®

HPR Cartridge
Instruction Manual

810992 – REVISION 0
ENGLISH
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is required.

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_______________________________________________________________________________________

Maintenance notes: ______________________________________________________________________

HPR, HPRXD, XD, True Bevel, ProNest, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United
States and other countries. All other trademarks are the property of their respective holders.

Environmental stewardship is one of Hypertherm’s core values. www.hypertherm.com/environment

100% Associate-owned

© 2022 Hypertherm, Inc.

HPR® Cartridge

Instruction Manual

810992
REVISION 0

ENGLISH
Original instructions

April 2022

Hypertherm, Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Hypertherm, Inc. Hypertherm (Shanghai) Trading Co., Ltd.
21 Great Hollow Road, P.O. Box 5010 B301, 495 ShangZhong Road
Hanover, NH 03755 USA Shanghai, 200231
603-643-3441 Tel (Main Office) PR China
603-643-5352 Fax (All Departments) 86-21-80231122 Tel
info@hypertherm.com (Main Office) 86-21-80231120 Fax
800-643-9878 Tel (Technical Service) 86-21-80231128 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service) techsupport.china@hypertherm.com (Technical Service)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service) South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Hypertherm México, S.A. de C.V. Guarulhos, SP – Brasil
52 55 5681 8109 Tel CEP 07115-030
52 55 5681 7978 Tel 55 11 2409 2636 Tel
soporte.tecnico@hypertherm.com (Technical Service) tecnico.sa@hypertherm.com (Technical Service)

Hypertherm Plasmatechnik GmbH Hypertherm Korea Branch

Sophie-Scholl-Platz 5 #3904. APEC-ro 17. Heaundae-gu. Busan.
63452 Hanau Korea 48060
Germany 82 (0)51 747 0358 Tel
00 800 33 24 97 37 Tel 82 (0)51 701 0358 Fax
00 800 49 73 73 29 Fax marketing.korea@hypertherm.com (Marketing)
31 (0) 165 596900 Tel (Technical Service) techsupportapac@hypertherm.com (Technical Service)
00 800 4973 7843 Tel (Technical Service)
technicalservice.emeia@hypertherm.com (Technical Service) Hypertherm Pty Limited
GPO Box 4836
Hypertherm (Singapore) Pte Ltd. Sydney NSW 2001, Australia
Solaris @ Kallang 164 61 7 3103 1695 Tel
164 Kallang Way #03-13 61 7 3219 9010 Fax
Singapore 349248, Republic of Singapore au.sales@hypertherm.com (Main Office)
65 6841 2489 Tel techsupportapac@hypertherm.com (Technical Service)
65 6841 2490 Fax
marketing.asia@hypertherm.com (Marketing) Hypertherm (India) Thermal Cutting Pvt. Ltd
techsupportapac@hypertherm.com (Technical Service) A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Hypertherm Japan Ltd. Mathura Road, New Delhi 110044, India
Level 9, Edobori Center Building 91-11-40521201/ 2/ 3 Tel
2-1-1 Edobori, Nishi-ku 91-11 40521204 Fax
Osaka 550-0002 Japan htindia.info@hypertherm.com (Main Office)
81 6 6225 1183 Tel technicalservice.emeia@hypertherm.com (Technical Service)
81 6 6225 1184 Fax
htjapan.info@hypertherm.com (Main Office)
techsupportapac@hypertherm.com (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
technicalservice.emeia@hypertherm.com (Technical Service)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at
www.hypertherm.com/hci.
ENGLISH FR (FRANÇAIS/FRENCH)
WARNING! Before operating any Hypertherm equipment, read the safety AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes
instructions in your product’s manual, the Safety and Compliance Manual (80669C), de sécurité du manuel de votre produit, du Manuel de sécurité et de conformité
Waterjet Safety and Compliance Manual (80943C), and Radio Frequency Warning (80669C), du Manuel de sécurité et de conformité du jet d’eau (80943C)
Manual (80945C). Failure to follow safety instructions can result in personal injury et du Manuel d'avertissement relatif aux radiofréqunces (80945C).
or in damage to equipment. Les exemplaires des manuels qui accompagnent le produit peuvent être sous forme
Copies of the manuals can come with the product in electronic and printed formats. électronique ou papier. Les manuels sous forme électronique se trouvent également
Electronic copies are also on our website. Many manuals are available in multiple sur notre site Internet. Plusieurs manuels sont offerts en plusieurs langues
languages at www.hypertherm.com/docs. à www.hypertherm.com/docs.

BG (БЪЛГAPCКИ/BULGARIAN) GR (ΕΛΛΗΝΙΚΆ/GREEK)
ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο
продукт, „Инструкция за безопасност и съответствие“ (80669C), „Инструкция εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο ασφάλειας και
за безопасност и съответствие на Waterjet“ (80943С) и „Инструкция συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο προειδοποιήσεων για τις
за предупреждение за радиочестота“ (80945С). ραδιοσυχνότητες (80945C).
Продуктът може да е съпроводен от копия на ръководствата в електронен Το προϊόν μπορεί να συνοδεύεται από αντίγραφα των εγχειριδίων σε ηλεκτρονική
и в печатен формат. Тези в електронен формат са достъпни също на уебсайта και έντυπη μορφή. Τα ηλεκτρονικά αντίγραφα υπάρχουν επίσης στον ιστότοπό μας.
ни. Много ръководства са налице на няколко езика Πολλά εγχειρίδια είναι διαθέσιμα σε διάφορες γλώσσες στο
на адрес www.hypertherm.com/docs. www.hypertherm.com/docs.

CS (ČESKY/CZECH) HU (MAGYAR/HUNGARIAN)
VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu si přečtěte VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne,
bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági
a dodržování předpisů (80669C), Manuálu pro bezpečnost a dodržování és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági
předpisů při řezání vodním paprskem (80943C) a Manuálu varování ohledně és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás
rádiových frekvencí (80945C). figyelmeztetéseket tartalmazó kézikönyvben (80945C).
Kopie příruček mohou být součástí dodávky produktu, a to v elektronické i tištěné A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve
formě. Elektronické kopie jsou k dispozici i na našich webových stránkách. Mnoho lehetnek. Az elektronikus példányok webhelyünkön is megtalálhatók. Számos
příruček je k dispozici v různých jazycích na stránce www.hypertherm.com/docs. kézikönyv áll rendelkezésre több nyelven a www.hypertherm.com/docs weboldalon.

DA (DANSK/DANISH) ID (BAHASA INDONESIA/INDONESIAN)

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne
PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah petunjuk
i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C),
keselamatan dalam manual produk Anda, Manual Keselamatan dan Kepatuhan
Manual om sikkerhed og overholdelse af krav for vandstråleskæring (80943C),
(80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C), dan Manual
og Manual om radiofrekvensadvarsel (80945C), gennemlæses.
Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti petunjuk keselamatan
Kopier af manualerne kan leveres med produktet i elektronisk og trykt format. dapat menyebabkan cedera pribadi atau kerusakan pada peralatan.
Elektroniske kopier findes også på vores hjemmeside. Mange manualer
Produk mungkin disertai salinan manual atau petunjuk dalam format elektronik
er tilgængelige på flere sprog på www.hypertherm.com/docs.
maupun cetak. Salinan elektronik juga tersedia di situs web kami. Berbagai manual
tersedia dalam beberapa bahasa di www.hypertherm.com/docs.
DE (DEUTSCH/GERMAN)
WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die IT (ITALIANO/ITALIAN)
Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit
AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla
und Übereinstimmung (80669C), das Handbuch für Sicherheit und Compliance bei
sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la conformità
Wasserstrahl-Schneidanlagen (80943C) und das Handbuch für Hochfrequenz-
(80669C), nel Manuale sulla sicurezza e la conformità Waterjet (80943C) e nel
Warnung (80945C).
Manuale di avvertenze sulla radiofrequenza (80945C).
Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form Copie del manuale possono accompagnare il prodotto in formato cartaceo
oder als Druckversion beiliegen. In elektronischer Form liegen sie auch auf unserer
o elettronico. Le copie elettroniche sono disponibili anche sul nostro sito web. Molti
Website vor. Viele Handbücher stehen in verschiedenen Sprachen auf manuali sono disponibili in diverse lingue all’indirizzo www.hypertherm.com/docs.
www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH) JA (日 本語 /JAPANESE)
¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea las 警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報、「安全
instrucciones de seguridad del manual de su producto, del Manual de seguridad とコンプライアンスマニュアル」(80669C) 、「ウォータージェットの安全とコ
y cumplimiento (80669C), del Manual de seguridad y cumplimiento en corte con ンプライアンス」(80943C)、「高周波警告」(80945C) をお読みください。
chorro de agua (80943C) y del Manual de advertencias de radiofrecuencia
説明書のコピーは、電子フォーマット、または印刷物として製品に同梱されて
(80945C).
います。電子コピーは当社ウェブサイトにも掲載されています。説明書の多く
El producto puede incluir copias de los manuales en formato digital e impreso. は www.hypertherm.com/docs にて複数の言語でご用意しています。
Las copias digitales también están en nuestra página web. Hay diversos manuales
disponibles en varios idiomas en www.hypertherm.com/docs.
KO (한국어 /KOREAN)
ET (EESTI/ESTONIAN) 경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 준수
HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote 설명서(80669C), 워터젯 안전 및 규정 준수 설명서(80943C) 그리고 무선 주파수
kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend (80669C), 경고 설명서(80945C)에 나와 있는 안전 지침을 읽으십시오.
Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse hoiatusjuhend 전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될 수 있습니다.
(80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada 전자 사본도 Hypertherm 웹사이트에서 보실 수 있으며 설명서 사본은
seadmeid. www.hypertherm.com/docs 에서 여러 언어로 제공됩니다.
Juhiste koopiad võivad tootega kaasas olla elektrooniliselt või trükituna.
Elektroonilised koopiad on saadaval ka meie veebilehel. Paljud kasutusjuhendid NE (NEDERLANDS/DUTCH)
on erinevates keeltes saadaval veebilehel www.hypertherm.com/docs. WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
de veiligheidsinstructies in de producthandleiding, in de Veiligheids-
FI (SUOMI/FINNISH) en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding
VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen voor waterstralen (80943C) en in de Waarschuwingshandleiding radiofrequentie
käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden ja vaatimustenmukaisuuden (80945C).
käsikirja (80669C), vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden De handleidingen kunnen in elektronische en gedrukte vorm met het product worden
käsikirja (80943C) ja radiotaajuusvaroitusten käsikirja (80945C). meegeleverd. Elektronische versies zijn ook beschikbaar op onze website. Veel
Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa handleidingen zijn in meerdere talen beschikbaar via www.hypertherm.com/docs.
muodossa. Sähköiset kopiot ovat myös verkkosivustollamme. Monet käyttöoppaat
ovat myös saatavissa useilla kielillä www.hypertherm.com/docs.
NO (NORSK/NORWEGIAN) SV (SVENSKA/SWEDISH)
ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och
sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet
samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C), (80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig
og håndboken om radiofrekvensadvarsler (80945C). säkerhetsinformation innan du använder eller underhåller Hypertherm-utrustning.
Eksemplarer av håndbøkene kan følge med produktet i elektronisk og trykt form. Kopior av manualerna kan medfölja produkten i elektroniskt och tryckt format.
Elektroniske eksemplarer finnes også på nettstedet vårt. Mange håndbøker Elektroniska kopior finns också på vår webbplats. Många manualer finns på flera
er tilgjengelig i flere språk på www.hypertherm.com/docs. språk på www.hypertherm.com/docs.

PL (POLSKI/POLISH) TH (ภาษาไทย/THAI)
OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu คําเตือน! กอนการใชงานอุปกรณของ Hypertherm ทั้งหมด โปรดอานคําแนะนําดานความ
firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi ปลอดภัยในคูมือการใชสินคา คูมือดานความปลอดภัยและการปฏิบัติตาม (80669C), คูมือ
w podręczniku produktu, w podręczniku bezpieczeństwa i zgodności (80669C),
ดานความปลอดภัยและการปฏิบัติตามสําหรับการใชหัวตัดระบบวอเตอรเจ็ต (80943C)
podręczniku bezpieczeństwa i zgodności systemów strumienia wody (80943C)
oraz podręczniku z ostrzeżeniem o częstotliwości radiowej (80945C). และ คูมือคําเตือนเกี่ยวกับความถี่วิทยุ (80945C) การไมปฏิบัติตามคําแนะนําดานความ
ปลอดภัยอาจสงผลใหเกิดการบาดเจ็บหรือเกิดความเสียหายตออุปกรณ
Do produktu mogą być dołączone podręczniki użytkownika w formie elektronicznej
i drukowanej. Kopie elektroniczne znajdują się również w naszej witrynie internetowej. สําเนาคูมือทั้งในรูปแบบอิเล็กทรอนิกสและแบบสิ่งพิมพจะถูกแนบมาพรอมกับ
Wiele podręczników jest dostępnych w różnych językach pod adresem ผลิตภัณฑ สําเนาคูมือในรูปแบบอิเล็กทรอนิกสของผลิตภัณฑและสําเนาคูมือตาง
www.hypertherm.com/docs. ๆ ในหลากหลายภาษานั้นยังมีใหบริการบนเว็บไซต www.hypertherm.com/docs
ของเราอีกดวย
PT (PORTUGUÊS/PORTUGUESE)
ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, TR (TÜRKÇE/TURKISH)
leia as instruções de segurança no manual do seu produto, no Manual
UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürününüzün kullanım
de Segurança e de Conformidade (80669C), no Manual de Segurança
kılavuzunda, Güvenlik ve Uyumluluk Kılavuzu’nda (80669C), Su Jeti Güvenlik
e de Conformidade do Waterjet (80943C) e no Manual de Advertência
ve Uyumluluk Kılavuzu’nda (80943C) ve Radyo Frekansı Uyarısı Kılavuzu’nda
de radiofrequência (80945C).
(80945C) yer alan güvenlik talimatlarını okuyun.
Cópias dos manuais podem vir com o produto nos formatos eletrônico e impresso.
Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir. Elektronik
Cópias eletrônicas também são encontradas em nosso website. Muitos manuais
kopyalar web sitemizde de yer alır. Kılavuzların birçoğu www.hypertherm.com/docs
estão disponíveis em vários idiomas em www.hypertherm.com/docs.
adresinde birçok dilde mevcuttur.
RO (ROMÂNĂ/ROMANIAN)
VI (TIẾNG VI ỆT/VIETNAMESE)
AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți
CẢNH BÁO! Trước khi vận hành bất kỳ thiết bị Hypertherm nào, hãy đọc các
instrucțiunile de siguranță din manualul produsului, manualul de siguranță
hướng dẫn an toàn trong hướng dẫn sử dụng sản phẩm của bạn, Sổ tay An toàn
și conformitate (80669C), manualul de siguranță și conformitate Waterjet (80943C)
và Tuân thủ (80669C), Sổ tay An toàn và Tuân thủ Tia nước (80943C), và Hướng
și din manualul de avertizare privind radiofrecvența (80945C).
dẫn Cảnh báo Tần số Vô tuyến (80945C). Không tuân thủ các hướng dẫn an toàn
Produsul poate fi însoțit de copii ale manualelor în format tipărit și electronic. có thể dẫn đến thương tích cá nhân hoặc hư hỏng thiết bị.
Exemplarele electronice sunt disponibile și pe site-ul nostru web.
Bản sao của sổ tay có thể đi kèm với sản phẩm ở định dạng điện tử và in. Bản
Numeroase manuale sunt disponibile în mai mult limbi la adresa:
điện tử cũng có trên trang web của chúng tôi. Nhiều sổ tay có sẵn bằng nhiều
www.hypertherm.com/docs.
ngôn ngữ tại www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)
ZH-CN (简 体中文/CHINESE SIMPLIFIED)
БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь
с инструкциями по безопасности, представленными в руководстве, которое 警告！ 在操作任何海宝设备之前，请阅读产品手册、《安全和法规遵守手册》
поставляется вместе с продуктом, в Руководстве по безопасности и (80669C)、《水射流安全和法规遵守手册》 (80943C) 以及 《射频警告手册》
соответствию (80669С), в Руководстве по безопасности и соответствию для (80945C)  中的安全操作说明。
водоструйной резки (80943C) и Руководстве по предупреждению о 随产品提供的手册可提供电子版和印刷版两种格式。电子版本同时也在我们的网
радиочастотном излучении (80945С). 站上提供。很多手册有多种语言版本，详见 www.hypertherm.com/docs.
Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Электронные копии также ZH-TW (繁 體中文/CHINESE TRADITIONAL)
доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких
языках по ссылке www.hypertherm.com/docs. 警告！在操作任何 Hypertherm 設備前，請先閱讀您產品手冊內的安全指示，
包括 《安全和法規遵從手冊》(80669C) 、《水刀安全和法規遵從手冊》
（80943C），以及 《無線電頻率警示訊號手冊》（80945C）。
SK (SLOVENČINA/SLOVAK)
電子版和印刷版手冊複本可能隨產品附上。您也可以前往我們的網站下載電子版
VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si
手冊。我們的網站上還以多種語言形式提供多種手冊，請造訪
prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia a v Manuáli
www.hypertherm.com/docs。
o bezpečnosti a súlade s normami (80669C), Manuáli o bezpečnosti a súlade
s normami pre systém rezania vodou (80943C) a v Manuáli s informáciami
o rádiofrekvencii (80945C).
Návod na obsluhu sa dodáva spolu s produktom v elektronickej a tlačenej podobe.
Jeho elektronický formát je dostupný aj na našej webovej stránke. Mnohé z návodov
na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke
www.hypertherm.com/docs.

SL (SLOVENŠČINA/SLOVENIAN)
OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna
navodila v priročniku vašega izdelka, v Priročniku za varnost in skladnost (80669C),
v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom (80943C)
in v Priročniku Opozorilo o radijskih frekvencah (80945C).
Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki. Elektronski
izvodi so na voljo tudi na našem spletnem mestu. Številni priročniki so na voljo
v različnih jezikih na naslovu www.hypertherm.com/docs.

SR (SRPSKI/SERBIAN)
UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte
uputstva o bezbednosti u svom priručniku za proizvod, Priručniku o bezbednosti
i usaglašenosti (80669C), Priručniku o bezbednosti i usaglašenosti Waterjet
tehnologije (80943C) i Priručniku sa upozorenjem o radio-frekvenciji (80945C).
Уз производ се испоручују копије приручника у електронском или штампаном
формату. Електронске копије су такође доступне на нашем веб-сајту. Многи
приручници су доступни на више језика на адреси www.hypertherm.com/docs.
 Contents

Electromagnetic Compatibility (EMC)..............................................................................................9

Warranty............................................................................................................................................... 11

1 Specifications............................................................................................................................. 13
Introduction............................................................................................................................................................13
Compatible cutting systems ..............................................................................................................................14
HPR cartridge torch ............................................................................................................................................15
HPR cartridges.....................................................................................................................................................16
Weights and dimensions ....................................................................................................................................16
Weights ...........................................................................................................................................................16
Dimensions..................................................................................................................................................... 17

2 Installation .................................................................................................................................. 19
Before you begin..................................................................................................................................................19
Select and install the cartridge.........................................................................................................................20
Install the torch .....................................................................................................................................................22

HPR Cartridge Instruction Manual 810992 7

 Contents

3 Operating Instructions..............................................................................................................23
Overview ................................................................................................................................................................23
Monitor the gas purge during the power-on cycle.......................................................................................24
Use the HPRXD cut charts to select a process...........................................................................................25
True Bevel™ cutting .............................................................................................................................................28
Bevel-head calibration .................................................................................................................................29
Bevel cutting with 80 A and 130 A cartridges ......................................................................................29
Get the most out of your cartridges.................................................................................................................30
Signs that a cartridge is near end-of-life ........................................................................................................30
Cartridge disposal at end-of-life ...............................................................................................................31

4 Regular Maintenance Tasks.....................................................................................................33

Why regular maintenance is important............................................................................................................33
Recommended maintenance parts and schedule based on plasma arc hours..............................33
Regular maintenance tasks................................................................................................................................34
Lubricate the O-rings on the cartridge shield ........................................................................................34
Lubricate the O-rings on the torch and retaining cap ..........................................................................35
Use the torch-rebuild kit (528106) for regular torch maintenance....................................................36

5 Parts.............................................................................................................................................37
Usual parts............................................................................................................................................................. 37
Torch starter and O-ring kits..............................................................................................................................38
Torch starter kit – 528101 ..........................................................................................................................38
Torch O-ring kit – 528107 ..........................................................................................................................38
Preventive maintenance kits ..............................................................................................................................38
Torch-rebuild kit – 528106 .........................................................................................................................38
Electronics kit HPR130XD cartridge – 528108 ...................................................................................38
Electronics kit HPR260XD cartridge (200 V – 240 V) – 528109 ...................................................39
Electronics kit HPR400XD / HPR800XD cartridge (200 V – 240 V) – 528110.........................39
Electronics kit HPR260XD / HPR400XD / HPR800XD cartridge
(380 V – 600 V) – 528111 .......................................................................................................................39

8 810992 Instruction Manual HPR Cartridge

 Electromagnetic Compatibility (EMC)

Introduction Methods of reducing emissions

Hypertherm’s CE-marked equipment is built in compliance with standard Mains supply
EN60974-10. The equipment should be installed and used in
accordance with the information below to achieve electromagnetic Cutting equipment must be connected to the mains supply according to
compatibility. the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
The limits required by EN60974-10 may not be adequate to completely supply.
eliminate interference when the affected equipment is in close proximity
or has a high degree of sensitivity. In such cases it may be necessary to Consideration should be given to shielding the supply cable of
use other measures to further reduce interference. permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
This cutting equipment is designed for use only in an industrial length. The shielding should be connected to the cutting mains supply so
environment. that good electrical contact is maintained between the conduit and the
cutting power source enclosure.
Installation and use
Maintenance of cutting equipment
The user is responsible for installing and using the plasma equipment
according to the manufacturer’s instructions. The cutting equipment must be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and
If electromagnetic disturbances are detected then it shall be the
covers should be closed and properly fastened when the cutting
responsibility of the user to resolve the situation with the technical
equipment is in operation. The cutting equipment should not be modified
assistance of the manufacturer. In some cases this remedial action may in any way, except as set forth in and in accordance with the
be as simple as earthing the cutting circuit, see Earthing of the
manufacturer’s written instructions. For example, the spark gaps of arc
workpiece. In other cases, it could involve constructing an
striking and stabilizing devices should be adjusted and maintained
electromagnetic screen enclosing the power source and the work according to the manufacturer’s recommendations.
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome. Cutting cables
The cutting cables should be kept as short as possible and should be
Assessment of area positioned close together, running at or close to the floor level.

Before installing the equipment, the user shall make an assessment of Equipotential bonding
potential electromagnetic problems in the surrounding area. The
following shall be taken into account: Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.
a. Other supply cables, control cables, signaling and telephone
cables; above, below and adjacent to the cutting equipment. However, metallic components bonded to the workpiece will increase
b. Radio and television transmitters and receivers. the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
c. Computer and other control equipment. same time.
d. Safety critical equipment, for example guarding of industrial
equipment. The operator should be insulated from all such bonded metallic
components.
e. Health of the people around, for example the use of
pacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User shall
ensure that other equipment being used in the environment is
compatible. This may require additional protection measures.
h. Time of day that cutting or other activities are to be carried
out.

The size of the surrounding area to be considered will depend on the

structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.

Safety and compliance 9

Electromagnetic Compatibility (EMC)

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor
connected to earth because of its size and position, for example, ship’s
hull or building steel work, a connection bonding the workpiece to earth
may reduce emissions in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct
connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable
capacitances selected according to national regulations.

Note: The cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a
person who is competent to assess whether the changes will increase
the risk of injury, for example, by allowing parallel cutting current return
paths which may damage the earth circuits of other equipment.
Further guidance is provided in IEC 60974-9, Arc Welding Equipment,
Part 9: Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of the
entire plasma cutting installation may be considered for special
applications.

10 Safety and compliance

 Warranty

Attention The warranty set forth above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise with respect to the
Genuine Hypertherm parts are the factory-recommended replacement Products or as to the results which may be obtained therefrom, and all
parts for your Hypertherm system. Any damage or injury caused by the implied warranties or conditions of quality or of merchantability or fitness
use of other than genuine Hypertherm parts may not be covered by the for a particular purpose or against infringement. The foregoing shall
Hypertherm warranty, and will constitute misuse of the Hypertherm constitute the sole and exclusive remedy for any breach by Hypertherm
Product. of its warranty.

You are solely responsible for the safe use of the Product. Hypertherm Distributors/OEMs may offer different or additional warranties, but
does not and cannot make any guarantee or warranty regarding the safe Distributors/OEMs are not authorized to give any additional warranty
use of the product in your environment. protection to you or make any representation to you purporting to be
binding upon Hypertherm.

General
Patent indemnity
Hypertherm, Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth Except only in cases of products not manufactured by Hypertherm or
herein and as follows: if Hypertherm is notified of a defect (i) with respect manufactured by a person other than Hypertherm not in strict conformity
to the plasma power supply within a period of two (2) years from the date with Hypertherm’s specifications and in cases of designs, processes,
of its delivery to you, with the exception of Powermax brand power formulae, or combinations not developed or purported to be developed
supplies, which shall be within a period of three (3) years from the date of by Hypertherm, Hypertherm will have the right to defend or settle, at its
delivery to you, and (ii) with respect to the torch and leads within a period own expense, any suit or proceeding brought against you alleging that
of one (1) year from its date of delivery to you, with the exception of the the use of the Hypertherm product, alone and not in combination with
HPRXD short torch with integrated lead, which shall be within a period of any other product not supplied by Hypertherm, infringes any patent of
six (6) months from the date of delivery to you, and with respect to torch any third party. You shall notify Hypertherm promptly upon learning of any
lifter assemblies within a period of one (1) year from its date of delivery to action or threatened action in connection with any such alleged
you, and with respect to Automation products one (1) year from its date infringement (and in any event no longer than fourteen (14) days after
of delivery to you, with the exception of the EDGE Connect CNC, learning of any action or threat of action), and Hypertherm’s obligation to
EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC, defend shall be conditioned upon Hypertherm’s sole control of, and the
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which indemnified party’s cooperation and assistance in, the defense of the
shall be within a period of two (2) years from the date of delivery to you, claim.
and (iii) with respect to HyIntensity fiber laser components within a
period of two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which shall be within
Limitation of liability
a period of one (1) year from its date of delivery to you. In no event shall Hypertherm be liable to any person or entity for
All third-party engines, engine accessories, alternators, and alternator any incidental, consequential direct, indirect, punitive or
accessories are covered by the respective manufacturers’ warranties and exemplary damages (including but not limited to lost profits)
not covered by this warranty. regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty, failure of
This warranty shall not apply to any Powermax brand power supplies that essential purpose, or otherwise, and even if advised of the
have been used with phase converters. In addition, Hypertherm does not possibility of such damages. Hypertherm shall not be liable for
warranty systems that have been damaged as a result of poor power any losses to Distributor based on down time, lost production or
quality, whether from phase converters or incoming line power. This lost profits. It is the intention of the Distributor and Hypertherm
warranty shall not apply to any product which has been incorrectly that this provision be construed by a court as being the
installed, modified, or otherwise damaged. broadest limitation of liability consistent with applicable law.

Hypertherm provides repair, replacement or adjustment of the Product as

the sole and exclusive remedy, if and only if the warranty set forth herein National and local codes
properly is invoked and applies. Hypertherm, at its sole option, shall
repair, replace, or adjust, free of charge, any defective Products covered National and local codes governing plumbing and electrical installation
by this warranty which shall be returned with Hypertherm’s prior shall take precedence over any instructions contained in this manual.
authorization (which shall not be unreasonably withheld), properly In no event shall Hypertherm be liable for injury to persons or property
packed, to Hypertherm’s place of business in Hanover, New Hampshire, damage by reason of any code violation or poor work practices.
or to an authorized Hypertherm repair facility, all costs, insurance and
freight pre paid by the customer. Hypertherm shall not be liable for any
repairs, replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph and with
Hypertherm’s prior written consent.

Safety and compliance 11

Warranty

Liability cap
In no event shall Hypertherm’s liability, if any, whether such
liability is based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or otherwise,
for any claim, action, suit or proceeding (whether in court,
arbitration, regulatory proceeding or otherwise) arising out of or
relating to the use of the Products exceed in the aggregate the
amount paid for the Products that gave rise to such claim.

Insurance
At all times you will have and maintain insurance in such quantities and
types, and with coverage sufficient and appropriate to defend and to hold
Hypertherm harmless in the event of any cause of action arising from the
use of the products.

Transfer of rights
You may transfer any remaining rights you may have hereunder only in
connection with the sale of all or substantially all of your assets or capital
stock to a successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty. Within thirty (30) days before any
such transfer occurs, you agree to notify in writing Hypertherm, which
reserves the right of approval. Should you fail timely to notify Hypertherm
and seek its approval as set forth herein, the Warranty set forth herein
shall be null and void and you will have no further recourse against
Hypertherm under the Warranty or otherwise.

Waterjet product warranty coverage

Product Parts coverage
HyPrecision pumps 27 months from the ship date, or 24 months
from the date of proven installation, or
4,000 hours, whichever occurs first

PowerDredge 15 months from the ship date or 12 months

abrasive removal from the date of proven installation,
system whichever occurs first

EcoSift abrasive 15 months from the ship date or 12 months

recycling system from the date of proven installation,
whichever occurs first

Abrasive metering 15 months from the ship date or 12 months

devices from the date of proven installation,
whichever occurs first

On/off valve air 15 months from the ship date or 12 months

actuators from the date of proven installation,
whichever occurs first

Diamond orifices 600 hours of use with the use of a thimble

filter and compliance with Hypertherm’s
water quality requirements

Consumable parts are not covered by this warranty. Consumable parts

include, but are not limited to, high-pressure water seals, check valves,
cylinders, bleed-down valves, low-pressure seals, high-pressure tubing,
low- and high-pressure water filters and abrasive collection bags. All
third-party pumps, pump accessories, hoppers, hopper accessories,
dryer boxes, dryer box accessories and plumbing accessories are
covered by the respective manufacturers’ warranties and not covered by
this warranty.

12 Safety and compliance

 Specifications

Introduction

The HPR cartridge is for cutting mild steel with all HPRXD cutting systems. An HPR cartridge is
compatible only with an HPR cartridge torch (420729), water tube (420728), and retaining cap
(420708).

The HPR cartridge torch installs on the HPRXD receptacle (220705) and is the interface for an
HPR cartridge. The cartridge installs on the head of the cartridge torch. The retaining cap, which
also installs on the torch head, keeps the cartridge in position.

2
1 3 4

1 HPR cartridge torch 3 HPR cartridge

2 Water tube 4 Retaining cap

There are three HPR cartridges. The cartridges are amperage specific. Refer to HPR cartridges on
page 16 for more information.

The HPR cartridge torch uses the standard HPRXD cut chart settings. Adjustments to the CNC or
nesting software are not necessary.

HPR Cartridge Instruction Manual 810992 13

1 Specifications

Compatible cutting systems

The HPR cartridge torch is compatible with all Hypertherm HPRXD cutting systems. For related
information, refer to the following documents:
 HPR130XD Manual Gas Instruction Manual (806320)
 HPR130XD Auto Gas Instruction Manual (806330)
 HPR260XD Manual Gas Instruction Manual (806340)
 HPR260XD Auto Gas Instruction Manual (806350)
 HPR400XD Manual Gas Instruction Manual (806170)
 HPR400XD Auto Gas Instruction Manual (806160)
 HPR800XD Manual Gas Instruction Manual (806490)
 HPR800XD Auto Gas Instruction Manual (806500)

 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.

14 810992 Instruction Manual HPR Cartridge

 Specifications 1

HPR cartridge torch

The front of the torch supplies cooling to the nozzle and has a non-threaded contact that supplies
current to the cartridge.

Nozzle cooling

Non-threaded contact

Nozzle cooling

The rear of the torch is the same as the HPRXD torch (220706) and has the same connectors.
1

2 2 6

3
4 5

1 Plasma vent* 5 Coolant return

2 Ohmic contact pin 6 Pilot arc
3 Plasma gas 7 Shield gas
4 Coolant supply

* The cartridge and torch do not contain plasma-vent channels. The bullet connector for the plasma vent keeps
contamination out of the HPRXD receptacle.

HPR Cartridge Instruction Manual 810992 15

 1 Specifications

HPR cartridges

The three HPR cartridges are compatible with the following four mild steel processes:
 80 A standard cutting
 130 A standard cutting
 260 A standard cutting / 260 A bevel cutting

The cartridges are amperage specific. For example, a 260 A

cartridge is for use only with 260 A processes. To make
identification easier, the amperage and part number are on each
cartridge.

Do not try to disassemble a cartridge. The single-piece cartridge

cannot be disassembled and has no replaceable parts. It must be
replaced as a unit.

Weights and dimensions

Weights
Component Weight
Torch with water tube 0.63 kg (1.39 lb)
Cartridge 0.08 kg (0.18 lb)
Retaining cap 0.20 kg (0.44 lb)
HPR cartridge torch assembly: torch, water tube, cartridge, and retaining cap 0.91 kg (2.01 lb)

16 810992 Instruction Manual HPR Cartridge

 Specifications 1

Dimensions
153 mm (6.01 in.)*
49 mm (1.91 in.) 104 mm (4.10 in.)*

57 mm
(2.23 in.)

43°

* This dimension can be different based on cartridge type. This example shows a 260 A cartridge.

HPR Cartridge Instruction Manual 810992 17

 1 Specifications

18 810992 Instruction Manual HPR Cartridge

 Installation

Before you begin

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance.
The line-disconnect switch must REMAIN in the OFF position until all
of the installation or maintenance steps are complete.
Refer to the Safety and Compliance Manual (80669C) for more safety
information.

HPR Cartridge Instruction Manual 810992 19

2 Installation

Select and install the cartridge

Before cartridge installation, make sure that the O-rings on the torch, cartridge, and retaining cap
are lubricated. This prevents coolant and gas leaks.

1. Lubricate the O-rings as shown below. Apply a thin layer of silicone lubricant to each O-ring.
Make sure that the O-rings look shiny, but that there is not too much lubricant.
 4 O-rings on the torch 1

 2 O-rings on the cartridge shield 2

 1 O-ring on the retaining cap 3

Image cutaway shows O-ring location 1 2 3

 The torch, water tube, and retaining cap that come with the HPR cartridge
torch starter kit (528101) have pre-lubricated O-rings.

 The electrode O-ring 4 and the nozzle

O-ring 5 on the cartridge interior do not 4 5
require silicone lubricant.

20 810992 Instruction Manual HPR Cartridge

 Installation 2
2. Make sure that the water tube (420728) is in the torch before installing the cartridge. Install a
water tube if necessary.

Water tube

 Put the water tube into the torch until it comes to a stop. The water tube
will move slightly to align with the electrode in the cartridge.

3. Install the cartridge by pushing it onto the torch.

or

4. Install the retaining cap (420708) on the torch. Turn the retaining cap until it comes to a stop.

 The retaining cap moves the cartridge into the correct position on
the torch to seal the O-rings. The retaining cap turns approximately
1/2 of a rotation before it comes to a stop.

HPR Cartridge Instruction Manual 810992 21

2 Installation

5. Make sure that the retaining cap is fully

installed. A coolant leak at the torch
electrode can occur if the retaining cap
is not fully installed.

Install the torch

1. Before installing the torch on the HPRXD receptacle (220705), do the following steps to
disconnect the electrical 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. Install the torch on the HPRXD receptacle. The cartridge torch has the same installation steps
as the standard HPRXD torch.

22 810992 Instruction Manual HPR Cartridge

 Operating Instructions

Overview

The cartridge torch uses the standard HPRXD cut chart settings. Adjustments to the CNC or
nesting software are not necessary.

Because the HPRXD cut chart settings for 260 A mild steel are the same for both standard and
bevel processes, the 260 A cartridge is compatible with both standard and bevel processes.

Because the HPRXD cut chart settings for 80 A and 130 A mild steel are different for standard and
bevel processes, the 80 A and 130 A cartridges will cause a small edge-angle if used with bevel
processes.

Amperage (A) Standard process Bevel process

80 A Compatible -5° angle*
130 A Compatible +3° angle*
260 A Compatible Compatible
* The bevel angle can be adjusted to 0° by making a custom cut chart with standard shield-gas
settings or by making an angle adjustment manually in the ProNest® nesting software.

The screenshots shown on page 25 through page 27 show example cut charts for 260 A, 130 A,
and 80 A standard and bevel processes.

HPR Cartridge Instruction Manual 810992 23

3 Operating Instructions

Monitor the gas purge during the power-on cycle

A gas-purge cycle occurs automatically when electrical power is supplied to the cutting system.
This automatic gas purge usually removes all coolant from the plasma-gas and shield-gas lines. It is
extremely important to keep the gas clean and dry.

1. During the gas purge, look for coolant mist from the cartridge. If no mist is seen, the torch is
ready for cutting.

2. If mist is seen, use the CNC to select Test Cutflow and do a gas purge for approximately
15 seconds. If no mist is seen, the cartridge is ready for cutting.

3. If mist continues to be seen, do the following steps:

a. Disconnect the electrical power from the cutting system.
b. Remove the retaining cap and cartridge. Gently shake them to remove coolant.
c. Examine the electrode O-ring in the cartridge. If the electrode O-ring is dirty, rinse or wipe it
to remove contamination that can prevent good sealing to the torch.
d. Lubricate the O-rings on the torch, cartridge, and retaining cap, as described in step 1 of
Select and install the cartridge on page 20.
e. Install the cartridge on the torch and then turn the cartridge approximately 1/8 of a rotation.
This helps the O-rings to seal onto the torch.
f. Install the retaining cap on the torch. Turn the retaining cap until it comes to a stop. Make
sure that the retaining cap is fully installed. A coolant leak at the torch electrode can occur if
the retaining cap is not fully installed.
g. Supply electrical power to the cutting system. Power restoration starts an automatic
gas-purge cycle.
h. If no mist is seen, the cartridge is ready for cutting. If mist is seen, repeat step 2.

4. If mist continues to be seen, repeat step 3 using a new cartridge or a new retaining cap.

24 810992 Instruction Manual HPR Cartridge

 Operating Instructions 3
Use the HPRXD cut charts to select a process

Figure 1 – Example 260 A standard cut chart settings

Figure 2 – Example 260 A bevel cut chart settings

HPR Cartridge Instruction Manual 810992 25

3 Operating Instructions

Figure 3 – Example 130 A standard cut chart settings

Figure 4 – Example 130 A bevel cut chart settings*

22 28

* When a 130 A cartridge is used with bevel cut chart settings, the Auto shield-gas value (15) gives a +3°
edge angle. To get a 0° angle, adjust the Auto shield-gas setting from 15 to 22, which is the same as the
setting in the standard cut charts in Figure 3.

26 810992 Instruction Manual HPR Cartridge

 Operating Instructions 3
Figure 5 – Example 80 A standard cut chart settings

Figure 6 – Example 80 A bevel cut chart settings**

23 30

** When a 80 A cartridge is used with bevel cut chart settings, the Auto shield-gas value (39) gives a -5° edge
angle. To get a 0° angle, adjust the Auto shield-gas setting from 39 to 23, which is the same as the setting in
the standard cut charts in Figure 5.

HPR Cartridge Instruction Manual 810992 27

3 Operating Instructions

True Bevel™ cutting

An HPR cartridge can be used for True Bevel cutting because it has the same torch length 1 , cone
angle 2 , and shield-face diameter 3 as a standard HPRXD torch with HPRXD bevel
consumables.

Standard HPRXD torch with a set of 260 A bevel consumables

2 3

Cartridge torch with a 260 A cartridge

2 3

The 260 A cartridge can do the same True Bevel cutting as a set of 260 A HPRXD bevel
consumables. Table 1 shows the workpiece thicknesses that a 260 A cartridge can cut with
True Bevel settings.

Table 1 – Workpiece thicknesses that a 260 A cartridge can cut with True Bevel settings

Metric
mm 19 20 22 25 32 38

English
Inches 0.750 0.875 1.000 1.250 1.500

28 810992 Instruction Manual HPR Cartridge

 Operating Instructions 3

Bevel-head calibration
Before using a cartridge for bevel cutting, it is necessary to complete bevel-head calibration with
the standard HPRXD torch. After the bevel-head calibration, remove the standard HPRXD torch
and replace it with the HPR cartridge torch.

For information about True Bevel theory and how to do bevel-head calibration, refer to the True
Bevel Technology – HPRXD Compensation Cut Charts White Paper (807830).

Bevel cutting with 80 A and 130 A cartridges

The cut chart settings for the 80 A and 130 A bevel processes are different than cut chart settings
for standard processes because of the conical shape of the bevel shield.

The 80 A and 130 A cartridges are optimized for use with the standard HPRXD cut chart settings.
If used with True Bevel settings, the 80 A and 130 A cartridges will make edge-angles of -5° and
+3°, respectively. This is because of the difference in the shield-gas settings for the 80 A and
130 A mild steel bevel and standard processes.

Torch with 80 A or 130 A Torch with 80 A or 130 A Torch with 80 A or 130 A

HPR cartridge HPRXD bevel consumables HPRXD standard consumables

HPR Cartridge Instruction Manual 810992 29

3 Operating Instructions

Get the most out of your cartridges

How often it is necessary to replace the cartridge is related to the following:

 Gas supply pressures
 It is extremely important that the cutting system is in good condition with no gas leaks
and no incorrect inlet gas pressures. If consumables wear out quickly because of gas
leaks or incorrect inlet gas pressures, a cartridge will also get to end-of-life quickly. Do a
test for gas leaks to make sure that the gas supply lines are in good condition and that
the settings for inlet gas pressures use Hypertherm recommendations.
 Gas supply quality
 It is extremely important to keep the gas supply lines clean and dry. Oil, water, vapor, and
other contamination in the gas supply line can have a bad effect on cut quality and
decrease cartridge life.
 Cutting technique
 Whenever possible, stop cutting when the plasma arc is on the workpiece. Stopping a
cut when the plasma arc is not on the workpiece can cause wear on the cartridge.
 Shield maintenance
 Carefully remove molten metal that can cause blockages that prevent airflow through the
holes in the cartridge shield. These holes are necessary for airflow. Do not push the
unwanted metal into the nozzle and shield in the cartridge.

Signs that a cartridge is near end-of-life

The HPR cartridges can make quality cuts over a long period of time on a well-maintained cutting
system that uses the recommended cut chart settings. Usually, the best indication about when to
install a new cartridge is when the cut quality is no longer satisfactory.

Do not try to disassemble a cartridge. The single-piece cartridge cannot be disassembled and
has no replaceable parts. It must be replaced as a unit.

The following signs can be indications that a cartridge is near or at end-of-life:

 Examine the nozzle hole. A nozzle hole in good condition is circular. If the nozzle hole is
not circular, replace the cartridge or use it for severing cuts only.
 Examine the shield hole. A shield hole in good condition is circular. If the shield hole is not
circular, replace the cartridge or use it for severing cuts only.

30 810992 Instruction Manual HPR Cartridge

 Operating Instructions 3
 Look for higher rates of 020 or 021 error codes. As the cartridge wears, the electrode pit
gets larger. This makes it difficult to start the pilot arc or to transfer the plasma arc to the
workpiece. A typical error for a cartridge at end-of-life is a failure to start rather than an
electrode blowout.

Nozzle hole

Shield hole

Cartridge disposal at end-of-life

If possible, use recycling and other alternatives to landfill waste when a cartridge or other system
component is at end-of-life. Environmental stewardship is one of Hypertherm’s core values. For
more information go to www.hypertherm.com/environment.

HPR Cartridge Instruction Manual 810992 31

3 Operating Instructions

32 810992 Instruction Manual HPR Cartridge

 Regular Maintenance Tasks

Why regular maintenance is important

Regular maintenance is an important part of cutting system ownership. Regular maintenance

extends the life of the cutting system and consumables, optimizes cutting system performance, and
keeps operating costs to a minimum.

Recommended maintenance parts and schedule based on plasma arc hours

Frequency in
Part number Description plasma arc hours
528106 Kit: Torch-rebuild 500
028872 Coolant solution 70/30 PG 3.79 liter (1 US gallon) 500
011110 Air filter element 500
027664 Coolant filter 500
528108 Preventive maintenance (PM) kit: Electronics, HPR130XD cartridge
528109 PM kit: Electronics, HPR260XD cartridge (200 V – 240 V)
528110 PM kit: Electronics, HPR400XD / HPR800XD cartridge (200 V – 240 V) 1,000

528111 PM kit: Electronics, HPR260XD / HPR400XD / HPR800XD cartridge

(380 V – 600 V)
220705 HPRXD receptacle 2,000

HPR Cartridge Instruction Manual 810992 33

4 Regular Maintenance Tasks

Instruction manuals for preventive maintenance tasks

For additional information about preventive (PM) maintenance tasks, refer to the Preventive
Maintenance Program (PMP) Instruction Manual for your cutting system.

PMP Instruction PMP Instruction

Cutting system Manual part number Cutting system Manual part number
HPR130XD auto gas 808620 HPR400XD auto gas 808660
HPR130XD manual gas 808630 HPR400XD manual gas 808650
HPR260XD auto gas 808250 HPR800XD auto gas 808680
HPR260XD manual gas 808640 HPR800XD manual gas 808670

Technical documentation is available at www.hypertherm.com/docs.

Regular maintenance tasks

Lubricate the O-rings on the cartridge shield

It is necessary to lubricate the two O-rings on the cartridge shield 1 before using a cartridge for the
first time and any time these two O-rings are dry. Make sure the O-rings look shiny, but that there is
not too much lubricant.

1 2 3

 The electrode O-ring 2 and the nozzle O-ring 3 on the cartridge interior
do not require silicone lubricant. These O-rings are not easy to access. If
the electrode O-ring is dirty, rinse or wipe it to remove contamination that
can prevent good sealing to the torch.

34 810992 Instruction Manual HPR Cartridge

 Regular Maintenance Tasks 4

Lubricate the O-rings on the torch and retaining cap

The four O-rings on the front of the torch 1 require frequent lubrication. The O-ring on the retaining
cap 2 also requires frequent lubrication. This helps cartridge O-rings to seal to the torch.

 Make sure that the O-rings look shiny, but that there is not too much
lubricant.

The five O-rings on the rear of the torch 3 require less frequent lubrication. Lubricate these O-rings
when they are dry or as necessary to keep good sealing to the HPRXD receptacle.

Lubricate frequently

Image cutaway shows O-ring location 1 2

Lubricate as necessary

HPR Cartridge Instruction Manual 810992 35

4 Regular Maintenance Tasks

Use the torch-rebuild kit (528106) for regular torch maintenance

1. Before using the torch-rebuild kit (528106) for torch maintenance, do the following steps to
disconnect the electrical 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 torch from the HPRXD receptacle and remove the retaining cap and cartridge from
the torch.

3. Replace the following parts:

1
 Water tube 1

 Put the water tube into the torch until it comes to a stop. The
2
water tube will move slightly to align with the electrode in the
cartridge.
 Four O-rings 2 on the front of the torch
 Apply a thin layer of silicone lubricant to each O-ring before
installation. Make sure that the O-rings look shiny, but that there is
not too much lubricant.
 One O-ring on the coolant-in connector 3 and the four bullet
connectors with corresponding O-rings 4 on the rear of the torch
 Use pliers to pull the old bullet connectors straight out. 3
 Apply a thin layer of silicone lubricant to each O-ring before
installation. Make sure that the O-rings look shiny, but that there is
not too much lubricant.
 Install the new O-ring on the coolant-in connector.
 Install the new bullet connectors. Make sure that each bullet
connector is fully installed. Do not use tools to push the bullet 4
connectors into the slots. Tools can cause damage to the bullet
connectors.
 Large O-ring 5 on the HPRXD receptacle
 Do not lubricate this O-ring.

4. Examine the cartridge and retaining cap and remove any contamination. 5

5. Install the cartridge by pushing it onto the torch and then install the
retaining cap. Turn the retaining cap until it comes to a stop.

6. Assemble the torch and HPRXD receptacle.

 To prevent damage, make sure to correctly align the torch and HPRXD receptacle.
 Make sure that there is no space between the torch and the O-ring on the HPRXD
receptacle.

36 810992 Instruction Manual HPR Cartridge

 Parts

Usual parts

Part number Description

420729 Torch head: HPRXD cartridge
420728 Water tube: HPRXD cartridge
420803 Cartridge: HPRXD 80 A mild steel (standard cutting)
420705 Cartridge: HPRXD 130 A mild steel (standard cutting)
420715 Cartridge: HPRXD 260 A mild steel (standard cutting / bevel cutting)
420708 Retaining cap: HPRXD cartridge
528101 Torch starter kit: HPRXD cartridge
528107 Kit: Torch O-ring, HPRXD cartridge
528106 PM kit: Torch-rebuild
528108 PM kit: Electronics, HPR130XD cartridge
528109 PM kit: Electronics, HPR260XD cartridge (200 V – 240 V)
528110 PM kit: Electronics, HPR400XD / HPR800XD cartridge (200 V – 240 V)
PM kit: Electronics, HPR260XD / HPR400XD / HPR800XD cartridge (380 V –
528111
600 V)
026934 O-ring: HPRXD cartridge, lower shield, silicone 70 duro .945 in. X .059 in.
026919 O-ring: HPRXD cartridge, upper shield, silicone .846 in. X .059 in.

HPR Cartridge Instruction Manual 810992 37

5 Parts

Torch starter and O-ring kits

Torch starter kit – 528101

Part number Description Quantity
420729 Torch head: HPRXD cartridge 1
420728 Water tube: HPRXD cartridge 1
420708 Retaining cap: HPRXD cartridge 1
528107 Kit: Torch O-ring, HPRXD cartridge 1

Torch O-ring kit – 528107

Part number Description Quantity
026029 O-ring: silicone 1.489 in. X .070 in. 2
044027 O-ring: buna-N 70 duro 1.301 in. X .070 in. 2

Preventive maintenance kits

For information about how to use the parts in the preventive maintenance (PM) kits, refer to the
Preventive Maintenance Program (PMP) Instruction Manual for your cutting system. A list of PMP
instruction manuals is shown on page 34.

Torch-rebuild kit – 528106

Part number Description Quantity
220161 Bullet connector 4
026009 O-ring: bullet connector 10
420728 Water tube: HPRXD cartridge 1
058224 O-ring: HPRXD receptacle VITON 75 duro 1.734 in. X .139 in. 1
528107 Kit: Torch O-ring, HPRXD cartridge 1
027055 Silicone lubricant: tube, 1/4 ounce 1

Electronics PM kit, HPR130XD cartridge – 528108

Part number Description Quantity
003149 Relay: 120 VAC DPDT AG CDO NO/NC 1
003249 Contactor: 90 A 3P 120 VAC W/2 AUX CONT 1
420729 Torch head: HPRXD cartridge 1

38 810992 Instruction Manual HPR Cartridge

 Parts 5

Electronics PM kit, HPR260XD cartridge (200 V – 240 V) – 528109

Part number Description Quantity
003149 Relay: 120 VAC DPDT AG CDO NO/NC 1
003217 Contactor: 185 A IEC AC-3 120 VAC coil 1
420729 Torch head: HPRXD cartridge 1

Electronics PM kit, HPR400XD / HPR800XD cartridge (200 V – 240 V) – 528110

Part number Description Quantity
003149 Relay: 120 VAC DPDT AG CDO NO/NC 1
003218 Contactor: 265 A IEC AC-3 120 VAC coil 1
420729 Torch head: HPRXD cartridge 1

Electronics PM kit, HPR260XD / HPR400XD / HPR800XD cartridge (380 V – 600 V) –

528111
Part number Description Quantity
003149 Relay: 120 VAC DPDT AG CDO NO/NC 1
003233 Contactor: 150 A AC-3 120 VAC coil 1
420729 Torch head: HPRXD cartridge 1

HPR Cartridge Instruction Manual 810992 39

5 Parts

40 810992 Instruction Manual HPR Cartridge