut is near.
 Stop the plasma arc before the part is completely cut (allow completion of the cut during
rampdown).
 Program the path of the torch into the scrap area for rampdown.

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Recommendations for piercing processes

For the best piercing outcomes follow these recommendations:
 Always start with the default settings for piercing the thickness of metal that you want to
pierce.
 Allow a lead-in distance that is approximately the same thickness as the metal to be pierced.
For example, for 50 mm (2 inch) metal, use a 50 mm (2 inch) lead-in.
 Keep the torch above cut height until it passes over the puddle of molten metal created by
the pierce. Puddle avoidance minimizes shield damage.
 Make sure to follow transfer height and pierce height recommendations during piercing
processes. (See the XPR Cut Charts Instruction Manual (809830.)
 If it is difficult to pierce the workpiece (because of metal type or thickness):
 Increase the shield pierce flow (if this function is available with your CNC).

 For this to work, the shield pierce signal must be activated. For information
about how to activate the shield pierce signal, see the instruction manual
that came with your CNC.

 Use a “moving” or “flying” pierce technique, but only if you are an experienced operator.

 With a “moving” or “flying” pierce technique, torch motion starts

immediately after arc transfer and during piercing. Do not attempt this
technique unless you are an experienced operator. Damage to the
torch, lifter, or other system components is possible.

 Choose an argon-assist process to pierce thicker than 45 mm (1.75 inch) for mild steel.

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Hypertherm’s pierce control and assist technology can minimize timing and torch height issues that
can have a negative effect on piercing processes.

Pierce control* and assist technology

Pierce delay settings • The operator selects the time (in seconds) necessary to pierce through
the full thickness of the metal.
• The operator enters this setting from the CNC or XPR web interface.
• For recommendations on how to choose the best pierce-delay setting,
see the cut charts. See the XPR Cut Charts Instruction Manual
(809830).
Shield pierce gas signal • This signal enables the shield pierce flow function.
• This signal must be activated with the Plasma Start command. (See Wait
for start State (5) on page 204.) For information about commands and
signals, see the CNC Communication Protocol for the XPR Cutting
System (809810).
Shield pierce flow setting • The shield pierce gas setting is used during pierce operation.
• The shield pierce gas setting is active until pierce delay expires.
• The shield pierce gas setting can be offset or overridden.

* Also known as “pierce complete.”

Recommendations for marking processes

 Alternate between marking and cutting processes. Marking without intermittent cutting can
shorten the life of consumables.

Recommendations for bevel-cutting processes

 When possible, pierce with the torch perpendicular to the workpiece and then tilt the torch.
 Limit tilt rotation speed if necessary.
 Maintain 2 mm – 3 mm (0.08 inch – 0.12 inch) of clearance between the torch and the
workpiece.
 Use the effective thickness of the workpiece you are cutting to select cut speed.

 With True Bevel™ technology, Hypertherm provides you with flexible and
adjustable bevel compensation cut charts, or process parameter tables,
that automatically compensate key settings such as torch height and cut
speed.

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How to maximize the life of consumable parts

 LongLife process settings can minimize erosion on the emitter surface of the electrodes. The
following steps occur automatically with LongLife electrode protection:
 Gas and current flow automatically ramp-up at the start of a cut
 Gas and current flow automatically ramp-down at the end of a cut
 To achieve the full benefits of Hypertherm’s LongLife and Arc Response Technology, avoid
firing the torch into the air. (See Arc Response Technology on page 228.)

 It is acceptable to start a cut at the edge of the workpiece.

 Use the pierce settings in the cut chart database. (See Piercing on page 211.)
 To achieve the full benefits of Hypertherm’s automatic rampdown error protection (see
Automatic rampdown error protection on page 229), select processes that have cut speeds
of 3,560 mm/min (140 in/min) or less.
 To minimize the risk of catastrophic failure of a consumable part when cutting speeds are
greater than 3,560 mm/min (140 in/min), always take the following steps when cutting:
 Decrease the cutting speed when the end of the cut is near.
 Program torch movement into the scrap area of the workpiece.

 If possible, use a chain cut so that the path of torch movement leads
directly from one cut part into the next. This will minimize multiple plasma
arc starts and stops for multi-part cutting that damage electrodes.

Arc Response Technology

The plasma power supply is equipped with choppers that monitor the current and arc voltage load
once every 33 microseconds (30 kilohertz), letting the system detect and react nearly
instantaneously to events happening at the torch during cutting.

Arc Response Technology lets the XPR cutting system react to certain events at the torch that can
lead to decreased consumable life or possible torch damage.

Automatic torch protection

When consumables fail catastrophically (blow out) at high current settings, torch damage can
occur. This damage can occur either through arcing damage or from molten copper and/or brass
that gets into the coolant paths of the torch.

If catastrophic consumable failure occurs, the choppers can detect the event at the onset through
the electromagnetic interference (EMI) or noise signature of the current being delivered to the torch.
The choppers respond quickly to stop the cutting system and prevent damage to the torch. The
electrode will still blow out and other consumables can also be affected, but catastrophic damage
to the torch will not occur.

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Automatic rampdown error protection

LongLife technology requires a controlled stop of the current and gas pressure to preserve
electrode life for mild steel cut processes. A failure to complete the cut on the workpiece causes
most uncontrolled stops (rampdown errors). Failure to complete the cut on the workpiece causes
the arc to stretch and then snap out in a rampdown error, which can drastically decrease
consumable life. Common causes for a rampdown error are:
 Incorrect hole lead outs
 Running off the edge of the workpiece

The cutting system can detect a rampdown error before the arc snaps out and can respond quickly
to do a controlled stop of the current and gas pressure. This can significantly increase the electrode
life, especially when cut speeds are less than 3,560 mm/min (140 in/min).

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 Maintenance

Overview

Hypertherm cutting systems can operate in harsh conditions for many years. To maintain cutting
system performance, minimize operating costs, and lengthen cutting system life, it is important to
follow all maintenance procedures and schedules.

 If you have questions about how to maintain your cutting system, contact
your cutting machine supplier or regional Hypertherm Technical Service
team. You can find contact information for your regional office at
www.hypertherm.com on the “Contact us” page.

This section of the manual describes maintenance steps that you must do daily, before system
operation.
 For instructions about preventive maintenance (such as weekly, monthly, and yearly tasks)
see the XPR Preventative Maintenance Program (PMP) Instruction Manual (809490).
 For recommendations about how to diagnose and troubleshoot performance issues, see
Diagnostics and Troubleshooting on page 253.
 For printed circuit board (PCB) drawings and LED locations, see PCB information on
page 343.

 See Table 31 on page 232 for a list of preventive maintenance steps. The
PMP Instruction Manual (809490) explains how to do them.

 Usually, operators can do the daily, weekly, and bi-monthly tasks. Usually
qualified maintenance personnel are needed for monthly, every-6-month,
and yearly tasks.

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7 Maintenance

Table 31 – Inspection, preventive maintenance, and cleaning tasks

Every
Maintenance task or activity Daily Weekly Monthly 6 months
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 and coolant check X
valve

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How to do daily inspections

Always do the following at least once daily, before system operation:

 Examine the gas regulators on page 235
 Examine the shield water regulator (if applicable) on page 235
 Examine the connections and fittings on page 235
 Examine the consumable parts, torch, and torch receptacle on page 236
 Examine the torch lead on page 241

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Remove the power from the cutting system

WARNING
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before doing any installation or maintenance.
The line-disconnect switch must REMAIN in the OFF position until all
installation or maintenance steps are complete.
In the United States, use a “lock out/tag out” procedure until installation or
maintenance is complete. In other countries, follow the appropriate national
and local safety procedures.
See the Safety and Compliance Manual (80669C) for more safety
precautions.

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

WARNING
MACHINE MOTION CAN CAUSE INJURY
The end-use customer and the cutting machine supplier are responsible for providing
protection against the hazardous moving parts of this cutting system.
Read and follow the instruction manual provided by the cutting machine supplier.
See the Safety and Compliance Manual (80669C) for more safety precautions.

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Many procedures in this section require you to remove the power from the cutting system. To do this
safely, use the following procedure.

 Before you remove the power from the cutting system, it can be helpful to
move the torch to the edge of the cutting table and raise the torch lifter to
its highest point. This provides easier access to the torch and consumable
parts.

1. Set the line-disconnect switch to the OFF position.

2. If the cutting system is not hard wired, disconnect the main power from the electric power. If the
cutting system is hard wired, you cannot disconnect the main power from the electric power.

 Even if you remove the power from the cutting system, you can still get a
serious electric shock if the plasma power supply remains connected to
an electric power source. Use extreme care during service and
maintenance when the cutting system is connect to electricity.

3. Make sure that the power-indicator LED is not illuminated on the plasma power supply, gas
connect console, or torch connect console.

Examine the gas regulators

Before you start cutting system operation, examine the regulator (regulators) for the supply gases.
Make sure that the supply gas pressures and flow rates are within the recommended range. (See
Table 7 on page 36.) Adjust the regulator (regulators) if necessary.

Examine the shield water regulator (if applicable)

If your cutting system uses water as a shield fluid, examine the shield water settings before you start
cutting system operation. Make sure that the water pressure and flow rate is within the
recommended range. (See Table 9 on page 41.) The regulator on the gas connect console cannot
be adjusted. If you have a regulator on the water supply, adjust that regulator if necessary.

Examine the connections and fittings

1. Remove the power from the cutting system. See Remove the power from the cutting system on
page 234.

2. Examine all of the hoses, cables, and leads that connect system components. Look for:
 Kinks
 Cracks
 Cuts
 Frays
 Bulges or bubbles

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7 Maintenance

3. Replace any hose, cable, or lead if you find damage or excessive wear.

 See Installation on page 61 for information about how to do this.

4. 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.

 See Table 11 on page 42 for torque specifications.

b. Order a replacement hose, cable, or lead set if you find its fitting has damage or excess
wear. Replacement sets 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).

 Some hose fittings inside of the plasma power supply are replaceable.
For part numbers and specifications, see the Parts List on page 353.

5. Make sure that the hoses, cables, and leads do not twist or kink during torch movement and
system operation. Adjust them if needed.

6. Before you supply power to the cutting system, always complete all inspection and maintenance
tasks.

Examine the consumable parts, torch, and torch receptacle

Remove the torch and consumable parts
1. Remove the power from the cutting system. See Remove the power from the cutting system on
page 234.

2. Loosen the torch coupler nut to release the torch from the torch receptacle.

 The torch and consumables can be hot. Wear gloves to protect your
hands.

3. Put the torch and torch receptacle on a surface that is:

 Clean
 Dry
 Oil-free

4. Turn the shield cap counter-clockwise to release and remove the shield.

5. Turn the nozzle retaining cap counter-clockwise to release and remove the nozzle and swirl ring.

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 Maintenance 7
6. Use the consumable tool (104119) to turn the electrode counter-clockwise. Remove the
electrode.

7. Put the used consumables on a surface that is:

 Clean
 Dry
 Oil-free

Examine the consumable parts

1. Complete the following procedures before continuing:
a. Remove the power from the cutting system on page 234
b. Remove the torch and consumable parts on page 236

2. Examine the consumable parts for damage and excess wear. (See Table 32 on page 237 for a
list of inspection tasks.)

Table 32 – Inspection tasks for consumables

Inspect Look for Action if found

Shield cap Erosion or missing material Replace the shield cap.
Cracks
Melted, eroded, or missing material
Damaged O-rings
Molten material attached If there is no damage to the shield cap, you can
remove the molten material.
If there is damage, replace the shield cap.
Dry O-rings Apply a thin film of silicone lubricant (027055)
to O-rings that appear dry.
Shield A center hole that is not circular Replace the shield.
Damaged O-rings
Over-lubricated O-rings Use a clean, lint-free cloth to remove excess
lubricant.
Dry O-rings Apply a thin film of silicone lubricant (027055)
to O-rings that appear dry.

Nozzle retaining cap Damage Replace the nozzle retaining cap.

Poor cut quality after replacing
other consumables
Damaged O-rings
Dry O-rings Apply a thin film of silicone lubricant (027055)
to O-rings that appear dry.

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7 Maintenance

Inspect Look for Action if found

Nozzle Erosion or missing material Replace the nozzle.
Blocked gas holes
A center hole that is not circular
Damaged O-rings
Over-lubricated O-rings Use a clean, lint-free cloth to remove excess
silicone lubricant.
Dry O-rings Apply a thin film of silicone lubricant (027055)
to O-rings that appear dry.
Swirl ring Chips or cracks Replace the swirl ring.
Blocked gas holes
Damaged O-rings
Dirt or debris Use compressed air to remove dirt or debris.
Replace the swirl ring if you find damage.
Over-lubricated O-rings Use a clean, lint-free cloth to remove excess
silicone lubricant.
Dry O-rings Apply a thin film of silicone lubricant (027055)
to O-rings that appear dry.
Electrode Damaged O-rings Replace the electrode.
Over-lubricated O-rings Use a clean, lint-free cloth to remove excess
lubricant.
Dry O-rings Apply a thin film of silicone lubricant (027055)
to O-rings that appear dry.
Emitter wear Replace the electrode and nozzle.
For guidance about how to identify
emitter wear, refer to How to
identify emitter wear on page 243.

 If an electrode needs replacement because of emitter wear, always

replace the nozzle at the same time as the electrode.

3. If any consumable part needs replacement, see How to install the consumables on page 129
for the installation steps.

4. Clean the consumable parts that do not need replacement:

a. Use a clean, lint-free cloth to wipe the internal and external surfaces.
b. Use compressed air to remove debris from internal and external surfaces.

 The nozzle retaining cap can retain debris. Make sure to clean it
thoroughly.

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c. Use clean water if you choose to wash consumables parts in water. Use water from the
faucet to soak or rinse them. Never use the water from a cutting table to wash
consumable parts. Cutting table water has contaminants that will damage consumable
parts.
d. Apply a thin film of silicone lubricant (027055) to any O-ring that looks dry.

 The O-rings should look shiny. Too much lubricant can prevent gas flow.
Remove excess lubricant if found.

5. Before you supply power to the cutting system, install the following components:
 Consumables in the torch. (See How to install the consumables on page 129.)
 Torch in the torch receptacle. (See How to install the torch into the torch receptacle on
page 131.)

Examine the torch

1. Complete the following procedures before continuing:
a. Remove the power from the cutting system on page 234
b. Remove the torch and consumable parts on page 236

2. Examine the torch for:

 Damage or excess wear on the external
O-rings that are on the front of the torch

External O-rings (2) at front of torch

 Damage or excess wear on the internal

O-rings that are on the rear of the torch
 Dry O-rings
 Over-lubricated O-rings
 Cracks in the torch main body
 Cracks in the torch insulator

3. Replace any O-rings that have damage or excess Internal O-rings (4) at rear of torch
wear.

 Torch rebuild kits are available from Hypertherm.

(See Preventive maintenance kits on page 393 of the Parts List.)

4. If you find cracks in the torch main body or torch insulator, replace the entire torch main body.
(See How to install the torch into the torch receptacle on page 131.)

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7 Maintenance

5. Replace the torch water tube if you find pitting or bends. (See How to replace the water tube on
page 242.)

6. Clean and lubricate the torch if it does not need Figure 57 – Wipe the internal and external
replacement: surfaces of the torch
a. Use a clean, lint-free cloth to wipe the internal
and external surfaces. (See Figure 57.)
b. Use compressed air to remove debris from the
internal and external surfaces.

 A cotton swab can be used for internal

surfaces that are difficult to reach. Do not
leave cotton fibers inside of the torch.

c. Apply a thin film of silicone lubricant (027055) to any O-ring that does not need
replacement and that looks dry.

 The O-rings should look shiny. Too much lubricant can prevent gas flow.
Remove excess lubricant if found.

7. Before you supply power to the cutting system, install the following components:
 Consumables in the torch. (See How to install the consumables on page 129.)
 Torch in the torch receptacle. (See How to install the torch into the torch receptacle on
page 131.)

Examine the torch receptacle

1. Complete the following procedure before continuing:
a. Remove the power from the cutting system on page 234

2. Examine the torch receptacle. Look for:

 Cuts, nicks, damage or excess
wear on the O-ring on the torch
The O-ring on the
receptacle
torch receptacle

 The O-ring on the torch

receptacle does not require
lubricant. The O-ring is for
dust protection only.

 Cracks in the torch receptacle

body

3. Replace the O-ring if it has damage

or excess wear.

 Torch rebuild kits are available from Hypertherm. (See Preventive

maintenance kits on page 393 of the Parts List.)

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 Maintenance 7
4. If you find cracks in the torch main body or torch insulator, replace the entire torch receptacle.
(See Connect the EasyConnect torch lead assembly to the torch receptacle on page 121.)

5. Clean the torch receptacle if it does not need replacement:

a. Use a clean, lint-free cloth to wipe the internal and external surfaces.
b. Use compressed air to remove debris from the internal and external surfaces.

 A cotton swab can be used for internal surfaces that are difficult to reach.
Do not leave cotton fibers inside the torch receptacle.

6. Before you supply power to the cutting system, make sure that the following components are
installed:
 Consumables in the torch. (See How to install the consumables on page 129.)
 Torch in the torch receptacle. (See How to install the torch into the torch receptacle on
page 131.)

Examine the torch lead

Before cutting system operation, examine the torch lead. Look for damage or wear.
 Look for kinks, cracks, cuts, or excess wear. Replace the torch lead if you find these
conditions.
 Make sure that all connections between the torch and torch lead are tight. Tighten loose
connections if found, but do not make the connections too tight. Do not use tools to tighten
these connections.
 If you have a power track that supports hoses, cables, and leads, examine their position on
the track. Look for evidence that the hoses, cables, and leads are exceeding bend radius
requirements during cutting system operation. (See Bend radius requirements for hoses,
cables, and leads on page 51.)
 Make adjustments if you find evidence of kinking, bending, or twisting.

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7 Maintenance

How to replace the water tube

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any installation or maintenance.
The line-disconnect switch must REMAIN in the OFF position until all
installation or maintenance steps are complete.
See the Safety and Compliance Manual (80669C) for more safety
precautions.

1. Complete the following procedures before continuing:

a. Remove the power from the cutting system on page 234
b. Remove the torch and consumable parts on page 236

2. Remove the water tube from the torch.

3. 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. (See Preventive

maintenance kits on page 393 of the Parts List.)

b. Apply a thin film of silicone lubricant (027055) if the O-ring is dry.

 The O-ring should look shiny. Too much lubricant can restrict water tube
motion. Remove excess lubricant if found.

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 Maintenance 7
4. Install a water tube in the torch.

 When correctly installed, the water tube can seem loose. Any side-to-side
looseness will disappear after electrode installation.

5. Before you supply power to the cutting system, install the following components:
 Consumables in the torch. (See How to install the consumables on page 129.)
 Torch in the torch receptacle. (See How to install the torch into the torch receptacle on
page 131.)

How to identify emitter wear

Emitter wear can indicate when to replace the electrode. Emitter wear can be described by the
width, depth, and appearance of the electrode pit. The number of starts and the arc-on time can
have an effect on emitter wear.

Emitter wear can cause the cut quality to degrade. Your cut quality requirements will indicate when
to replace the electrode.

 If an electrode needs replacement because of emitter wear, always

replace the nozzle at the same time as the electrode.

The following guidelines for how to evaluate emitter wear apply to hafnium-emitter electrodes.

The face of a new electrode looks shiny and smooth (Figure 58).

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7 Maintenance

Figure 58 – Face of a new electrode (note hafnium emitter and electrode pit)
Electrode face

Hafnium emitter

Electrode pit

If the electrode pit diameter extends beyond the hafnium (Figure 59), replace the electrode and
nozzle.

Figure 59 – Wide electrode pit that extends beyond the hafnium

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 Maintenance 7
In general, if the electrode pit depth exceeds the guidelines below, replace the electrode and nozzle.

Electrode Replacement pit

Description
amperage depth*
< 130 A ≥ 1 mm (0.04 in) In general, for electrodes less than 130 A, replace the electrode
when the pit depth is 1 mm (0.04 in) or greater.
≥ 130 A and ≥ 1.25 mm (0.05 in) In general, for electrodes greater than or equal to 130 A and less
< 300 A than 300 A, replace the electrode when the pit depth is 1.25 mm
(0.05 in) or greater.
300 A ≥ 1.5 mm (0.06 in) In general, for 300 A electrodes, replace the electrode when the pit
depth is 1.5 mm (0.06 in) or greater.

* Based on your cut-quality requirements, it can be necessary to replace your electrode at a pit depth that is
shallower or deeper than the guidelines above.

 For information about how to measure electrode pit depth, see How to
measure the pit depth of an electrode on page 246.

If you see a non-symmetrical, rough-edged pit and rough-surfaced electrode face (Figure 60),
replace the electrode and nozzle.

Figure 60 – Non-symmetrical, rough-edged pit and rough-surfaced electrode face

 If an electrode needs replacement because of emitter wear, always

replace the nozzle at the same time as the electrode.

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7 Maintenance

How to measure the pit depth of an electrode

1. Complete the following procedures before continuing:

a. Remove the power from the cutting system on page 234
b. Remove the torch and consumable parts on page 236

2. Use an electrode pit-depth gauge to measure the pit depth on the electrode. (See Figure 61 on
page 246.)

 A pit-depth gauge (004630) is available from Hypertherm. (See Other

consumable and torch parts on page 384 of the Parts List.)

Figure 61 – Use an electrode pit-depth gauge to measure pit depth

0
90 10
0
1 4

2 3
80
20

Pit 70 30

60 40
50

Electrode
(not to scale)

Replace gauge point (004629) if damaged

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 Maintenance 7

How to do coolant maintenance

If the CNC alerts you that the coolant level is low (see Low coolant flow codes (540 – 542) on
page 312), remove the power from the cutting system and refill the coolant reservoir immediately.

WARNING
COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF
SWALLOWED.
Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if
swallowed. When you come into contact, flush skin or eyes with water. If swallowed, seek
immediate medical attention.

NOTICE
Never operate the cutting system if you get a low coolant level notice.
There is a risk of serious damage to the cutting system and to the coolant pump if you operate the
cutting system with no coolant or with low coolant.
If your coolant pump is damaged, it may need to be replaced.

NOTICE
Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that
damage the torch coolant system.

NOTICE
If you use the wrong coolant, it can cause damage to the cutting system. See Coolant requirements on
page 44.

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7 Maintenance

Estimate the total coolant volume for your cutting system

The capacity of the coolant reservoir for the XPR cutting system is 22.7 liters to 45 liters
(6 US gallons to 12 US gallons).

A cutting system with long leads requires more coolant than a cutting system with short leads.

To calculate the estimated total coolant volume necessary for your cutting system, use the
calculations below:

For total estimated volume in liters:

Length of leads (in meters) between the

26 + 0.2534 X plasma power supply and gas connect = Total estimated volume (in liters)
console for your cutting system

For total estimated volume in US gallons:

Length of leads (in feet) between the

Total estimated volume (in
6.8 + 0.0204 X plasma power supply and gas connect =
US gallons)
console for your cutting system

 See Coolant Installation on page 193.

Replace all of the coolant

The use of old coolant can decrease coolant flow, which can cause higher torch temperatures that
shorten the life of consumable parts.

Hypertherm recommends that you replace all of the coolant at least once every 6 months, as part of
routine preventive maintenance. More frequent replacement can be necessary because of
environmental conditions including but not limited to contaminants in your coolant or diagnostic
codes that indicate coolant problems.

 For instructions about preventive maintenance (such as weekly, monthly,

and yearly tasks) see the XPR Preventative Maintenance Program (PMP)
Instruction Manual (809490).

Adding new coolant to the reservoir when the coolant level is low is not the same as replacing all of
the coolant. All of the coolant must be removed in order to flush the coolant system.

The steps below describe how to remove all of the old coolant. Refill the cutting system with new
coolant only after you remove all of the old coolant.

 For coolant installation steps, see Coolant Installation on page 193.

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 Maintenance 7

Remove old coolant from the coolant system

1. Remove the power from the cutting system. See Remove the power from the cutting system on
page 234.

2. Remove the right external panel from the plasma power supply (this is the panel on the right
when you look at the front of the unit).

 M6 (10 mm hex) screws hold the panel in position.

3. Remove old coolant from the coolant reservoir:

a. Connect a 3/8-inch inner diameter tube to the outlet of the valve on the bottom of the
reservoir.
b. Put the other end of the tube into an empty container.

 Use a container that holds the approximate total coolant volume for your
cutting system.

c. Open the valve located on the bottom of the reservoir.

d. Remove the cap on the reservoir inlet to allow the coolant to flow out of the reservoir.

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7 Maintenance

4. Remove old coolant from the heat exchanger:

a. Keep the 3/8-inch inner diameter tube connected to the outlet of the valve on the bottom of
the reservoir on one end and the other end in the container.

Green Red

b. Remove the coolant return hose (red band) from the rear of the plasma power supply.
c. Attach compressed air (no more than 6.89 bar/100 psi) to the coolant return hose fitting on
the rear of the plasma power supply where the return coolant hose (red band) was
previously connected.
d. For no more than 30 seconds, use the compressed air to blow all of the coolant back into to
the reservoir and filter housing.

 System components need the coolant to lubricate rotating surfaces. If air

flows through the cutting system for longer than 30 seconds, it can
eliminate the coolant necessary for lubrication.

e. Close the valve at the bottom of the reservoir and remove the 3/8-inch inner diameter tubing
from the outlet.

 Do not store the 3/8-inch diameter tubing inside of the plasma power
supply.

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 Maintenance 7
f. Leave the coolant return hose (red band) disconnected from the rear of the plasma power
supply.
g. Put a container under the pump plug.
h. Remove the plug and coolant pump screen and
set them aside.
i. Remove the coolant supply hose (green band)
from the rear of the plasma power supply.
j. Attach compressed air (no more than
3.45 bar/50 psi) to the coolant supply hose
fitting on the rear of the plasma power supply
where the coolant supply hose (green band) was
previously connected.
k. For no more than 30 seconds, use the
compressed air to blow all of the coolant into the
container.
l. Leave the coolant supply hose (green band)
disconnected.

 System components need the coolant to

lubricate rotating surfaces. If air flows through
the cutting system for longer than 30 seconds,
it can eliminate the coolant necessary for
lubrication.

5. Clean and, if needed, replace the coolant pump

screen:
a. Clean the coolant pump screen. Rinse it with
water if you find debris.
b. Examine the coolant pump screen.
c. If you find damage on the coolant pump screen, replace it (127559).
d. Install the coolant pump screen.
e. Wipe the O-ring on the plug. Make sure that the O-ring is free of debris, cracks, and nicks.
f. Install the plug on the coolant pump housing.

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7 Maintenance

6. Remove old coolant from the filter housing and

replace the coolant filter:
a. Remove the filter housing from inside of the
plasma power supply.
b. Discard all of the coolant from inside of the filter
housing.
c. Remove and discard the coolant filter.
d. Examine the filter housing for debris. Rinse the
filter housing to remove any debris, if found.
e. Install a new coolant filter (027005).
f. Install the filter housing.

7. Remove old coolant from hoses and leads:

 Cutting system hoses and leads can hold a

large volume of coolant.

 Make sure to remove all of the old coolant from

the hoses and leads. If you do not, the new
coolant will mix with the old coolant. This will
cause the new coolant to degrade faster.

a. Put the disconnected end of the coolant return

hose into an empty container.

 Use a container that holds the approximate total

coolant volume for your cutting system.

b. Attach compressed air (no more than 6.89 bar/100 psi) to the disconnected end of the
coolant supply hose (green band).
c. For approximately 3 minutes, inject compressed air into the coolant supply hose fitting to
force coolant out of the coolant return hose (red band) into an empty container.
d. After 3 minutes, look for coolant flow out of the coolant return hose (red band). Repeat this
process until coolant flow from the coolant return hose (red band) stops.
e. When coolant flow from coolant return hose (red band) stops, connect both hoses to the
rear of the plasma power supply.

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 Diagnostics and Troubleshooting

Overview

This section of the manual includes information about how to diagnose and troubleshoot
performance issues. It includes the following:
 A list of diagnostic codes and steps to troubleshoot them.
 Drawings for PCBs.

For information about daily inspections and preventive maintenance, see the following:
 How to do daily inspections on page 233 of this manual.
 XPR Preventive Maintenance Program (PMP) Instruction Manual (809490).

 If you have questions about how to care for your cutting system, contact
your cutting machine supplier or regional Hypertherm Technical Service
team. You can find contact information for each regional office at
www.hypertherm.com on the “Contact us” page.

The cutting system software generates a diagnostic code for most conditions that decrease cutting
system performance. Some conditions have multiple diagnostic codes.

Diagnostic codes appear on the XPR web interface and can be queried by the CNC.

 For information about how to view diagnostic codes on your CNC, see the
instruction manual that came with your CNC. Codes show on the Log
screen of the XPR web interface. See Log on page 183.

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8 Diagnostics and Troubleshooting

Safety considerations
For maximum safety, follow these safety guidelines when you diagnose or troubleshoot performance
issues:
 Before you attempt to diagnose or troubleshoot a problem, make sure to read, understand,
and follow all of the safety instructions (in this manual and on the cutting system).
 Unless the instructions tell you otherwise, always remove the power from the cutting system
before you attempt to diagnose or troubleshoot a performance issue.
 Use a licensed electrician to install, modify, inspect, or repair any electrical equipment or
electrical systems.
 Use a licensed plumber to install, modify, inspect, or repair any plumbing equipment or
plumbing systems.

 For more information, refer to Qualifications of service personnel on

page 31 and the Safety and Compliance Manual (80669C).

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

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 Diagnostics and Troubleshooting 8

Initial inspection steps

Some conditions do not give a diagnostic code. For example, there are no diagnostic codes (and
the cutting system does not work) if electric power is removed from the cutting system.

Before you attempt to find or resolve a performance issue that does not result in a diagnostic code,
make sure to first look for obvious problems or damage. Always start with the following inspection
steps:
 Make sure that the cutting system is connected to electric power. (See How to connect
electric power to the cutting system on page 133.)
 Make sure that the line-disconnect switch is set to ON. (See Line-disconnect switch
requirements on page 33.)
 Examine the PCBs. (See page 257.)
 Use a licensed electrician to measure the line voltage between the terminals that are inside
of the plasma power supply. (See page 259.)

Remove the power from the cutting system

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

WARNING
ELECTRIC SHOCK CAN KILL
The line-disconnect switch must be in the OFF position before you connect the power
cord to the cutting system.
The line-disconnect switch must REMAIN in the OFF position until all installation steps are
complete.
In the United States, use a “lock out/tag out” procedure until installation is complete. In
other countries, follow the appropriate national and local safety procedures.

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8 Diagnostics and Troubleshooting

WARNING

ELECTRIC SHOCK CAN KILL

When the line-disconnect switch is in the ON position, there is line voltage throughout the
cutting system.
Voltages present throughout the cutting system can cause injury or death.
Use extreme caution if you do diagnosis or maintenance tasks when the line-disconnect
switch is in the ON position.

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

WARNING
MACHINE MOTION CAN CAUSE INJURY
The end-use customer and the cutting machine supplier are responsible for providing
protection against the hazardous moving parts of this cutting system.
Read and follow the instruction manual provided by the cutting machine supplier.
See the Safety and Compliance Manual (80669C) for more safety precautions.

Many procedures in this section require you to remove the power from the cutting system. To do this
safely, use the following procedure.

 Even if you use the remote on-off switch to turn OFF the cutting system,
electricity remains inside the cutting system. You can still get a serious
electric shock when the cutting system is connected to an electric power
source.

 Before you remove the power from the cutting system, it can be helpful to
move the torch to the edge of the cutting table and raise the torch lifter to
its highest point. This provides easier access to the torch and consumable
parts.

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 Diagnostics and Troubleshooting 8
1. Set the line-disconnect switch to the OFF position.

2. If the cutting system is not hard wired, disconnect the main power cord from the electric power.
If the cutting system is hard wired, you cannot disconnect the main power cord from the electric
power.

 Even if you remove the power from the cutting system, you can still get a
serious electric shock if the plasma power supply remains connected to
an electric power source. Use extreme care during service and
maintenance when the cutting system is connected to electricity.

3. Make sure that the power-indicator LED is not illuminated on the plasma power supply, gas
connect console, or torch connect console.

Examine the PCBs

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

1. Remove the power from the cutting system. (See Remove the power from the cutting system on
page 255.)

2. Remove the external panel or panels from the system component that has the PCB that you
want to examine. (See Table 33.)

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8 Diagnostics and Troubleshooting

Table 33 – PCB names and locations

PCB name Location See the following drawings to PCB location page
Power distribution PCB Plasma power supply See Control side – view 1 on page 360.
Control PCB Plasma power supply See Control side – view 2 on page 361.
Chopper assembly PCB Plasma power supply See Control side – view 2 on page 361.
Start-circuit assembly Plasma power supply See Control side – view 1 on page 360.
PCB
I/O PCB Plasma power supply See Control side – view 2 on page 361.
Fan power distribution Plasma power supply See Fans on page 355.
PCB
Control PCB Gas connect console See Gas connect console manifold side parts on page 365.
High-frequency, Gas connect console See Gas connect console high-voltage side parts on
high-voltage ignition page 364.
PCB
Ohmic contact PCB Torch connect console See Torch connect console manifold side – view 1 on
page 375.
Control PCB Torch connect console See Torch connect console manifold side – view 1 on
page 375.

3. Examine the PCB. Look for:

 Loose or disconnected PCB connectors
 Loose or disconnected PCBs
 Discoloration
 Damage

4. If you find a PCB that is loose, reconnect it if possible.

5. If you find a PCB that has damage or discoloration, replace it.

 See Parts List on page 353 for part numbers and reorder information.

6. If all PCBs are in good condition, measure the line voltage between the terminals inside of the
plasma power supply. (See Measure the line voltage between the terminals inside the plasma
power supply on page 259.)

7. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

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 Diagnostics and Troubleshooting 8

Measure the line voltage between the terminals inside the plasma power supply

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

WARNING

ELECTRIC SHOCK CAN KILL

When the line-disconnect switch is in the ON position, there is line voltage at the
contactor and the power distribution PCB.
Voltages present at the terminal block and contactors can cause injury or death.
Use extreme caution when you measure the primary power in these areas.

It is necessary for the cutting system to have electric power to measure line voltage. Use extreme
caution if you do diagnosis or maintenance tasks when the plasma power supply remains plugged in
and the panels on the plasma power supply are removed.

1. Measure the line voltage between the terminals (Figure 62 on page 260) in the following order:
 U to V
 U to W
 V to W

 Verify each line to ground.

2. Determine if the voltage between any 2 of the 3 lines is equal to the supply voltage.

3. If any 1 line is equal to or 10% greater than the other 2 lines, examine with the incoming electric
supply lines.

 If the incoming electric supply lines are good, contact a licensed

electrician or the electric company that supplies electricity for more
information.

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8 Diagnostics and Troubleshooting

4. If the voltage between any 2 of the 3 lines is less than the supply voltage:
a. Remove the power from the cutting system. (See Remove the power from the cutting
system on page 255.)
b. Examine the power cord for damage.
c. Examine the fuses at the line-disconnect switch. Look for continuity.
d. Repair or replace any damaged or defective parts if found.

5. Repeat these steps until the line voltage between any 2 of the 3 lines is equal to the supply
voltage.

Figure 62

U
V
W
GND

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 Diagnostics and Troubleshooting 8

Diagnostic codes

How to diagnose and troubleshoot diagnostic codes

Use the Corrective action column of Table 35 on page 263 to respond to the diagnostic codes that
show on the CNC or XPR web interface.

Diagnostic codes can include the following abbreviations:

GCC – Gas connect console

CAN – Controller area network

TCC – Torch connect console

t/o – Time out

HF – High frequency

IGBT – Insulated-gate bipolar transistor

Ch1 – Chopper

Ch2 – Chopper 2

DC – Direct current, current

Ind – Inductor

MagFan – Magnetics fan

HxFan – Heat exchanger fan

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8 Diagnostics and Troubleshooting

Table 34 – Diagnostic codes in the web interface

Type Description
Information These codes contain information about the current conditions. In many cases, operator action is
not necessary for Information codes. If action is necessary, the steps are usually simple.
Alert These codes describe conditions that can reduce productivity or quality.
Resolve an Alert code as soon as possible.
Error These codes describe conditions that usually reduce productivity or quality, or cause damage to
cutting system components.
Resolve an Error code as soon as possible.
Failure These codes describe conditions where you cannot start the arc until the condition is resolved.
Failure mode protects the cutting system and system components from permanent damage.

 Certain codes can occur if the cutting system has old firmware. Make sure
that you have the most recent XPR firmware. Log into the Xnet at
www.hypertherm.com to download it.

 If you cannot find or resolve the problem with the corrective actions in
Table 35, contact your cutting machine supplier or regional Hypertherm
Technical Service team listed in the front of this manual.

262 809480 Instruction Manual XPR300

 Table 35 – Diagnostic codes

XPR300
Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
500 GCC->Main CAN The gas connect console See CAN codes (500 – 503, 510 – 513 for gas Shut down Remote on-off
Failure t/o (Core, VWI, or OptiMix) connect console, 504 – 505, 514 – 515 for CAN
cannot receive cable and jumper block, 507 – 508 for CAN
communications (at least network and bus, 600 – 602 for no CAN

Instruction Manual
once-per-second) from the communication) on page 304.
main control though the CAN.
501 Mix->Main CAN t/o The gas connect console Shut down Remote on-off

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Failure (Core, VWI, or OptiMix)
cannot receive
communications (at least
once-per-second) from the
main control through the
CAN.
503 TCC->Main CAN The torch connect console Shut down Remote on-off
Failure t/o (Core, VWI, or OptiMix)
cannot receive
communications (at least
once-per-second) from the
main control through the
CAN.
504 Ch1->Main CAN Chopper 1 cannot receive Shut down Remote on-off
Failure t/o communications (at least
once-per-second) from the
main control through the
CAN.
505 Ch2->Main CAN Chopper 2 cannot receive See CAN codes (500 – 503, 510 – 513 for gas Shut down Remote on-off
Failure t/o communications (at least connect console, 504 – 505, 514 – 515 for CAN
once-per-second) from the cable and jumper block, 507 – 508 for CAN
main control trough the CAN. network and bus, 600 – 602 for no CAN
communication) on page 304.
Diagnostics and Troubleshooting
8

263
 Diagnostic code

264
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
507 Main no CAN There is a problem with the See CAN codes (500 – 503, 510 – 513 for gas None Remote on-off
Failure CAN network when power is connect console, 504 – 505, 514 – 515 for CAN
supplied to the cutting cable and jumper block, 507 – 508 for CAN
system. network and bus, 600 – 602 for no CAN
communication) on page 304.
508 CAN Busy The CAN bus is overloaded None Remote on-off
Error (for 10 milliseconds or more).
Diagnostics and Troubleshooting

510 Main->GCC CAN The main control cannot Ramp down Remote on-off
Failure t/o receive communications (at
least once-per-second) from
the gas connect console
(Core, VWI, or OptiMix)
through the CAN.
511 Main->Mix CAN t/o The main control cannot Ramp down Remote on-off
Failure receive communications (at
least once-per-second) from
the gas connect console’s
mix module through the CAN.
513 Main->TCC CAN The main control cannot Ramp down Remote on-off
Failure t/o receive communications (at
least once-per-second) from
the torch connect console

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(Core, VWI, or OptiMix)
through the CAN.

514 Main->Ch1 CAN The main control cannot None Remote on-off

Instruction Manual
Failure t/o receive communications (at
least once-per-second) from
Chopper 1 through the CAN.

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
515 Main->Ch2 CAN The main control cannot See CAN codes (500 – 503, 510 – 513 for gas None Remote on-off
Failure t/o receive communications (at connect console, 504 – 505, 514 – 515 for CAN
least once-per-second) from cable and jumper block, 507 – 508 for CAN
Chopper 2 through the CAN. network and bus, 600 – 602 for no CAN
communication) on page 304.

Instruction Manual
520 Ignite t/o (no pilot The sensor in Chopper 1 did 1. Make sure that the transfer height is correct and End of cycle Start or set
Alert arc) not measure current during that the torch is not in contact with the process; remote
the 600 millisecond ignite workpiece. on-off
period. 2. Examine the consumables. Replace the

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No current path completes consumables that have damage or excess wear.
between the nozzle and 3. Make sure that both spark arrestors (also
electrode for at least known as spark ignitors) illuminate brightly.
600 milliseconds.
4. Inspect the main contactor:
5. Look for black or rough surfaces that are
difficult to remove.
6. Make sure that the contactor closes
immediately after the Start command is applied.
7. If the contactor is bad, replace it. If the
contactor is good, examine the pilot arc relay.
8. Examine the pilot arc relay. Make sure that it
closes.
9. If the pilot arc relay is good, examine the wiring.
Make sure that the coil receives 120 VAC.
10. Inspect the Start circuit/Pilot PCB. If the Start
circuit/Pilot PCB is bad, replace it.
11. Do a torch lead test. (See How to test
continuity between the nozzle and workpiece
on page 335.)
Diagnostics and Troubleshooting
8

265
 Diagnostic code

266
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
521 Pilot arc t/o (no arc No current detected on the End of cycle Start or set
Alert transfer) work lead for 500 1. Make sure that the transfer height is correct. process; remote
milliseconds after the pilot arc on-off
current is established. 2. Examine the consumables. Replace the
consumables that have damage or excess wear.
The sensor in the work lead is
unable to measure current 3. Do a torch lead test. (See How to test
greater than the transfer continuity between the nozzle and workpiece
reference value for a minimum on page 335.)
Diagnostics and Troubleshooting

of 3 milliseconds.
522 Preflow t/o The cutting system cannot End of cycle Start or set
Alert complete the preflow routine process; remote
within 30 seconds. on-off
523 Preflow purge t/o The preflow purge cannnot None Set process;
Error get to the setpoint within 1. Review the diagnostic code history for previous remote on-off
45 seconds. gas-related codes. Previous codes can indicate
where to look for flow or pressure problems.
524 Cutflow purge t/o The preflow purge cannnot None Set process;
get to the setpoint within 2. Examine the consumables, valves, and inlet remote on-off
Error hoses. Make sure that they are correct. Replace
45 seconds.
them if you find damage or excess wear.
525 Inert gas purge t/o The XPR cutting system is None Set process;
Error unable to complete the N2 remote on-off
purge within 45 seconds. The
process did not get selected.

809480
Instruction Manual
XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
530 Low psi-Line A • The Line A pressure (P5) 1. Review the diagnostic code history for previous Ramp down Set process;
Alert is less than 75% of the pressure-related codes. Previous codes can remote on-off
setpoint for 200 indicate where to look for flow or pressure
milliseconds, for any problems.
process; or 2. Make sure that the inlet gas pressure for Line A

Instruction Manual
• P5 is less than 75% of (P2) or Line B (P1) are in the correct range.
the P21 sensor reading 3. If the measurement is too high or too low, use
for 4 seconds, for a the regulators to adjust the pressure for the
mixed-fuel gas process; Line A/Line B gas or F5 gas to the correct

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or range.
• P5 is less than 75% of 4. Examine the consumables:
the P7 setpoint for 4
• Make sure that the correct consumables are
seconds, for a F5 installed.
process. • Make sure that there is no damage or excess
wear.
5. Replace incorrect consumables or
consumables that have damage or excess wear.
6. Use the gas volume monitors located near the
pressure transducers to look for gas leaks.
Diagnostics and Troubleshooting
8

267
 Diagnostic code

268
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
531 Low psi-Line B For a minimum of 1. Review the diagnostic code history for previous Ramp down Set process;
Alert 200 milliseconds, Line B pressure-related codes. Previous codes can remote on-off
pressure is less than 75% of indicate where to look for flow or pressure
setpoint. problems.
2. Make sure that the inlet gas pressure for Line A
(P2) or Line B (P1) are in the correct range.
3. If the measurement is too high or too low, use
the regulators to adjust the pressure for the
Diagnostics and Troubleshooting

Line A/Line B gas or F5 gas to the correct

range.
4. Examine the consumables:
• Make sure that the correct consumables are
installed.
• Make sure that there is no damage or excess
wear.
5. Replace incorrect consumables or
consumables that have damage or excess wear.
6. Use the gas volume monitors located near the
pressure transducers to look for gas leaks.
532 Low psi-H2O For a minimum of See Low shield water pressure code (532) on Ramp down Set process;
Alert 200 milliseconds, the shield page 310. remote on-off
water pressure (P9) is less
than 50% of the setpoint
(2.7 bar/39 psi) and the

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setpoint is greater than 0.

Instruction Manual
XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
533 Low psi-F5 For a minimum of 200 1. Review the diagnostic code history for previous Ramp down Set process;
Alert milliseconds, the F5 pressure pressure-related codes. Previous codes can remote on-off
sensor (P7) is less than 75% indicate where to look for flow or pressure
of setpoint. problems.
2. Make sure that the inlet gas pressure for Line A

Instruction Manual
(P2) or Line B (P1) are in the correct range.
3. If the measurement is too high or too low, use
the regulators to adjust the pressure for the
Line A/Line B gas or F5 gas to the correct

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range.
4. Examine the consumables:
• Make sure that the correct consumables are
installed.
• Make sure that there is no damage or excess
wear.
5. Replace incorrect consumables or
consumables that have damage or excess wear.
6. Use the gas volume monitors located near the
pressure transducers to look for gas leaks.
534 Low psi-Shield For a minimum of See Low shield gas pressure code (534) on Ramp down Set process;
Alert 600 milliseconds, the shield page 311. remote on-off
gas pressure is less than
75% of the setpoint, and the
setpoint is more than 0.
540 Low flow For a minimum of 40 seconds See Low coolant flow codes (540 – 542) on Shut down Remote on-off
Error 1-Coolant after the Plasma Start switch page 312.
is turned ON, the coolant
flow rate is less than 1.9
L/min (0.5 gal/min).
Diagnostics and Troubleshooting
8

269
 Diagnostic code

270
8
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
541 Low flow For a minimum of 10 seconds See Low coolant flow codes (540 – 542) on Shut down Remote on-off
Error 2-Coolant after the coolant flow rate page 312.
gets to 1.9 L/min (0.5
gal/min), the flow rate stays
less than 3.03 L/min (0.8
gal/min).
542 Low flow-Coolant The coolant flow is less than Shut down Remote on-off
Failure 3.79 L/min (1 gal/min) for a
Diagnostics and Troubleshooting

minimum of 1 second.

543 High flow The coolant flow is more than See High coolant flow codes (543 – 544) on Shut down Set process;
Error 1-Coolant 3.03 L/min (0.8 gal/min) for a page 314. remote on-off
minimum of 5 seconds after
the coolant pump stops.
544 High flow-Coolant The coolant flow rate is more Shut down Remote on-off
Failure than 11.36 L/min
(3.0 gal/min), for a minimum
of 1 second. This error can
also occur when air is in the
line or when there is a torch
blow out.

809480
Instruction Manual
XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
550 No plasma arc For a minimum of 1. Examine the consumables. Replace End of cycle Start or set
Alert 10 milliseconds during a consumables that have damage or excess wear. process; remote
Steady State, the total 2. Do a test for gas leaks. Replace leaking on-off
electric current decreases components if found.
50% below the electric
3. Examine contactors. Replace damaged
current setpoint, and the

Instruction Manual
components if found.
setpoint is more than the
setpoint for that process 4. Look for DC bus errors.
(setpoints vary by process 5. Exchange the choppers. See if the code follows
type). the change.

809480
552 DC below The Chopper 1 current • If yes, it confirms the bad chopper. Replace it. End of cycle Set process;
limit-Ch1 decreases below 50% of the • If no, go to step 6. remote on-off
Alert
setpoint for 50 milliseconds 6. Examine the following components:
and the setpoint is more than • Choppers
10 A. • Inductors
7. Replace damaged choppers or inductors if
found.
8. Make sure that the arc remains on workpiece
during XPR cutting system operation.
9. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.
Diagnostics and Troubleshooting
8

271
 Diagnostic code

272
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
553 DC below The Chopper 2 current 1. Examine the consumables. Replace End of cycle Set process;
Alert limit-Ch2 decreases below 50% of the consumables that have damage or excess wear. remote on-off
setpoint for 50 milliseconds 2. Do a test for gas leaks. Replace leaking
and the setpoint is more than components if found.
10 A.
3. Examine contactors. Replace damaged
components if found.
4. Look for DC bus errors.
Diagnostics and Troubleshooting

5. Exchange the choppers. See if the code follows

the change.
• If yes, it confirms the bad chopper. Replace it.
• If no, go to step 6.
6. Examine the following components:
• Choppers
• Inductors
7. Replace damaged choppers or inductors if
found.
8. Make sure that the arc remains on workpiece
during XPR cutting system operation.
9. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.

809480
Instruction Manual
XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
555 DC exceeds For at least 10 milliseconds, 1. Examine the consumables. Replace Shut down Remote on-off
Failure limit-Ch1 the electric current for consumables that have damage or excess wear.
Chopper 1 is more than 2. Do a test for gas leaks. Replace leaking
170 A. components if found.
3. Examine contactors. Replace damaged

Instruction Manual
components if found.
4. Look for DC bus errors.
5. Exchange the choppers. See if the code follows
the change.

809480
• If yes, it confirms the bad chopper. Replace it.
• If no, go to step 6.
6. Examine the following components:
• Choppers
• Inductors
7. Replace damaged choppers or inductors if
found.
8. Make sure that the arc remains on workpiece
during XPR cutting system operation.
9. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.
Diagnostics and Troubleshooting
8

273
 Diagnostic code

274
8
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
556 DC exceeds For a minimum of 1. Examine the consumables. Replace Shut down Remote on-off
Failure limit-Ch2 10 milliseconds, the electric consumables that have damage or excess wear.
current for Chopper 2 is more 2. Do a test for gas leaks. Replace leaking
than 170 A. components if found.
3. Examine contactors. Replace damaged
components if found.
4. Look for DC bus errors.
Diagnostics and Troubleshooting

5. Exchange the choppers. See if the code follows

the change.
• If yes, it confirms the bad chopper. Replace it.
• If no, go to step 6.
6. Examine the following components:
• Choppers
• Inductors
7. Replace damaged choppers or inductors if
found.
8. Make sure that the arc remains on workpiece
during XPR cutting system operation.
9. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.
560 Over temp-Ch1 The insulated-gate bipolar See Over temp diagnostic codes – Choppers Ramp down –
Error transistor (IGBT) temperature (560 – 561) and Coolant (587) on page 315.

809480
sensor for Chopper 1
measured more than 75°C
(167°F).
561 Over temp-Ch2 The insulated-gate bipolar See Over temp diagnostic codes – Choppers Ramp down –
Error transistor (IGBT) temperature (560 – 561) and Coolant (587) on page 315.
sensor for Chopper 2
measured more than 75°C

Instruction Manual
(167°F).

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
570 Start on Powerup The Plasma Start switch is See Start switch diagnostic codes (570 – 577) None Start or set
Alert turned ON before the cutting on page 318. process; remote
systems goes into Powerup on-off
State.

571 Start on wait-start The plasma start switch is None Start or set

Instruction Manual
Alert turned ON before the cutting process; remote
system enters a on-off
Wait-for-Start State.

809480
574 Start removed The plasma start switch goes See Start switch diagnostic codes (570 – 577) End of cycle Start or set
Info preflow OFF during Preflow State. on page 318. process; remote
on-off
575 Start removed The Plasma Start switch goes End of cycle Start or set
Info ignite OFF during Ignite State. process; remote
on-off
576 Start removed pilot The Plasma Start switch goes End of cycle Start or set
Info OFF during Pilot arc state. process; remote
on-off
577 Start removed The Plasma Start switch goes End of cycle Start or set
Info rampup OFF during a Ramp-Up process; remote
State. on-off
Diagnostics and Troubleshooting
8

275
 Diagnostic code

276
8
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
580 Over temp-Ind1 The temperature for See Over temp diagnostic codes – Inductors Ramp down —
Error Inductor 1(1A)or 2 (1B) is (580 – 583), Transformers (586) on page 320.
more than 160°C (320°F).
When conditions are normal,
581 Over temp-Ind2 Ramp down —
it takes approximately 10
Error minutes for the XPR cutting
system to cool.
Over-temp error codes can
Diagnostics and Troubleshooting

occur when cooling takes

more than 10 minutes.
A high ambient temperature
can have an effect on cooling
time.
582 Over temp-Ind3 The temperature for See Over temp diagnostic codes – Inductors Ramp down —
Error Inductor 3 (2A) or 4 (2B) is (580 – 583), Transformers (586) on page 320.
more than 160°C (320°F).
When conditions are normal,
583 Over temp-Ind4 Ramp down —
it takes approximately 10
Error minutes for the XPR cutting
system to cool.
Over-temp error codes can
occur when cooling takes
more than 10 minutes.
A high ambient temperature

809480
can have an effect on cooling
time.
586 Over temp-Xfmr The temperature for the See Over temp diagnostic codes – Inductors Ramp down —
Error transformer is more than (580 – 583), Transformers (586) on page 320.
160°C (320°F) for a minimum
of 5 seconds.

Instruction Manual
587 Over temp-Coolant The coolant temperature is See Over temp diagnostic codes – Choppers Ramp down —
Error more than 85°C (185°F). (560 – 561) and Coolant (587) on page 315.

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
588 Fan timeout Fan timeout error codes can Shut down —
Failure occur when cooling takes
1. Identify the over-temp diagnostic codes that
more than 1 hour.
appear on the XPR web interface.
A high ambient temperature
2. Follow the troubleshooting steps for the codes.
can have an effect on cooling

Instruction Manual
time.
600 No TCC found The torch connect console See CAN codes (500 – 503, 510 – 513 for gas Shut down Remote on-off
Error does not identify itself to the connect console, 504 – 505, 514 – 515 for CAN
main control PCB through cable and jumper block, 507 – 508 for CAN

809480
the CAN for a minimum of network and bus, 600 – 602 for no CAN
30 seconds after power is communication) on page 304.
supplied to the cutting
system.
601 No chopper found Chopper 1 does not identify 1. Confirm that the chopper ID connector is Shut down Remote on-off
Error itself to the main control PCB connected to J8.
through the CAN for a 2. Connect the connectors if necessary.
minimum of 30 seconds after
3. If connected, see CAN codes (500 – 503,
power is supplied to the
510 – 513 for gas connect console, 504 –
cutting system.
505, 514 – 515 for CAN cable and jumper
block, 507 – 508 for CAN network and bus,
600 – 602 for no CAN communication) on
page 304.
602 No GCC found The gas connect console See CAN codes (500 – 503, 510 – 513 for gas Shut down Remote on-off
Error (Core, VWI, or, OptiMix) does connect console, 504 – 505, 514 – 515 for CAN
not identify itself to the main cable and jumper block, 507 – 508 for CAN
control PCB for a minimum of network and bus, 600 – 602 for no CAN
30 seconds after power is communication) on page 304.
supplied to the cutting
system.
Diagnostics and Troubleshooting
8

277
 Diagnostic code

278
8
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
604 No Chopper 2 The inductor thermocouples 1. Make sure that the connector (J8) on None Start or set
Alert found for Chopper 2 were detected, Chopper 2 is fully engaged. process; remote
but Chopper 2 was not 2. Make sure that the connector (J2) on on-off
detected. Chopper 2 is fully engaged.
3. If connected, see CAN codes (500 – 503,
510 – 513 for gas connect console, 504 –
505, 514 – 515 for CAN cable and jumper
block, 507 – 508 for CAN network and bus,
Diagnostics and Troubleshooting

600 – 602 for no CAN communication) on

page 304.
610 Ch1 Torch Protect A catastrophic failure of a Ramp down Remote on-off
Failure ChA consumable part is found on
the Channel A Chopper 1 1. Inspect the consumable parts for damage and
current signature. excess wear.
611 Ch1 Torch Protect A catastrophic failure of a 2. If any consumable part needs replacement, see Ramp down Remote on-off
Failure ChB consumable part is found on How to install the consumables on page 129.
the Channel B Chopper 1
current signature.
612 Ch2 Torch Protect A catastrophic failure of a Ramp down Remote on-off
Failure ChA consumable part is found on
the Channel A Chopper 2 1. Inspect the consumable parts for damage and
current signature. excess wear.
613 Ch2 Torch Protect A catastrophic failure of a 2. If any consumable part needs replacement, see Ramp down Remote on-off

809480
Failure ChB consumable part is found on How to install the consumables on page 129,
the Channel B Chopper 2
current signature.

Instruction Manual
XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
620 Rampdown error The chopper duty cycle Make sure that you are following correct cutting Ramp down Start or set
Alert (arc stretch) exceeds the programmed techniques: process; remote
detected limit. A rampdown error can • Use a workpiece that is large enough for the on-off
be the cause. selected parts or nesting program.
During a ramp-down error, • Use the correct parts or nesting program.
Rampdown errors can occur when crossing

Instruction Manual
the arc distance between the
large kerfs or cutting at incorrect heights.
torch and workpiece
increases rapidly. • End every cut with the plasma arc still attached
to the workpiece.
Rampdown errors can • Decrease the cutting speed when the end of

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decrease consumable life. the cut is near.
The XPR cutting system can • Stop the plasma arc before the part is
detect and react to completely cut (allow completion of the cut
rampdown errors. This helps during rampdown).
extend the life of consumable • Program the path of the torch into the scrap
area for rampdown.
parts. (See Automatic
rampdown error protection on
page 229.)
621 Over voltage-DC The DC bus voltage is more 1. Confirm the input-line voltage is within+/-14% Shut down Remote on-off
Failure bus than 414 V. of nominal (see Input power requirements on
page 32).
2. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.
Diagnostics and Troubleshooting
8

279
 Diagnostic code

280
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
622 Under voltage DC The DC bus voltage is less 1. Confirm the input-line voltage is within+/-14% Shut down Remote on-off
Failure bus than 280 V. of nominal (see Input power requirements on
page 32).
2. Remove the power from the cutting system.
3. Remove the cover from the contactor.
4. Inspect the contacts for excess wear. Replace
the contactor, if excess wear is found.
Diagnostics and Troubleshooting

5. Inspect the following contactor components for

loose connections:
• Contactor
• Input to chopper
• Power cord
6. Tighten loose connections if found.
7. Examine the connections from the control PCB
on J6. Look for loose or bad connections on
pins 5 and 6. Tighten loose connections or
replace bad connections.
8. Make sure that LED D1 on the power
distribution board (141425) is illuminated.
9. If not illuminated, examine the power
distribution board. Look for:
• 120 VAC at the input (J1 pins 5 – 6)
• Continuity on fuse FH2 (with power OFF)

809480
• 120 VAC at the output (J5 pins 7 – 8 and pins
9 – 10)
10. If 120 VAC is not present on the J5 contactor
output pins, inspect J4 and K1 Relay
connections for damage.
11. If K1 is bad, replace either the power
distribution board (141425) or the K1 relay

Instruction Manual
(003257).
12. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
623 Ch1 DC at Idle Chopper 1 is in idle state and 1. Look for 24 VDC from the power sources (J2 None Remote on-off
Error the chopper current is more pins 1 – 3).
than 10 A. 2. If you find 24 VDC from the power sources, the
chopper is bad.
3. Replace the chopper if necessary.

Instruction Manual
624 Ch2 DC at Idle Chopper 2 is in idle state and 1. Look for 24 VDC from the power sources (J2 None Remote on-off
Error the chopper current is more pins 1 – 3).
than 10 A. 2. If you find 24 VDC from the power sources, the

809480
chopper is bad.
3. Replace the chopper if necessary.
626 No DC output-Ch1 Chopper 1 does not make 1. Inspect the consumable parts for damage and End of cycle Remote on-off
Error current for a minimum of excess wear.
250 milliseconds after 2. If any consumable part needs replacement, see
Arc-On State starts. How to install the consumables on page 129.
Pilot arc was established but 3. If the code continues, contact your cutting
then lost prior to transfer. machine supplier or regional Hypertherm
Technical Service team.
627 No DC output-Ch2 No current produced within 1. Inspect the consumable parts for damage and End of cycle Remote on-off
Error 250 milliseconds after excess wear.
Arc-On State starts 2. If any consumable part needs replacement, see
How to install the consumables on page 129.
3. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.
631 DC at wait-start The current in the work lead See Current sensor diagnostic codes (631) on Shut down Remote on-off
Failure is more than 5 A while the page 323.
XPR cutting system is in the
Wait-for-Start State.
Diagnostics and Troubleshooting
8

281
 Diagnostic code

282
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
640 No error For your information: There No operator action necessary. None —
Info are no active faults.

642 System powered For your information: Power is None Start or set
Info supplied to the XPR cutting process; remote
system and the on-off
customer-supplied, remote
on-off switch is in the ON
position (enabled).
Diagnostics and Troubleshooting

643 No process loaded For your information: Power is It is necessary to select a process to end the Initial None Start or set
Info supplied to the XPR cutting checks (2) State of operation and start the Gas process; remote
system and no process is purge State (there is no limit for how long the on-off
selected. system waits for input). (See Sequence of operation
on page 201.)
645 System is off For your information: Power is No operator action necessary. XPR cutting system None Start or set
Info supplied to the cutting operation continues when the remote on-off switch process; remote
system and the is set to the ON position. (See Sequence of on-off
customer-supplied, remote operation on page 201.)
on-off switch is in the OFF
position (disabled).
646 System turned off For your information: Power is Shut down Start or set
Info removed from the XPR process; remote
cutting system. on-off
647 Process selected Shows the operator-selected No operator action necessary. None Start or set

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Info process. process; remote
on-off
654 CH1ArcOnTimeout During Ignite State, Chopper 1. Remove the power from the cutting system. End of cycle Remote on-off
Alert 1 does not enter Arc-On 2. Restore electrical power to the cutting system.
State for at least 100
3. Send a process command to the cutting
milliseconds.
system.

Instruction Manual
4. If the code continues, contact your cutting
system supplier or regional Hypertherm
Technical Service team.

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
655 Current (DC) During Preflow State, a 1. Inspect the consumable parts for damage and Shut down Start or set
Alert preflow chopper finds current. excess wear. process; remote
2. If any consumable part needs replacement, see on-off
How to install the consumables on page 129.
3. Examine the torch lead. Look for a short or open

Instruction Manual
line condition.
660 Thermistor The main control finds a Use a digital multimeter to measure the resistance Shut down Remote on-off
Error Fault-Ind 1 shorted temperature sensor from the thermistor. (See How to measure
in Inductor 1A. resistance from thermistors on page 336.)

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661 Thermistor The main control finds a Shut down Remote on-off
Error Fault-Ind 2 shorted temperature sensor
in Inductor 1B.
662 Thermistor The main control finds a Use a digital multimeter to measure the resistance Shut down Remote on-off
Error Fault-Ind 3 shorted temperature sensor from the thermistor. (See How to measure
in Inductor 2A. resistance from thermistors on page 336.)
663 Thermistor The main controls finds a Shut down Remote on-off
Error Fault-Ind 4 shorted temperature sensor
in Inductor 2B.
666 Thermistor The main control finds a Use a digital multimeter to measure the resistance Shut down Remote on-off
Error Fault-Xfmr shorted temperature sensor from the thermistor. (See How to measure
in the transformer. resistance from thermistors on page 336.)
667 Thermistor Chopper 1 finds a shorted Ramp down Remote on-off
Error Fault-Ch1 temperature sensor near the
insulated-gate bipolar
transistor (IGBT).

668 Thermistor Chopper 2 finds a shorted Use a digital multimeter to measure the resistance Ramp down Remote on-off
Error Fault-Ch2 temperature sensor near the from the thermistor. (See How to measure
IGBT. resistance from thermistors on page 336.)
Diagnostics and Troubleshooting
8

283
 Diagnostic code
8

284
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
670 Thermistor The main control finds a Use a digital multimeter to measure the resistance Shut down Remote on-off
Error Fault-Coolant shorted coolant temperature from the thermistor. (See How to measure
sensor. resistance from thermistors on page 336.)
671 No Thermistor-Ind The main control finds an Shut down Remote on-off
Error 1 open circuit in Inductor 1
(1A).
672 No Thermistor-Ind The main control finds an Shut down Remote on-off
Diagnostics and Troubleshooting

Error 2 open circuit in Inductor 2

(1B).
673 No Thermistor-Ind The main control finds an Use a digital multimeter to measure the resistance Shut down Remote on-off
Error 3 open circuit in Inductor 3 from the thermistor. (See How to measure
(2A). resistance from thermistors on page 336.)
674 No Thermistor-Ind The main control finds an Use a digital multimeter to measure the resistance Shut down Remote on-off
Error 4 open circuit in Inductor 4 from the thermistor. (See How to measure
(2B). resistance from thermistors on page 336.)
677 No Thermistor-Xfmr The main control finds an Use a digital multimeter to measure the resistance Shut down Remote on-off
Error open circuit in the from the thermistor. (See How to measure
transformer. resistance from thermistors on page 336.)
678 No Thermistor-Ch1 The XPR cutting system 1. Make sure that the 2 wires for J9 are fully Ramp down Remote on-off
Error cannot detect the engaged.
temperature sensor for 2. Use a digital multimeter to measure the
Chopper 1. resistance from the thermistor. (See How to

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measure resistance from thermistors on
page 336.)
679 No Thermistor-Ch2 The XPR cutting system 1. Make sure that the 2 wires for J9 are fully Ramp down Remote on-off
Error cannot detect the engaged.
temperature sensor for 2. Use a digital multimeter to measure the
Chopper 2. resistance from the thermistor. (See How to
measure resistance from thermistors on

Instruction Manual
page 336.)

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
681 No Thermistor- The main control detects an Use a digital multimeter to measure the resistance Shut down Remote on-off
Error Coolant open circuit in the coolant from the thermistor. (See How to measure
sensor. resistance from thermistors on page 338.)

691 Node reset The main control receives a 1. Inspect the grounding for the cutting system. Shut down Set process;
Error “console reset” message High frequency electromagnetic interference remote on-off

Instruction Manual
after power is supplied to the (also known as noise) can reset the CAN node.
XPR cutting system. 2. Make sure that the green (power-indicator) LED
on the gas connect console and torch connect
console is illuminated.

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3. If the LEDs are not illuminated, examine the
power distribution board (141425). Look for:
• Loose and poorly-connected connectors and
CAN cables.
• Evidence of 120 V (D1 illuminated).
4. If D1 is illuminated, examine the plasma power
supply control PCB (141322). Make sure that
the remote on-off switch is in the ON position
(enabled) (D89 illuminated). Re-set the switch if
necessary.
5. Contact your cutting machine supplier or
regional Hypertherm Technical Service team.
Make sure that you have the Record ID
associated with the error.
Diagnostics and Troubleshooting
8

285
 Diagnostic code

286
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
695 Low Inlet H2-Mix The hydrogen (H2) inlet See Low inlet pressure for H2, Ar, N2, and H2O None Set process;
Alert pressure (P10) for the mixing diagnostic codes (695 – 697, 700, 701) on remote on-off
module in the gas connect page 324.
(OptiMix only)
console (only for OptiMix) is
less than 8.3 bar ± 0.4
(120 psi ± 5).
696 Low Inlet Ar-Mix The argon (Ar) inlet pressure
Alert (P11) for the mixing module
Diagnostics and Troubleshooting

in the gas connect console

(OptiMix only)
(only for OptiMix) is less than
8.3 bar ± 0.4 (120 psi ± 5).
697 Low Inlet N2-Mix The nitrogen (N2) inlet None Set process;
Alert pressure (P12) for the mixing remote on-off
module in the gas connect
(OptiMix only)
console (only for OptiMix) is
less than 8.3 bar ± 0.4
(120 psi ± 5).
699 Mix Fault The main control finds a No operator action necessary. Ramp down Set process;
Error mixing-module fault in the gas remote on-off
connect console (OptiMix
only).
700 Gas Inlet F5-GCC The F5 inlet pressure (P6) in See Low inlet pressure for H2, Ar, N2, and H2O None Set process;
Alert the gas connect console diagnostic codes (695 – 697, 700, 701) on remote on-off
(only for VWI or OptiMix) is page 324.

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less than 5.52 bar (80 psi) or
more than 8.61 bar (105 psi).
701 Low Inlet H2O The water (H2O) inlet None Set process;
Alert GCC pressure (P8) in the gas remote on-off
connect console (only for
VWI and OptiMix) is less than

Instruction Manual
2.07 bar (30 psi).

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
702 Shield Gas Inlet N2 For a minimum of If you have a cutting system equipped with a Core None Set process;
Alert TCC 200 milliseconds, the or VWI gas connect console, refer to Gas inlet remote on-off
nitrogen (N2) inlet pressure pressure codes (768 – 771) on page 330.
(P4) in the torch connect If you have a cutting system equipped with a
console is less than 5.52 bar OptiMix gas connect console, refer to Process-gas
(80 psi) or more than

Instruction Manual
inlet pressure in the torch connect console
8.61 bar (125 psi). diagnostic codes (702, 705, 769, 770) for
703 Shield Gas Inlet O2 For a minimum of OptiMix-equipped cutting systems on page 327. None Set process;
Alert TCC 200 milliseconds, the oxygen remote on-off

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(O2) inlet gas pressure (P4) in
the torch connect console is
less than 5.52 bar (80 psi) or
more than 8.61 bar (125 psi).
704 Shield Gas Inlet Air For a minimum of None Set process;
Alert TCC 200 milliseconds, the air inlet remote on-off
pressure (P4) in the torch
connect console is less than
5.52 bar (80 psi) or more
than 8.61 bar (125 psi)
705 Shield Gas Inlet For a minimum of None Set process;
Alert Ar-TCC 200 milliseconds, the argon remote on-off
(Ar) inlet pressure (P4) in the
torch connect console is less
than 5.52 bar (80 psi) or
more than 8.61 bar (125 psi)
for at least 200 milliseconds.
706 No sensor P1-TCC The P1 pressure sensor in See Pressure transducer diagnostic codes (706 – Ramp down Set process;
Error the torch connect console is 715) on page 329. remote on-off
not detected.
Diagnostics and Troubleshooting
8

287
 Diagnostic code

288
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
707 No sensor P2-TCC The P2 pressure sensor in See Pressure transducer diagnostic codes (706 – Ramp down Set process;
Error the torch connect console is 715) on page 329. remote on-off
not detected.
708 No sensor P3-TCC The P3 pressure sensor in Ramp down Set process;
Error the torch connect console is remote on-off
not detected.
709 No sensor P4-TCC The P4 pressure sensor in Ramp down Set process;
Diagnostics and Troubleshooting

Error the torch connect console is remote on-off

not detected.
710 No sensor P5-TCC The P5 pressure sensor in Ramp down Set process;
Error the torch connect console is remote on-off
not detected.
711 No sensor P14- The P14 pressure sensor in Ramp down Set process;
Error TCC the torch connect console is remote on-off
not detected.
712 No sensor The P6 pressure sensor in Ramp down Set process;
Error P6-GCC the gas connect console is remote on-off
not detected.
(VWI and OptiMix
only)
713 No sensor The P7 pressure sensor in Ramp down Set process;
Error P7-GCC the gas connect console is remote on-off
not detected.
(VWI and OptiMix

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only)
714 No sensor The P8 pressure sensor in Ramp down Set process;
Error P8-GCC the gas connect console is remote on-off
not detected.
(VWI and OptiMix
only)

Instruction Manual
715 No sensor The P9 pressure sensor in Ramp down Set process;
Error P9-GCC the gas connect console is remote on-off
not detected.

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
716 Process Invalid The operator-selected Refer to the smart-fault data value (number) that None Set process;
Error process is not supported by accompanies the diagnostic code in the XPR web remote on-off
this XPR cutting system. interface to identify the unsupported process and
Smart-fault data values: best corrective action for each:

1: invalid id Refer to the XPR Cut Charts Instruction Manual None Set process;

Instruction Manual
Process ID = 0 (809830) for guidance about how to select the remote on-off
process ID for a supported process.
2: invalid user Refer to the Connect for Communication on None Set process;

809480
Another interface has control page 143 and How to change the device that has remote on-off
of the cutting system. control on page 186 for guidance about how to
select or change the interface that controls the
Note: Only 1 communication
cutting system.
method (Serial, EtherCAT or
Wireless) at a time can send
a process ID to the XPR
cutting system.
3: invalid user source None Set process;
Another interface has control remote on-off
of the cutting system.
Note: Only 1 wireless
interface at a time can send a
process ID to the XPR
cutting system.
4: invalid process Refer to the XPR Cut Charts Instruction Manual None Set process;
Incorrect process ID was (809830) for guidance about how to select the remote on-off
sent. process ID for a supported process.
Diagnostics and Troubleshooting
8

289
 Diagnostic code

290
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
716 Process Invalid 5: not allowed or system Wait until gas purge or cutting is complete. The None Set process;
Error not ready cutting system cannot accept a new process ID remote on-off
The cutting system is not during gas purge or cutting.
ready for a new process ID. If the code continues, contact your cutting machine
It can only accept a process supplier or regional Hypertherm Technical Service
ID during the following Team.
states: “Initial Checks (2),”
“Inert Gas Purge (4),” “Wait
Diagnostics and Troubleshooting

for Start (5),” “Manual Leak

Test (20)” or “End of Cycle
(14)” states.
6: not supported See How to choose the torch positions and process None Set process;
Note: The 3 XPR gas settings you need on page 211 for information remote on-off
connect consoles (OptiMix, about different process capabilities.
VWI, Core) can have different
capabilities. For example,
argon assist and argon
marking for mild steel are
available for cutting systems
equipped with OptiMix or
VWI gas connect consoles,
but not with Core.
717 Low voltage-mix The supply voltage for the Confirm the output voltage of the 24 VDC power Ramp down Set process;
Alert gas mixer in the gas connect source in the gas connect console (only for remote on-off

809480
console is less than 21 V. OptiMix). The output voltage should be 24 VDC.
718 High voltage-mix The supply voltage for the Ramp down Set process;
Alert gas mixer in the gas connect remote on-off
console is more than 27 V.

Instruction Manual
XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
719 Mix pwm 100% 100% duty is reached on H2, None Start or set
Ar, or N2 proportional valve 1. Make sure that the consumables are correct. process; remote
Alert
supply voltage. Total flow is 2. Make sure that the inlet pressures for N2, Ar, on-off
decreased to keep the mix and H2 are consistently within acceptable
percentage of the other range.
gases accurate.

Instruction Manual
3. Make sure that you have the most recent XPR
Because the mixer tries to firmware. Log into the Xnet at
deliver a flow, the outlet www.hypertherm.com to download it.
pressure can continue to rise.

809480
720 Mix Pout>Pin Pressure out (P21) is more None
Alert than one of the pressures on 1. Make sure that the consumables are correct.
the inlet side of the mixer
(P10 – P12) by at least 0.069 2. Increase N2, Ar, and H2 pressure during test
bar (1 psi). cutflow within acceptable range.
When this occurs, the mixer 3. Make sure that you have the most recent XPR
reduces flow to prevent firmware. Log into the Xnet at
backflow, which can affect www.hypertherm.com to download it.
cut quality.
721 Mix param There was a failure of the Ramp down Set process;
Error checksum mixing parameter checksum. remote on-off
1. Use the remote on-off switch to turn OFF and
722 Mix flow cal There was a failure of the then turn ON the cutting system. Ramp down Set process;
Error mixing flow calibration. 2. If the code continues, replace the gas connect remote on-off
console.
723 Mix pressure cal There was a failure of the Ramp down Set process;
Error mixing pressure calibration. remote on-off
Diagnostics and Troubleshooting
8

291
 Diagnostic code

292
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
724 Mix I2C1 There is a mixing 1. Examine the cable used to ground the gas Ramp down Set process;
Error communication error on connect console. Connect a disconnected remote on-off
I2C1. cable or repair a damaged cable if found.
725 Mix I2C2 There is a mixing 2. Make sure that all external panels for all system Ramp down Set process;
communication error on components are correctly installed. Install loose remote on-off
Error
I2C2. or missing panels if found.
3. Make sure that all hardware that holds the
external panels is in position and is tight.
Diagnostics and Troubleshooting

Tighten loose connections if found.

726 Mix system clock There is a problem with the 1. Use the remote on-off switch to turn OFF and Ramp down Set process;
Error mixing system clock. then turn ON the cutting system. remote on-off
2. If the code continues, replace the gas connect
console.
730 Solenoid error V1 There is an over-current 1. Inspect the valve driver cable connections for Ramp down Set process;
Alert condition for receptacle valve the valve receptacle in the torch connect remote on-off
V1 at the PCB in the torch console.
connect console. 2. Replace the torch V1 valve if you find damage
or excess wear.

809480
Instruction Manual
XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
733 Solenoid error V4 There is an over-current Ramp down Set process;
Alert condition for receptacle valve remote on-off
V4 at the PCB in the torch
connect console.
734 Solenoid error V5 There is an over-current Ramp down Set process;

Instruction Manual
Alert condition for receptacle valve remote on-off
V5 at the PCB in the torch
connect console.
735 Solenoid error V6 There is an over-current Ramp down Set process;

809480
Alert condition for receptacle valve remote on-off
V6 at the PCB in the torch 1. Examine the wiring for the valve.
connect console. 2. Connect the valve wire to another valve. If the
736 Solenoid error V7 There is an over-current error goes away, the valve is bad. Ramp down Set process;
Alert condition for receptacle valve 3. Replace the bad valve. remote on-off
V7 at the PCB in the torch
connect console.
737 Solenoid error V8 There is an over-current Ramp down Set process;
Alert condition for receptacle valve remote on-off
V8 at the PCB in the torch
connect console.
738 Solenoid error V9 There is an over-current Ramp down Set process;
Alert condition for receptacle valve remote on-off
V9 at the PCB in the torch
connect console.
Diagnostics and Troubleshooting
8

293
 Diagnostic code

294
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
739 Solenoid error V10 There is an over-current Ramp down Set process;
Alert condition for receptacle valve remote on-off
V10 at the PCB in the torch
connect console.
740 Solenoid error V11 There is an over-current 1. Examine the wiring for the valve. Ramp down Set process;
Alert condition for receptacle valve 2. Connect the valve wire to another valve. If the remote on-off
V11 at the PCB in the torch error goes away, the valve is bad.
connect console. 3. Replace the bad valve.
Diagnostics and Troubleshooting

741 Solenoid error V12 There is an over-current Ramp down Set process;
Alert condition for receptacle valve remote on-off
V12at the PCB in the torch
connect console.
742 Mix I2C1 Alert There is a mixing alert for 1. Examine the cable used to ground the gas Ramp down Set process;
Alert I2C1. connect console. Connect any disconnected remote on-off
cable or repair a damaged cable if found.
743 Mix I2C2 Alert There is a mixing alert for Ramp down Set process;
2. Make sure that all external panels for all system
Alert I2C2. remote on-off
components are correctly installed. Install loose
or missing panels if found.
3. Make sure that all hardware that holds the
external panels is in position and is tight.
744 Low Speed- The fan tach feedback is 1. Examine the fan. Make sure that the following None Set process;
Alert MagFan 1 below the minimum. fan connections are good: remote on-off
2. The fan connector.

809480
745 Low Speed- The fan tach feedback is None Set process;
MagFan 2 below the minimum. 3. The wiring to J2 and J5 on the fan power remote on-off
Alert
distribution PCB.
748 Low Speed- HxFan The fan tach feedback is 4. The wiring to J7 on the Control PCB 1. None Set process;
Alert 1 below the minimum. remote on-off
5. Tighten loose connections if found.
6. Verify 48 VDC power source output. If not
correct, replace the 48 VDC power source.

Instruction Manual
7. If you do not find any loose connections and the
48 VDC power source is good, replace the fan.

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
749 Low Speed- HxFan The fan tach feedback is 1. Examine the fan. Make sure that the following None Set process;
Alert 2 below the minimum. fan connections are good: remote on-off
• The fan connector.
• The wiring to J2 and J3 (HxFan1) and to J4
(HxFan2) on the fan power distribution PCB.
• The wiring to J7 on the Control PCB 1.

Instruction Manual
2. Tighten loose connections if found.
3. Verify 48 VDC power source output. If not
correct, replace the 48 VDC power source.

809480
4. If you do not find any loose connections and the
48 VDC power source is good, replace the fan.
750 Low speed CAB Fan speed is below the 1. Examine the fan. Make sure that the following None Set process;
Alert FAN1 (Control minimum acceptable RPM fan connections are good: remote on-off
Side) Fan 1 value. • The fan connector.
• The wiring to J7 Low speed CAB FAN1
(Control Side) Fan 1 on the fan power
distribution PCB.
• The wiring to J7 on the Control PCB 1.
2. Tighten loose connections if found.
3. Verify 48 VDC power source output. If not
correct, replace the 48 VDC power source.
4. If you do not find any loose connections and the
48 VDC power source is good, replace the fan.
751 Low speed CAB Fan speed is below the 1. Examine the fan. Make sure that the following None Set process;
Alert FAN1 (Control minimum acceptable RPM fan connections are good: remote on-off
Side) Fan 2 value. • The fan connector.
• The wiring to J8 Low speed CAB FAN2
(Control Side) Fan 2 on the fan power
distribution PCB.
• The wiring to J8 on the Control PCB 1.
2. Tighten loose connections if found.
3. Verify 48 VDC power source output. If not
Diagnostics and Troubleshooting

correct, replace the 48 VDC power source.

4. If you do not find any loose connections and the
8

48 VDC power source is good, replace the fan.

295
 Diagnostic code

296
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
752 Phase Fault Ch1 There is a 3-phase error in 1. Confirm the input-line voltage is within+/-14% Shut down Remote on-off
Error Chopper 1. of nominal (see Input power requirements on
page 32).
2. Remove the power from the cutting system.
3. Remove the cover from the contactor.
4. Inspect the contacts for excess wear. Replace
the contactor, if excess wear is found.
Otherwise, continue with the following steps.
Diagnostics and Troubleshooting

5. Inspect the following contactor components for

loose connections:
• Contactor
• Input to chopper
• Power cord
6. Tighten loose connections if found. Otherwise,
continue with the following steps.
7. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.

809480
Instruction Manual
XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
753 Phase Fault Ch2 There is a 3-phase error in 1. Confirm the input-line voltage is within+/-14% Shut down Remote on-off
Error Chopper 2. of nominal (see Input power requirements on
page 32).
2. Remove the power from the cutting system.
3. Remove the cover from the contactor.

Instruction Manual
4. Inspect the contacts for excess wear. Replace
the contactor, if excess wear is found.
Otherwise, continue with the following steps.
5. Inspect the following contactor components for

809480
loose connections:
• Contactor
• Input to chopper
• Power cord
6. Tighten loose connections if found. Otherwise,
continue with the following steps.
7. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.
755 Low level-Coolant The coolant level is low. Fill the coolant reservoir with coolant. (See Coolant None Set process;
Alert Installation on page 193.) remote on-off
Diagnostics and Troubleshooting
8

297
 Diagnostic code

298
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
756 Leak test results Reports the result of a gas See How to do a gas leak test (VWI and OptiMix) None Start or set
Info leak test: on page 331. process; remote
0: leak in v1 v12 or hose on-off
1: leak in b1
2: leak in v1 or b1
3: leak in v1 Vv0 or hose
4: leak in b3); break;
Diagnostics and Troubleshooting

5: leak in v10 or b3
6: manual leak test failed
7: manual leak test passed
8: leak in v4 v5 v6 or v7
9: leak in b2
10: leak in v10 or hose
11: no n2 inlet or v5
12: leak in p7 volume
13: leak in line A or v1
14: auto leak test failed
15: auto leak test passed
16: timeout
757 DC work exceeds The work lead current Make sure that you have the most recent XPR End of cycle Remote on-off
Error limits exceeds the setpoint by 5 A. firmware.

809480
If the code continues, contact your cutting machine
supplier or regional Hypertherm Technical Service
team.
758 Main 24 V dip The 24 V DC bus decreases Make sure that you have the most recent XPR None Set process;
Alert to less than 20 V on the main firmware. remote on-off
control. If the code continues, contact your cutting machine

Instruction Manual
759 Main 24 V bus low The 24 V bus decreases to supplier or regional Hypertherm Technical Service Ramp down Set process;
less than 20 V on the gas team. remote on-off
Alert
connect console.

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
763 Coolant solenoid The coolant solenoid driver 1. Inspect the coolant solenoid and wiring. None Set process;
Alert fault finds an over-current Replace them if you find damage or excess remote on-off
condition. wear.
2. Make sure that you have the most recent XPR
firmware. You can log in to the Xnet at

Instruction Manual
www.hypertherm.com to download it.
3. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.

809480
764 Main contactor The main contactor driver 1. Inspect the main contactor and wiring. Replace None Set process;
Alert fault finds an over-current them if you find damage or excess wear. remote on-off
condition. 2. Make sure that you have the most recent XPR
firmware. You can log in to the Xnet at
www.hypertherm.com to download it.
3. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.
765 Inrush contactor The inrush contactor driver 1. Inspect the inrush contactor, inrush contactor None Set process;
Alert fault finds an over-current relay, and wiring for damage. Replace them if remove on-off
condition. you find damage or excess wear.
2. Make sure that you have the most recent XPR
firmware. You can log in to the Xnet at
www.hypertherm.com to download it.
3. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team.
Diagnostics and Troubleshooting
8

299
 Diagnostic code

300
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
766 Pump enable fault The pump enable driver finds 1. Inspect the pump solid state relay for damage. None Set process;
Alert an over-current condition. Replace them if you find damage or excess remote on-off
wear.
2. Make sure that you have the most recent XPR
firmware. You can log in to the Xnet at
www.hypertherm.com to download it.
3. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Diagnostics and Troubleshooting

Technical Service team.

767 Remote relay fault The remote on-off relay driver 1. Inspect the pump solid state relay for damage. None Set process;
Alert finds an over-current Replace them if you find damage or excess remote on-off
condition. wear.
2. Make sure that you have the most recent XPR
firmware. You can log in to the Xnet at
www.hypertherm.com to download it.
3. If the code continues, contact your cutting
machine supplier or regional Hypertherm
Technical Service team
768 Gas inlet – O2 Line Line A O2 inlet pressure (P2) See Gas inlet pressure codes (768 – 771) on None Set process;
Alert A is below 5.52 bar (80 psi) or page 330. remote on-off
above 8.62 bar (125 psi).
769 Gas Inlet – Argon Line B Argon inlet pressure If you have a cutting system equipped with a Core None Set process;
Alert Line B (P1) is below 5.52 bar or VWI gas connect console, refer to Gas inlet remote on-off

809480
(80 psi) or above 8.62 bar pressure codes (768 – 771) on page 330.
(125 psi). If you have a cutting system equipped with a
770 Gas Inlet – N2 Line Line B N2 inlet pressure (P1) OptiMix gas connect console, refer to Process-gas None Set process;
B is below 5.52 bar (80 psi) or inlet pressure in the torch connect console remote on-off
Alert
above 8.62 bar (125 psi). diagnostic codes (702, 705, 769, 770) for
OptiMix-equipped cutting systems on page 327.
771 Gas Inlet – Air Line Line A Air inlet pressure (P2) See Gas inlet pressure codes (768 – 771) on None Set process;

Instruction Manual
Alert A is below 5.52 bar (80 psi) or page 330. remote on-off
above 8.62 bar (125 psi).

XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
772 High Inlet – Line A Line A inlet pressure (P2) is Lower the air or O2 inlet pressure. Ramp down Set process;
Alert more than 9.99 bar (145 psi). remote on-off

774 P5 >=P2 Line A (H2-mix) outlet Increase air inlet pressure. Ramp down Set process;
Alert pressure (P5) exceeds air remote on-off
inlet pressure (P2) and Line A

Instruction Manual
type is “mix.” The system will
automatically stop cutting
system operation.

809480
775 Node update Informs the status of the node Refer to the XPR Firmware Updates Field Service None Start or set
Alert update. The alert occurs Bulletin (809820). process; remote
when the PCB updates via on-off
wireless connection.
776 Wifi reset The GS2011 wireless Reduce wireless connections to the XPR cutting None Start or set
Alert module has been reset. system. process; remote
on-off
777 Pilot relay fault The pilot relay driver detects 1. Remove the power for the XPR cutting system. None Set process;
Alert an over current condition. 2. Remove the control-side panel from the plasma remote on-off
power supply.
3. Examine the control PCB (PCB 1).
4. Remove J6 from the control PCB.
5. Remove the cover from the pilot arc relay.
6. Use an ohmmeter to measure the coil
resistance across wires 21 and 22. You can
expect a resistance of approximately 280 ohms.
7. If the ohms value is more than 10% above or
below 280 ohms, replace the pilot arc relay.
8. If the ohms value is within acceptable range,
make sure that the most-recently released XPR
firmware is installed. Install the most recent
firmware, if necessary.
Diagnostics and Troubleshooting
8

301
 Diagnostic code

302
Diagnostic code Code cancels
number and Description Corrective action XPR action
name with
category
778 Hv relay fault The high-voltage relay driver 1. Remove the power for the XPR cutting system. None Set process;
Alert detects an over current 2. Remove the top and side panels from the torch remote on-off
condition. connect console.
This code occurs
only with cutting 3. Examine the ohmic PCB inside the torch
systems that have connect console.
firmware at Rev J 4. Remove J2 from the ohmic PCB.
or earlier
5. Use an ohmmeter and needle probes to
Diagnostics and Troubleshooting

measure the coil resistance across the 2

sockets (J2, 2 female connector). You can
expect a resistance of approximately 126 ohms.
6. If the ohms value is more than 10% above or
below 126 ohms, replace the ohmic relay
(Hv relay).
7. If the ohms value is within acceptable range,
make sure that you have the most recent XPR
firmware. Log into the Xnet at
www.hypertherm.com to download it.
779 Ch1 15V bus The Chopper 1 15 V bus is 1. Verify the 24 VDC on the connector J2, pins 1 None Set process;
Alert out of range (below 13 V or and 2 on the Chopper 1 assembly. remote on-off
above 17 V).
2. If the 24 VDC is absent, examine the wiring on
J2 of Chopper 1. Look for loose connections.
3. If you measure 24 VDC, replace the Chopper 1
assembly.

809480
780 Ch2 15V bus The Chopper 2 15 V bus is 1. Verify the 24 VDC on the connector J2, pins 1 None Start or set
Alert out of range (below 13 V or and 2 on the Chopper 1 assembly. process; remote
above 17 V). 2. If the 24 VDC is absent, examine the wiring on on-off
J2 of Chopper 2. Look for loose connections.
3. If you measure 24 VDC, replace the Chopper 2
assembly.

Instruction Manual
XPR300
 Diagnostic code
Diagnostic code Code cancels
number and Description Corrective action XPR action

XPR300
name with
category
782 Mix low psi-P2 The Air inlet pressure (P2) in Increase air pressure None Clears with
Alert the torch connect console is start, set
less than 7.58 bar (110 psi) process, and
during a mix gas process remote
(OptiMix only). ON-OFF

Instruction Manual
See Sequence of operation on page 201 for descriptions of XPR cutting system operation.


809480
Diagnostics and Troubleshooting
8

303
8 Diagnostics and Troubleshooting

CAN codes (500 – 503, 510 – 513 for gas connect console, 504 – 505, 514 – 515 for CAN cable and
jumper block, 507 – 508 for CAN network and bus, 600 – 602 for no CAN communication)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

Multiple codes at the same time can indicate a problem with the CAN cable. If there is only one
code, the problem is more likely to be caused by what the code says (not the CAN cable).

1. Remove the power from the cutting system. (See Remove the power from the cutting system on
page 255.)

2. For chopper-related codes, make sure that the chopper ID cable connector is fully engaged in
J8 on Chopper 1 and Chopper 2. If the chopper ID cable connection is good, continue with the
following steps:
a. For code 504 alone:
 Examine the CAN cable connection between Chopper 1 and Chopper 2. Look for loose
connections, bent pins, and bent sockets.
 Tighten loose connections if found.
 If you find bent sockets, order a new cable.
 If you find a bent pin, try to straighten it. If this does not work, order a new cable.
b. For code 503 and 504 together:
 Examine the CAN cable connection between Chopper 2 and the control board (PCB 1)
on the plasma power supply. Look for loose connections, bent pins, and bent sockets.
 Tighten loose connections if found.
 If you find bent sockets, order a new cable.
 If you find a bent pin, try to straighten it. If this does not work, order a new cable.
c. If the CAN cable connections are good, examine the PCB for Chopper 1/PCB 2 and
Chopper 2/PCB 3. Make sure that the following green LEDS are illuminated on each PCB:
 D22 (+18/-5 VDC)
 D14 (+5 VDC)
 D21 (+3.3 VDC)

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 Diagnostics and Troubleshooting 8

 These LEDs indicate power to the chopper control boards (PCB 2 and
PCB 3).

d. If any LEDs are not illuminated, continue with the following steps:
 If all of the LEDs are not illuminated, make sure that the power connector for J2 is fully
engaged.
 If the connector for J2 is fully engaged, make sure that the wiring to the connector is
good.
 Check for 24 V DC, Chopper 1 J2, Pins 1 and 3.Chopper 2, Pins 2 and 4
 If the wiring is good and the code continues, contact your cutting machine supplier
or regional Hypertherm Technical Service team.
 If only 1 or 2 LEDs are not illuminated, PCB replacement can be necessary. Contact
your cutting machine supplier or regional Hypertherm Technical Service team.
e. If the green LEDs on both boards are illuminated, examine the PCB 2 and PCB 3 chopper
boards:
 Make sure that LED D3 and D4 on PCB 2 and PCB 3 are blinking once-per-second
(indicates the microprocessor on the control board is functional).
 Make sure that the DIP switches on S2 are in the following positions:
 1 – OFF
 2 – OFF
 3 – OFF
 4 – OFF
 Make sure that the CAN cable connector is fully engaged in J7.
f. If the LEDs are not functioning as described above, contact your cutting machine supplier
or regional Hypertherm Technical Service team.
g. If LEDs are functioning as described above, examine LEDs D33 and D34. Flickering
indicates the communications on the CAN cable is functional.
h. If LED D33 and D34 are not flickering, contact your cutting machine supplier or regional
Hypertherm Technical Service team.
i. If the CAN cable connectors and microprocessor are good and the LEDs appear functional,
but the code continues, contact your cutting machine supplier or regional Hypertherm
Technical Service team.

3. If the code is for the Core or VWI gas connect console (GCC), go to step 6.

4. If the code is for the OptiMix GCC, go to step 7.

5. If the code is for the torch connect console (TCC), go to step 8.

6. For Core and VWI GCC codes, examine the CAN cable connections between the plasma
power supply and gas connect console:
a. Look for loose connections. Tighten loose connections if found.

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8 Diagnostics and Troubleshooting

b. If the connections are good, make sure that the control board inside of the gas connect
console is tightly mounted to the chassis. Tighten loose connections if found.
c. Examine control board (141375) inside of the gas connect console. Make sure that the
following LEDs are illuminated:
 D16 (+5 VDC)
 D18 (+3.3 VDC)

 These LEDs indicate power to the PCB. See PCB information on

page 343.

d. If the LEDs are illuminated, examine LEDs D30 and D31. Look for once-per-second blinking
(indicates the microprocessor on the PCB is functional).
e. If LED D30 and D31 are blinking once-per-second, examine LEDs D24 and D25. Flickering
indicates the microprocessor on the PCB is functional.
f. If LED D24 and D25 are flickering and you have codes 600 and 602, make sure that the
connection between the main power supply and gas connect console is good:
 Make sure that the CAN cable between the plasma power supply and gas connect
console is connected.
 Disconnect the CAN cable connection between the gas connect console and torch
connect console.
g. If D24 and D25 stop flickering, one of the following conditions can be the problem:
 There is a bad connection between the plasma power supply and the gas connect
console. Reconnect or replace the CAN cable if necessary.
 There is a bad connection between the small CAN jumper cable for the gas connect
console control board (141375) and the sheet metal (located inside of the gas connect
console). Reconnect or replace the CAN cable if necessary.
h. If the control board is functional and the code continues, there is a problem with either the
CAN cable between the gas connect console and torch connect console or with the small
CAN jumper cable for the gas connect console control board (141375) and the sheet metal
(located inside of the gas connect console). Continue with the following steps to identify the
problem cable:
 Disconnect and examine each cable. Look for look loose connections, bent pins, and
bent sockets.
 Tighten loose connections if found.
 If you find bent sockets, order a new cable.
 If you find a bent pin, try to straighten it. If this does not work, order a new cable.
i. If D24 and D25 are not illuminated and not flickering, the CAN cable to the plasma power
supply is disconnected. Reconnect the CAN cable if necessary.
j. If D24 is not illuminated and D25 is flickering, examine the control board for shorts. Look for
a shorting block across pins 1 and 2 of J16.
k. If there is a shorting block, remove it and restart the cutting system.
l. If J16 is open, replace the control board (141375).

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 Diagnostics and Troubleshooting 8
7. For OptiMix GCC codes, examine the CAN cable connections between the plasma power
supply and gas connect console:
a. Look for loose connections. Tighten loose connections if found.
b. Make sure that the control board (141375) inside of the gas connect console is tightly
mounted to the chassis. Tighten loose connections if found.
c. Examine the control board inside of the gas connect console. Make sure that the following
LEDs are illuminated on the control board:
 D16 (+5 VDC)
 D18 (+3.3 VDC)

 These LEDs indicate power to the PCB. See PCB information on

page 343.

d. If the LEDs are illuminated, examine LEDs D30 and D31. Look for once-per-second blinking
(indicates the microprocessor on the PCB is functional).
e. If LED D30 and D31 are blinking once-per-second, examine LEDs D24 and D25. Flickering
indicates the microprocessor on the PCB is functional.
f. If LED D24 and D25 are flickering and you have codes 600 and 602, make sure that the
connection between the main power supply and gas connect console is good:
 Make sure that the CAN cable between the plasma power supply and gas connect
console is connected.
 Disconnect the CAN cable connection between the gas connect control board
(141375) and the mixer in the same console.

 The gas connect console, mixer, and torch connect consoles can appear
to communicate, even when the CAN cable between them is
disconnected.

g. If D24 and D25 stop flickering, the CAN cable is bad. One of the following conditions can
be the problem:
 The CAN cable is damaged. Use a Ohm meter to verify the continuity at the end of each
connector of the CAN cable. Verify pin-by-pin and in the same order as the CAN
connectors. For example, Pin_1 on End A corresponds to Pin_1 on End B of the cable.
Replace the cable if no continuity is found.
3 End A End B 1 2

4 2 5

5 4 3

 There is a bad connection between the plasma power supply and the gas connect
console. Reconnect or replace the CAN cable if necessary.
 There is a bad connection between the small CAN jumper cable for the gas connect
console control board (141375) and the sheet metal (located inside of the gas connect
console). Reconnect or replace the CAN cable if necessary.

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8 Diagnostics and Troubleshooting

h. If the control board is functional and the code continues, continue with the following steps:
 Replace the CAN cable between the control board (141375) and the mixer.
 Disconnect the CAN cable between the gas connect console and torch connect
console.
 Make sure that the green LEDs on the mixer are functional, and that the XPR web
interface or CNC screen indicates that the cutting system is equipped with a OptiMix
gas connect console.
i. If D24 and D25 are not illuminated and not flickering, the CAN cable to the plasma power
supply is disconnected. Reconnect the CAN cable if necessary.
j. If D24 is not illuminated and D25 is flickering, examine the control board for shorts. Look for
a shorting block across pins 1 and 2 of J16.
k. If there is a shorting block, remove it and restart the cutting system.
l. Look for CAN problems with the mixer inside of the OptiMix gas connect console. There are
3 LEDs located side-by-side. Look for the green LED. Examine the green LED on the board
of the mixer:
 If the green LED is blinking once-per-second and the yellow LED is flickering, the CAN
cable is good and the cutting system is ready for use.
 If the green LED is blinking once-per-second and the yellow LED is not illuminated, a
CAN communication failure can be the problem. Examine the CAN cable between the
control board (141375) and the mixer. Look for a loose connection or bent pins.
 If the green LED is blinking once-per-second and the red LED is illuminated (steady, no
flickering), the mixer in the gas connect console can be the problem. Contact your
cutting machine supplier or regional Hypertherm Technical Services team. Technical
Services can help you decide if it is necessary to replace the gas connect console.

8. For TCC codes, examine the CAN cable connections between the gas connect console and
the torch connect console:
a. Look for loose connections. Tighten loose connections if found.
b. Examine the control board (141334) inside of the torch connect console. Make sure that the
following LEDs are illuminated on the control board:
 D43 (+5 VDC)
 D46 (+3.3 VDC)
c. If D43 and D46 are not illuminated, use a digital volt meter to measure the power output for
PS1.
 If there is no 24 VDC output, examine the 120 VAC input to PS1. If there is no
120 VAC, examine the power cable connection to the torch connect console and the
120 VAC-out connection from the gas connect console. Tighten loose connections if
found.
d. If D43 and D46 are illuminated, make sure that 120 VAC-out from the gas connect console
is connected, then verify that the Activity LED (D88) and Status LED (D87) are blinking.
Look for once-per-second blinking (indicates the microprocessor on the PCB is functional).

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 Diagnostics and Troubleshooting 8
 If the LEDs are not blinking once-per-second, replace the control board. If replacement
is necessary, contact your cutting machine supplier or Hypertherm Technical Service
team.
e. If the power LEDs are good, examine CAN TX LED (D35) and RX LED (D34). Flickering
indicates the microprocessor on the PCB is functional.
f. If the RX LED (D34) is not flickering, the CAN cable between the gas connect console and
torch connect console is disconnected. Reconnect the CAN cable, if necessary.
g. If the RX LED is flickering and the CAN TX LED (D35) is not flickering, replace the control
board (141334) inside of the torch connect console. If replacement is necessary, contact
your cutting machine supplier or regional Hypertherm Technical Service team.

9. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

XPR300 Instruction Manual 809480 309

 8 Diagnostics and Troubleshooting

Low shield water pressure code (532)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

1. Make sure that the shield water pressure supplied to the cutting system is between 2.76 bar –
7.93 bar (40 psi – 115 psi).

 If the pressure is less than 2.76 bar (40 psi), then a “booster” water pump
can be necessary to avoid system shut down or bad cut quality. See
Shield water requirements (VWI and OptiMix) on page 41.

2. Examine all water hoses and water hose inlet fittings. Look for:
 Damage or kinks that can restrict flow.
 Leaks that can decrease pressure.

3. Replace any hoses with damage or kinks.

4. Reposition the hoses if you find fixable kinks.

5. Replace any fitting that has damage.

6. Tighten loose connections if found.

7. Examine water regulators. Look for debris that can block the flow path.

8. Adjust the inlet water pressures to at least 2.77 bar (40 psi) when cutting, if necessary.

 The Hypertherm-supplied regulator that is connected to the gas connect

console is pre-set at the factory. Do not adjust this regulator.

9. If you cannot find or fix the problem with these corrective actions, contact your cutting machine
supplier or regional Hypertherm Technical Service team.

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 Diagnostics and Troubleshooting 8

Low shield gas pressure code (534)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

1. Make sure that the consumables are correct for the operator-selected process.

2. Examine gas hoses and fittings. Look for:

 Damage and kinks that can restrict flow.
 Leaks that can decrease pressure.

3. If the hoses and fittings are good, look at the CNC or XPR web interface to identify the shield
gas pressure.

 For information about the recommended shield gas pressure by process

type, see the cut charts. See the XPR Cut Charts Instruction Manual
(809830).

4. Send a command to test preflow. Make sure that the pressure is within the correct range for the
active process.

 For information about how to do this, see the instruction manual that came
with your CNC.

5. Send a command to test cutflow and continue with the following steps:

 Make sure that the pressure on P14 is achieved. An error occurs only if
the value is less than 75% of the setpoint for at least 600 milliseconds.

a. If the pressure is too high or too low, use the optional external shield gas regulator to
decrease or increase the pressure.
b. Examine voltage going to J21.1 and J21.2 for B2 and J7 for V11 (See Valve states during
operation on page 402 to identify if V11 is enabled). Look for voltage between 5 VDC –
24 VDC.
c. If B2 and V11 do not have the correct voltage, examine the connections between the
control board (141334) and the valves. Make sure that the connections are fully engaged.

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 8 Diagnostics and Troubleshooting

 If the connections are fully engaged but the code continues, replace the
control board.

6. If you cannot get the recommended pressure, or if pressure is within range but the code
continues, exchange B2 with B1 or B3, or exchange P14 with a different transducer, to see if
the code follows the exchange. If yes, replace B2 or P14, as needed.

7. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

Low coolant flow codes (540 – 542)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

1. Make sure that the coolant level in the coolant reservoir is acceptable.

 You can see the coolant level from the fill port inlet located on the top of
the plasma power supply. You also can see coolant levels on the CNC
screen or XPR web interface.

2. If the coolant reservoir is not full, fill it with coolant. (See Coolant Installation on page 193.)

3. If the coolant reservoir level is acceptable, but the code continues:

a. Make sure that the coolant pump is ON and the gauge is spinning.
b. Make sure that the bypass is working.
c. Examine the coolant hoses. Look for restrictions or blockages.
d. Examine the consumables. Make sure they are correct for the operator-selected process.
e. Examine the coolant filter. Replace it if necessary. (See Table 31 – Inspection, preventive
maintenance, and cleaning tasks on page 232.)
f. Examine the coolant pump screen. Replace it if you find damage. Clean it if you find debris.

4. If coolant filter or coolant pump screen replacement is not necessary, do a coolant flow test to
identify the source of a coolant leak or obstruction. (See How to measure coolant flow on
page 333.)

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 Diagnostics and Troubleshooting 8
5. Send a process command to start the coolant pump.

 The coolant pump starts automatically any time a process command is

sent. (See Sequence of operation on page 201.)

6. If the coolant flow test value (see step 4) is equal to or greater than 3.78 L/min (1.0 gal/min), but
the XPR web interface shows a lower value, complete the following steps:
a. Examine the control PCB. Look for +15 VDC on J8 pin 1 and pin 2.

 If there is no voltage on J8 pin 1 and pin 2, examine the wiring harness

that connects to J8. Look for a short. If no short is found, replace the
control PCB.

b. If the voltage on J8 pin 1 and pin 2 is +15 VDC, examine the flow sensor output (in
frequency) at the control PCB. Measure the frequency on J8 pin 3 (pulse) and pin 2
(ground).

Flow rate
Liters per minute US gallons per minute Frequency (Hz)
(L/min) (gal/min)
1.89 L/min 0.5 gal/min 15 Hz
3.78 L/min 1.0 gal/min 34 Hz
5.67 L/min 1.5 gal/min 54 Hz

 If the value differs more than 0.8 L/min (0.2 gal/min), or if there are no
pulses (0 Hz), replace the flow sensor.

7. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

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 8 Diagnostics and Troubleshooting

High coolant flow codes (543 – 544)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

A failed coolant pump can cause a high coolant flow diagnostic code (543). To make sure that the
coolant pump is operational:

1. Look at the CNC or XPR web interface to make sure that the coolant pump is operational.

2. For diagnostic code 543, examine the coolant hoses. Make sure that you have
Hypertherm-supplied coolant hoses. Replace the bad hoses with Hypertherm-supplied coolant
hoses, if necessary.

3. For diagnostic code 544, do the following steps to re-set the cutting system:
a. Set the line-disconnect switch to the OFF position.
b. Examine the torch. Missing or severely damaged consumables can cause the flow meter to
give a higher flow value.

 A missing water tube can have an effect on coolant flow.

c. Set the line-disconnect switch to the ON position.

d. Use the CNC or XPR web interface to send a process command to the cutting system.

 The coolant pump starts automatically any time a process command is

sent.

e. If the code continues:

 Examine the flow meter. Look for air bubbles in the sight glass. Air bubbles can cause
the flow meter to give a higher flow value.
 Make sure the coolant level is slightly above the level switch.
 Examine the hoses and hose fittings. Look for damage or loose connections.

4. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

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 Diagnostics and Troubleshooting 8

Over temp diagnostic codes – Choppers (560 – 561) and Coolant (587)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

CAUTION

MOVING BLADES CAN CAUSE INJURY

Keep your hands away from moving parts.

1. Make sure that the clearance around the plasma power supply is adequate.

 For adequate ventilation, Hypertherm recommends a minimum separation

distance of 1 meter (3.3 feet) between the plasma power supply and any
other objects or equipment.

2. Make sure that the ambient temperature where the plasma power supply is located is within the
acceptable temperature range for cutting system operation (See Table 1.)

 If the temperature where your plasma power supply is located is above the
temperature limit, you can see reduced performance and over-temp
diagnostic codes.

3. While all of the fans continue to operate, allow the cutting system to cool.

4. Reference the XPR web interface. Make sure that the heat-exchanger fan speed is within the
acceptable range (heat-exchanger fan 1; heat-exchanger fan 2).

Fan type Acceptable range of speed

Large fans (254 mm / 10 inch) 2,800 RPM – 3,400 RPM
Small fans (120 mm / 4.7 inch) 5,600 RPM – 6,400 RPM

5. If the fan speed is within acceptable range, remove the power from the cutting system. (See
Remove the power from the cutting system on page 255.)

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 8 Diagnostics and Troubleshooting

6. Remove the pump-side and front panels of the plasma power supply.

7. If you find obstructions, debris, or dust, use compressed air to remove the obstruction, debris, or
dust from the fans and heat-exchanger area.

 The heat-exchanger area can retain large amounts of dust or debris.

Multiple uses of compressed air is often necessary to clear this area.
Consider the use of personal protective equipment to protect yourself
from airborne particulates and debris.

 Make sure to minimize fan rotation during compressed air use. You can
use a gloved hand to hold a fan in position, if necessary.

8. Make sure that the heat-exchanger fans have no obvious obstruction, dust, or debris:
a. Disconnect the connector for the choppers or remove the coolant thermistor wires from the
connector. This makes it easier to measure only the resistance for the thermistors.
b. Use a digital multimeter to measure the resistance from each thermistor wire, based on the
following codes and connector-pin locations:

Location of thermistor
Diagnostic code Thermistor location Pins
wires / connector
587, 670, 681 Heat exchanger, top PCB 1 J1.2 pin 7 J1.2 pin 8
560, 667, 678 Chopper 1 (cold plate) PCB 2 J9 pin 1 J9 pin 2
561, 668, 679 Chopper 2 (cold plate) PCB 3 J9 pin 1 J9 pin 2

c. Look for a resistance value that is outside of the minimum or maximum in Table 36:

85 750 1250
95 600 1000
105 400 800
115 300 600
125 200 500
135 150 400
145 150 250
155 125 225
165 100 175

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 Diagnostics and Troubleshooting 8
Table 36 – Minimum and maximum ohmic resistance values for thermistors

Thermistor temperature Minimum resistance (Ohms) Maximum resistance (Ohms)

25ºC (77ºF) 9,000 11,000
35ºC (95ºF) 5,000 7,000
45ºC (113ºF) 3,900 4,900
55ºC (131ºF) 2,500 3,500
65ºC (149ºF) 1,500 2,500
75ºC (167ºF) 1,000 2,000
85ºC (185ºF) 750 1,250
95ºC (203ºF) 600 1,000
105ºC (221ºF) 400 800
115ºC (239ºF) 300 600
125ºC (257ºF) 200 500
135ºC (275ºF) 150 400
145ºC (293ºF) 150 250
155ºC (311ºF) 125 225
165ºC (329ºF) 100 175

 At approximately 25ºC (77ºF), you can expect a resistance of

approximately 10,000 ohms.

d. If the resistance value is outside the minimum or maximum value in Table 36 on page 317,
contact your cutting machine supplier or regional Hypertherm Technical Service team. They
can help you to decide if there is a wiring fault or if thermistor replacement is necessary.
e. If the resistance value is at or very near 0 ohms:
 Inspect the wiring between each thermistor and its connector pins.
 Look for shorts between wires or to the ground.
f. If the resistance value is above 100 ohms and below the minimum:
 Remove the electrical power from the cutting system. (See Remove the power from the
cutting system on page 255.)
 Allow the coolant to reach 85ºC (185ºF) or below.

 It can take a long time for the coolant to reach 85ºC (185ºF) if the ambient
temperature is high. Contact your cutting machine supplier or regional
Hypertherm Technical Service team for guidance about how to cool the
cutting system, if necessary.

 Restore electrical power to the cutting system.

 Repeat step 8.

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 8 Diagnostics and Troubleshooting

g. If the resistance remains below the minimum ohmic value or does not change after you allow
the coolant to reach 85ºC (185ºF) or below, do one or more of the following steps, based
on the diagnostic code(s):
 Replace chopper 1 (PCB 2) for error code 560 (over temp-Ch1).
 Replace chopper 2 (PCB 3) for error code 561 (over temp-Ch2).
 Replace copper pipe thermistor assembly for error code 587 (Over temp-Coolant).
h. If the resistance is within range, continue cutting system operation.
i. If the thermistor resistance is within range when the thermistor is disconnected from the
control PCB and the code continues when the thermistor is reconnected to the control
PCB, contact your cutting machine supplier or regional Hypertherm Technical Service team.
They can help you decide if control PCB replacement is necessary. (See Plasma power
supply control PCB (141322) on page 344 or Plasma power supply chopper PCB
(141319) on page 347.)

9. If the code continues, or if you cannot find or resolve the problem with these corrective actions,
contact your cutting machine supplier or regional Hypertherm Technical Service team.

Start switch diagnostic codes (570 – 577)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

1. Use the CNC or XPR web interface to verify the status of the cutting system. Make sure that a
cutting sequence is not active.

2. Remove the power from the cutting system. (See Remove the power from the cutting system on
page 255.)

3. Remove the control-side panel from the plasma power supply.

4. Supply power to the cutting system.

5. If the code continues after you supply power to the cutting system, examine LED D50 on
PCB 1. Look for illumination.

6. If the LED is not illuminated, there is a CNC problem.

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 Diagnostics and Troubleshooting 8

 See the instruction manual that came with your CNC for troubleshooting
recommendations.

7. If LED D50 is illuminated:

a. Remove the power from the cutting system. (See Remove the power from the cutting
system on page 255.)
b. Remove the connector from J14 on the rear of the plasma power supply.
c. Supply power to the cutting system.
d. Examine the LED D50 on PCB 1. Look for illumination.

8. If LED D50 is illuminated (when the discrete cable remains disconnected), examine the PCB for
dust or other contaminants. Use compressed air to remove any dust, debris, or obstruction if
found.

9. If LED D50 is still illuminated after the wire is removed, there is a problem with the board.
Contact your cutting machine supplier.

10. If the LED is not illuminated, skip to step 12.

11. If the code stops and LED D50 is not illuminated with the discrete cable still disconnected,
examine the discrete cable for damage. Look for:
 Shorts across the line
 Damaged cable
 Bad relays
 Loose connections

 Replace the discrete cable if you find damage. (See Discrete CNC
interface cable on page 389 in Parts List.)

12. If you do not find visible damage to the discrete cable, remove the discrete cable from PCB 1.
Look for an open circuit between pins 3 and 4 of J14.

13. If the cable is good, make sure that the CNC output is set to OFF.

14. If there is a short circuit, make sure that the discrete cable is not shorted and that the CNC start
signal output is set to OFF.

 A closed circuit can indicate that the CNC sent a plasma-start signal or
damage on the discrete cable.

15. If you cannot find or resolve the issue with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

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8 Diagnostics and Troubleshooting

Over temp diagnostic codes – Inductors (580 – 583), Transformers (586)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

CAUTION

MOVING BLADES CAN CAUSE INJURY

Keep your hands away from moving parts.

1. Make sure that the clearance around the plasma power supply is adequate.

 For adequate ventilation, Hypertherm recommends a minimum separation

distance of 1 meter (3.3 feet) between the plasma power supply and any
other objects or equipment.

2. Make sure that the ambient temperature where the plasma power supply is located is within the
acceptable temperature range for cutting system operation (See Table 1 on page 22.)

 If the temperature where your plasma power supply is located is above the
temperature limit, you can experience reduced performance and
over-temp diagnostic codes.

3. While all of the fans continue to operate, allow the cutting system to cool.

 Before you continue with the next step, make sure that the magnetics
reach a temperature of 160ºC (320ºF) or below.

4. Without removing the external side panel on the plasma power supply, look through the
ventilation trusses on the plasma power supply to examine both magnetic fans inside.

 Look through the ventilation trusses on the front of the plasma power
supply to locate the 2 magnetic (254 mm / 10 inch) fans inside. It is not
necessary to remove the external panels to view the magnetics fans.
Magnetic fans are near the front and bottom.

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 Diagnostics and Troubleshooting 8
5. Examine the XPR web interface. Make sure that the speed for each magnetics fan is within the
acceptable range (magnetics fan 1; magnetics fan 2).

Fan type Acceptable range of speed

Large fans (254 mm / 10 inches) 2,800 RPM – 3,400 RPM
Small fans (120 mm / 4.7 inches) 5,600 RPM – 6,400 RPM

 During normal operation, it is usually difficult to see individual blades

because of the fast speed of the fan rotation). If you can easily see
individual blades without the use of a strobe lamp, the rotation speed is
probably too slow.

6. If the speed of the fans is below the acceptable range (see table above), remove the electrical
power from the cutting system. (See Remove the power from the cutting system on page 255.)

7. Remove the front panel of the plasma power supply.

8. If you find obstructions, debris, or dust, use compressed air to remove the obstruction, debris, or
dust from the fans and magnetics area.

 The magnetics area can retain large amounts of dust or debris. Multiple
uses of compressed air is often necessary to clear this area. Consider the
use of personal protective equipment to protect yourself from airborne
particulates and debris.

 Make sure to minimize fan rotation during compressed air use. You can
use a gloved hand to hold a fan in position, if necessary.

9. If both magnetics fans have no obvious obstruction, dust, or debris:

a. Disconnect the connector from the control board PCB 1 (for the magnetics).
b. Use a digital multimeter to measure the resistance from each thermistor wire, based on the
following connector-pin locations:

1st 2nd
Location of thermistor
Diagnostic code Thermistor location connector connector
wires/connector
pin pin
580, 660, 671 Inductor 1A PCB 1 J1.4 pin 3 J1.4 pin 4
581, 661, 672 Inductor 1B PCB 1 J1.4 pin 5 J1.4 pin 6
582, 662, 673 Inductor 2A PCB 1 J1.4 pin 7 J1.4 pin 8
583, 663, 674 Inductor 2B PCB 1 J1.2 pin 1 J1.2 pin 2
586, 666, 677 Transformer PCB 1 J1.4 pin 1 J1.4 pin 2

 Thermistors are located on the magnetics.

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8 Diagnostics and Troubleshooting

c. Look for a resistance value from each thermistor wire that is outside of the minimum or
maximum in Table 37:

Table 37 – Minimum and maximum ohmic resistance values for thermistors

Thermistor temperature Minimum resistance (Ohms) Maximum resistance (Ohms)

25ºC (77ºF) 9,000 11,000
35ºC (95ºF) 5,000 7,000
45ºC (113ºF) 3,900 4,900
55ºC (131ºF) 2,500 3,500
65ºC (149ºF) 1,500 2,500
75ºC (167ºF) 1,000 2,000
85ºC (185ºF) 750 1,250
95ºC (203ºF) 600 1,000
105ºC (221ºF) 400 800
115ºC (239ºF) 300 600
125ºC (257ºF) 200 500
135ºC (275ºF) 150 400
145ºC (293ºF) 150 250
155ºC (311ºF) 125 225
165ºC (329ºF) 100 175

 At approximately 25ºC (77ºF), you can expect a resistance of

approximately 10,000 ohms.

d. If the ohmic resistance is outside of the minimum or maximum value in Table 37 on

page 322, contact your cutting machine supplier or regional Hypertherm Technical Service
team. They can help you to decide if there is a wiring fault or if thermistor replacement is
necessary.
e. If the resistance is at or very near 0 ohms:
 Inspect the wiring between each thermistor and its connector pins.
 Look for shorts between wires or to the ground.

10. If the thermistor resistance is within range when the thermistor is disconnected from the control
PCB and the code continues when the thermistor is reconnected to the control PCB, contact
your cutting machine supplier or regional Hypertherm Technical Service team. They can help you
decide if control PCB replacement is necessary. (See Plasma power supply control PCB
(141322) on page 344.)

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Current sensor diagnostic codes (631)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

1. Remove the power from the cutting system. (See Remove the power from the cutting system on
page 255.)

2. Examine J1.8 on PCB 1 (control PCB) and the work lead sensor located on the I/O panel on
PCB5 (I/O PCB).

3. Look for:
 Damage
 Loose connections

4. If the connections are good and the code continues, replace PCB5 (I/O PCB).

5. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

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8 Diagnostics and Troubleshooting

Low inlet pressure for H2, Ar, N2, and H2O diagnostic codes (695 – 697, 700, 701)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

1. During test cutflow and test preflow, look at the CNC or XPR web interface to identify the gas
or water inlet pressure in the mixing module inside the gas connect console. Look at:
 The H2 inlet pressure (P10) for code 695.
 The Ar inlet pressure (P11) for code 696.
 The N2 inlet pressure (P12) for code 697.
 The H2O inlet pressure (P8) for code 701.

2. If you have a Core, VWI, or OptiMix gas connect console, make sure that the gas inlet pressures
inside the gas connect console are acceptable:

Gas connect Acceptable gas inlet pressures in the gas connect console
console H2 N2 Ar
7.5 bar ± 0.4
Core – –
(110 psi ± 5)
7.5 bar ± 0.4 7.5 bar ± 0.4
VWI –
(110 psi ± 5) (110 psi ± 5)
8.3 bar ± 0.4 8.3 bar ± 0.4 8.3 bar ± 0.4
OptiMix
(120 psi ± 5) (120 psi ± 5) (120 psi ± 5)

3. If you have a VWI or OptiMix gas connect console, make sure that the water inlet pressure is at
least 2.07 bar (40 psi).

4. When gas flow is less than the pressure range, use the regulators to increase the pressure, if
necessary. Do not exceed the recommended pressures.

5. If the pressure remains too low, examine the gas hoses and gas inlet fittings. Look for:
 Damage or kinks that can restrict flow.
 Leaks that can decrease pressure.

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 Diagnostics and Troubleshooting 8
6. Replace the hoses if you find damage or kinks.

7. Reposition the hoses if you find fixable kinks.

8. Replace any fitting that has damage.

9. Tighten loose connections if found.

10. If you have an XPR cutting system equipped with a VWI or OptiMix gas connect console, make
sure that the shield water quality is good [See Shield water requirements (VWI and OptiMix) on
page 41.]. Bad quality can have a negative effect on the shield water regulator. This can cause
diagnostic codes for low inlet pressure.

11. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

Shield gas inlet pressure in the torch connect console diagnostic codes (702 – 705)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

1. Look at the CNC screen or XPR web interface to identify the inlet pressure inside the torch
connect console. Look at:
 The N2 inlet pressure (P4) for code 702.
 The O2 inlet pressure (P4) for code 703.
 The air inlet pressure (P4) for code 704.
 The Ar inlet pressure (P4) for code 705.

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8 Diagnostics and Troubleshooting

2. Make sure that the gas inlet pressures inside the torch connect console are acceptable:

Gas connect Acceptable gas inlet pressures in the torch connect console
console N2 O2 Air Ar
7.5 bar ± 0.4 7.5 bar ± 0.4 7.5 bar ± 0.4
Core –
(110 psi ± 5) (110 psi ± 5) (110 psi ± 5)
7.5 bar ± 0.4 7.5 bar ± 0.4 7.5 bar ± 0.4 7.5 bar ± 0.4
VWI
(110 psi ± 5) (110 psi ± 5) (110 psi ± 5) (110 psi ± 5)
8.3 bar ± 0.4 8.3 bar ± 0.4 7.9 bar ± 0.4 8.3 bar ± 0.4
OptiMix
(100 psi ± 5) (115 psi ± 5) (115 psi ± 5) (100 psi ± 5)

3. Use the regulators to increase or decrease the inlet pressure.

4. If the pressure remains too low, examine gas hoses and gas inlet fittings. Look for:
 Damage or kinks that can restrict flow.
 Leaks that can decrease pressure.

5. Replace the hoses if you find damage or kinks.

6. Reposition the hoses if you find fixable kinks.

7. Replace any fitting that has damage.

8. Tighten loose connections if found.

9. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

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 Diagnostics and Troubleshooting 8

Process-gas inlet pressure in the torch connect console diagnostic codes (702, 705, 769, 770) for
OptiMix-equipped cutting systems

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

The N2 and Ar gas regulators inside the OptiMix gas connect console (078633) are set at
Hypertherm. They are set when the process gas is flowing with 7.9 bar – 8.6 bar (115 psi –
125 psi) pressure on the gas inlet and 6.9 bar (100 psi) on the gas outlet. A downstream 1.6 mm
(0.063 inch) orifice is part of both regulator configurations.

It can be necessary to adjust the regulators, if the following conditions occur:

 N2 shield inlet (P4) pressure is above 7.5 bar (110 psi) or below 6.2 bar (90 psi)
 Ar shield inlet (P4) pressure is above 7.5 bar (110 psi) or below 6.2 bar (90 psi)

Follow these steps to adjust the N2 regulator

1. Install 1 of the following sets of consumables:

 300 A O2/Air
 300 A N2/N2
 300 A Mix/N2
 170 A O2/Air
 170 A N2/N2
 170 A Mix/N2

2. Use the XPR web interface to choose 1 of the following processes:

 2100 for 300 A N2/N2 aluminum or stainless steel
 2057 for 170 A N2/N2 aluminum or stainless steel

3. Remove the cover from OptiMix gas connect console.

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8 Diagnostics and Troubleshooting

4. Pull up the N2 regulator knob so the orange indicator is visible.

N2

Ar

5. Go to Gas System in the XPR web interface.

6. Choose TEST PREFLOW.

7. While the gas flows, adjust the regulator until the shield inlet sensor (P4) on the XPR web
interface is 6.9 bar (100 psi).

Follow these steps to adjust the Ar regulator

1. Install 1 of the following sets of consumables:

 300 A O2/Air
 170 A O2/Air

2. Use the XPR web interface to choose 1 of the following processes:

 1205 for O2/N2 mild steel
 1157 for O2/Air (Ar pierce assist) mild steel

3. Remove the cover for OptiMix gas connect console.

4. Pull up the Ar regulator knob so the orange indicator is visible.

N2

Ar

5. Go to Gas System in the XPR web interface.

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 Diagnostics and Troubleshooting 8
6. Choose TEST PIERCEFLOW.

7. While the gas flows, adjust the regulator until the shield inlet sensor (P4) on the web interface is
6.9 bar (100 psi).

Pressure transducer diagnostic codes (706 – 715)

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any troubleshooting or diagnostic
work.
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.

1. Remove the power from the cutting system. (See Remove the power from the cutting system on
page 255.)

2. Examine the pressure transducer that is referenced in the diagnostic code. For example, if the
code references “P1-TCC,” examine the P1 pressure transducer for the torch connect console,
or if the code references “P6-GCC,” examine the P6 pressure transducer for the gas connect
console.

3. Make sure that the pressure transducer is plugged in correctly on the following PCBs:
 Torch connect console control PCB
 Gas connect console control PCB

4. Re-install the pressure transducer if any incorrect connections are found.

5. If you find damage, replace the damaged control PCB.

6. Replace the pressure transducer.

7. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

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8 Diagnostics and Troubleshooting

Gas inlet pressure codes (768 – 771)

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

WARNING

ELECTRIC SHOCK CAN KILL

When the line-disconnect switch is in the ON position, there is line voltage at the
contactor and the power distribution PCB.
Voltages present at the terminal block and contactors can cause injury or death.
Use extreme caution when you measure the primary power in these areas.

It is necessary for the cutting system to have electric power to verify gas inlet pressures. Use
extreme caution if you do diagnosis or maintenance tasks when the plasma power supply
remains connected to electricity and the panels on the plasma power supply are removed.

Gas pressure drops are more likely to occur if the supply gas hoses are long. For the best results
position a gas regulator within 3 meters (10 feet) of the gas connect console (See Configuration
with Core gas connect console on page 73 and Configuration with VWI or OptiMix gas connect
console on page 74.)

1. Use the CNC or XPR web interface to select Test Cutflow to start the gas flow.

2. Make sure that the gas inlet pressures are within the acceptable range (Process gas
requirements (Core, VWI, and OptiMix gas connect consoles) on page 36).

3. If the gas inlet pressure is not within the acceptable range, adjust it
a. Use a 2-stage regulator that can delivery the necessary gas flow and can maintain
consistent gas pressure with high-pressure gas cylinders.

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 Diagnostics and Troubleshooting 8
b. Review the diagnostic code history for previous pressure-related codes that can indicate
where to look for flow or pressure problems.
c. If you identify a code for a pressure transducer (P1 or P2), exchange the transducers. See if
the code follows the transducer change. Replace the bad transducer if necessary. For
instructions, refer to “Replace a pressure transducer” in the XPR Replacement Parts
Procedures Field Service Bulletin (809970),

4. If you have a cutting system equipped with a OptiMix gas connect console, refer to Process-gas
inlet pressure in the torch connect console diagnostic codes (702, 705, 769, 770) for
OptiMix-equipped cutting systems on page 327.

5. If you have a Core or VWI gas connect console, or if the code continues, or if you cannot find or
resolve the problem with these corrective actions, contact your cutting machine supplier or
regional Hypertherm Technical Service team.

How to do a gas leak test (VWI and OptiMix)

NOTICE
Gas leaks or pressure and flow rates that are outside of recommended ranges can:
• Cause problems with system performance
• Result in bad cut quality
• Shorten the life of consumables
If the quality of the gas is bad or if the pressure setting is incorrect, it can decrease:
• Cut quality
• Cut speed
• Cut thickness capabilities

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8 Diagnostics and Troubleshooting

WARNING
If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to
the oxygen-enriched atmosphere that collects.
Hypertherm recommends that you install an exhaust ventilation system to remove the
oxygen-enriched atmosphere that can collect when oxygen is used as the plasma gas for
cutting.
Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).
As an installer or user, you must supply the flashback arrestors for your cutting system. You
can get them from your cutting machine supplier.

Hydrogen is a flammable gas that presents an explosion hazard. Keep flames away from
cylinders and hoses that contain hydrogen. Keep flames and sparks away from the torch
when using hydrogen as a plasma gas.
Consult your local safety, fire, and building code requirements for the storage and use of
hydrogen.
Hypertherm recommends that you install an exhaust ventilation system to remove the
hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas
for cutting.
Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless
a flashback arrestor is not available for a specific gas or pressure).
As an installer or user, you must supply the flashback arrestors for your cutting system. You
can get them from your cutting machine supplier.

 See Table 7 on page 36 for the recommended pressure and flow rates.

If you suspect a cutting system gas leak:

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 error log for information and guidance about how to diagnose or troubleshoot a
possible gas leak.

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 Diagnostics and Troubleshooting 8

How to measure coolant flow

WARNING
ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can cause injury or
death.
Even if the plasma power supply is turned OFF, you can still get a serious electric shock if
the plasma power supply remains connected to an electric power source.
Use extreme caution if you do diagnosis or maintenance tasks when the plasma power
supply remains connected to an electric power source and the outer cover or panels are
removed.

It is necessary for power to be supplied to the cutting system to measure coolant flow. Use
extreme caution if you do diagnosis or maintenance tasks when the plasma power supply
remains connected to electric power.

Use the CNC or XPR web interface

1. Look at the CNC or XPR web interface to identify the coolant flow rate.

2. Make sure that the coolant flow rate is above 3.79 L/min (1 gal/min).

 If the flow rate is outside of the correct range, an internal obstruction or

leak can be the cause.

Do a container test
1. Obtain an empty container that has a capacity of at least 3.79 liters (1 US gallon) and volume
measurements, if possible.

2. Remove the power from the cutting system. (Refer to Remove the power from the cutting
system on page 255.)

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8 Diagnostics and Troubleshooting

3. Disconnect the coolant return hose (red) from the coolant return fitting (red) inside the rear of
the plasma power supply. Use the container to catch coolant leaks if needed, but empty it
before you start the test

4. Put the end of the coolant return hose into the container.

5. Restore electrical power to the cutting system.

6. Send a process to the cutting system.

7. When you hear the coolant pump turn ON, begin a 30-second count while coolant flows into
the container.

8. After 30 seconds look at the amount of coolant in the container. It should be at least 1.89 liters
(0.5 US gallon).

9. If the flow rate is outside of the correct range, an internal obstruction or leak can be the cause.

10. If you find obstructions, remove them. Replace damaged parts if found.

11. If coolant flow remains slow, and it has been more than 6 months since the last coolant
replacement, replace the coolant. (See Replace all of the coolant on page 248.)

 Hypertherm recommends coolant replacement every 6 months. For

complete preventative maintenance information, see the XPR Preventative
Maintenance Program (PMP) Instruction Manual (809490).

12. If coolant flow remains slow after replacement, verify that the following function and components
are good:
 Bypass is working
 Coolant pump motor

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 Diagnostics and Troubleshooting 8
 Consumables and torch
 Coolant check valve

13. If you cannot find or resolve the problem with these corrective actions, contact your cutting
machine supplier or regional Hypertherm Technical Service team.

How to test continuity between the nozzle and workpiece

1. Remove the power from the cutting system. (See Remove the power from the cutting system on
page 255.)

2. Locate the start-circuit assembly PCB 4 1 .

XPR300 Instruction Manual 809480 335

8 Diagnostics and Troubleshooting

3. Install a temporary jumper wire between J5 (nozzle) 2 and J1 (work) 3 on the start circuit
PCB 4 (141360).

D4

D6

NOTICE
Never fire an arc when a temporary jumper wire is installed on the PCB. Sparking and damage to the
PCB can occur.

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 Diagnostics and Troubleshooting 8
4. Locate the pilot arc relay (CR 1) 4 and remove the dust cover 5 .

5. Have a second person close (push in) the contact on the pilot arc relay.
(-)
(+)

22
21

6. Measure the ohms between the nozzle and the workpiece. Less than 3 ohms is good. A value
greater than 3 ohms indicates a faulty connection between the torch and ignition console, or
between the ignition console and the power supply, or between the power supply work lead and
workpiece.

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8 Diagnostics and Troubleshooting

7. Examine the work lead. Replace it if you find damage or excess wear.

8. Examine the pilot arc circuit (plasma power supply to gas connect console, to torch connect
console, to torch receptacle).
a. If the pilot arc wire is damaged, replace the damaged item.
b. If the pilot arc wire is not damaged, replace the torch and receptacle.

9. Release the pilot arc relay and measure the ohms between the nozzle and workpiece. The
acceptable range is 9,000 – 11,000 ohms. If the ohms value is low (approximately 5,000 ohms
or less), examine the pilot arc circuit (power supply to gas connect console, to torch connect
console, to torch receptacle). Look for insulation damage and short circuits to ground.

How to measure resistance from thermistors

1. Use a digital multimeter to measure the resistance from each thermistor wire, based on the
following connector-pin locations:

Location of thermistor 1st connector 2nd connector

Thermistor location
wires/connector pin pin
Inductor 1A PCB 1 J1.4 pin 3 J1.4 pin 4
Inductor 1B PCB 1 J1.4 pin 5 J1.4 pin 6
Inductor 2A PCB 1 J1.4 pin 7 J1.4 pin 8
Inductor 2B PCB 1 J1.2 pin 1 J1.2 pin 2
Transformer PCB 1 J1.4 pin 1 J1.4 pin 2
Chopper 1 PCB 2 J9 pin 1 J9 pin 2
Chopper 2 PCB 3 J9 pin 1 J9 pin 2
Coolant temperature PCB 1 J1.2 pin 7 J1.2 pin 8

2. Look for a resistance value that is outside of the minimum or maximum in Table 38:

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 Diagnostics and Troubleshooting 8
Table 38 – Minimum and maximum ohmic resistance values for thermistors

Thermistor temperature Minimum resistance (Ohms) Maximum resistance (Ohms)

25ºC (77ºF) 9,000 11,000
35ºC (95ºF) 5,000 7,000
45ºC (113ºF) 3,900 4,900
55ºC (131ºF) 2,500 3,500
65ºC (149ºF) 1,500 2,500
75ºC (167ºF) 1,000 2,000
85ºC (185ºF) 750 1,250
95ºC (203ºF) 600 1,000
105ºC (221ºF) 400 800
115ºC (239ºF) 300 600
125ºC (257ºF) 200 500
135ºC (275ºF) 150 400
145ºC (293ºF) 150 250
155ºC (311ºF) 125 225
165ºC (329ºF) 100 175

 At approximately 25ºC (77ºF), you can expect a resistance of

approximately 10,000 ohms.

3. If the resistance is above the maximum value, contact your cutting machine supplier or regional
Hypertherm Technical Service team. They can help you to decide if there is a wiring fault or if
thermistor replacement is necessary.

4. If the resistance is at or near 0 ohms:

a. Inspect the wiring between each thermistor and its connector pins.
b. Look for shorts between wires or to the ground.

5. If the resistance is within range, continue cutting system operation.

6. If the resistance remains below the minimum ohmic value or does not change after you allow the
coolant to reach 85ºC (185ºF) or below, contact your cutting machine supplier or Hypertherm
Technical Service team.

7. If the thermistor resistance is within range when the thermistor is disconnected from the control
PCB and the code continues when the thermistor is reconnected to the control PCB, contact
your cutting machine supplier or regional Hypertherm Technical Service team. They can help you
decide if control PCB replacement is necessary. (See Plasma power supply control PCB
(141322) on page 344.)

8. If the code continues, or if you cannot find or resolve the problem with these corrective actions,
contact your cutting machine supplier or regional Hypertherm Technical Service team.

XPR300 Instruction Manual 809480 339

8 Diagnostics and Troubleshooting

How to do an ohmic-contact test

WARNING

ELECTRIC SHOCK CAN KILL

When the line-disconnect switch is in the ON position, there is line voltage throughout the
cutting system.
Voltages present throughout the cutting system can cause injury or death.
Use extreme caution if you do diagnosis or maintenance tasks when the line-disconnect
switch is in the ON position.

1. Remove the power from the cutting system. See Remove the power from the cutting system on
page 255.

2. Examine the J2 connector on the ohmic contact PCB. Make sure that the ohmic relay coil is
connected. Reconnect or tighten the ohmic relay coil if needed.

3. Disconnect the ohmic relay connector to access the bullet connector 1 on the torch receptacle
block-side located inside the torch connect console.

4. Use a digital multimeter to measure the resistance from the torch tip to the ohmic relay. See
Figure 63 on page 341.

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 Diagnostics and Troubleshooting 8
Figure 63 – Measure the resistance from the torch tip to the ohmic relay

< 100 Ohms

J4 J3
J27

J2

J1

a. If the resistance is infinite (open), replace the torch lead.

b. If the resistance is less than 100 Ohms, continue with step step 5.

5. Reconnect the ohmic relay connector.

6. Examine the ohmic contact PCB. See Torch connect console ohmic PCB (141368) on
page 351.
a. If configured for internal ohmic, make sure that the ohmic wire from the ohmic relay is
connected to J3.
b. If configured for external ohmic, make sure that the ohmic wire from the ohmic relay is
connected to J4 pin 2 and that the ohmic wire from the lifter is connected to J4 pin 1.
c. Adjust or tighten connections, if needed, then continue with step 7.

7. Supply electrical power to the cutting system.

8. Make sure that the torch is not touching the workpiece.

9. Use a digital multimeter to look for 24 VDC between the workpiece, or chassis ground, and the
torch tip (J3 or J4).

10. If there is no 24 VDC, examine the wiring to the ohmic PCB (141368). Make sure that the J3 or
J4 connector is not clamped onto the wire insulation and that the connection between the J2 or
J2A connector and the relay coil is good.

 If the connections are good but there is no 24 VDC, contact your cutting
machine supplier or regional Hypertherm Technical Service Team.

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8 Diagnostics and Troubleshooting

11. If you find 24 VDC, continue with the following steps:

a. Make sure that both the workpiece and the torch connect console are grounded in the same
location.
b. Touch the torch tip to the workpiece or attach a jumper wire between the torch tip and the
chassis ground.
c. Examine LED D2 on the ohmic contact PCB. See Torch connect console ohmic PCB
(141368) on page 351.
d. Examine LED D15 on the control PCB. See Torch connect console control PCB (141334)
on page 352.
e. Make sure that LED D2 and D15 both illuminate.
f. If both LEDs illuminate, make sure that the CNC is receiving ohmic contact signals from the
cutting system or torch height controller.

 If receiving ohmic contact signals, refer to the instruction manual that

came with your CNC for troubleshooting recommendations.

g. If LED D2 is not illuminated, replace the ohmic contact board (141368).

h. If LED D2 is illuminated and D15 is not, examine the wiring harness between both boards.
Look for loose wiring.

12. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical
Service Team.

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 Diagnostics and Troubleshooting 8

PCB information

Plasma power supply power distribution PCB

(141425)
LED Signal
D1 120 VAC

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8 Diagnostics and Troubleshooting

Plasma power supply control PCB (141322)

D84

D85
D82
PROG
WIFI MODE SEL
RUN
D81

D80

D52 D51 D4

D49

D104
D105 D47
D78 D79
D43

D41

D38

D36

D33

D31

D28

D20

D24

D86

D50 D45

D15
D56
D94 D17
D64
D53 D108
D95
D54 D89
ENABLE
CNC +24V OUT
DISABLE

D3 D6
D61

D10

D66
D19
D68
D25
D69
D97
D103 D2
D100

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 Diagnostics and Troubleshooting 8

LED Signal LED Signal

D84 WiFi LED 1 D50 PLASMA START
D85 WiFi LED 2 D56 MOTION
D82 WiFi RX D64 HOLD OUT
D81 WiFi TX D53 HOLD IN
D80 EtherCAT EEProm D54 PIERCE COMPLETE
D52 RS-422 RX D61 CNC ERROR
D51 RS-422 TX D66 READY FOR START
D4 A3.3 V D68 AUTO PIERCE DETECT
D49 USB FLAG D69 OHMIC CONTACT OUTPUT
D104 STATUS D15 SURGE INJ EN (UNUSED IN THIS
SYSTEM)
D105 ACTIVITY
D108 PILOT ARC ENABLE
D78 CAN RX
D89 REMOTE ON-OFF RELAY ENABLE
D79 CAN TX
D6 PILOT ARC RELAY
D47 CONTROL-SIDE FAN 2 FEEDBACK
D10 MARK RELAY
D43 CONTROL-SIDE FAN 1 FEEDBACK
D19 MAIN CONTACTOR
D41 HX FAN 2 FEEDBACK
D25 INRUSH CONTACTOR
D38 HX FAN 1 FEEDBACK
D97 COOLANT SOLENOID
D31 MAG FAN 2 FEEDBACK
D100 PUMP ENABLE
D28 MAG FAN 1 FEEDBACK
D94 +15 V
D5 +3.3 V
D95 -15 V
D20 MAGNETIC FANS ENABLE
D3 +5 V
D24 HEAT EXCHANGER FAN ENABLE
D2 +24 V
D45 COOLANT FLOW
D103 COOLANT LEVEL
D86 REMOTE ON-OFF

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8 Diagnostics and Troubleshooting

DIP switch positions

DIP switch 1 positions

1 RS-422 RX termination – Default is ON
2 RS-422 TX termination – Default is OFF
3 Not used – Default is ON
ON = 121 Ohms
4 CAN termination resistor Default is ON
OFF = Open

DIP switch 2 positions

ON = DFU
1 Micro-controller DFU programming mode Default is OFF
OFF = Run
ON = USB OTG
2 3.3V logic power Default is OFF
OFF = Internal power supply
3 RS-422 Serial ID0 – Default is OFF
4 RS-422 Serial ID1 – Default is OFF

DIP switch 3 positions

ON = Enabled
1 Wireless module programming Default is OFF
OFF = Disabled
ON = From micro-controller
2 Wireless module transmit: Default is ON
OFF = Disabled
ON = From J20 programming
3 Wireless module transmit connector Default is OFF
OFF = Disabled
ON = Wireless disabled
4 Wireless enable Default is OFF
OFF = Wireless enabled

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 Diagnostics and Troubleshooting 8

Plasma power supply chopper PCB (141319)

D6 D10

D1 D2

D96 D3 D4 D33D34
D22
D14

D21D32 D31

LED Signal LED Signal

D22 +15V AND -15V POWER D1 DCA
D14 +5 V D2 DCB
D21 +3.3 V D3 STATUS
D32 OVER CURRENT CHANNEL B D4 ACTIVITY
D31 OVER CURRENT CHANNEL A D10 +5VB
D96 USBFLAG D33 CAN TX
D6 +18V AND -5V POWER D34 CAN RX

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8 Diagnostics and Troubleshooting

Plasma power supply start circuit PCB (141360)

D4

D6

LED Signal LED Signal

D4 PILOT ARC ENABLE D6 +18V AND -5V POWER

Plasma power supply I/O PCB (141371)

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 Diagnostics and Troubleshooting 8

Plasma power supply fan power distribution PCB (141384)

XPR300 Instruction Manual 809480 349

8 Diagnostics and Troubleshooting

Gas connect console control PCB (141375)

D15

D26 D29

D25
D18
D24
D30 D31

D16

D1
D17

D5 D6

LED Signal LED Signal

D15 +24 V D24 CAN RX
D29 B5 D30 Status
D26 B4 D31 Activity
D19 HF D1 USBFLAG
D18 +3.3 V D16 +5 V
D25 CAN TX D17 A3.3

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 Diagnostics and Troubleshooting 8

Gas connect console high frequency PCB (141354)

LED Signal
D1 HIGH FREQUENCY ENABLE

Torch connect console ohmic PCB

(141368)
LED Signal
D2 Ohmic contact

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8 Diagnostics and Troubleshooting

Torch connect console control PCB (141334)

D70

D69 D76
D4
D58
D18

D8
D75
D45 D49
D63
D51 D46 D15
D43

D87
D88
D34 D44
D35
D23

D24

D25
D41 D57
D84

D16
D48
D64

LED Signal LED Signal

D58 V7 D87 STATUS LED
D69 V9 D88 ACTIVITY LED
D75 V10 D45 A3.3 V
D51 V6 D4 V11
D41 V5 D63 B3
D84 V12 D46 +3.3 V
D16 V4 D23 USB FLAG
D64 V8 D43 +5 V
D34 CAN RX D44 +24 V
D35 CAN TX D70 V1 TORCH VALVE
D48 B1 D76 V2 (NOT USED IN THIS
SYSTEM)
D57 B2 D18 V3 (NOT USED IN THIS
SYSTEM)
D49 HV RELAY D8 (NOT USED IN THIS
SYSTEM)
D15 OHMIC CONTACT

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 Parts List

Plasma power supply

Part number Voltage (AC)

078620 200
078621 208
078622 220
078623 240
078624 380
078625 400
078626 415
078627 440
078628 480
078629 600

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9 Parts List

Outer panels

2 2 7

6
3
5

Part number Description Quantity

1 428728 Top panel with labels 1
2 428727 Side panel with labels and handles 2
3 101300 Base 1
4 428725 Front panel with “H” (not shown) and power-indicator LED label 1
5 101314 Lower right (liquid-cooling) rear corner panel 1
6 101307 Lower left (control) rear corner panel 1
7 428726 Rear panel with label and handles 1

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 Parts List 9

Fans

1 4

Part number Description Designator Quantity

1 429002 Power-indicator LED – 1
Fan: 292 cfm, 48 VDC,120 mm (4.7 inch) CAB FAN3,
2 229821 2
diameter CAB FAN4
HX FAN1,
Fan: 890 cfm, 48 VDC, 254 mm (10 inch) HX FAN2,
3 229822 4
diameter MAG FAN1,
MAG FAN2
4 229717 Heat-exchanger only – 1
5 003266 Solid state relay – 1
6 141384 Fan power distribution PCB PCB6 1

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9 Parts List

Coolant system
1 13
3
2

10

9
6

11
8

7
12

Part number Description Quantity

1 127014 Coolant reservoir cap 1
2 229741 Flow meter 1
3 229775 Coolant level sensor 1
4 101281 Coolant filter bracket 1
5 127344 Coolant filter housing 1
027005 Coolant filter (fine) 1
6 229777 Coolant hose (1 inch) 1
Coolant pump and motor assembly:
Adapter: 1-5/8 inch UNF X 1 inch NPT X #16 JIC
Plug with O-ring
Coolant pump screen (coarse)
7 428729 Pump and motor 1
Adapter: 1 inch MNPT X 1 inch MNPT hexagonal collar
Adapter: 1 inch MNPT X 3/8 inch FNPT X 1/4 inch FNPT
Adapter: 3/8 inch hexagonal
Coolant solenoid valve assembly
8 006132 Coolant bypass check valve 1
9 229721 Coolant solenoid valve assembly 1
10 229654 Thermistor: Copper pipe clip with electrical connector 1
11 127559 Coolant pump screen (coarse) 1

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 Parts List 9

Part number Description Quantity

12 229843 Plug and O-ring 1
13 002561 Coolant reservoir 1
428330 Kit: Tubing (1 inch hose not included) 1

Coolant adapters in the rear compartment

1 3

4
6

4 5

Part number Description Quantity

1 015889 Elbow adapter: 1/2 inch NPT X 1/2 inch tube, 45° swivel 2
2 006154 Coolant check valve 1
3 015903 Red ring: 1.13 inches inner diameter 1
4 015888 Adapter: 1/2 inch FNPT X 1-1/2 inch length bulkhead 2
015899 Red ring: 0.87 inch inner diameter (not shown) 1
5 015029 Adapter: 1/2 inch NPT X #8 male 2
015898 Green ring: 0.87 inch inner diameter (not shown) 1
6 015902 Green ring: 1.13 inch inner diameter 1

XPR300 Instruction Manual 809480 357

9 Parts List

Other adapters not shown

Part number Description Location Quantity
Male adapter: 3/8 inch NPT X 1/2 inch
015669 in coolant solenoid valve 1
tube
Coolant drain valve: 1/4 inch NPT X in the bottom of the coolant
006099 1
3/8 inch tube reservoir
in the bottom of the coolant
015073 Adapter: 1/4 inch NPT X 1/4 FPT 1
reservoir
Elbow adapter: 1/4 inch NPT X in the top of the coolant
015738 1
1/2 inch tube, 45° swivel reservoir
between the flow meter and
015510 Adapter: 1/4 inch X hexagonal collar 1
coolant reservoir
in the flow meter and coolant
015663 Adapter: 1/4 inch NPT X 1/2 inch tube 2
bypass check valve
Elbow adapter: 1/2 inch NPT X in the coolant filter (fine)
015668 2
1/2 inch tube, 90° assembly
104807 Nut for chopper fitting on the back of choppers 4
Elbow fitting: 1/2 inch tube X 1/2 inch on the back of the choppers (4)
015815 5
tube, 90° and the heat-exchanger inlet (1)
015820 Fitting: 1/2 inch tube X 1/2 inch tube heat-exchanger outlet 1

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 Parts List 9

Transformers and inductors

Part number Description Designator Quantity

1 428844 Kit: Inductor 1A (top)/1B (bottom) L1 1
2 428845 Kit: Inductor 2A (top)/2B (bottom) L2 1
Transformer, horizontal, 63 kW, 3-phase*
– 200 V, 50 Hz – 60 Hz
– 208 V, 60 Hz
– 220 V, 50 Hz – 60 Hz
– 240 V, 60 Hz
3 – 380 V, 50 Hz – 60 Hz
T2 1
– 400 V, 50 Hz
– 415 V, 50 Hz
– 440 V, 50 Hz – 60 Hz
– 480 V, 60 Hz
– 600 V, 60 Hz

* You cannot purchase this part. Shown for reference only.

XPR300 Instruction Manual 809480 359

9 Parts List

Control side – view 1

1

Part number Description Designator Quantity

Power source: 88 VAC – 264 VAC to
1 229671 PS2 1
48 VDC, 600 W
2 141425 Power distribution PCB PCB7 1
108709 Fuse: 10 A, 250 VAC, time delay (on PCB7) F3, F4, F5 3
Control transformer assembly, 3 kVA
229809 200 V, 50 Hz – 60 Hz
229810 208 V, 60 Hz, 3 kVA
229811 220 V, 50 Hz – 60 Hz
229812 240 V, 60 Hz
3 229813 380 V, 50 Hz
T1 1
229814 400 V, 50 Hz
229815 415 V, 50 Hz
229816 440 V, 50 Hz – 60 Hz
229794 480 V, 60 Hz
229817 600 V, 60 Hz
4 229678 Start circuit assembly PCB4 1

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 Parts List 9

Control side – view 2

Part number Description Designator Quantity

Power source: 88 VAC – 264 VAC to
1 229640 PS1 1
24 VDC
2 428750 Control PCB PCB1 1
3 208394 Fuse holder: 2P, 30 A, 600 V – 1
Fuse: 8 A, 600 V, Class R (used in 380 V,
208395
400 V, 415 V, 440 V, 480 V, 600 V)
F1, F2 2
Fuse: 15 A, 600 V, Class R (used in 200 V,
208397
208 V, 220 V, 240 V)
4 141371 I/O PCB PCB5 1
Pilot arc relay: 24 VDC, coil, 60 A 28 VDC
5 003277 CR1 1
contacts
6 101316 Pilot arc relay cover – 1

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9 Parts List

Part number Description Designator Quantity

Chopper 1,
7 229679 Chopper assembly 2
Chopper 2
229956 XPR170 wire harness – 1
229711 XPR300 wire harness – 1

Rear compartment of the plasma power supply

6
6

200 V, 208 V, 220 V, 240 V plasma 380 V, 400 V, 415 V, 440 V, 480 V,
power supplies 600 V plasma power supplies

Part number Description Designator Quantity

Inrush contactor assembly: 80 A, IEC AC-3,
1 229697 IR_CON 1
3-phase, 120 VAC
2 209274 Inrush resistor assembly, 2 Ω X 3 – 1
Terminal block 600 V, 200 A (200 V, 208 V,
3 229033
220 V, 240 V, 380 V, 400 V, 415 V)
TB1 1
Terminal block 600 V, 140 A (380 V, 440 V,
4 029316
480 V, 600 V)
003276 Main contactor (200 V, 208 V, 220 V, 240 V)
5 Main contactor assembly (380 V, 400 V, M_CON 1
429060
415 V, 440 V, 480 V, 600 V)
VDC3 PCB (Optional, for use with RS-422
6 141511 – 1
and discrete cutting systems)

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 Parts List 9

Gas connect consoles

Core VWI OptiMix

Part number Description

078631 Core gas connect console
078632 VWI gas connect console
078633 OptiMix gas connect console

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9 Parts List

Gas connect console high-voltage side parts

1

Inside view

Part number Description Console Designator Quantity

1 002570 Insulator Core, VWI, OptiMix – 1
2 229837 Coil assembly Core, VWI, OptiMix T2 1
High-frequency,
3 229838 Core, VWI, OptiMix T1 1
high-voltage transformer
4 009045 EMI filter Core, VWI, OptiMix – 1
High-frequency,
5 141354 Core, VWI, OptiMix PCB2 1
high-voltage ignition PCB
Socket head cap screw:
6 075678 M5 – 0.8 X 10 mm Core, VWI, OptiMix – 1
hexagonal

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 Parts List 9

Gas connect console manifold side parts

Core, VWI, and OptiMix gas connect console manifold side
1
2
3

4
5

6
7
8

7 9

11
10
7

Part number Description Console Designator Quantity

1 011151 Air filter assembly Core, VWI, OptiMix – 1
011110 Air filter element Core, VWI, OptiMix – 1
Male elbow adapter:
2 015853 1/4 inch NPT X 5/16 inch Core, VWI, OptiMix – 2
tube
Power source:
3 229640 88 VAC – 264 VAC to VWI, OptiMix only – 1
24 VDC
4 141375 Control PCB Core, VWI, OptiMix PCB1 1
Green power-indicator LED
5 229825 Core, VWI, OptiMix – 1
assembly
6 104757 Coolant manifold Core, VWI, OptiMix – 1
Adapter: 1/2 inch NPT X
7 015029 Core, VWI, OptiMix – 4
#8 male
Green ring: 0.87 inches
8 015898 Core, VWI, OptiMix – 2
inner diameter
Red ring: 0.87 inches inner
9 015899 Core, VWI, OptiMix – 2
diameter
10 075218 Washer Core, VWI, OptiMix – 1
11 075140 Bolt Core, VWI, OptiMix – 1

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9 Parts List

Core gas connect console manifolds and adapters

8 9

7 7

6
6
3 3

4 4

5 4

2
1

Part number Description Quantity

1 104806 Manifold: Gas output (no adapters) 1
2 104802 Manifold: Gas input (no adapters) 1
Push-to-connect adapters
3 015876 1/4 inch NPT X 1/4 inch tube 2
4 015811 1/4 inch NPT X 8 mm tube 3
5 015853 Male elbow: 1/4 inch NPT X 5/16 inch tube 1
Threaded adapters with thread sealant applied
6 015012 1/4 inch NPT X #6 male (air output and input) 2
7 015103 1/4 inch NPT X RH ‘B’ inert female (nitrogen output and input) 2
8 015116 1/8 inch NPT X RH ‘A’ male (oxygen output) 1
9 015009 1/4 inch NPT X RH ‘B’ male (oxygen input) 1

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 Parts List 9

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XPR300 Instruction Manual 809480 367

9 Parts List

VWI gas connect console input and output manifolds and adapters

3 9
14
12
11
12 8
14
6
7
13 11
6
15 5
4

2
8 18

17
5
16
6 12
7 10
11

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 Parts List 9

Part number Description Quantity

1 229792 Manifold: Gas input (no adapters) 1
2 104843 Manifold: Gas output (no adapters) 1
3 229844 Water regulator 1
4 006157 Check valve 1
Push-to-connect adapters
5 015905 1/8 inch NPT X 1/4 inch tube 2
6 015910 3/8 inch NPT X 5/16 inch tube 2
7 015907 1/4 inch NPT X 3/8 inch tube 1
8 015876 1/4 inch NPT X 1/4 inch tube 1
9 015853 Elbow: 1/4 inch NPT X 5/16 inch tube, 90° 1
10 015909 Elbow: 3/8 inch NPT X 5/16 inch tube, 90° –
Threaded adapters with thread sealant applied
11 015103 1/4 inch NPT X RH ‘B’ inert female 3
12 015012 1/4 inch NPT X #6 male 3
13 015009 1/4 inch NPT X RH ‘B’ male 1
14 015922 1/4 inch X hexagonal collar 2
15 015230 1/4 inch NPT X LH ‘B’ 1
16 015116 Adapter: 1/8 inch NPT X RH ‘A’ (oxygen outlet) 1
17 015210 Adapter: 1/8 inch NPT X LH ‘A’ male (hydrogen mix outlet) 1
18 015197 Adapter: 1/8 inch NPT X #5 male (argon outlet) 1

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9 Parts List

OptiMix gas connect console input and output manifolds and adapters

3
14
15

16
4 10
9
8
7
13 4 6
17
5

2
7 20

19
11
18
10 14
12 9
13

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Part number Description Quantity

1 229793 Manifold: Gas input (no adapters) 1
2 104843 Manifold: Gas output (no adapters) 1
3 229844 Water regulator 1
4 006157 Check valve 4
Push-to-connect adapters
5 015905 1/8 inch NPT X 1/4 inch tube 1
6 015853 Elbow: 1/4 inch NPT X 5/16 inch tube 1
7 015876 1/4 inch NPT X 1/4 inch tube 1
8 015907 1/4 inch NPT X 3/8 inch tube 1
9 015909 Elbow: 3/8 inch NPT X 5/16 inch tube 1
10 015910 3/8 inch NPT X 5/16 inch tube 1
11 015906 Dual connection: 1/8 inch NPT X 1/4 inch tube 1
12 015908 Elbow: 1/4 inch NPT X 3/8 inch tube 1
Threaded adapters with thread sealant applied
13 015103 1/4 inch NPT X RH ‘B’ inert female 3
14 015012 1/4 inch NPT X #6 male 3
15 015009 1/4 inch NPT X RH ‘B’ male 1
16 015922 1/4 inch X hexagonal collar 5
17 015230 1/4 inch NPT X LH ‘B’ 1
18 015116 1/8 inch NPT X RH ‘A’ 1
19 015210 1/8 inch NPT X LH ‘A’ 1
20 015197 1/8 inch NPT X #5 1

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VWI and OptiMix gas connect console mixer, transducers, and valves

2
1

VWI 3 OptiMix

Part number Description Console Designator Quantity

Mixer (You cannot purchase
1 – this part. Shown for OptiMix – 1
reference only.)
2 011101 Regulator OptiMix – 2
3 223398 Pressure transducer VWI and OptiMix P6 – P9 4
4 006167 Solenoid valve VWI and OptiMix B4, B5 2

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Gas connect console wire harness, hose kit, and CAN cables
Part number Description Console Quantity
229718 Wire harness Core
229719 Wire harness VWI 1
229720 Wire harness OptiMix
428490 Kit: Tubing Core
428491 Kit: Tubing VWI 1
428492 Kit: Tubing OptiMix
223709 CAN cable 0.38 m (1.2 ft) to external connector Core, VWI, OptiMix 1
223710 CAN cable 0.48 m (1.6 ft) male-female Core, VWI 1
223711 CAN cable 0.5 m (1.6 ft) male-female OptiMix 1
223712 CAN cable 0.39 m (1.3 ft) male-female OptiMix 1

Torch connect console

Part number Description

078618 Torch connect console

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Torch connect console Easy Connect side

Part number Description Designator Quantity

1 428730 Torch receptacle block – 1
2 229882 Ohmic relay and bracket – 1
3 420376 Torch lead connector – 1
Machine screw: M6 X 10 mm
4 075544 – 4 (3 shown)
Phillips, pan head

Torch connect console – top

Part number Description Designator Quantity

1 428338 Kit: Tubing – 1
2 006152 Check valve – 2

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Torch connect console manifold side – view 1

1

6
3

2 5

Part number Description Designator Quantity

Pressure transducer with wire and
1 223477 P1 – P5, P14 6
connector
Power source: 88 VAC – 264 VAC
2 229640 PS1 1
to 24 VDC
3 141334 Control PCB PCB1 1
4 141368 Ohmic contact PCB PCB2 1
Green power-indicator LED
5 229825 – 1
assembly
6 101366 Bracket – 2 (1 shown)
229780 Valve cable 40 mm (1.6 inches) – 8
229800 Valve cable 279.4 mm (11 inches) – 1
229655 Wire harness – 1

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9 Parts List

Torch connect console manifold side – view 2

1 6

2
3
4

Part number Description Designator Quantity

229895 Manifold assembly: – 1
• Solenoid valves
• Proportional valves
• All manifolds
• All fittings
1 229965 Solenoid valve V4 – V12 9 (8 shown)
229917 Solenoid valve (229965) tool –
015905 Adapter: 1/8 inch NPT O-ring seal X – 2
2
1/4 inch tube
428756 Bottom manifold assembly: – 1
• Bottom manifold
3 • Adapter
• Critical orifice
• Solenoid valve
015811 Adapter: 1/4 inch NPT O-ring seal X 8 mm – 1
4
tube

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Part number Description Designator Quantity

104406 Adapter: 1/8 inch FPT X1/8 inch NPT – 1
5
X1-5/8 inch
6 006167 Proportional valve B1 – B3 3
044508 O-ring 7

Front adapters and valves

9
8

3 5
1 4

Part number Description Designator Quantity

1 006077 Check valve: 1/8 inch FPT – 2
2 006157 Check valve: 1/4 inch NPT female – 1
Threaded adapters with thread sealant applied
3 015517 1/8 inch hexagonal collar – 2
4 015116 1/8 inch NPT X RH ‘A’ – 1
5 015226 1/8 inch NPT X #6 male – 1
6 015103 1/4 inch NPT X RH ‘B’ inert female – 1
7 015007 1/4 inch NPT X #5 male – 1
8 015922 1/4 inch hexagonal collar – 1
9 015210 1/8 inch NPT X LH ‘A’ male – 1

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9 Parts List

Torch assembly

7
6 4

Part number Description

1 420500 Torch mount sleeve assembly: Standard
420501 Torch mount sleeve assembly: Short
420502 Torch mount sleeve assembly: Extended
2 420220 Quick-disconnect/torch receptacle
3 420221 Quick-disconnect torch
4 420368 Water tube
O-ring for quick-disconnect torch (Refer to Preventive maintenance
5 044028
kits on page 393.)
6 006155 Torch solenoid valve (V1)
7 229918 Torch solenoid valve (V1) tool
006169 Torch solenoid valve connector
428488 Torch assembly, 300 A mild steel consumables
104879 2.25 inch spanner wrench

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Torch bracket

Part number Description

428646 Torch lifter bracket: 2.25 inch diameter sleeve

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9 Parts List

Consumable starter kits

 See Sample configurations for consumables on page 135 or the XPR Cut
Charts Instruction Manual (809830) for specific applications.

Mild steel consumable starter kit (428616)

Part number Description Quantity
420240 Electrode: 80 A 2
420243 Nozzle: 80 A 2
420246 Shield: 80 A 2
420242 Swirl ring: 80 A – 130 A 2
420249 Electrode: 130 A 3
420252 Nozzle: 130 A 3
420255 Shield: 130 A 2
420261 Nozzle: 170 A 3
420258 Electrode: 170 A 3
420513 Shield: 170 A 2
420260 Swirl ring: 170 A 1
420276 Electrode: 300 A 3
420279 Nozzle: 300 A 3
420491 Shield: 300 A 2
420406 Swirl ring: 300 A 1
420368 Water tube 1
420200 Shield retaining cap 1
420365 Nozzle retaining cap 1
104879 2.25 inch spanner wrench 1
104119 Consumable tool 1
027055 Silicone lubricant, 1/4 ounce 1

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Stainless steel and aluminum consumable starter kit (428617)

Part number Description Quantity
420288 Nozzle: 40 A 3

420291 Shield: 40 A 2

420297 Nozzle: 60 A 1

420296 Nozzle: 60 A H2O 1

420306 Nozzle: 80 A 2

420290 Nozzle: 80 A H2O 2

420469 Shield: 130 A H2O 1

420356 Electrode: 130 A – 300 A 4

420315 Nozzle: 130 A 2

420318 Shield: 130 A 1

420472 Shield: 170 A H2O 1

420324 Nozzle: 170 A 3

420327 Shield: 170 A 1

420358 Swirl ring: 300 A fuel 1

420475 Shield: 300 A H2O 1

420359 Nozzle: 300 A 2

420362 Shield: 300 A 2

420303 Electrode: 40 A – 80 A 3

420309 Shield: 60 A – 80 A 2

420294 Electrode: 40 A – 80 A aluminum air/air 1

420300 Shield: 60 A – 80 A H2O 1

420314 Swirl ring: 40 A – 170 A multiple processes 1

420323 Swirl ring: 60 A – 300 A multiple processes 1

420368 Water tube 1
420200 Shield retaining cap 1
420365 Nozzle retaining cap 1
104879 2.25 inch spanner wrench 1
104119 Consumable tool 1
027055 Silicone lubricant, 1/4 ounce 1

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Mild steel consumable starter kit with torch (428618)

Part number Description Quantity
420221 Quick-disconnect torch head 1
420240 Electrode: 80 A 2
420243 Nozzle: 80 A 2
420246 Shield: 80 A 2
420242 Swirl ring: 80 A – 130 A 2
420249 Electrode: 130 A 3
420252 Nozzle: 130 A 3
420255 Shield: 130 A 2
420261 Nozzle: 170 A 3
420258 Electrode: 170 A 3
420513 Shield: 170 A 2
420260 Swirl ring: 170 A 1
420276 Electrode: 300 A 3
420279 Nozzle: 300 A 3
420491 Shield: 300 A 2
420406 Swirl ring: 300 A 1
420368 Water tube 2
420200 Shield retaining cap 2
420365 Nozzle retaining cap 2
104879 2.25 inch spanner wrench 1
104119 Consumable tool 1
027055 Silicone lubricant, 1/4 ounce 1

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Stainless steel and aluminum consumable starter kit with torch (428619)
Part number Description Quantity
420221 Quick-disconnect torch head 1
420288 Nozzle: 40 A 3
420291 Shield: 40 A 2
420297 Nozzle: 60 A 1
420296 Nozzle: 60 A H2O 1
420306 Nozzle: 80 A 2
420290 Nozzle: 80 A H2O 2
420469 Shield: 130 A H2O 1
420356 Electrode: 130 A – 300 A 4
420315 Nozzle: 130 A 2
420318 Shield: 130 A 1
420472 Shield: 170 A H2O 1
420324 Nozzle: 170 A 3
420327 Shield: 170 A 1
420358 Swirl ring: 300 A fuel 1
420475 Shield: 300 A H2O 1
420359 Nozzle: 300 A 2
420362 Shield: 300 A 2
420303 Electrode: 40 A – 80 A 3
420309 Shield: 60 A – 80 A 2
420294 Electrode: 40 A – 80 A aluminum air/air 1
420300 Shield: 60 A – 80 A H2O 1
420314 Swirl ring: 40 A – 170 A multiple processes 1
420323 Swirl ring: 60 A – 300 A multiple processes 1
420368 Water tube 2
420200 Shield retaining cap 2
420365 Nozzle retaining cap 2
104879 2.25 inch spanner wrench 1
104119 Consumable tool 1
027055 Silicone lubricant, 1/4 ounce 1

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9 Parts List

Other consumable and torch parts

0
90 10
0
1 4

2 3
80
20

70 30

60 40
50

Part number Description

1 004630 Pit depth gauge
2 004629 Gauge point
027055 Silicone lubricant, 1/4 ounce
104119 Consumable tool
428764 XPR robotic torch teach accessory
429013 XPR electrode torque tool

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Plasma power supply to gas connect console connections

Pilot arc lead with strain relief

Part number Length Part number Length

223529 3 m (9.8 feet) 223535 25 m (82 feet)
223530 4.5 m (14.8 feet) 223536 35 m (114.8 feet)
223531 7.5 m (24.6 feet) 223537 45 m (147.6 feet)
223532 10 m (32.8 feet) 223538 60 m (196.9 feet)
223533 15 m (49.2 feet) 223539 75 m (246.1 feet)
223534 20 m (65.6 feet) – –

Negative lead with strain relief

Part number Type Length Part number Type Length

223573 2/0 3 m (9.8 feet) 223527 4/0 60 m (196.9 feet)
223574 2/0 4.5 m (14.8 feet) 223528 4/0 75 m (246.1 feet)
223575 2/0 7.5 m (24.6 feet) 223551* 2/0 3 m (9.8 feet)
223576 2/0 10 m (32.8 feet) 223552* 2/0 4.5 m (14.8 feet)
223577 2/0 15 m (49.2 feet) 223553* 2/0 7.5 m (24.6 feet)
223578 2/0 20 m (65.6 feet) 223554* 2/0 10 m (32.8 feet)
223579 2/0 25 m (82 feet) 223555* 2/0 15 m (49. 2 feet)
223525 4/0 35 m (114.8 feet) 223556* 2/0 20 m (65.6 feet)
223526 4/0 45 m (147.6 feet) 223557* 2/0 25 m (82 feet)

* Leads labeled with CCC mark only. CCC is defined in Symbols and marks on page 26.

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9 Parts List

Power cable

Description: 3-position, male-female

Part number Length Part number Length
223436 3 m (9.8 feet) 223446 25 m (82 feet)
223437 4.5 m (14.8 feet) 223447 35 m (114.8 feet)
223439 7.5 m (24.6 feet) 223448 45 m (147.6 feet)
223441 10 m (32.8 feet) 223449 60 m (196.9 feet)
223444 15 m (49.2 feet) 223450 75 m (246.1 feet)
223445 20 m (65.6 feet) – –

Coolant hose set

Description: 1.27 cm (0.50 inch) internal diameter

Part number Length Part number Length
428475 3 m (9.8 feet) 428481 25 m (82 feet)
428476 4.5 m (14.8 feet) 428482 35 m (114.8 feet)
428477 7.5 m (24.6 feet) 428483 45 m (147.6 feet)
428478 10 m (32.8 feet) 428484 60 m (196.9 feet)
428479 15 m (49.2 feet) 428485 75 m (246.1 feet)
428480 20 m (65.6 feet) – –

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 Parts List 9

CAN cable

Description: 5-position, male-female

Part number Length Part number Length
223417 3 m (9.8 feet) 223427 25 m (82 feet)
223418 4.5 m (14.8 feet) 223428 35 m (114.8 feet)
223420 7.5 m (24.6 feet) 223429 45 m (147.6 feet)
223422 10 m (32.8 feet) 223430 60 m (196.9 feet)
223425 15 m (49.2 feet) 223431 75 m (246.1 feet)
223426 20 m (65.6 feet) – –

Gas connect console to torch connect console connections

Pilot arc and coolant hose set assembly (Core)

Part number Length Part number Length

428454 3 m (9.8 feet) 428457 7.5 m (24.6 feet)
428455 4.5 m (14.8 feet) 428458 10 m (32.8 feet)
428456 6 m (19.7 feet) 428459 15 m (49.2 feet)

Power, CAN, and 3-gas assembly (Core)

Part number Length Part number Length

428464 3 m (9.8 feet) 428467 7.5 m (24.6 feet)
428465 4.5 m (14.8 feet) 428468 10 m (32.8 feet)
428466 6 m (19.7 feet) 428469 15 m (49.2 feet)

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9 Parts List

Pilot arc, coolant hose set, and shield water assembly (VWI or OptiMix)

Part number Length Part number Length

428353 3 m (9.8 feet) 428356 7.5 m (24.6 feet)
428354 4.5 m (14.8 feet) 428357 10 m (32.8 feet)
428355 6 m (19.7 feet) 428358 15 m (49.2 feet)

Power, CAN, and 5-gas assembly (VWI or OptiMix)

Part number Length Part number Length

428363 3 m (9.8 feet) 428366 7.5 m (24.6 feet)
428364 4.5 m (14.8 feet) 428367 10 m (32.8 feet)
428365 6 m (19.7 feet) 428368 15 m (49.2 feet)

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Plasma power supply to CNC connections

EtherCAT CNC interface cable

Description: RJ-45 connector, male-male, SF/UTP shield, 2 twisted pairs, 22 AWG

For more information on EtherCAT cable specifications, see How to connect to the plasma power
supply with EtherCAT on page 145.
Part number Length Part number Length
223506 0.3 m (1 foot) 223512 10 m (32.8 feet)
223507 0.6 m (2 feet) 223513 15 m (49.2 feet)
223508 1.5 m (4.9 feet) 223514 22.5 m (73.8 feet)
223672 2.5 m (8.2 feet) 223515 30 m (98.4 feet)
223509 3 m (9.8 feet) 223516 45 m (147.6 feet)
223510 6 m (19.7 feet) 223517 60 m (196.9 feet)
223511 7.5 m (24.6 feet) 223714 75 m (246.1 feet)

Discrete CNC interface cable

J14 J19

1 12 1 8

Part number Length Part number Length

223691 3 m (9.8 feet) 223700 20 m (65.6 feet)
223692 4.5 m (14.8 feet) 223701 22.5 m (73.8 feet)
223693 6 m (19.7 feet) 223702 25 m (82 feet)
223694 7.5 m (24.6 feet) 223703 30 m (98.4 feet)
223695 10 m (32.8 feet) 223704 35 m (114.8 feet)
223696 12 m (39.4 feet) 223705 37.5 m (123 feet)
223697 13.5 m (44.3 feet) 223706 45 m (147.6 feet)
223698 15 m (49.2 feet) 223707 60 m (196.9 feet)
223699 16.5 m (54.1 feet) 223708 75 m (246.1 feet)

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9 Parts List

Serial CNC interface cable

2 3 4 5 2 3 4 5
7 7

Description: 9-position, D-subminiature (D-sub) connector, male-male, RS-422

Part number Length Part number Length
223673 3 m (9.8 feet) 223682 20 m (65.6 feet)
223674 4.5 m (14.8 feet) 223683 22.5 m (73.8 feet)
223675 6 m (19.7 feet) 223684 25 m (82.0 feet)
223676 7.5 m (24.6 feet) 223685 30 m (98.4 feet)
223677 10 m (32.8 feet) 223686 35 m (114.8 feet)
223678 12 m (39.4 feet) 223687 37.5 m (123 feet)
223679 13.5 m (44.3 feet) 223688 45 m (147.6 feet)
223680 15 m (49.2 feet) 223689 60 m (196.9 feet)
223681 16.5 m (54.1 feet) 223690 75 m (246.1 feet)

Plasma power supply to cutting table connection

Work lead

Part number Type Length Part number Type Length

223628 2/0 3 m (9.8 feet) 223648 4/0 60 m (196.9 feet)
223629 2/0 4.5 m (14.8 feet) 223649 4/0 75 m (246.1 feet)
223630 2/0 7.5 m (24.6 feet) 223661* 2/0 3 m (9.8 feet)
223631 2/0 10 m (32.8 feet) 223662* 2/0 4.5 m (14.8 feet)
223632 2/0 15 m (49.2 feet) 223663* 2/0 7.5 m (24.6 feet)
223633 2/0 20 m (65.6 feet) 223664* 2/0 10 m (32.8 feet)
223634 2/0 25 m (82 feet) 223665* 2/0 15 m (49.2 feet)
223646 4/0 35 m (114.8 feet) 223666* 2/0 20 m (65.6 feet)
223647 4/0 45 m (147.6 feet) 223667* 2/0 25 m (82 feet)

* Leads labeled with CCC mark only. CCC is defined in Symbols and marks on page 26.

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 Parts List 9

Torch connect console to torch receptacle connection

Torch lead

Part number Length Part number Length

428383 2 m (6.6 feet) 428386 3.5 m (11.5 feet)
428384 2.5 m (8.2 feet) 428387 4.5 m (14.8 feet)
428385 3 m (9.8 feet) – –

Bevel torch lead

Strain relief Strain relief
Part number Lead length Part number Lead length
length length
428825 2 m (6.6 feet) 428831 2 m (6.6 feet)
428826 2.5 m (8.2 feet) 428832 2.5 m (8.2 feet)
428827 3 m (9.8 feet) 0.5 m (20 inches) 428833 3 m (9.8 feet) 1.2 m (48 inches)
428828 3.5 m (11.5 feet) 428834 3.5 m (11.5 feet)
428830 4.5 m (14.8 feet) 428836 4.5 m (14.8 feet)

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9 Parts List

Supply hoses

Oxygen hose (blue)

Fittings: RH type “B” female

Part number Length Part number Length

124003 3 m (9.8 feet) 124009 25 m (82 feet)
124004 4.5 m (14.8 feet) 124107 30 m (98.4 feet)
124005 7.5 m (24.6 feet) 124010 35 m (114.8 feet)
124006 10 m (32.8 feet) 124011 45 m (147.6 feet)
124007 15 m (49.2 feet) 124012 60 m (196.9 feet)
124008 20 m (65.6 feet) 124013 75 m (246.1 feet)

Nitrogen or Argon hose (black)

Fittings: RH type “B” male

Part number Length Part number Length

124014 3 m (9.8 feet) 124020 25 m (82 feet)
124015 4.5 m (14.8 feet) 124108 30 m (98.4 feet)
124016 7.5 m (24.6 feet) 124021 35 m (114.8 feet)
124017 10 m (32.8 feet) 124022 45 m (147.6 feet)
124018 15 m (49.2 feet) 124023 60 m (196.9 feet)
124019 20 m (65.6 feet) 124024 75 m (246.1 feet)

Air hose (black)

Fittings: JIC-6 female

Part number Length Part number Length

124025 3 m (9.8 feet) 124031 25 m (82 feet)
124026 4.5 m (14.8 feet) 124109 30 m (98.4 feet)
124027 7.5 m (24.6 feet) 124032 35 m (114.8 feet)
124028 10 m (32.8 feet) 124033 45 m (147.6 feet)
124029 15 m (49.2 feet) 124034 60 m (196.9 feet)
124030 20 m (65.6 feet) 124035 75 m (246.1 feet)

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 Parts List 9

Hydrogen or nitrogen-hydrogen (F5) (red)

Fittings: LH type “B” female

Part number Length Part number Length

124036 3 m (9.8 feet) 124042 25 m (82 feet)
124037 4.5 m (14.8 feet) 124110 30 m (98.4 feet)
124038 7.5 m (24.6 feet) 124043 35 m (114.8 feet)
124039 10 m (32.8 feet) 124044 45 m (147.6 feet)
124040 15 m (49.2 feet) 124045 60 m (196.9 feet)
124041 20 m (65.6 feet) 124046 75 m (246.1 feet)

Water (optional shield fluid) (blue)

Fittings: JIC-6 female

Part number Length Part number Length

124047 3 m (9.8 feet) 124053 25 m (82 feet)
124048 4.5 m (14.8 feet) 124111 30 m (98.4 feet)
124049 7.5 m (24.6 feet) 124054 35 m (114.8 feet)
124050 10 m (32.8 feet) 124055 45 m (147.6 feet)
124051 15 m (49.2 feet) 124056 60 m (196.9 feet)
124052 20 m (65.6 feet) 124057 75 m (246.1 feet)

Preventive maintenance kits

Part number Length

428639 Kit: Filter, torch rebuild without coolant
428640 Kit: Filter, torch rebuild with coolant
428920 Kit: Shield-fluid treatment
428878 Kit: Electronics (200 V – 240 V)
428641 Kit: Electronics (200 V – 240 V)
428879 Kit: Electronics (380 V – 600 V)
428642 Kit: Electronics (380 V – 600 V)

XPR300 Instruction Manual 809480 393

9 Parts List

Tools

Part number Length

229917 Torch connect console solenoid valve tool
229918 Torch solenoid valve tool
104879 2.25 inch spanner wrench
004629 Pit depth gauge
104119 Consumable tool
1-13897 (Hypertherm Waterjet part number) TDS meter

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 Parts List 9

Recommended spare parts

Plasma power supply – recommended spare parts

Part number Description Designator Quantity
428810 Shield-fluid treatment filter – 1
027005 Coolant filter (fine) – 1
006154 Coolant check valve – 1
229640 Power source: 88 VAC – 264 VAC to 24 VDC PS1 1
Power source: 88 VAC – 264 VAC to 48 VDC,
229671 PS2 1
600 W
229679 Chopper assembly Chopper 1 1
141322 Control PCB PCB1 1
141371 I/O PCB PCB5 1
141384 Fan power distribution PCB PCB6 1
141425 Power distribution PCB PCB7 1
108709 Fuse:10 A, 250 VAC, time delay (on PCB7) F3, F4, F5 2
Fuse: 15 A, 600 V, Class R (used in 200 V,
208397* 2
208 V, 220 V, 240 V)
F1, F2
Fuse: 8 A, 600 V, Class R (used in 380 V,
208395* 2
400 V, 415 V, 440 V, 480 V, 600 V)
003277 Pilot arc relay CR1 1
Inrush contactor assembly: 80 A, IEC AC-3,
229697 IR_CON 1
3-phase, 120 VAC

003276* Main contactor (200 V, 208 V, 220 V, 240 V) 1

M_CON
Main contactor (380 V, 400 V, 415 V, 440 V,
003268* 1
480 V, 600 V)

* Voltage dependent - Select accordingly

Gas connect consoles – recommended spare parts

Part number Description Designator Quantity
011110 Air filter element – 1
223398 Pressure transducer (VWI and OptiMix only) P6 – P9 1
006128 Solenoid valve (VWI and OptiMix only) B4 – B5 1
141354 High-frequency, high-voltage ignition PCB PCB2 1

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9 Parts List

Torch connect console – recommended spare parts

Part number Description Designator Quantity
141368 Ohmic contact PCB PCB2 1
223477 Pressure transducer with wire and connector P1 – P5, P14 1

Torch – recommended spare parts

Part number Description Designator Quantity
420220 Quick-disconnect/torch receptacle – 1
420221 Quick-disconnect torch – 1
420368 Water tube – 1
006155 Torch solenoid valve – 1

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 Parts List 9

Descriptions of warning label icons 1. Cutting sparks can cause

explosion or fire.
This warning label is affixed to some power supplies. It is important that the 1.1 Do not cut near flammables.
operator and maintenance technician understand the intent of these 1.2 Have a fire extinguisher nearby
warning symbols as described. The numbered text corresponds to the and ready to use.
numbered boxes on the label. 1.3 Do not use a drum or other
closed container as a cutting
table.
2. Plasma arc can injure and burn;
point the nozzle away from
yourself. Arc starts instantly when
triggered.
2.1 Turn off power before
disassembling torch.
2.2 Do not grip the workpiece near
the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of
electric shock or burn.
3.1 Wear insulating gloves. Replace
gloves when wet or damaged.
3.2 Protect from shock by insulating
yourself from work and ground.
3.3 Disconnect power before
servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local
exhaust to remove the fumes.
4.3 Do not operate in closed spaces.
Remove fumes with ventilation.
5. Arc rays can burn eyes and injure
skin.
5.1 Wear correct and appropriate
protective equipment to protect
head, eyes, ears, hands, and
body. Button shirt collar. Protect
ears from noise. Use welding
helmet with the correct shade of
filter.
6. Become trained. Only qualified
110647 Rev. B
www.hypertherm.com/weee personnel should operate this
equipment. Use torches specified
in the manual. Keep non-qualified
personnel and children away.
7. Do not remove, destroy, or cover
this label. Replace if it is missing,
damaged, or worn.

XPR300 Instruction Manual 809480 397

9 Parts List

398 809480 Instruction Manual XPR300

 Wiring Diagrams

This section contains the wiring diagrams for the system. When you trace a signal path, or reference
the Parts List or Troubleshooting sections, the following conventions will help you understand the
organization of the wiring diagrams:
 Sheet numbers are located in the lower, right-hand corner of each page.
 References to other pages use the following connection symbol:

Sheet C
4-D3

Sheet number Coordinates Reference block

Use the sheet number to find the reference sheet. Line up the coordinates A–D on the Y axis and
numbers 1–4 on the X axis of each sheet to find the reference blocks (similar to a road map).

XPR300 Instruction Manual 809480 399

10 Wiring Diagrams

Wiring diagram symbols

Battery Ground clamp Receptacle

Cap, polarized Ground, chassis Relay, coil

Cap, not polarized Ground, earth Relay, normally closed

Cap, feed-through IGBT Relay, normally open

Circuit breaker Inductor Relay, solid state, AC

Coax shield LED Relay, solid state, DC

Current sensor Lamp Relay, solid state

Current sensor MOV Resistor

DC supply Pin SCR

Diode Socket Shield

Door interlock Plug Shunt

Fan PNP transistor Spark gap

Feed-through LC Potentiometer Switch, flow

Push button, Switch, level,

Filter, AC
normally closed normally closed
Push button, Switch, pressure,
Fuse
normally open normally closed

400 809480 Instruction Manual XPR300

 Wiring Diagrams 10

Switch, pressure, Time delay open,

Valve, solenoid
normally open NO/off

Time delay open,

Switch, 1 pole, 1 throw Voltage source
NC/on

Time delay closed,

Switch, 1 pole, 2 throw Zener diode
NO/off

Switch, 1 pole, 2 throw,

Transformer
center off

Switch, temperature,
Transformer, air core
normally closed

Switch, temperature,
Transformer, coil
normally open

Terminal block Triac

Time delay closed,

VAC source
NC/off

Torch symbols

Electrode

Nozzle

Shield

Torch

Torch, HyDefinition®

XPR300 Instruction Manual 809480 401

10 Wiring Diagrams

Valve states during operation

During each stage of cutting system operation, different valves are active (ON) or inactive (OFF).
The type of gas connect console and the type and timing of the active process changes the valves
that are active or inactive.

Refer to the CNC or XPR web interface to see the most current information about the
state (ON-OFF) of each valve.
 For information about how to view valve states on the CNC, refer to the instruction manual
that came with your CNC.
 The following steps describe how to view valve states on the XPR web interface:
 Use the XPR web interface to select the process you want to view.
 Go to the Gas System screen. (See Gas system on page 182.)

 On this screen you can see which valves are active when the gas is
flowing. Active valves are indicated with a gray highlight.

 On the Gas System screen, enable the desired mode (Test Preflow, Test Pierceflow, or
Test Cutflow) for the process you want to view.

 Active valves are indicated with a gray highlight.

Valve states by process ID

Process IDs: 1001, 1002, 1003, 1152, 1153, 1155, 1004, 1005, 1151, 1156

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off On Off Off Off

Cutflow O2/Air On Off Off On Off Off On Off On On

Piercing O2/Air On Off Off On Off Off On Off Off On

Process IDs: 7001, 7004, 7005, 7007, 7008, 7009, 7010, 7011, 7012, 7013, 7018

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off On Off Off Off

Cutflow O2/O2 On Off Off Off On Off On Off On On

Piercing O2/Air On Off Off On Off Off On Off Off On

402 809480 Instruction Manual XPR300

 Wiring Diagrams 10

Process ID: 8001

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/N2 Off Off On Off Off Off On Off Off Off

Cutflow N2/N2 Off Off On Off Off Off On Off On Off

Piercing N2/N2 Off Off On Off Off Off On Off Off Off

Process IDs: 9001, 9010, 9018

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow Ar/Air Off Off Off On Off On Off Off On Off

Cutflow Ar/Air Off Off Off On Off On Off Off On Off

Piercing Ar/Air Off Off Off On Off On Off Off On Off

Process IDs: 2051, 2054, 2057, 2100, 8004, 8005, 8006

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/N2 Off Off On Off Off Off Off Off Off Off

Cutflow N2/N2 Off Off On Off Off Off Off Off Off Off

Piercing N2/N2 Off Off On Off Off Off Off Off Off Off

Process IDs: 2010, 2011, 2028, 2052, 2055, 2058

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/H2O Off Off Off Off Off Off Off Off Off Off

Cutflow N2/H2O Off Off Off Off Off Off Off Off Off Off

Piercing N2/H2O Off Off Off Off Off Off Off Off Off Off

Process IDs: 2053, 2056, 2059, 2060, 2061, 2062, 2063, 2064, 2065, 2066

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/N2 Off Off On Off Off Off Off Off Off Off

Cutflow Mix/N2 On Off On Off Off Off Off On Off Off

Piercing Mix/N2 On Off On Off Off Off Off On Off Off

XPR300 Instruction Manual 809480 403

10 Wiring Diagrams

Process IDs: 1201, 1203, 1206

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off On Off Off Off

Cutflow O2/Air On Off Off On Off Off On Off Off On

Piercing O2/Air On Off Off On Off Off On Off Off On

Process IDs: 1051, 7014, 7015

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/O2 Off Off Off Off On Off On Off Off Off

Cutflow O2/O2 On Off Off Off On Off On Off On On

Piercing O2/O2 On Off Off Off On Off On Off Off On

Process IDs: 1102, 1101

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off On Off Off Off

Cutflow O2/Air On Off Off On Off Off On Off On Off

Piercing O2/Air On Off Off On Off Off On Off Off Off

Process IDs: 1103, 1104, 1105, 1106, 1107

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off On Off Off Off

Cutflow O2/Air On Off Off On Off Off On Off On Off

Piercing O2/Air On Off Off On Off Off On Off Off Off

Process IDs: 7002, 7003, 7006

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off On Off Off Off

Cutflow O2/O2 On Off Off Off On Off On Off On Off

Piercing O2/Air On Off Off On Off Off On Off Off Off

404 809480 Instruction Manual XPR300

 Wiring Diagrams 10

Process IDs: 2001, 2002, 2003, 2004, 2005

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/N2 Off Off On Off Off Off Off On Off Off

Cutflow F5/N2 On Off On Off Off Off Off On On Off

Piercing F5/N2 On Off On Off Off Off Off On On Off

Process IDs: 2006, 2007, 2012, 2013, 2014, 2015, 2024, 2025, 2026

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/N2 Off Off On Off Off Off Off Off Off Off

Cutflow N2/N2 Off Off On Off Off Off Off Off On Off

Piercing N2/N2 Off Off On Off Off Off Off Off On Off

Process IDs: 2008, 2009

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Of Off On Off Off Off Off Off Off

Cutflow Air/Air On Off Off On Off Off Off Off On Off

Piercing Air/N2 On Off On Off Off Off Off Off On Off

Process IDs: 2016, 2017, 2018, 2019

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off Off Off Off Off

Cutflow Air/Air On Off Off On Off Off Off Off On Off

Piercing Air/Air On Off Off On Off Off Off Off On Off

Process IDs: 2020, 2021, 2022, 2023

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/N2 Off Off On Off Off Off Off On Off Off

Cutflow F5/N2 On Off On Off Off Off Off On Off Off

Piercing F5/N2 On Off On Off Off Off Off On Off Off

XPR300 Instruction Manual 809480 405

10 Wiring Diagrams

Process IDs: 9004, 9005, 9006, 9014, 9015, 9016, 9017

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow Ar/N2 Off Off On Off Off On Off Off Off Off

Cutflow Ar/N2 Off Off On Off Off On Off Off Off Off

Piercing Ar/N2 Off Off On Off Off On Off Off Off Off

Process ID: 8007

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off On Off Off Off

Cutflow N2/Air Off Off Off On Off Off On Off Off Off

Piercing N2/Air Off Off Off On Off Off On Off Off Off

Process ID: 9007

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow Ar/Air Off Off Off On Off On On Off On Off

Cutflow Ar/Air Off Off Off On Off On On Off On Off

Piercing Ar/Air Off Off Off On Off On On Off On Off

Process ID: 9008

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow Ar/Air Off Off Off On Off On Off Off Off Off

Cutflow Ar/Air Off Off Off On Off On Off Off Off Off

Piercing Ar/N2 Off Off On Off Off On Off Off Off Off

Process IDs: 9002, 9003, 9009

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow Ar/N2 Off Off On Off Off On Off Off On Off

Cutflow Ar/N2 Off Off On Off Off On Off Off On Off

Piercing Ar/N2 Off Off On Off Off On Off Off On Off

406 809480 Instruction Manual XPR300

 Wiring Diagrams 10

Process IDs: 1202, 1204, 1207

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/N2 Off Off On Off Off Off On Off Off Off

Cutflow O2/N2 On Off On Off Off Off On Off Off On

Piercing O2/N2 On Off On Off Off Off On Off Off On

Process IDs: 2027, 2101

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off Off Off Off Off

Cutflow Air/Air On Off Off On Off Off Off Off On Off

Piercing Air/Air On Off Off On Off Off Off Off Off Off

Process ID: 8002

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/N2 Off Off On Off Off Off Off Off On Off

Cutflow N2/N2 Off Off On Off Off Off Off Off On Off

Piercing N2/N2 Off Off On Off Off Off Off Off On Off

Process ID: 1205

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/N2 Off Off On Off Off Off On Off Off Off

Cutflow O2/N2 On Off On Off Off Off On Off Off On

Piercing O2/Ar On On Off Off Off Off On Off Off On

Process IDs: 9011, 9012, 9013

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow Ar/N2 Off On On Off Off On Off Off On Off

Cutflow Ar/N2 Off On On Off Off On Off Off Off Off

Piercing Ar/N2 Off On On Off Off On Off Off Off Off

XPR300 Instruction Manual 809480 407

10 Wiring Diagrams

Process IDs: 1060, 1061, 7016, 7017

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off On Off On Off

Cutflow O2/Air On Off Off On Off Off On Off On On

Piercing O2/Air On Off Off On Off Off On Off On On

Process ID: 1157

Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12

Preflow N2/Air Off Off Off On Off Off On Off Off Off

Cutflow O2/Air On Off Off On Off Off On Off On On

Piercing O2/Ar On On Off Off Off Off On Off Off On

408 809480 Instruction Manual XPR300

Overview (Sheet 1 of 22)

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Plasma power supply 1 (Sheet 2 of 22)

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Plasma power supply 2 (Sheet 3 of 22)

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Plasma power supply 3 (Sheet 4 of 22)

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Plasma power supply 4 (Sheet 5 of 22)

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Plasma power supply 5 (Sheet 6 of 22)

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Plasma power supply 6 (Sheet 7 of 22)

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Plasma power supply 7 (Sheet 8 of 22)

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Gas connect console 1 (Sheet 9 of 22)

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Gas connect console 2 (Sheet 10 of 22)

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Torch connect console (Sheet 11 of 22)

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Coolant system (Sheet 12 of 22)

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Gas system 1 (Sheet 13 of 22)

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Gas system 2 (Sheet 14 of 22)

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Gas system 3 (Sheet 15 of 22)

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EtherCAT multi-system interface (Sheet 16 of 22)

Unit 1 Unit 2 Unit 3 Unit 4

Plasma power supply Plasma power supply Plasma power supply Plasma power supply

141322 141322 141322 141322

Control board Control board Control board Control board
S1 S2 S1 S2 S1 S2 S1 S2
ON ON ON ON ON ON ON ON

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch

U47 U49 U47 U49 U47 U49 U47 U49

In Out In Out In Out In

Out

EtherCAT cable EtherCAT cable EtherCAT cable

EtherCAT cable

Notes:

1. Serial terminators (S1) and Serial IDs (S2) are not used for EtherCAT
connections to EDGE Connect or EDGE Connect TC installations.

EtherCAT cable
2. Serial Terminators (S1) and Serial IDs (S2) are not used for EtherCAT
connections to EtherCAT enabled CNC and/or THC installations.
DIP switch setting example

S2
ON
ON
4
3
1 2 3 4 2
1

EDGE Connect/TC and/ or EtherCAT-enabled

CNC/THC
Switch 3 is in the ON position.
Switches 1, 2, and 4 are in the OFF position.

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Serial RS-422 and discrete multi-system interface (Sheet 17 of 22)

Unit 1 Unit 2 Unit 3 Unit 4

Plasma power supply Plasma power supply Plasma power supply Plasma power supply

141322 141322 141322 141322

Control board Control board Control board Control board
S1 S2 S1 S2 S1 S2 S1 S2
ON ON ON ON ON ON ON ON

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch

J14 J19 J12 J13 J14 J19 J12 J13 J14 J19 J12 J13 J14 J19 J12 J13

Serial RS-422 cable Serial RS-422 cable Serial RS-422 cable

Serial RS-422 cable

Discrete cable Discrete cable Discrete cable Discrete cable

Discrete cable Discrete cable

Notes:

Serial RS-422 cable

1. For single plasma power supply installations, set Serial terminators (S1) as shown in Unit 4 and

Discrete cable
Serial IDs (S2) as shown in Unit 1.

2. On multi-plasma power supply installations see the illustration. Switch S1 position 1 and 2 are
DIP switch setting example Switch 3 is in the ON position.
OFF in all plasma power supplies except for the last one where they are set to ON.
Switches 1, 2, and 4 are in the OFF
Termination resistors (120 Ω) or termination jumpers must be installed and set at the CNC for S2 position.
ON
each of the RS-422 RX and TX signal pairs. ON
4
3
1 2 3 4 2
1

3. If a Hypertherm CNC is used and there are intermittent communication failures (PS Link Failure),
Serial RS-422 CNC interface
try reversing switch S1 position 1 and position 2 on the control board, and the termination jumper
(Customer supplied)
(J6 or J8) on the serial isolation board in the controller. Only remove the termination jumper on the
serial isolation board that is connected to the plasma power supply.

RX termination

TX termination
120 120
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Discrete multi-system interface (Sheet 18 of 22)

Unit 1 Unit 2 Unit 3 Unit 4

Plasma power supply Plasma power supply Plasma power supply Plasma power supply

141322 141322 141322 141322

Control board Control board Control board Control board
S1 S2 S1 S2 S1 S2 S1 S2
ON ON ON ON ON ON ON ON

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch

J14 J19 J14 J19 J14 J19 J14 J19

Discrete cable Discrete cable Discrete cable Discrete cable

Discrete cable Discrete cable

Notes:

Discrete cable
1. Serial terminator DIP switches (S1) and Serial ID DIP switches (S2) are not used for
discrete-only CNC connections.
DIP switch setting example
2. The CNC must provide separate inputs and outputs for each XPR plasma power
S2
supply. Sole exceptions are PLASMA START+/- and HOLD+/-. These can be wired ON
ON
in parallel from one set of CNC outputs to all XPR plasma power supplies. 3
4
1 2 3 4 2
1

CNC interface
Switch 3 is in the ON position.
Switches 1, 2, and 4 are in the OFF position.

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EtherCAT connection to EDGE Connect/TC (Sheet 19 of 22)

Notes:

1. Hypertherm EDGE Connect/TC CNC examples shown

with EtherCAT drives. Please see the CNC documentation
for installation and connection details.
EtherCAT cable
2. Torch height controller not shown. See the THC
documentation for voltage divider installation and
EtherCAT cable connection details.

EtherCAT cable

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Discrete and serial RS-422 CNC connections (Sheet 20 of 22)

Serial RS-422 cable

Notes:

1. See the CNC documentation for installation and

connection details.
Discrete cable 2. Torch height controller not shown. See the THC
documentation for voltage divider installation and
connection details.

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Discrete CNC connections (Sheet 21 of 22)

Notes:
Discrete cable

1. See the CNC documentation for installation and

connection details.

2. Torch height controller not shown. See the THC

documentation for voltage divider installation and
connection details.

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Wireless subsystem block diagram (Sheet 22 of 22)

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