Component-replacement schedule and its significance
This is a list of components and their usual replacement schedule. The schedule uses arc hours to make an estimate of when to replace a component. The use of arc hours is the most accurate method to make an estimate of when to replace a component.
If you do not have a Hypertherm® Computer Numerical Control (CNC) and your CNC cannot monitor arc hours, use the information below to make an estimate of arc hours per year. This guide uses the usual number of eight-hour shifts that the system operates during a usual work day. For more information about how to calculate arc hours, speak to your cutting machine supplier or regional Hypertherm Tech Service team.
| Number of shifts per day | Number of arc hours per year |
|---|---|
| 1 | 500 |
| 2 | 1,000 |
| 3 | 1,500 |
Your cutting area and operations can have an effect on this schedule. Refer to Conditions that have an effect on replacement schedules.
Keep information about your system and its replacement requirements in the
these locations:
| Warning | |
|---|---|
  | ELECTRIC SHOCK CAN KILL
The plasma power supply contains dangerous electric voltages that can
seriously injure or kill you. 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. All work that requires removal of the plasma power
supply outer cover or panels must be done by a qualified technician. Refer to
the Safety and Compliance Manual (80669C) for more safety
information.
|
| Part number | Quantity | Description | Number of arc hours in each year | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 500 | 1,000 | 1,500 | 2,000 | 2,500 | 3,000 | 3,500 | 4,000 | 4,500 | 5,000 | 5,500 | 6,000 | |||
| 428639 | 1 | Kit: Torch-rebuild components, air filter (011110), and coolant filter (027005), without coolant | X | X | X | X | X | X | X | X | X | X | X | X |
| 428640 | 1 | Kit: Torch-rebuild components, air filter (011110), and coolant filter (027005), with coolant | X | X | X | X | X | X | X | X | X | X | X | X |
| 028872 | 6 – 12 | Coolant (in U.S. gallons)1 | X | X | X | X | X | X | X | X | X | X | X | X |
| 1 | Kit: Electronics2 | |||||||||||||
| 4288783 | 200 V – 240 V (XPR170®) | X | X | X | X | X | X | |||||||
| 4288794 | 380 V – 600 V (XPR170) | X | X | X | X | X | X | |||||||
| 4286415 | 200 V – 240 V (XPR300®) | X | X | X | X | X | X | |||||||
| 4286426 | 380 V – 600 V (XPR300) | X | X | X | X | X | X | |||||||
| 100839027 | 200 V – 240 V (XPR460®) | X | X | X | X | X | X | |||||||
| 100839038 | 380 V – 600 V (XPR460) | X | X | X | X | X | X | |||||||
| 420220 | 1 | Quick-disconnect torch receptacle | X | X | X | |||||||||
| –9 | 1 | Torch lead | X | X | X | |||||||||
| –9 | 1 | Bevel or robotic torch lead | X | X | X | X | X | X | ||||||
| 006113 | 1 | Coolant check valve | X | X | ||||||||||
| 22982110 | 1 – 2 | Fan assembly, 120 mm (4.7 inch) diameter | X | X | ||||||||||
| 22982210 | 3 – 5 | Fan assembly, 254 mm (10 inch) diameter | X | X | ||||||||||
| 229741 | 1 | Kit: Coolant flow meter | X | X | ||||||||||
| – 9 | 1 | Gas lead | X | X | ||||||||||
| –9 | 1 | Pilot arc lead | X | X | ||||||||||
| 141425 | 1 | Power distribution Printed Circuit Board (PCB) (PCB7) (XPR170, XPR300) | X | X | ||||||||||
| 141577 | 1 | Power distribution PCB (PCB7) (XPR460) | X | X | ||||||||||
| 141354 | 1 | Ignition PCB (PCB2) for gas connect consoles with a serial number that is less than 5,000 | X | |||||||||||
| 141595 | 1 | Spark gap PCB that goes on the ignition PCB for gas connect consoles with a serial number that is more than 5,000. | X | X | ||||||||||
| 10081573 | 1 | Plasma power supply Input/Output (I/O) PCB (XPR170, XPR300) | X | |||||||||||
| 10085206 | 1 | Plasma power supply I/O PCB (PCB5) (XPR460) | X | |||||||||||
| 229838 | 1 | High-frequency transformer (T1) | X | |||||||||||
| 229640 | 1 | Power source: 24 VDC | X | |||||||||||
| 229671 | 1 | Power source: 48 VDC | X | |||||||||||
| 10082976 | 1 | Power source: 48 VDC with bracket (XPR460) | X | |||||||||||
| 229882 | 1 | Kit: Ohmic contact PCB (PCB2) and ohmic relay | X | |||||||||||
| 10085251 | 1– 3 | Chopper | X | |||||||||||
1 The number of gallons that is necessary changes for
different leads. Refer to the instruction manual that came with your cutting system for more
information. Keep this number in Coolant requirements. 2 Refer to the instruction manual that came with your cutting
system for the correct voltage. Keep this number in System voltage. 3 Kit 428878 includes a pilot arc relay (003277), primary contactor (003276), and
torch main body (420221). 4 Kit 428879 includes a pilot arc relay (003277), primary contactor (003294), and
torch main body (420221). 5 Kit 428641 includes a pilot arc relay (003277), primary contactor (003276), inrush
contactor (229697), and torch main body (420221). 6 Kit 428642 includes a pilot arc relay (003277), primary contactor (003294), inrush
contactor (229697), and torch
main
body (420221). 7 Kit 10083902 includes pilot arc relays (003277 and 003298), main contactors
(003297 and 003302), and torch main body (420221). 8 Kit 10083903 includes pilot arc relays (003277 and 003298), main contactors
(003297 and 003293), and torch main body (420221). 9 Part number can be different. Refer to the Parts List in the
instruction manual that came with your cutting system. 10 The type of plasma power supply you have has an effect on the quantity that is necessary. | ||||||||||||||