Hypertherm HyDefinition HD4070 Instruction Manual
HyDefinition
®
HD4070
Plasma Arc Cutting / Marking System
Instruction Manual
803760 – Revision 2
4070.97
Changed Page Description
Rev 1 to 2
12/17/01
2.12
Changed dimension from 2.4" to 2.8". 2 rail lifter change.
3.6 & .12,
3A.2 &. 23,
3B.2,.12 &
Updated art to show off-valve cover
.21, 5.3
4.14 & 6.13 Added CCW consumables for 200A M.S.
5.35
Text changed to match figure change in Rev1 (P2 Jumper for 265V is now for
211V block position changed from 265V to 211V)
5.37&5.39 Updated art to show 2 rail lifter.
6.8
Added Lo-Profile Filter art. P/Ns 128714 & 027927 and Pump sub-assembly, P/N
129738. Rearranged order of part #s.
6.11 Gas console art updated. Shows valves in the current orientation.
Lifter assembly P/N (128050) changed to 2 rail version 128606. Driving block P/N
6.17
(027552) changed to 027903. Rail and block bearing P/N (027551) changed to
027904. Lead screw assembly P/N (129266) changed to 129699. AddedP/N
128607- band seal kit.
6.18 P/N (075508) changed to 075583.
6.19 Cable P/N 123596 given an item # (3a).
Page 1
Changed Page Description IM376 Rev 0 to 1
4/26/01
Cover
2.5
2.11
iv &3.1
3.3
3.14
3A.3
Section 4
4.5
4.19
5.15 & 5.16
Added HyDefinition to title
H35 percentages corrected to H35 = 35% Hydrogren, 65% Argon
Updated dimension from 2.25" to 3.5" and metric equivalent
Correction to table of contents: 3-19 canged to 3-20, 3-20 to 3-21
Caution box text realigned
Note added under power requirements table (Pg still says 0 not 1.1)
Cables and hoses header changed from German to English
Cutcharts added: 30A S.S. & AL, 70A S.S. & AL, 100A S.S. & AL
Note added "The screen displays the choices..."
English cutchart: ipm & mmm were reversed
Notes added to top of error code tables 1 & 2
5.25 & 26
5.35
6.12
PC-104 art and test procedure removed. Incomplete procedure and parts. Pg
#'s after bumped up
P2 Jumper for 265V is now for 211V block position changed from 265V to
211V
Added part #'s 058224, 044030 & 128654. Renumbered parts, updated art
Page 2
HD4070
Instruction Manual
(P/N 803760)
Revision 2 – December, 2001
© Copyright 2001 Hypertherm, Inc.
All Rights Reserved
Hypertherm, HyDefinition and Command THC are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
800-643-9878 Tel (Technical Service)
800-737-2978 Tel (Customer Service)
Hypertherm Automation
5 Technology Drive
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm Singapore Pte Ltd
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 841 2489 Tel
65 841 2490 Fax
65 841 2489 (Technical Service)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
Hypertherm UK Ltd
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
0805 050 111 Tel
0805 050 222 Fax
Hypertherm S.r.L.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm B.V.
Burg. Haverkampstraat 13
7091 CN Dinxperlo, Nederland
31 315 655866 Tel
31 315 655886 Fax
Hypertherm B.V. (ETSO)
Vaartveld 9
4704 SE Roosendaal, Nederland
00 800 49 73 7843 – toll-free in Europa
31 165 596900 Tel
31 165 596901 Fax
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax
10/30/01
ELECTROMAGNETIC COMPATIBILITY (EMC)
EMC INTRODUCTION
Hypertherm's CE-marked equipment is built
in compliance with standard EN50199. The
equipment should be installed and used in
accordance with the information below to
achieve electromagnetic compatibility.
The limits required by EN50199 may not be
adequate to completely 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 use other measures to further
reduce interference.
This plasma equipment is designed for use
only in an industrial environment.
INSTALLATION AND USE
The user is responsible for installing and
using the plasma equipment according to
the manufacturer's instructions. If electromagnetic disturbances are detected then it
shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as
earthing the cutting circuit, see Earthing of
Workpiece. In other cases it could involve
constructing an electromagnetic screen
enclosing the power source and the work
complete with associated input filters. In all
cases electromagnetic disturbances must
be reduced to the point where they are no
longer troublesome.
ASSESSMENT OF AREA
Before installing the equipment the user
shall make an assessment of potential electromagnetic problems in the surrounding
area. The following shall be taken into
account:
a. Other supply cables, control cables,
signalling and telephone cables; above,
below and adjacent to the cutting equipment.
b. Radio and television transmitters and
receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example
guarding of industrial equipment.
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.
Earthing of 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 steelwork, 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 given in IEC
TC26 (sec)94 and IEC TC26/108A/CD Arc
Welding Equipment 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
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.
METHODS OF REDUCING EMISSIONS
Mains Supply
Cutting equipment must be connected to the
mains supply according to the manufacturer's recommendations. If interference
occurs, it may be necessary to take
additional precautions such as filtering of
the mains supply. Consideration should be
given to shielding the supply cable of permanently installed cutting equipment, in
metallic conduit or equivalent. Shielding
should be electrically continuous throughout
its length. The shielding should be connected to the cutting mains supply so that good
electrical contact is maintained between the
conduit and the cutting power source
enclosure
Maintenance of Cutting Equipment
The cutting equipment must be routinely
maintained according to the manufacturer's
recommendations. All access and service
doors and covers should be closed and
properly fastened when the cutting
equipment is in operation. The cutting
equipment should not be modified in any
way except for those changes and adjustments covered in the manufacturer's
instructions. In particular, the spark gaps of
arc striking and stabilizing devices should
be adjusted and maintained according to
the manufacturer's recommendations.
Cutting Cables
The cutting cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor
level.
Equipotential Bonding
Bonding of all metallic components in the
cutting installation and adjacent to it should
be considered. However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a
shock by touching these metallic
components and the electrode at the same
time. The operator should be insulated from
all such bonded metallic components.
Hypertherm Plasma Systems i
WARRANTY
ii Hypertherm Plasma Systems
9-01
WARNING
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any damage
caused by the use of other than genuine Hypertherm parts may
not be covered by the Hypertherm warranty.
WARNING
You are responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
warranty regarding the safe use of the Product in your
environment.
GENERAL
Hypertherm, Inc. warrants that its Products shall be free from
defects in materials and workmanship, if Hypertherm is notified
of a defect (i) with respect to the power supply within a period
of two (2) years from the date of its delivery to you, with the
exception of G3 Series power supplies, which shall be within a
period of three (3) years from the date of delivery to you, and
(ii) with respect to the torch and leads within a period of one (1)
year from its date of delivery to you. This warranty shall not
apply to any Product which has been incorrectly installed,
modified, or otherwise damaged. Hypertherm, at its sole
option, shall repair, replace, or adjust, free of charge, any
defective Products covered by this warranty which shall be
returned with Hypertherm’s prior authorization (which shall not
be unreasonably withheld), properly packed, to Hypertherm’s
place of business in Hanover, New Hampshire, or to an
authorized Hypertherm repair facility, all costs, insurance and
freight prepaid. Hypertherm shall not be liable for any repairs,
replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph or with
Hypertherm’s prior written consent. The warranty above is
exclusive and is in lieu of all other warranties, express,
implied, statutory, or otherwise with respect to the
Products or as to the results which may be obtained
therefrom, and all implied warranties or conditions of
quality or of merchantability or fitness for a particular
purpose or against infringement. The foregoing shall
constitute the sole and exclusive remedy for any breach
by Hypertherm of its warranty. Distributors/OEMs may offer
different or additional warranties, but Distributors/OEMs are
not authorized to give any additional warranty protection to you
or make any representation to you purporting to be binding
upon Hypertherm.
PATENT INDEMNITY
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’s
specifications and in cases of designs, processes, formulae, or
combinations not developed or purported to be developed by
Hypertherm, Hypertherm will defend or settle, at its own
expense, any suit or proceeding brought against you alleging
that the use of the Hypertherm product, alone and not in
combination with any other product not supplied by
Hypertherm, infringes any patent of any third party. You shall
notify Hypertherm promptly upon learning of any action or
threatened action in connection with any such alleged
infringement, and Hypertherm’s obligation to indemnify shall be
conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the defense
of the claim.
LIMITATION OF LIABILITY
In no event shall Hypertherm be liable to any person or
entity for any incidental, consequential, indirect, or
punitive damages (including but not limited to lost profits)
regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranties, failure of
essential purpose or otherwise and even if advised of the
possibility of such damages.
LIABILITY CAP
In no event shall Hypertherm’s liability, 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 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.
NATIONAL AND LOCAL CODES
National and Local codes governing plumbing and electrical
installation shall take precedent over any instructions
contained in this manual. In no event shall Hypertherm be
liable for injury to persons or property damage by reason of any
code violation or poor work practices.
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.
TABLE OF CONTENTS
0
HD4070 Instruction Manual iii
Electromagnetic Compatibility (EMC) ...........................................................................................................................i
Warranty.......................................................................................................................................................................ii
General................................................................................................................................................................ii
Patent Indemnity..................................................................................................................................................ii
Limitation of Liability ............................................................................................................................................ii
Liability Cap.........................................................................................................................................................ii
Insurance.............................................................................................................................................................ii
National and Local Codes....................................................................................................................................ii
Transfer of Rights................................................................................................................................................ii
Section 1 Safety...................................................................................................................................................1-1
Recognize Safety Information...................................................................................................................................1-2
Follow Safety Instructions.........................................................................................................................................1-2
Cutting Can Cause Fire or Explosion .......................................................................................................................1-2
Electric Shock Can Kill..............................................................................................................................................1-3
Cutting Can Produce Toxic Fumes...........................................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns ..............................................................................................................1-4
Arc Rays Can Burn Eyes and Skin...........................................................................................................................1-4
Grounding Safety......................................................................................................................................................1-4
Compressed Gas Equipment Safety ........................................................................................................................1-5
Gas Cylinders Can Explode If Damaged..................................................................................................................1-5
Noise Can Damage Hearing.....................................................................................................................................1-5
Pacemaker and Hearing Aid Operation....................................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes................................................................................................................1-5
Additional Safety Information....................................................................................................................................1-5
Warning Label...........................................................................................................................................................1-6
Section 1a Sécurité............................................................................................................................................1a-1
Identifier les consignes de sécurité.........................................................................................................................1a-2
Suivre les instructions de sécurité ..........................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion....................................................................................1a-2
Les chocs électriques peuvent être fatals...............................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3
L'arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4
Mise à la masse et à la terre...................................................................................................................................1a-4
Les rayons de l'arc peuvent brûler les yeux et la peau...........................................................................................1a-4
Sécurité des bouteilles de gaz comprimé...............................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5
Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5
Pacemakers et prothéses auditives........................................................................................................................1a-5
Étiquette de sécurité...............................................................................................................................................1a-6
Section 2 Specifications .....................................................................................................................................2-1
System Description...................................................................................................................................................2-2
General ............................................................................................................................................................2-2
Power Supply ..................................................................................................................................................2-2
Machine Torch..................................................................................................................................................2-2
Off-V alve Assembly..........................................................................................................................................2-3
Gas Console ....................................................................................................................................................2-3
Ignition Console ...............................................................................................................................................2-3
Options.............................................................................................................................................................2-3
Options – continued.........................................................................................................................................2-4
Specifications............................................................................................................................................................2-5
TABLE OF CONTENTS
1.1
iv HD4070 Instruction Manual
System Gas Requirements..............................................................................................................................2-5
Power Supply...................................................................................................................................................2-6
Gas Console Assembly ...................................................................................................................................2-8
Ignition Console Assembly...............................................................................................................................2-9
Off-V alve Assembly........................................................................................................................................2-10
Torch Specifications .......................................................................................................................................2-11
X-Y Lifter Assembly........................................................................................................................................2-12
Torch Breakaway Kit ......................................................................................................................................2-13
Section 3 Installation...........................................................................................................................................3-1
Upon Receipt............................................................................................................................................................3-2
Claims.......................................................................................................................................................................3-2
Installation Requirements .........................................................................................................................................3-2
Gas Requirements....................................................................................................................................................3-2
Torch Coolant Requirements....................................................................................................................................3-3
Water Purity Requirements.......................................................................................................................................3-4
Noise levels ..............................................................................................................................................................3-4
Torch Lifter Requirement ..........................................................................................................................................3-4
Placement of System Components ..........................................................................................................................3-5
HD4070 Installation – Basic Requirements ..............................................................................................................3-6
Place System Components:.............................................................................................................................3-7
Customer-Supplied Cables and Hoses:...........................................................................................................3-7
Install Cables and Hoses: ................................................................................................................................3-7
Remote Display Option....................................................................................................................................3-7
Placement of the Power Supply.......................................................................................................................3-8
Placement of the Gas Console Assembly........................................................................................................3-9
Mount the Ignition Console Assembly............................................................................................................3-10
Install the Off-Valve Assembly........................................................................................................................3-11
Grounding Requirements........................................................................................................................................3-12
Supply Gas Plumbing .............................................................................................................................................3-13
Connect the Supply Gases ............................................................................................................................3-13
Power Requirements ..............................................................................................................................................3-14
General ..........................................................................................................................................................3-14
Line Disconnect Switch..................................................................................................................................3-14
Power Cable...................................................................................................................................................3-14
Connect the Power.........................................................................................................................................3-15
Install the Power Supply to Gas Console and CNC Cables ...................................................................................3-16
Signal Cable – Power Supply to Gas Console...............................................................................................3-17
Power Cable – Power Supply to Gas Console...............................................................................................3-17
CNC Interface Cable – Power Supply to CNC...............................................................................................3-18
Install the Remote Display Cable............................................................................................................................3-20
Remote Display..............................................................................................................................................3-20
Signal Cable – Power Supply to Remote Display..........................................................................................3-20
Display Mounting Dimensions........................................................................................................................3-21
Section 3A 1 Torch Installation........................................................................................................................3A-1
HD4070 1-Torch Installation...................................................................................................................................3A-2
System Components..............................................................................................................................................3A-3
Cables and Hoses..................................................................................................................................................3A-3
Install the Coolant Hoses...............................................................................................................................3A-4
Coolant Hose Assembly – Green Supply.......................................................................................................3A-5
Coolant Hose Assembly – Red Return..........................................................................................................3A-5
Install the Power Supply to Ignition Console Leads.......................................................................................3A-6
TABLE OF CONTENTS
0
HD4070 Instruction Manual v
Install the Work Lead.....................................................................................................................................3A-6
Pilot Arc Lead.................................................................................................................................................3A-7
Negative Lead................................................................................................................................................3A-7
Work Lead .....................................................................................................................................................3A-7
Install the Gas Console to Ignition Console Cable ........................................................................................3A-8
Cable – Gas Console to Ignition Console......................................................................................................3A-9
Install the Ignition Console to Off-Valve Cable and Gas Hose Assembly....................................................3A-10
Hoses – Gas Console to Off-Valve .............................................................................................................3A-11
Cable – Ignition Console to Off-Valve..........................................................................................................3A-11
Cable – Off-Valve ........................................................................................................................................3A-11
THC and Torch Installation...................................................................................................................................3A-12
X-Y Lifter Assembly .....................................................................................................................................3A-12
Torch Mounting Block Kit ............................................................................................................................3A-13
Torch Breakaway Kit (Optional) ..................................................................................................................3A-14
Install the Torch (without torch breakaway option).......................................................................................3A-16
Install the Torch (with torch breakaway option)............................................................................................3A-17
Integrated Command THC Option – Cable Installation ...............................................................................3A-18
Cable – Lifter Interface ................................................................................................................................3A-19
Cable – Motor Drive.....................................................................................................................................3A-19
Ohmic Contact Wire.....................................................................................................................................3A-19
Lifter interface cable signals........................................................................................................................3A-20
Motor drive cable signals.............................................................................................................................3A-20
Torch Connections................................................................................................................................................3A-21
Connecting the Torch to Torch Leads..........................................................................................................3A-21
Torch Mounting and Alignment ....................................................................................................................3A-22
Install the Torch and Lead Assembly....................................................................................................................3A-23
Torch and Lead Assembly............................................................................................................................3A-23
Fill the Power Supply with Coolant.......................................................................................................................3A-24
Section 3B 2 Torch Installation........................................................................................................................3B-1
HD4070 2-Torch Installation...................................................................................................................................3B-2
System Components..............................................................................................................................................3B-3
Cables and Hoses..................................................................................................................................................3B-3
Install the Coolant Hoses...............................................................................................................................3B-4
Coolant Hose Assembly – Green Supply.......................................................................................................3B-5
Coolant Hose Assembly – Red Return..........................................................................................................3B-5
Install the Pilot Arc Leads..............................................................................................................................3B-6
Pilot Arc Lead.................................................................................................................................................3B-7
Install the Negative and Work Leads.............................................................................................................3B-8
Negative Lead................................................................................................................................................3B-9
Work Lead .....................................................................................................................................................3B-9
Install the Gas Console to Ignition Console Cable ......................................................................................3B-10
Cable – Gas Console to Ignition Console....................................................................................................3B-11
Install the Gas Hose Assembly....................................................................................................................3B-12
Hoses – Gas Console to Off-valve .............................................................................................................3B-13
Install the Ignition Console to Off-Valve Cables...........................................................................................3B-14
Cable – Ignition Console to Off-valve..........................................................................................................3B-15
Cable – Off-Valve ........................................................................................................................................3B-15
Install the Integrated Command THC Option ......................................................................................................3B-16
Cable – Lifter Interface ................................................................................................................................3B-17
Cable – Motor Drive.....................................................................................................................................3B-17
Ohmic Contact Wire.....................................................................................................................................3B-17
Lifter interface cable signals........................................................................................................................3B-18
Motor drive cable signals.............................................................................................................................3B-18
TABLE OF CONTENTS
1
vi HD4070 Instruction Manual
Torch Connections................................................................................................................................................3B-19
Connecting the Torch to Torch Leads..........................................................................................................3B-19
Torch Mounting and Alignment ....................................................................................................................3B-20
Install the Torch and Lead Assembly....................................................................................................................3B-21
Torch and Lead Assembly............................................................................................................................3B-21
Fill the Power Supply with Coolant.......................................................................................................................3B-22
Section 4 Operation.............................................................................................................................................4-1
Power Supply Controls and Indicators......................................................................................................................4-2
General ............................................................................................................................................................4-2
Power Switch ...................................................................................................................................................4-2
Power Indicators ..............................................................................................................................................4-2
Power Supply Display......................................................................................................................................4-3
System Setup screens navigation ............................................................................................................................4-4
System Operation screens navigation......................................................................................................................4-6
Daily Start-up............................................................................................................................................................4-7
Check Torch.....................................................................................................................................................4-7
Turn Power Supply ON....................................................................................................................................4-8
System Setup Screens.....................................................................................................................................4-8
System Operation Screens ............................................................................................................................4-11
Consumables Selection..........................................................................................................................................4-14
Install Consumables ...............................................................................................................................................4-15
Cut Charts...............................................................................................................................................................4-16
Changing Consumable Parts..................................................................................................................................4-29
Remove Consumables...................................................................................................................................4-29
Inspect Consumables.....................................................................................................................................4-30
Inspect Torch..................................................................................................................................................4-31
Inspect Electrode Pit Depth............................................................................................................................4-32
Replace Torch Water Tube .....................................................................................................................................4-33
Common Cutting Faults..........................................................................................................................................4-34
Cutting Techniques.................................................................................................................................................4-35
How to Get Better Cut Quality........................................................................................................................4-35
How to Get Longer Consumable Life.............................................................................................................4-37
How to Get Better Pierces..............................................................................................................................4-38
How to Increase Cutting Speed .....................................................................................................................4-38
Technical Questions................................................................................................................................................4-38
Section 5 Maintenance........................................................................................................................................5-1
Introduction...............................................................................................................................................................5-2
Routine Maintenance................................................................................................................................................5-2
HD4070 System Description.....................................................................................................................................5-3
Control and Signal Cables ...............................................................................................................................5-3
Power Supply Coolant System Servicing .................................................................................................................5-4
Torch Coolant Draining.............................................................................................................................................5-6
Power Supply Coolant Draining................................................................................................................................5-6
Coolant System Filter and Strainer...........................................................................................................................5-7
Coolant Flow Test Procedure....................................................................................................................................5-9
HD4070 Process Sequence ...................................................................................................................................5-10
Initial Checks...........................................................................................................................................................5-12
Power Measurement...............................................................................................................................................5-13
Service Display Screens.........................................................................................................................................5-14
Error Codes ............................................................................................................................................................5-15
Error Code Trouble Shooting (1 of 4).............................................................................................................5-16
Error Code Trouble Shooting (2 of 4).............................................................................................................5-17
TABLE OF CONTENTS
1
HD4070 Instruction Manual vii
Error Code Troubleshooting- 3 of 4................................................................................................................5-18
Error Code Troubleshooting- 4 of 4................................................................................................................5-19
Electrical PC Boards and Power Supplies..............................................................................................................5-20
Plasma Interface Board PCB5 status Indicators............................................................................................5-21
Breakout Board PCB6 status Indicators.........................................................................................................5-22
Control Board PCB3 status Indicators ...........................................................................................................5-26
Power Distribution Board PCB4 Status Indicators.........................................................................................5-27
Start Circuit Assembly Board PCB2...............................................................................................................5-28
Pilot Arc Current Levels..................................................................................................................................5-28
Start Circuit Functional Schematic.................................................................................................................5-29
Start Circuit Troubleshooting..........................................................................................................................5-29
Gas Console Relay Board PCB1...................................................................................................................5-30
Gas Console Relay Board PCB3...................................................................................................................5-32
Gas Console Control Board PCB2 .........................................................................................................................5-34
Leak Test Procedure...............................................................................................................................................5-35
Chopper Module Test Procedure............................................................................................................................5-36
Phase Loss Detection Board PCB1 Status Indicators and Operation....................................................................5-38
THC Routine Maintenance .....................................................................................................................................5-39
X-Y Lifter Sealing Band- Replace ..................................................................................................................5-39
THC Motor Drive Board ..........................................................................................................................................5-43
THC Power Supply .................................................................................................................................................5-44
THC Control Board .................................................................................................................................................5-45
Preventive Maintenance Schedule.........................................................................................................................5-47
Section 6 Parts List .............................................................................................................................................6-1
Power Supply............................................................................................................................................................6-2
Front Panel Outside.........................................................................................................................................6-2
Left Side Interior...............................................................................................................................................6-3
Right Side Interior ............................................................................................................................................6-4
PC Boards and Interlock Switches...................................................................................................................6-5
I/O Panel..........................................................................................................................................................6-6
Control Box: Shown with Parts for Two THC Option.......................................................................................6-7
Cooling System................................................................................................................................................6-8
Ignition Console .......................................................................................................................................................6-9
Gas Console – 1 of 2..............................................................................................................................................6-10
Gas Console – 2 of 2 ..............................................................................................................................................6-11
HD4070 Torch.........................................................................................................................................................6-12
Consumable Configurations ...................................................................................................................................6-13
Consumable Parts Kit.............................................................................................................................................6-14
Off-valve Assembly.................................................................................................................................................6-15
Recommended Spare Parts ...................................................................................................................................6-15
Integrated Command THC......................................................................................................................................6-17
X-Y Lifter Assembly........................................................................................................................................6-17
X-Y Lifter Torch Mounting Block Kit................................................................................................................6-18
X-Y Lifter Breakaway Kit – Optional...............................................................................................................6-19
Ohmic Contact Wire ......................................................................................................................................6-20
Least Replaceable Units List ..................................................................................................................................6-21
Section 7 Wiring Diagrams .................................................................................................................................7-1
Introduction...............................................................................................................................................................7-1
Wiring Diagram Symbols ..........................................................................................................................................7-2
Gas and Electrical Schematics.................................................................................................................................7-4
TABLE OF CONTENTS
0
viii HD4070 Instruction Manual
Appendix A System Grounding.............................................................................................................................a-1
System Grounding Requirements.............................................................................................................................a-1
Suggested Ground Cable Routing............................................................................................................................a-1
Power Supply...................................................................................................................................................a-1
Equipment Grounding......................................................................................................................................a-1
Work Table Grounding......................................................................................................................................a-2
Appendix B Propylene Glycol Safety Data........................................................................................................b-1
Benzotriazole Safety Data..............................................................................................................b-1
Appendix C Gas Regulators ...............................................................................................................................c-1
Appendix D Service Screen (#18) Status Table ..................................................................................................d-1
Appendix E Integrated Command THC Supplemental Information ................................................................e-1
Command THC serial protocol..................................................................................................................................e-2
CNC Serial Interface.................................................................................................................................................e-4
Appendix F PC-104 Stack: Jumper Positions....................................................................................................f-1
Hypertherm Plasma Systems 1-1
Section 1
SAFETY
In this section:
Recognize Safety Information.........................................................................................................................1-2
Follow Safety Instructions...............................................................................................................................1-2
Cutting Can Cause Fire or Explosion..............................................................................................................1-2
Electric Shock Can Kill....................................................................................................................................1-3
Cutting Can Produce Toxic Fumes..................................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns.....................................................................................................1-4
Arc Rays Can Burn Eyes and Skin .................................................................................................................1-4
Grounding Safety............................................................................................................................................1-4
Compressed Gas Equipment Safety...............................................................................................................1-5
Gas Cylinders Can Explode If Damaged ........................................................................................................1-5
Noise Can Damage Hearing...........................................................................................................................1-5
Pacemaker and Hearing Aid Operation...........................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes ......................................................................................................1-5
Additional Safety Information..........................................................................................................................1-5
Warning Label.................................................................................................................................................1-6
SAFETY
1-2 Hypertherm Plasma Systems
11-98
SAFETY
RECOGNIZE SAFETY INFORMATION
The symbols shown in this section are used to
identify potential hazards. When you see a safety
symbol in this manual or on your machine, understand
the potential for personal injury, and follow the related
instructions to avoid the hazard.
FOLLOW SAFETY INSTRUCTIONS
Read carefully all safety messages in this manual and
safety labels on your machine.
• Keep the safety labels on your machine in good
condition. Replace missing or damaged labels
immediately.
• Learn how to operate the machine and how to use
the controls properly. Do not let anyone operate it
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may
affect safety and machine service life.
DANGER WARNING CAUTION
A signal word DANGER or WARNING is used with a
safety symbol. DANGER identifies the most serious
hazards.
• DANGER and WARNING safety labels are located
on your machine near specific hazards.
• WARNING safety messages precede related
instructions in this manual that may result in injury
or death if not followed correctly.
• CAUTION safety messages precede related
instructions in this manual that may result in
damage to equipment if not followed correctly.
Fire Prevention
• Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of the
cutting area.
• Quench hot metal or allow it to cool before handling
or before letting it touch combustible materials.
• Never cut containers with potentially flammable
materials inside – they must be emptied and
properly cleaned first.
• Ventilate potentially flammable atmospheres before
cutting.
• When cutting with oxygen as the plasma gas, an
exhaust ventilation system is required.
Explosion Prevention
• Do not use the plasma system if explosive dust or
vapors may be present.
• Do not cut pressurized cylinders, pipes, or any
closed container.
• Do not cut containers that have held combustible
materials.
CUTTING CAN CAUSE FIRE OR EXPLOSION
WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away from
cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch
when using methane or argon-hydrogen plasma.
WARNING
Hydrogen Detonation with Aluminum Cutting
• When cutting aluminum underwater, or with the
water touching the underside of the aluminum, free
hydrogen gas may collect under the workpiece and
detonate during plasma cutting operations.
• Install an aeration manifold on the floor of the water
table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.
Touching live electrical parts can cause a fatal shock
or severe burn.
• Operating the plasma system completes an
electrical circuit between the torch and the
workpiece. The workpiece and anything touching
the workpiece are part of the electrical circuit.
• Never touch the torch body, workpiece or the water
in a water table when the plasma system is
operating.
Electric Shock Prevention
All Hypertherm plasma systems use high voltage
in the cutting process (200 to 400 VDC are
common). Take the following precautions when
operating this system:
• Wear insulated gloves and boots, and keep your
body and clothing dry.
• Do not stand, sit or lie on – or touch – any wet
surface when using the plasma system.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent any
physical contact with the work or ground. If you must
work in or near a damp area, use extreme caution.
• Provide a disconnect switch close to the power
supply with properly sized fuses. This switch allows
the operator to turn off the power supply quickly in
an emergency situation.
• When using a water table, be sure that it is correctly
connected to earth ground.
ELECTRIC SHOCK CAN KILL
• Install and ground this equipment according to the
instruction manual and in accordance with national
and local codes.
• Inspect the input power cord frequently for damage
or cracking of the cover. Replace a damaged power
cord immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch
leads.
• Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place
or on the workbench with the work cable attached
during the cutting process.
• Before checking, cleaning or changing torch parts,
disconnect the main power or unplug the power
supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system
enclosure cover, disconnect electrical input power.
Wait 5 minutes after disconnecting the main power
to allow capacitors to discharge.
• Never operate the plasma system unless the power
supply covers are in place. Exposed power supply
connections present a severe electrical hazard.
• When making input connections, attach proper
grounding conductor first.
• Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
substitute other torches which could overheat and
present a safety hazard.
Cutting can produce toxic fumes and gases that
deplete oxygen and cause injury or death.
• Keep the cutting area well ventilated or use an
approved air-supplied respirator.
• Do not cut in locations near degreasing, cleaning or
spraying operations. The vapors from certain
chlorinated solvents decompose to form phosgene
gas when exposed to ultraviolet radiation.
• Do not cut metal coated or containing toxic materials, such as zinc (galvanized), lead, cadmium or
CUTTING CAN PRODUCE TOXIC FUMES
beryllium, unless the area is well ventilated and the
operator wears an air-supplied respirator. The
coatings and any metals containing these elements
can produce toxic fumes when cut.
• Never cut containers with potentially toxic materials
inside – they must be emptied and properly cleaned
first.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth
defects and, in some cases, cancer.
Hypertherm Plasma Systems 1-3
8-99
SAFETY
SAFETY
1-4 Hypertherm Plasma Systems
4-99
SAFETY
Instant-On Torches
Plasma arc comes on immediately when the torch
switch is activated.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
The plasma arc will cut quickly through gloves and
skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
Eye Protection Plasma arc rays produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin.
• Use eye protection in accordance with applicable
national or local codes.
• Wear eye protection (safety glasses or goggles with
side shields, or a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s
ultraviolet and infrared rays.
Lens Shade
Arc Current AWS (USA) ISO 4850
Up to 100 A No. 8 No. 11
100-200 A No. 10 No. 11-12
200-400 A No. 12 No. 13
Over 400 A No. 14 No. 14
ARC RAYS CAN BURN EYES AND SKIN
Skin Protection Wear protective clothing to protect
against burns caused by ultraviolet light, sparks and
hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
• Cuffless trousers to prevent entry of sparks and
slag.
• Remove any combustibles, such as a butane lighter
or matches, from your pockets before cutting.
Cutting Area Prepare the cutting area to reduce
reflection and transmission of ultraviolet light:
• Paint walls and other surfaces with dark colors to
reduce reflection.
• Use protective screens or barriers to protect others
from flash and glare.
• Warn others not to watch the arc. Use placards or
signs.
Work Cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall
away when the cut is complete.
Work Table Connect the work table to an earth
ground, in accordance with appropriate national or
local electrical codes.
GROUNDING SAFETY
Input Power
• Be sure to connect the power cord ground wire to
the ground in the disconnect box.
• If installation of the plasma system involves
connecting the power cord to the power supply, be
sure to connect the power cord ground wire
properly.
• Place the power cord's ground wire on the stud first,
then place any other ground wires on top of the
power cord ground. Fasten the retaining nut tightly.
• Tighten all electrical connections to avoid excessive
heating.
SAFETY
Hypertherm Plasma Systems 1-5
11-98
SAFETY
• Never lubricate cylinder valves or regulators with oil
or grease.
• Use only correct gas cylinders, regulators, hoses
and fittings designed for the specific application.
• Maintain all compressed gas equipment and
associated parts in good condition.
• Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable
national or local codes.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
COMPRESSED GAS EQUIPMENT SAFETY
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national or local codes.
• Never use a cylinder that is not upright and secured
in place.
• Keep the protective cap in place over valve except
when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma
arc and a cylinder.
• Never expose cylinders to excessive heat, sparks,
slag or open flame.
• Never use a hammer, wrench or other tool to open
a stuck cylinder valve.
Prolonged exposure to noise from cutting or gouging
can damage hearing.
• Use approved ear protection when using plasma
system.
• Warn others nearby about the noise hazard.
NOISE CAN DAMAGE HEARING
Pacemaker and hearing aid operation can be affected
by magnetic fields from high currents.
Pacemaker and hearing aid wearers should consult a
doctor before going near any plasma arc cutting and
gouging operations.
To reduce magnetic field hazards:
• Keep both the work cable and the torch lead to one
side, away from your body.
• Route the torch leads as close as possible to the
work cable.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as
possible.
P ACEMAKER AND HEARING
AID OPERATION
ADDITIONAL SAFETY INFORMATION
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American
Welding Society, 550 LeJeune Road
P.O. Box 351020, Miami, FL33135
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and
Welding Processes, American National Standards Institute
1430 Broadway, New York, NY 10018
3. ANSI Standard Z87.1, Safe Practices for Occupation and
Educational Eye and Face Protection, American National
Standards Institute, 1430 Broadway, New York, NY 10018
4. AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL33135
5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL33135
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Cylinders, Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA22202
7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
Canadian Standards Association Standard Sales
178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
8. NFPAStandard 51B, Cutting and Welding Processes, National
Fire Protection Association
470 Atlantic Avenue, Boston, MA 02210
9. NFPAStandard 70–1978, National Electrical Code, National Fire
Protection Association, 470 Atlantic Avenue, Boston, MA 02210
10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402
A PLASMA ARC CAN
DAMAGE FROZEN PIPES
Frozen pipes may be damaged or can burst if you
attempt to thaw them with a plasma torch.
SAFETY
1-6 Hypertherm Plasma Systems
8-99
SAFETY
WARNING LABEL
This warning label is affixed to some power supplies. It is
important that the operator and maintenance technician
understand the intent of these warning symbols as described.
The numbered text corresponds to the numbered boxes on
the label.
1. Cutting sparks can cause explosion or fire.
1.1 Keep flammables away from cutting.
1.2 Keep a fire extinguisher nearby, and have
a watchperson ready to use it.
1.3 Do not cut on any closed containers.
2. The plasma arc can cause injury and
burns.
2.1 Turn off power before disassembling torch.
2.2 Do not hold the material near cutting path.
2.3 Wear complete body protection.
3. Electric shock from torch or wiring can kill.
Protect yourself from electric shock.
3.1 Wear insulating gloves. Do not wear wet or
damaged gloves.
3.2 Insulate yourself from work and ground.
3.3 Disconnect input plug or power before
working on machine.
4. Breathing cutting fumes can be hazardous
to your health.
4.1 Keep your head out of the fumes.
4.2 Use forced ventilation or local exhaust to
remove the fumes.
4.3 Use ventilating fan to remove the fumes.
5. Arc rays can burn eyes and injure skin.
5.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of filter.
Wear complete body protection.
6. Become trained and read the instructions
before working on the machine or cutting.
7. Do not remove or paint over (cover)
warning labels.
Hypertherm Systèmes plasma 1a-1
2/12/01
Section 1a
SÉCURITÉ
Dans cette section :
Identifier les consignes de sécurité...............................................................................................................1a-2
Suivre les instructions de sécurité.................................................................................................................1a-2
Danger Avertissement Précaution...............................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion...........................................................................1a-2
Prévention des incendies, Prévention des explosions .........................................................................1a-2
Risque d’explosion argon-hydrogène et méthane................................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium.................................................................1a-2
Les chocs électriques peuvent être fatals.....................................................................................................1a-3
Prévention des chocs électriques.........................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques..........................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures........................................................................1a-4
Torches à allumage instantané.............................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau.................................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ..........................................................1a-4
Mise à la masse et à la terre.........................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation.....................................................................................1a-4
Sécurité des bouteilles de gaz comprimé .....................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages....................................................1a-5
Le bruit peut provoquer des problèmes auditifs............................................................................................1a-5
Pacemakers et prothèses auditives..............................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés......................................................................................1a-5
Étiquette de sécurité .....................................................................................................................................1a-6
SÉCURITÉ
1a-2 Hypertherm Systèmes plasma
2/12/01
IDENTIFIER LES CONSIGNES
DE SÉCURITÉ
Les symboles indiqués dans cette section sont utilisés pour
identifier les risques éventuels. Si vous trouvez un symbole
de sécurité, que ce soit dans ce manuel ou sur
l’équipement, soyez conscient des risques de blessures et
suivez les instructions correspondantes afin d’éviter ces
risques.
SUIVRE LES INSTRUCTIONS
DE SÉCURITÉ
Lire attentivement toutes les consignes de sécurité dans le
présent manuel et sur les étiquettes de sécurité se trouvant
sur la machine.
• Les étiquettes de sécurité doivent rester lisibles.
Remplacer immédiatement les étiquettes manquantes ou
abîmées.
• Apprendre à faire fonctionner la machine et à utiliser
correctement les commandes. Ne laisser personne utiliser
la machine sans connaître son fonctionnement.
• Garder la machine en bon état. Des modifications non
autorisées sur la machine peuvent engendrer des
problèmes de sécurité et raccourcir la durée d’utilisation
de l’équipement.
DANGER AVERTISSEMENT PRÉCAUTION
Les signaux DANGER ou AVERTISSEMENT sont utilisés
avec un symbole de sécurité, DANGER correspondant aux
risques les plus sérieux.
• Les étiquettes de sécurité DANGER et AVERTISSEMENT
sont situées sur la machine pour signaler certains
dangers spécifiques.
• Les messages d’AVERTISSEMENT précèdent les
instructions d’utilisation expliquées dans ce manuel et
signalent les risques de blessures ou de mort au cas où
ces instructions ne seraient pas suivies correctement.
• Les messages de PRÉCAUTION précèdent les
instructions d’utilisation contenues dans ce manuel et
signalent que le matériel risque d’être endommagé si les
instructions ne sont pas suivies correctement.
Prévention des incendies
• Avant de commencer, s’assurer que la zone de coupage
ne présente aucun danger. Conserver un extincteur à
proximité.
• Éloigner toute matière inflammable à une distance d’au
moins 10 m du poste de coupage.
• Tremper le métal chaud ou le laisser refroidir avant de
le manipuler ou avant de le mettre en contact avec des
matériaux combustibles.
• Ne jamais couper des récipients pouvant contenir des
matières inflammables avant de les avoir vidés et
nettoyés correctement.
• Aérer toute atmosphère potentiellement inflammable
avant d’utiliser un système plasma.
• Lors de l’utilisation d’oxygène comme gaz plasma, un
système de ventilation par aspiration est nécessaire.
Prévention des explosions
• Ne pas couper en présence de poussière ou de vapeurs.
• Ne pas couper de bouteilles, de tuyaux ou autres
récipients fermés et pressurisés.
• Ne pas couper de récipients contenant des matières
combustibles.
LE COUPAGE PEUT PROVOQUER UN INCENDIE
OU UNE EXPLOSION
AVERTISSEMENT
Risque d’explosion
argon-hydrogène et méthane
L’hydrogène et le méthane sont des gaz inflammables et
potentiellement explosifs. Conserver à l’écart de toute
flamme les bouteilles et tuyaux contenant des mélanges à
base d’hydrogène ou de méthane. Maintenir toute flamme
et étincelle à l’écart de la torche lors de l’utilisation d’un
plasma d’argon-hydrogène ou de méthane.
AVERTISSEMENT
Détonation de l’hydrogène lors du
coupage de l’aluminium
• Lors du coupage de l’aluminium sous l’eau, ou si l’eau
touche la partie inférieure de la pièce d’aluminium, de
l’hydrogène libre peut s’accumuler sous la pièce à couper
et détonner lors du coupage plasma.
• Installer un collecteur d’aération au fond de la table à eau
afin d’éliminer les risques de détonation de l’hydrogène.
Se référer à l’annexe du manuel pour plus de
renseignements sur les collecteurs d’aération.
SÉCURITÉ
Hypertherm Systèmes plasma 1a-3
2/12/01
Toucher une pièce électrique sous tension peut provoquer
un choc électrique fatal ou des brûlures graves.
• La mise en fonctionnement du système plasma ferme un
circuit électrique entre la torche et la pièce à couper. La
pièce à couper et tout autre élément en contact avec cette
pièce font partie du circuit électrique.
• Ne jamais toucher le corps de la torche, la pièce à couper
ou l’eau de la table à eau pendant le fonctionnement du
système plasma.
Prévention des chocs électriques
Tous les systèmes plasma Hypertherm utilisent des hautes
tensions pour le coupage (souvent de 200 à 400 V). On
doit prendre les précautions suivantes quand on utilise le
système plasma :
• Porter des bottes et des gants isolants et garder le corps
et les vêtements au sec.
• Ne pas se tenir, s’asseoir ou se coucher sur une surface
mouillée, ni la toucher quand on utilise le système plasma.
• S’isoler de la surface de travail et du sol en utilisant des
tapis isolants secs ou des couvertures assez grandes
pour éviter tout contact physique avec le travail ou le sol.
S’il s’avère nécessaire de travailler dans ou près d’un
endroit humide, procéder avec une extrême prudence.
• Installer un sectionneur avec fusibles appropriés, à
proximité de la source de courant. Ce dispositif permet à
l’opérateur d’arrêter rapidement la source de courant en
cas d’urgence.
• En cas d’utilisation d’une table à eau, s’assurer que cette
dernière est correctement mise à la terre.
LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS
• Installer et mettre à la terre l’équipement selon les
instructions du présent manuel et conformément aux
codes électriques locaux et nationaux.
• Inspecter fréquemment le cordon d’alimentation primaire
pour s’assurer qu’il n’est ni endommagé, ni fendu.
Remplacer immédiatement un cordon endommagé.
Un câble dénudé peut tuer.
• Inspecter et remplacer les câbles de la torche qui sont
usés ou endommagés.
• Ne pas saisir la pièce à couper ni les chutes lors du
coupage. Laisser la pièce à couper en place ou sur la
table de travail, le câble de retour connecté lors du
coupage.
• Avant de vérifier, de nettoyer ou de remplacer les pièces
de la torche, couper l’alimentation ou débrancher la prise
de courant.
• Ne jamais contourner ou court-circuiter les verrouillages
de sécurité.
• Avant d’enlever le capot du système ou de la source de
courant, couper l’alimentation électrique. Attendre en
suite
5 minutes pour que les condensateurs se déchargent.
• Ne jamais faire fonctionner le système plasma sans que
les capots de la source de courant ne soient en place.
Les raccords exposés de la source de courant sont
extrêmement dangereux.
• Lors de l’installation des connexions, attacher tout d’abord
la prise de terre appropriée.
• Chaque système plasma Hypertherm est conçu pour être
utilisé uniquement avec des torches Hypertherm
spécifiques. Ne pas utiliser des torches inappropriées qui
pourraient surchauffer et présenter des risques pour la
sécurité.
Le coupage peut produire des vapeurs et des gaz toxiques
qui réduisent le niveau d’oxygène dans l’air et peuvent
provoquer des blessures, voire la mort.
• Conserver le poste de coupage bien aéré ou utiliser un
masque respiratoire homologué.
• Ne pas procéder au coupage près d’endroits où
s’effectuent le dégraissage, le nettoyage ou la vaporisation. Certains solvants chlorés se décomposent sous
l’effet des rayons ultraviolets et forment du phosgène.
• Ne pas couper des métaux peints ou contenant des
matières toxiques comme le zinc (galvanisé), le plomb, le
cadmium ou le béryllium, à moins que la zone de travail
LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES
soit très bien ventilée et que l’opérateur porte un masque
respiratoire. Les revêtements et métaux contenant ces
matières peuvent produire des vapeurs toxiques lors du
coupage.
• Ne jamais couper de récipients pouvant contenir des
matières inflammables avant de les avoir vidés et
nettoyés correctement.
• Quand on utilise ce produit pour le soudage ou le
coupage, il dégage des fumées et des gaz qui
contiennent des produits chimiques qui, selon l’État de
Californie, provoquent des anomalies congénitales et,
dans certains cas, le cancer.
SÉCURITÉ
1a-4 Hypertherm Systèmes plasma
2/12/01
Torches à allumage instantané
L’arc plasma s’allume immédiatement après que la torche
soit mise en marche.
L’ARC PLASMAPEUT PROVOQUER DES BLESSURES OU DES BRÛLURES
L’arc plasma coupe facilement les gants et la peau.
• Rester éloigné de l’extrémité de la torche.
• Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres
personnes.
Protection des yeux Les rayons de l’arc plasma
produisent de puissants rayons visibles ou invisibles
(ultraviolets et infrarouges) qui peuvent brûler les yeux et la
peau.
• Utiliser des lunettes de sécurité conformément aux codes
locaux ou nationaux en vigueur.
• Porter des lunettes de protection (lunettes ou masque
muni d’écrans latéraux ou encore masque de soudure)
avec des verres teintés appropriés pour protéger les yeux
des rayons ultraviolets et infrarouges de l’arc.
Puissance des verres teintés
Courant de l’arc AWS (É.-U.) ISO 4850
Jusqu’à 100 A No8N
o
11
100-200 A No10 No11-12
200-400 A No12 No13
Plus de 400 A No14 No14
Protection de la peau Porter des vêtements de sécurité
pour se protéger contre les brûlures que peuvent causer les
rayons ultraviolets, les étincelles et le métal brûlant :
LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées
du corps.
• Pantalon sans revers pour éviter que des étincelles ou
des scories puissent s’y loger.
• Avant le coupage, retirer de ses poches tout objet
combustible comme les briquets au butane ou les
allumettes.
Zone de coupage Préparer la zone de coupage afin de
réduire la réverbération et la transmission de la lumière
ultraviolette :
• Peindre les murs et autres surfaces de couleur sombre
pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin
de protéger les autres personnes de la lumière et de la
réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc.
Utiliser des affiches ou des panneaux.
Câble de retour Bien fixer le câble de retour (ou de
masse) à la pièce à couper ou à la table de travail de façon
à assurer un bon contact métal-métal. Ne pas fixer le câble
de retour à la partie de la pièce qui doit se détacher.
Table de travail Raccorder la table de travail à la terre,
conformément aux codes de sécurité locaux ou nationaux
appropriés.
MISE À LA MASSE ET À LA TERRE
Alimentation
• S’assurer que le fil de terre du cordon d’alimentation est
connecté à la terre dans le coffret du sectionneur.
• S’il est nécessaire de brancher le cordon d’alimentation à
la source de courant lors de l’installation du système,
s’assurer que le fil de terre est correctement branché.
• Placer tout d’abord le fil de terre du cordon d’alimentation
sur le plot de mise à la terre puis placer les autres fils de
terre par-dessus. Bien serrer l’écrou de retenue.
• S’assurer que toutes les connexions sont bien serrées
pour éviter la surchauffe.
SÉCURITÉ
Hypertherm Systèmes plasma 1a-5
2/12/01
• Ne jamais lubrifier les robinets des bouteilles ou les
régulateurs avec de l’huile ou de la graisse.
• Utiliser uniquement les bouteilles, régulateurs, tuyaux et
accessoires appropriés et conçus pour chaque application
spécifique.
• Entretenir l’équipement et les pièces d’équipement à gaz
comprimé afin de les garder en bon état.
• Étiqueter et coder avec des couleurs tous les tuyaux de
gaz afin d’identifier le type de gaz contenu dans chaque
tuyau. Se référer aux codes locaux ou nationaux en
vigueur.
LES BOUTEILLES DE GAZ
COMPRIMÉ PEUVENT EXPLOSER
EN CAS DE DOMMAGES
SÉCURITÉ DES BOUTEILLES DE
GAZ COMPRIMÉ
Les bouteilles de gaz contiennent du gaz à haute pression.
Si une bouteille est endommagée, elle peut exploser.
• Manipuler et utiliser les bouteilles de gaz comprimé
conformément aux codes locaux ou nationaux.
• Ne jamais utiliser une bouteille qui n’est pas placée à la
verticale et bien assujettie.
• Le capuchon de protection doit être placé sur le robinet
sauf si la bouteille est en cours d’utilisation ou connectée
pour utilisation.
• Éviter à tout prix le contact électrique entre l’arc plasma et
une bouteille.
• Ne jamais exposer des bouteilles à une chaleur
excessive, aux étincelles, aux scories ou aux flammes
nues.
• Ne jamais utiliser des marteaux, des clés ou d’autres
outils pour débloquer le robinet des bouteilles.
Une exposition prolongée au bruit du coupage ou du
gougeage peut provoquer des problèmes auditifs.
• Utiliser un casque de protection homologué lors de
l’utilisation du système plasma.
• Prévenir les personnes aux alentours des risques
encourus en cas d’exposition au bruit.
LE BRUIT PEUT PROVOQUER DES
PROBLÈMES AUDITIFS
Les champs magnétiques produits par les courants à haute
tension peuvent affecter le fonctionnement des prothèses
auditives et des pacemakers. Les personnes portant ce
type d’appareil doivent consulter un médecin avant de
s’approcher d’un lieu où s’effectue le coupage ou le
gougeage plasma.
Pour réduire les risques associés aux champs magnétiques :
• Garder loin de soi et du même côté du corps le câble de
retour et le faisceau de la torche.
• Faire passer le faisceau de la torche le plus près possible
du câble de retour.
• Ne pas s’enrouler le faisceau de la torche ou le câble de
retour autour du corps.
• Se tenir le plus loin possible de la source de courant.
PACEMAKERS ET
PROTHÈSES AUDITIVES
Les tuyaux gelés peuvent être endommagés ou éclater
si l'on essaie de les dégeler avec une torche plasma.
UN ARC PLASMA
PEUT ENDOMMAGER
LES TUYAUX GELÉS
SÉCURITÉ
1a-6 Hypertherm Systèmes plasma
2/12/01
Étiquette de sécurité
Cette étiquette est affichée sur la source de courant. Il est important
que l’utilisateur et le technicien de maintenance comprennent la
signification des symboles de sécurité. Les numéros de la liste
correspondent aux numéros des images.
1. Les étincelles produites par le coupage
peuvent provoquer une explosion ou un
incendie.
1.1 Pendant le coupage, éloigner toute matière
inflammable.
1.2 Conserver un extincteur à proximité et
s’assurer qu’une personne soit prête à
l’utiliser.
1.3 Ne jamais couper de récipients fermés.
2. L’arc plasma peut provoquer des blessures
et des brûlures.
2.1 Couper l’alimentation avant de démonter la
torche.
2.2 Ne pas tenir la surface à couper près de la
trajectoire de coupe.
2.3 Porter des vêtements de protection
couvrant tout le corps.
3. Un choc électrique causé par la torche ou
les câbles peut être fatal. Se protéger
contre les risques de chocs électriques.
3.1 Porter des gants isolants. Ne pas porter de
gants mouillés ou abîmés.
3.2 S’isoler de la surface de travail et du sol.
3.3 Débrancher la prise ou la source de
courant avant de manipuler l’équipement.
4. L’inhalation des vapeurs produites par le
coupage peut être dangereuse pour la
santé.
4.1 Garder le visage à l’écart des vapeurs.
4.2 Utiliser un système de ventilation par
aspiration ou d’échappement localisé pour
dissiper les vapeurs.
4.3 Utiliser un ventilateur pour dissiper les
vapeurs.
5. Les rayons de l’arc peuvent brûler les yeux
et provoquer des lésions de la peau.
5.1 Porter un casque et des lunettes de
sécurité. Se protéger les oreilles et porter
une chemise dont le col peut être
déboutonné. Porter un casque de soudure
dont la protection filtrante est suffisante.
Porter des vêtements protecteurs couvrant
la totalité du corps.
6. Se former à la technique du coupage et lire
les instructions avant de manipuler
l’équipement ou de procéder au coupage.
7. Ne pas retirer ou peindre (recouvrir) les
étiquettes de sécurité.
HD4070 Instruction Manual 2-1
0
Section 2
SPECIFICATIONS
In this section:
System Description.........................................................................................................................................2-2
General...................................................................................................................................................2-2
Power Supply ........................................................................................................................................2-2
Machine Torch........................................................................................................................................2-2
Off-V alve Assembly ................................................................................................................................2-3
Gas Console...........................................................................................................................................2-3
Ignition Console......................................................................................................................................2-3
Options...................................................................................................................................................2-3
Options - continued ................................................................................................................................2-4
Specifications..................................................................................................................................................2-5
System Gas Requirements.....................................................................................................................2-5
Power Supply .........................................................................................................................................2-6
Gas Console Assembly - 078085...........................................................................................................2-8
Ignition Console Assembly - 078088......................................................................................................2-9
Off-Valve Assembly - 129563 ...............................................................................................................2-10
Torch Specifications..............................................................................................................................2-11
X-Y Lifter Assembly..............................................................................................................................2-12
Torch Breakaway Kit - 128281......................................................................................................................2-13
SPECIFICATIONS
1
2-2 HD4070 Instruction Manual
System Description
General
The HD4070 is a fully automated 200-amp plasma cutting system that requires minimal input and adjustment by
the operator. Using the HD4070 display touch screen (or CNC), the operator enters the material and thickness to
be cut. The HD4070 system automatically selects and adjusts the power and gas required to optimize cutting,
including amperage, gas and gas flow rate.
Power supply
The power supply houses two 100-amp, 15 kHz choppers to produce up to 200Aof constant current DC output. The
HD4070 power supply provides the energy to cut 1/2" mild steel at up to 90 ipm (12 mm at up to 2515 mm/min).
Machine torch
The machine torch can cut 1/2" mild steel at 90 ipm (12 mm at up to 2515 mm/min). The maximum production
cutting capability of the torch is 3/4 inch (19 mm) HyDefinition and 1 inch (25 mm) conventional cutting. To achieve
consumable long life, all cuts must begin and end on the plate surface.
4070.97
SPECIFICATIONS
0
HD4070 Instruction Manual 2-3
Off-valve assembly
The off-valve assembly consists of 5 solenoid valves, a manifold block and a wiring harness with connector. The
assembly interfaces with the machine torch, the ignition console and the gas console.
Gas console
The gas console manages all incoming gasses for selection and flow rate and is controlled by the HD4070 power
supply. The gas console includes motor valves, solenoid valves, check valves and pressure transducers, all
mounted on a single manifold assembly. The manifold significantly reduces gas leaks by eliminating the use of
flexible hose. The gas console also houses 2 relay PC boards and a control PC board.
Ignition console
The ignition console generates a high-voltage, high-frequency signal and couples it to the cathode lead and pilot
arc lead. The ignition console is fully electronic, eliminating the use of a spark gap assembly.
Options
• 2-Torch Option - The HD4070 plasma cutting system has the ability to support 2 torches operated from a
single power supply and gas console. When one torch is selected for cutting, the second torch is in the offmode. This allows operators to configure the system for 2 different processes (i.e. 100-amp consumables
installed in one torch and 200-amp consumables installed in the second torch), and to select one torch or
the other from the HD4070 display (or CNC).
• Integrated Command THC Option - The Hypertherm Integrated Command THC takes full advantage of
the HD4070's automated capabilities. When the operator enters the material and thickness to be cut, using
the HD4070 display touch screen (or CNC), the Integrated Command THC automatically adjusts the torch
settings required for the specific process, including arc volts, torch-to-work distance, initial pierce height and
pierce time delay, using the plasma arc voltage to control the torch-to-work distance during cutting. IHS is
accomplished by ohmic contact sensing or by limited- force stall detection. HD4070 power supplies that are
equipped with the Integrated Command THC option include the THC motor drive board, the THC control PC
board and THC power supply required for torch lifter operation and control.
• X-Y lifter assembly (page 2-12) The torch lifter station, under control of the THC control module,
positions a- torch head vertically above the workpiece. Its maximum stroke is 8 inches (200 mm) between
the home and lower-limit switches. It is driven by a stepper motor attached to a leadscrew. An encoder is
provided for stall IHS sensing, and to detect gross errors during normal operation. Alower limit switch
detects maximum travel in the downward direction. Ahome switch is provided to detect when the lifter is
in the uppermost position. Apower-off brake is energized after power-up, and allows controlled motion of
the torch. It is powered on during "Maintenance Mode" to prevent the torch from being accidentally
moved. An optional torch breakaway kit is available.
• Torch Breakaway Kit (optional page 2-13) The torch breakaway (collision sensor) provides a level of
protection for the torch, lifter and X-Y table. Air pressure locks the torch to the THC lifter assembly. The
air pressure can be adjusted to change the force required to trip the breakaway. Upon side impact, the
breakaway releases from the lock position and allows the torch to float.See Page 2-12 for torch mounting
dimensions with and with out the breakaway.
SPECIFICATIONS
0
2-4 HD4070 Instruction Manual
Options - continued
• Touch Screen Display Option - The HD4070 display is a touch screen that provides all system control
functions and plasma process information at a single location. The torch consumables that are required
for the selected process are also listed. The power supply may be ordered in three configurations.
• No display
• Display installed in power supply
• Display for installation at a remote location
Warning: The HD4070 system can only support one touch screen display, either local or remote.
Installing displays at both locations on one system may cause malfunctions or damage.
SPECIFICATIONS
1.1
HD4070 Instruction Manual 2-5
Specifications
System gas requirements
Gas Quality and Pressure Requirements
Quality Pressure + 5% Flow Rate
O2Oxygen 99.5% pure (liquid gas recommended) 120 psi 133 scfh (3780 l/h)
Clean, dry, oil-free 8.3 bar / 827 kPa
N2Nitrogen 99.99% pure (liquid gas recommended) 120 psi 142 scfh 4020 l/h
Clean, dry, oil-free 8.3 bar / 827 kPa
Air Clean, dry, oil-free 120 psi 140 scfh 3960 l/h
8.3 bar / 827 kPa
CH4Methane 93% pure 120 psi 188 scfh 5340 l/h
8.3 bar / 827 kPa
H5 Argon-Hydrogen 99.995% pure (liquid gas recommended) 120 psi 122 scfh 3420 l/h
(H5=5% Hydrogen, 95% Argon) 8.3 bar / 827 kPa
H35 Argon-Hydrogen 99.995% pure (liquid gas recommended) 120 psi 146 scfh 4140 l/h
(H35=35% Hydrogen, 65% Argon) 8.3 bar / 827 kPa
CO2Carbon-Dioxide 99.5% pure 120 psi 113 scfh 3180 l/h
8.3 bar / 827 kPa
Mild Steel Stainless Steel Aluminum
Gas Types Plasma Shield Plasma Shield Plasma Shield
Marking N
2
N
2
H5 N
2
H5 N
2
Cutting 30 A O
2
O2& N
2
Air Air Air Air
Cutting 70 A O
2
O2& N
2
H35 & N
2
N
2
Air CH4& Air
Cutting 100 Ato 200 A O
2
O2& N
2
H35 & N
2
N
2
H35 & N
2
N
2
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