How to change XPR consumables

The XPR® plasma family represents the most significant advancement in mechanized plasma cutting technology, delivering improved cut quality on mild steel and expanding cutting outcomes on a broad range of stainless steel and aluminum applications. XPR plasma cutting systems improve cut consistency and cut quality through the life of consumables and dramatically improve consumable life on mild steel applications.

XPR’s arc response technology automatically reacts to certain events that can lead to decreased consumable life or possible torch damage. Automatic torch protection prevents catastrophic torch failures caused by overusing the electrode. Automatic ramp-down error protects the electrode’s life by automatically applying a controlled stop of the plasma process when the arc is over-stretched. They also reduce the impact of ramp-down errors on consumables, enabling XPR consumables to last up to three times longer than consumables without arc response technology.

Easy consumable installation for the XPR

XPR consumables are designed to be easy to use. The XPR plasma system is shipped with a consumable installation kit that includes both instructions and tools to help operators install the consumables into the XPR torch body.

Before you begin installing consumables, make sure to turn off power to the system. Once the power is turned off, locate and remove your marketing kit. It should be attached to the rear of the system in a plastic container.

XPR marketing kit components 

When you open the marketing kit, you will find the following items:

  • XPR torque tool handle

  • Hex drive adapter

  • 3/8-inch socket

  • XPR consumable tool

  • USB stick with instruction manuals

  • XPR consumable list

  • Consumable installation guide

  • Safety information card

Once you have successfully installed the consumables the first time, make sure to keep your XPR consumable tool, torque tool, and the installation instructions to help you replace the consumables when required.

If you did not receive your consumable installation and removal kit, contact your cutting table manufacturer.

Installing the XPR consumables

Before you can begin installing the consumables, you have to build the XPR torque tool. Remove the electrode torque tool handle and the hex drive adapter from the packaging. Insert the pointed end of the hex drive adapter into the torque tool handle until you hear an audible click. Install the socket onto this adapter and the torque tool is ready to use.

Next, lubricate the O-rings. Take a small amount of silicone lubricant and rub it between your fingers before applying it to the consumables. Make sure there is a very light film spread evenly across each O-ring surface, placing enough lubricant to make the O-rings appear wet. If you see a physical build-up of silicone, you have applied too much.

Silicone can clog or plug ports, so you need to be particularly careful with its application around the swirl ring to ensure the gas flow will work properly. Too much lubricant can also cause clogging and metal dust contamination in the torch, leading to uncontrolled arcing in the plasma chamber and ultimately torch failure.

To begin installing the consumables, insert the water tube into the torch body and push down until it is fully seated. Once the water tube is in position, insert the electrode into the torch body. Seat the electrode by rotating until finger tight. Once the electrode is seated, grab your torque tool and insert the socket onto the end of the electrode. Rotate the electrode torque tool clockwise until you hear a click.

Next, insert the swirl ring by gently pushing it into the nozzle until fully seated. Once seated, push the nozzle and swirl ring assembly into the torch body, making sure it is fully seated against the torch body. Grab the nozzle retaining cap and thread it on to the torch body by rotating it clockwise until tight.

Install the shield onto the nozzle retaining cap. Finally, install the shield cap and hand tighten to complete the installation. Your consumables are ready to use.

Removing XPR consumables

To remove the consumables, reverse the above steps. First remove the shield cap from the torch body. Pull the shield from the nozzle retaining cap. Remove the nozzle retaining cap by rotating it counterclockwise.

Grab the XPR consumable tool. Look for the machined U-shaped cutout at the end of the tool. Align the cutout with the groove on the nozzle. Squeeze the XPR consumable tool and firmly pull the nozzle straight out of the torch body.

To remove the electrode, align the center hexagon cutout on the XPR consumable tool and insert it over the end of the electrode. Squeeze firmly and rotate the electrode counterclockwise until loosened and pull the electrode straight out. If you find that the electrode has been overtightened or is difficult to remove, you may use the fixed hex cutout on the XPR consumable tool as an additional option for removal.

This completes removal of the consumables. You should now inspect the consumables to determine if they are damaged or worn and need to be replaced. To inspect the consumables, you need to carefully examine the shield cap, retaining cap, nozzle, electrode, and swirl ring to determine which parts are worn. You also need to carefully inspect the O-rings for cracks or damage. You should replace the worn parts and reinstall the consumables.

For most operators, the hardest part of changing consumables is knowing when to change them. You do not want to stop and inspect your consumables too often, because unnecessarily checking parts decreases productivity and increases the risk of damaging the parts you are inspecting. At the same time, cut quality decreases with worn consumables and overusing consumables risks damaging your torch and workpiece. Regular inspections of consumables are essential to maintain cut quality and torch health.   

Hypertherm’s XPR consumables are designed to be easy for operators to install and uninstall. Our step-by-step instructions for installation and removal of XPR consumables ensure you can safely install, remove, inspect, and reinstall the consumables to maximize cut quality and minimize time spent changing consumables. Contact a Hypertherm product expert today to learn more.

 

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