Hypertherm HD3070 User Manual

HD3070

Plasma Arc Cutting System

with Automatic Gas Console

Product Configuration Manual

802310 - Revision 4

HD3070

Plasma Arc Cutting System

with Automatic Gas Console

Product Configuration Manual

PM-231

Revision 4 - January 2000

Hypertherm, Inc.

Hanover, NH USA

http://www.hypertherm.com

email: [e-mail]

© Copyright 2000 Hypertherm, Inc.

All Rights Reserved

Htpertherm and HyDefinition are trademarks of Hypertherm, Inc. and may be

registered in the United States and/or other countries

Hypertherm Offices Worldwide

Hypertherm, Inc.

Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
Tel.: [phone] (Main Office)
Fax: [phone] (All Departments)
Tel.: [phone] (Technical Service – toll-free in USA and Canada)
Tel.: [phone] (Customer Service – toll-free in USA and Canada)
email: [e-mail] (General Information)
email: [e-mail] (Technical/Customer Services)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau
Rodenbacher Chaussee 6
D–63457 Hanau-Wolfgang, Germany
Tel.: [phone]
Fax: [phone]

Hypertherm Singapore Pte Ltd

No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847
Tel.: [phone]
Fax: [phone]

Hypertherm U.K.

9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
Tel.: [phone]
Fax: [phone]

:

France

15 Impasse des Rosiers
95610 Eragny, France
Tel.: [phone]
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Via Torino 2
20123 Milan, Italy
Tel.: [phone] (Customer Service)
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Hypertherm B.V.

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7091 CN Dinxperlo, The Netherlands
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Edisonstraat 12
3281 NC Numansdorp, The Netherlands
Tel.: [phone] (+800 Hypertherm) – (toll-free Technical Service)
Tel.: [phone]
Fax: [phone]

Japan

Shinjuku Park Tower 30th Floor
3-7-1 Nishi-Shinjuku
Shinjuku-ku, Tokyo
163-1030, Japan
81 03 5326 3142 Tel
81 03 5326 3001 Fax

2/00

1 Ordering Procedure

In this section:

Introduction ............................................................................................................... 1-2

Torches ................................................................................................................ 1-2

Cutting Machines ................................................................................................. 1-2

Multi-Torch Systems ................................................................................................. 1-3

Layout of Cutting Machine and HD3070 System ...................................................... 1-4

Ordering Information ................................................................................................. 1-5

Single-System Ordering Procedure .......................................................................... 1-6

Customized Ordering For HD3070 w/Automatic Gas Console ................................. 1-8

1 Power Supply ................................................................................................. 1-8

2 Automatic Gas Console.................................................................................. 1-8

3 RHF Console .................................................................................................. 1-8

4 Leads Between Power Supply and the RHF Console .................................... 1-8

5 Work Cable Between Power Supply and Work Table .................................... 1-10

6 Leads Between Power Supply and Gas Console........................................... 1-10

Torch Configuration................................................................................................... 1-12

13 Leads Between RHF Console and Torch ....................................................... 1-14

14 Off-Valve Assembly ........................................................................................ 1-14

15 Shield Hose .................................................................................................... 1-14

16 Plasma Hose .................................................................................................. 1-14

17 Leads Between Gas Console and Off-Valve Assembly ................................. 1-14

18 Control Cable Between Gas Console and Cutting Machine Interface ............ 1-16

19 Control Cable Between Power Supply and Cutting Machine Interface .......... 1-16

20 Current Setpoint Cable ................................................................................... 1-18

21 Timer Counter Cable ...................................................................................... 1-18

22 Remote Current Control (RCC) ...................................................................... 1-18

23 Timer-Counter ................................................................................................ 1-18

1-1HD3070 w/Automatic Gas Console

1-00

INTRODUCTION

Hypertherm’s HD3070 HyDefinition® plasma cutting system is a precision cutting dual gas

machine-torch system. The microprocessor-controlled system helps to provide extended life

for the torch consumables parts. To achieve consumable long life, all cuts must begin and

end on the plate surface; this allows for the proper ramping of gases and DC current to

extend the life of the nozzle and electrode. The HD3070 system consists of a power supply,

remote high frequency (RHF) console, gas console, off-valve assembly and torch. Optional

units include a timer-counter and a remote current control.

The HD3070 can be configured for either robotic applications or X-Y cutting tables. To

accommodate the different needs of these two types of systems, two different torches are

offered.

TORCHES

PAC184

If ordering for a robotic system, the PAC184 torch with 45° quick disconnect is recom-

mended. This torch, with a pointed front end, is designed to cut in a robotic environment.

PAC186

The PAC186 torch with the straight quick disconnect is more suitable for X-Y cutting tables.

A unique feature to the PAC184 and PAC186 torches is that the torch bodies, quick discon-

nects and mounting sleeves are all interchangeable.

CUTTING MACHINES

If cutting on an X-Y machine, it is extremely critical that the torch drive system has very

accurate vibration-free control of the X, Y, and Z axes. Placing a precision-cutting plasma

system on a cutting machine with poor positioning or poor contouring tolerance, or with

inadequate acceleration and deceleration characteristics will clearly show the effects on the

cut face. The Z-axis of the cutting machine must be controlled to +/-.005 in. Initial height

sensing (IHS) for plate piercing must also be accurate and repeatable to ensure long

consumable life.

Hypertherm recommends HD3070 units be installed on new, high-precision X-Y machines.

For robotic and hard tooling applications, any system that is laser compatible will generally

perform well with the HD3070 system.

12-96

1-2 HD3070 w/Automatic Gas Console

MULTI-TORCH SYSTEMS

If more than one torch is required, increase the quantity of each component by the number
of torches to be used.

To specify the correct components for each application, follow the guidelines in this section.

1-3HD3070 w/Automatic Gas Console

LAYOUT OF CUTTING MACHINE AND HD-3070 SYSTEM

When configuring an HD3070 system(s), it is important to know where each major compo-

nent will be placed. This will vary with the cutting machine manufacturer and with the particu-

lar installation. After the location of the major components has been determined, the inter-

connecting leads and cable lengths can be specified.

It is critical to follow the path that the interconnecting leads will follow and allow for some

slack when specifying their lengths. Do not try to get by with the next shorter length!

Pictured below is a diagram showing an overhead view of a typical precision cutting X-Y

machine. Installations vary, so use this figure as a guide.

Bridge

Rail

Torch

Water
Table

Rail

Figure 1-1 Gantry (Bridge) Layout)*

* Cables are usually in a power track or
festoon system. Cable, lead and hose lengths
must allow for routing through the system.

1-4 HD3070 w/Automatic Gas Console

ORDERING INFORMATION

The figure below represents an HD3070 plasma system with automatic gas console mounted in a
robotic environment. A complete robotic system is also represented in block diagram form on page
1-7. See pages 1-20 and 1-21 for representations of an HD3070 plasma system with automatic gas
console mounted on an X-Y cutting table.

Notes: • Block diagrams are offered to clarify connection points and do not necessarily

reflect relative sizes or distances between components.

• If the cutting system has a power track for cabling and hosing, be certain to see the

Specifications section to check hose, cable and connector diameters.

16

15

13

14

12

11

3

4

17

10

2

1

6

18

5

22

23

19

1 HD3070 Power Supply, Auto

2 HD3070 Automatic Gas Console
3 Remote High Frequency (RHF) Console
4 Leads Between Power Supply and RHF Console
5 Work Cable Between Power Supply and Work Table
6 Leads Between Power Supply and Auto Gas Console
7 PAC186 Torch (not shown)
8 Quick Disconnect Assembly - Straight (not shown)
9 10 Inch Torch Mounting Sleeve (not shown)
10 PAC184 Torch
11 Quick Disconnect Assembly - 45°
12 8 Inch Torch Mounting Sleeve
13a Shielded Leads Between RHF Console and Torch (with Blow

Down Check Valve & Hose)

Figure 1-2 HD3070 System in Robotic Environment

21

20

13b Shielded Leads Between RHF Console and Torch (without Blow

Down Check Valve & Hose)
14a Off-Valve Assembly (with Blow Down Solenoid Valve)
14b Off-Valve Assembly (without Blow Down Solenoid Valve)
15 48 Inch Shield Gas Hose Between Off-Valve Assy and Torch
16 48 Inch Plasma Gas Hose Between Off-Valve Assy and Torch
17 Leads Between Gas Console and Off-Valve Assy
18 Cable Between Gas Console and Cutting Machine Interface
19 Control Cable Between Power Supply and Cutting Machine Interface
20 Current Setpoint Cable Between Power Supply and Cutting Machine

Interface or Between Power Supply and RCC
21 Timer-Counter Cable Between Power Supply and Cutting Machine

Interface or Between Power Supply and Timer-Counter
22 Remote Current Control (RCC)
23 Timer-Counter

1-5HD3070 w/Automatic Gas Console

1-00

SINGLE-SYSTEM ORDERING PROCEDURE

SYSTEM ORDERING FOR HD3070 w/AUTOMATIC GAS CONSOLE ­ROBOTIC APPLICA TIONS

Special numbers have been established for ordering an entire HD3070 system. Under these
numbers, all cables, hoses and leads are at fixed lengths. Refer to the list below and Figure
1-3 on the following page for clarification of the system.

1 HD3070 Power Supply, Auto
2 HD3070 Automatic Gas Console
3 Remote High Frequency (RHF) Console
4 15 Ft Leads Between Power Supply and RHF Console
5 39.4 Ft Work Cable Between Power Supply and Work Table
6 6 Ft Leads Between Power Supply and Auto Gas Console
7 PAC184 Machine Torch Assy
8 PAC184 Machine Torch Quick Disconnect Assembly and Leads:

8a PAC184 45° Quick Disconnect
8b 8 Inch Torch Mounting Sleeve
8c Off-Valve Assy (Off-Valve comes with or without Blow Down Solenoid Valve)
8d 4 Ft Hoses from Off-Valve Assy to Torch
8e 35 Ft Leads from Gas Console to Off-Valve Assy
8f 19.7 Ft Leads from RHF Console to Torch (Leads come with or without Blow Down

Check Valve & Hose)
9 28.2 Ft Cable Between Gas Console and Cutting Machine Interface
10 28.2 Ft Control Cable Between Power Supply and Cutting Machine Interface
11 28.2 Ft Current Setpoint Cable Between Power Supply and Cutting Machine Interface
12 28.2 Ft Timer-Counter Cable Between Power Supply and Cutting Machine Interface

If this exact configuration will work for your particular site, simply order by using the
appropriate system number listed directly below.

078067 HD3070 Plasma System w/Auto Gas Console, 200V, 50/60 Hz, 3Ø
078068 HD3070 Plasma System w/Auto Gas Console, 208V, 60 Hz, 3Ø
078069 HD3070 Plasma System w/Auto Gas Console, 220/380/415V, 50/60 Hz, 3Ø
078070 HD3070 Plasma System w/Auto Gas Console, 240/480V, 60 Hz, 3Ø
078071 HD3070 Plasma System w/Auto Gas Console, 600V, 60 Hz, 3Ø

To customize a system, begin on page 1-8 and use the order form.

1-00

1-6 HD3070 w/Automatic Gas Console

Standard HD-3070 Plasma System w/Automatic Gas Console - Robotic

(Use Single System Number on This Sheet)

5

Power

Supply

12

RHF

8f

Console

4

1

Automatic

Plasma Gas

Shield Gas

Gas

3

8e

Console

2

6

10

11

9

Cutting

8c

8b

8d

8a

Machine

Interface

7

Ground Rod

Work Table

Figure 1-3 HD3070 w/Automatic Gas Console Single Order Number System Configuration

1-7HD3070 w/Automatic Gas Console

1-00

ORDERING PROCEDURE

CUSTOMIZED ORDERING FOR HD-3070 w/AUTOMATIC
GAS CONSOLE

1 SPECIFY THE POWER SUPPLY

The HD3070 power supply houses a 100-amp, 15kw chopper power supply which produces a
constant current DC output variable from 15 to 100 amps. It contains a microprocessor control
PC board which regulates all of the plasma system functions: start sequence, machine interface
functions, gas and cut parameters, and off sequence. The power supply also houses the
recirculating cooling system to cool the torch. The power supply interconnects with the RHF
console, machine interface, gas console, and the workpiece.

• Determine the placement of the power supply (supplies) and input line voltage available at the
site and order the appropriate power supply. See
dimensions and weight.

2 ORDER THE AUTOMATIC GAS CONSOLE

The gas console is designed to be mounted on the power supply. The unit interfaces with the
power supply, torch off-valve assembly, cutting machine interface and the supply gases. The
gas console must be located within 100 feet (30 m) of the torch off-valve assembly and 150 feet
(46 m) of the cutting machine interface.

Specifications

for details on power supply

• Order the gas console.

3 ORDER THE RHF CONSOLE

The RHF console houses the high-frequency starting circuit which is needed to initiate the
torch. The high-frequency starting circuit permits more effective RF shielding and allows the RHF
console to be installed at a distance of up to 125 feet (38 m) from the power supply and
40 feet (12 m) from the torch. A door interlock switch and a cathode manifold are also located in
the RHF console.

• Determine approximately where the console will be mounted on the cutting machine.
Check the mounting holes and weight of the console in the
where it can best be attached.

Specifications

section to determine

4 SPECIFY THE LEADS BETWEEN THE POWER SUPPLY AND THE

RHF CONSOLE

The lead set from the power supply to the RHF console consists of five components:
a pilot arc cable, a #4 negative lead cable, a cooling supply hose, a cooling return hose, and
a control cable.

• Based on the distance (the path that the leads will have to run) between the power supply
and the remote high-frequency console, order the appropriate lead package.

1-8 HD3070 w/Automatic Gas Console

4-98