Plasma Arc Cutting System
with Manual Gas Console
Instruction Manual
802170 – Revision 18
HyDefinition
®
HD3070
™
The world leader in
plasma cutting technology
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HyDefinition
HD3070
Instruction Manual
(P/N 802170)
Revision 18 – November, 2013
© Copyright 2013 Hypertherm, Inc.
All Rights Reserved
Hypertherm, HyDefinition and LongLife 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
220/380/415V CE Power Supplies
The 220/380/415V CE power supply complies with the EMC European standard
EN50199.
Information about this standard and
other line filtering information
pertaining to this power supply is
located in Appendix D of this manual.
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
HD3070 with Manual Gas Console Instruction Manual iii
16
Electromagnetic Compatibility (EMC).......................................................................................................................i
Warranty .....................................................................................................................................................................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
Description................................................................................................................................................................2-2
General ............................................................................................................................................................2-2
Power Supply ...................................................................................................................................................2-2
Gas Console ..................................................................................................................................................2-2
RHF Console....................................................................................................................................................2-3
PAC184 Machine Torch Assemblies................................................................................................................2-3
PAC186 Machine Torch Assemblies................................................................................................................2-3
45° Torch Quick Disconnect Assembly............................................................................................................2-3
Straight Torch Quick Disconnect Assembly ....................................................................................................2-3
Off-Valve Assemblies.......................................................................................................................................2-3
Optional Units...................................................................................................................................................2-4
Timer-Counter..............................................................................................................................................2-4
Remote Current Control (RCC) ...................................................................................................................2-4
TABLE OF CONTENTS
iv HD3070 with Manual Gas Console Instruction Manual
17
Specifications............................................................................................................................................................2-7
Power Supply ...................................................................................................................................................2-7
Gas Console ..................................................................................................................................................2-7
RHF Console....................................................................................................................................................2-8
PAC184 Machine Torch Assemblies................................................................................................................2-8
PAC186 Machine Torch Assemblies .............................................................................................................2-10
45° Torch Quick Disconnect Assembly..........................................................................................................2-11
Straight Torch Quick Disconnect Assembly ..................................................................................................2-11
Off-Valve Assemblies.....................................................................................................................................2-12
Optional Units.................................................................................................................................................2-12
Timer-Counter............................................................................................................................................2-12
Remote Current Control (RCC) .................................................................................................................2-12
IEC Symbols Used..................................................................................................................................................2-13
Section 3 PRE-INSTALLATION...........................................................................................................................3-1
Pre-Installation..........................................................................................................................................................3-2
Upon Receipt ...................................................................................................................................................3-2
HD3070 System Components..........................................................................................................................3-2
Claims ..............................................................................................................................................................3-2
Gas Requirements ...........................................................................................................................................3-3
Oxygen.........................................................................................................................................................3-3
Nitrogen .......................................................................................................................................................3-3
Air.................................................................................................................................................................3-3
Methane.......................................................................................................................................................3-3
Argon-Hydrogen (H35).................................................................................................................................3-4
Power Supply Placement .................................................................................................................................3-4
Power Requirements........................................................................................................................................3-6
Line Voltage Disconnect Box.......................................................................................................................3-6
Power Cable ................................................................................................................................................3-6
240/480V Power Supply Linkboard Configurations .....................................................................................3-8
220/380/415V Power Supply Linkboard Configurations ..............................................................................3-8
Work Table Grounding ....................................................................................................................................3-8
Equipment Grounding ......................................................................................................................................3-8
Connect Power Cable ....................................................................................................................................3-10
Power Supply.............................................................................................................................................3-10
Line Voltage Disconnect Box.....................................................................................................................3-10
Local/External Pierce Delay Function ............................................................................................................3-11
Local/External Current Set Function ..............................................................................................................3-11
Torch Lifter Requirement ...............................................................................................................................3-11
Installation...............................................................................................................................................................3-12
System Units Placement ................................................................................................................................3-12
Remote High Frequency Console..............................................................................................................3-12
Gas Console .............................................................................................................................................3-12
Torch Quick Disconnect Assemblies/Off-Valve Assembly.........................................................................3-12
Cable, Hose & Lead Set Interconnections .....................................................................................................3-16
Power Supply to RHF Console and Work Table Interconnections ............................................................3-18
Power Supply to Gas Console Interconnections........................................................................................3-22
Power Supply to Machine Interface/Timer-Counter/RCC Interconnections...............................................3-25
RHF to Torch Quick Disconnect Interconnections.....................................................................................3-28
Gas Console to Off-Valve Assembly Interconnections ..............................................................................3-30
Off-Valve Assembly to Torch Quick Disconnect Interconnections.............................................................3-32
Gas Supply Hose Connections..................................................................................................................3-34
PE Ground Cable Connections..................................................................................................................3-34
TABLE OF CONTENTS
HD3070 with Manual Gas Console Instruction Manual v
17
Mount PAC184/PAC186 Torch to Quick Disconnect .....................................................................................3-35
Torch Coolant Requirements .........................................................................................................................3-36
Filling the System...........................................................................................................................................3-38
Post Installation ......................................................................................................................................................3-38
Section 4 OPERATION ........................................................................................................................................4-1
Controls and Indicators.............................................................................................................................................4-2
Power Supply ...................................................................................................................................................4-2
Gas Console ....................................................................................................................................................4-4
Daily Start-Up Procedure..........................................................................................................................................4-7
Changing Consumable Parts....................................................................................................................................4-9
Removal and Inspection...................................................................................................................................4-9
Replacement ....................................................................................................................................................4-9
Blow Back Option to Purge Coolant Hoses ............................................................................................................4-12
How to Optimize Cut Quality...................................................................................................................................4-14
Tips for Table and Torch ................................................................................................................................4-14
Plasma Set-up Tips........................................................................................................................................4-14
Maximize the Life of Consumable Parts.........................................................................................................4-14
Additional Factors of Cut Quality....................................................................................................................4-15
Additional Improvements................................................................................................................................4-16
Technical Questions ...............................................................................................................................................4-17
Operating Data (Cut) Charts...................................................................................................................................4-18
Section 5 MAINTENANCE ...................................................................................................................................5-1
Introduction ...............................................................................................................................................................5-2
Routine Maintenance................................................................................................................................................5-3
Power Supply ...................................................................................................................................................5-3
RHF Console....................................................................................................................................................5-3
Gas Console ....................................................................................................................................................5-4
Torch, Quick Disconnect/Off-Valve and Torch Leads Inspection.....................................................................5-4
Staring Sequence of HD3070 ...................................................................................................................................5-5
Initial Checks ............................................................................................................................................................5-7
Troubleshooting ......................................................................................................................................................5-10
Status LED Troubleshooting...................................................................................................................................5-15
Power Supply Control Board Indicators..................................................................................................................5-19
Error Code LED..............................................................................................................................................5-19
Status Indicator LEDs ...................................................................................................................................5-21
Power Supply Relay Board Status Indicators .........................................................................................................5-22
Gas System Back Pressure Checks.......................................................................................................................5-28
CH130 Chopper Module Test Procedure ...............................................................................................................5-31
PAC186 Torch Maintenance...................................................................................................................................5-34
Water Tube Removal and Replacement ........................................................................................................5-34
Bullet Connector Removal and Replacement ................................................................................................5-36
High Current Contact Removal and Replacement .........................................................................................5-36
Section 6 PARTS LIST.........................................................................................................................................6-1
Introduction ...............................................................................................................................................................6-2
Power Supplies.........................................................................................................................................................6-2
Control Panel ...................................................................................................................................................6-2
Front Exterior ...................................................................................................................................................6-4
Front Interior-Right and Left Sides ...................................................................................................................6-5
CH130 Chopper Subassemblies......................................................................................................................6-6
Linkboard Subassemblies ................................................................................................................................6-7
TABLE OF CONTENTS
vi HD3070 with Manual Gas Console Instruction Manual
17
Center Panel and Bottom – Right Side ............................................................................................................6-9
Center Panel and Bottom – Left Side.............................................................................................................6-10
Rear Interior-Left and Right Sides..................................................................................................................6-11
HF I/O Panel Subassemblies .........................................................................................................................6-12
Rear Exterior ..................................................................................................................................................6-14
RHF Console ..........................................................................................................................................................6-16
Gas Console – Front Panel ....................................................................................................................................6-18
Gas Console – Right and Left Sides.......................................................................................................................6-20
PAC184 Machine Torch Assemblies ......................................................................................................................6-22
PAC186 Machine Torch Assemblies ......................................................................................................................6-23
45° Torch Quick Disconnect Assembly and Mounting Sleeve................................................................................6-24
Straight Torch Quick Disconnect Assembly, Mounting Sleeve and Spacer ...........................................................6-24
Off-Valve Assemblies .............................................................................................................................................6-25
PAC184 Torch Consumable Parts..........................................................................................................................6-26
PAC184 Consumable Parts Kits.............................................................................................................................6-26
PAC186 Torch Consumable Parts..........................................................................................................................6-27
PAC186 Consumable Parts Kits ............................................................................................................................6-28
System Interconnecting Leads, Cables and Hoses.................................................................................See Section 3
Section 7 WIRING DIAGRAMS............................................................................................................................7-1
Appendix A PROPYLENE GLYCOL SAFETY DATA .........................................................................................a-2
BENZOTRIAZOLE SAFETY DATA ...............................................................................................a-10
Appendix B TIMER-COUNTER ...........................................................................................................................b-1
Introduction ...............................................................................................................................................................b-2
Installation.................................................................................................................................................................b-2
Operation ..................................................................................................................................................................b-2
Timer-Counter Internal Wiring ..................................................................................................................................b-4
Parts List...................................................................................................................................................................b-5
Appendix C REMOTE CURRENT CONTROL (RCC)..........................................................................................c-1
Introduction ...............................................................................................................................................................c-2
Installation.................................................................................................................................................................c-2
RCC 1X2 to Thumbwheel Switch Wiring Interface ...................................................................................................c-3
Operation ..................................................................................................................................................................c-3
Parts List ...................................................................................................................................................................c-4
Appendix D ELECTROMAGNETIC COMPATIBILITY (EMC).............................................................................d-1
EMC Introduction ......................................................................................................................................................d-2
General .....................................................................................................................................................................d-3
Power Cable .............................................................................................................................................................d-3
Connect Power Cable...............................................................................................................................................d-3
EMI Filter Parts List ..................................................................................................................................................d-5
Appendix E SYSTEM GROUNDING....................................................................................................................e-1
System Grounding Requirements.............................................................................................................................e-1
Suggested Ground Cable Routing............................................................................................................................e-1
TABLE OF CONTENTS
HD3070 with Manual Gas Console Instruction Manual vii
17
Power Supply ...................................................................................................................................................e-1
Equipment Grounding ......................................................................................................................................e-1
Work Table Grounding .....................................................................................................................................e-2
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
5/6/02
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, and 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.
PACEMAKER 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, FL 33135
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, FL 33135
5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Cylinders, Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202
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. NFPA Standard 51B, Cutting and Welding Processes, National
Fire Protection Association
470 Atlantic Avenue, Boston, MA 02210
9. NFPA Standard 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.
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
5/6/02
Torches à allumage instantané
L’arc plasma s’allume immédiatement après que la torche
soit mise en marche.
L’ARC PLASMA PEUT 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 et 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.
HD3070 with Manual Gas Console Instruction Manual 2-1
17
Section 2
SPECIFICATIONS
In this section:
Description................................................................................................................................................................2-2
General ............................................................................................................................................................2-2
Power Supply ...................................................................................................................................................2-2
Gas Console ..................................................................................................................................................2-2
RHF Console....................................................................................................................................................2-3
PAC184 Machine Torch Assemblies.................................................................................................................2-3
PAC186 Machine Torch Assemblies.................................................................................................................2-3
45° Torch Quick Disconnect Assembly.............................................................................................................2-3
Straight Torch Quick Disconnect Assembly .....................................................................................................2-3
Off-Valve Assemblies .......................................................................................................................................2-3
Optional Units...................................................................................................................................................2-4
Timer-Counter..............................................................................................................................................2-4
Remote Current Control (RCC) ...................................................................................................................2-4
Specifications............................................................................................................................................................2-7
Power Supply ...................................................................................................................................................2-7
Gas Console ..................................................................................................................................................2-7
RHF Console....................................................................................................................................................2-8
PAC184 Machine Torch Assemblies.................................................................................................................2-8
PAC186 Machine Torch Assemblies ..............................................................................................................2-10
45° Torch Quick Disconnect Assembly...........................................................................................................2-11
Straight Torch Quick Disconnect Assembly ...................................................................................................2-11
Off-Valve Assemblies .....................................................................................................................................2-12
Optional Units.................................................................................................................................................2-12
Timer-Counter............................................................................................................................................2-12
Remote Current Control (RCC) .................................................................................................................2-12
IEC Symbols Used..................................................................................................................................................2-13
2-2 HD3070 with Manual Gas Console Instruction Manual
15
SPECIFICATIONS
Description
General
This manual provides the information needed to install, operate and maintain the HD3070 plasma cutting system
for either robotically controlled or x-y table cutting applications. This precision cutting, dual gas machine-torch
system consists of a power supply, RHF console, gas console, torch quick disconnect assembly, off-valve
assembly and machine torch assembly. Refer to Figures 2-1 and 2-2.
The HD3070 can be configured for different cutting applications by providing a selectable current output at 15, 30,
50, 70 or 100 amps for optimum performance on cutting most metals from gauge to 1/2-inch (12.7 mm) thick. This
allows the operator wide variations in cutting speeds on the same thickness of metal. The gas console provides
four inlets for the different plasma and shield gases required for different cutting applications. The HD3070 is
designed to cut mild steel, stainless steel, copper and aluminum with the appropriate gases and consumables
selected. Plasma gases required for cutting are oxygen, air, or H35 and nitrogen, depending on the application.
The shield gas aids in assisting cut quality by providing an atmosphere around the plasma arc on the surface of the
workpiece. The shield gas also cools the shield at the front end of the torch.
Under microprocessor control, the HD3070 provides extended life (LongLife) for the torch nozzle and electrode.
To get long life, all cuts must begin and end on the plate surface; this allows for the proper ramping up and down of
gases and DC current
Power Supply
This unit houses a 100-amp, 15 kw chopper which produces a constant current DC output, variable from 15 to 100
amps. It contains a microprocessor control PCB which regulates all the plasma system functions: start sequence,
machine interface functions, gas and cut parameters, and off sequence. The power supply main on/off power is
controlled locally or remotely by the CNC machine. The power supply also houses the cooling system required to
cool the torch. The power supply interconnects with the RHF console, machine interface, gas console, and
workpiece.
An EMI filter, standard with all 220/380/415V power supplies (078024), meets the CE requirement for filtering
incoming power. Refer to Appendix D to connect incoming power to the filter and for part numbers.
Gas Console
This unit houses the solenoid valves, flowmeters, pressure gauges, and switches used for plasma and shield gas
flow control. The four flowmeters (with metering valves) are used to set the test preflow flowrates and test cut
flowrates for the plasma and shield gases. The three pressure gauges, located on the left side of the console,
indicate the pressures of the set test preflow and test cut flowrates. These gauges should not be used to set the
flowrates. They should be used only in troubleshooting, if the correct flowrate values cannot be obtained.
This unit also provides a five inlet gas supply area where the required plasma and shield gases can be connected.
A toggle switch is used to select the plasma gases. The plasma and shield gases are monitored by three gas inlet
pressure gauges: one for oxygen or air, one for nitrogen or methane, and one for H35.
The gas console interconnects with the power supply, and the torch off-valve assembly via the gas lead set.
HD3070 with Manual Gas Console Instruction Manual 2-3
15
SPECIFICATIONS
RHF Console
This unit houses the high frequency starting circuit which is needed to fire the torch and permits more effective RF
shielding. The RHF Console has a water barrier to separate water and electrical components. Also housed in the
console is a door interlock switch and a cathode manifold. The cathode manifold is used to interface power/coolant
leads between the power supply and torch. The power/coolant leads and a pilot arc lead make up the shielded
torch lead set which connects with the torch.
PAC184 Machine Torch Assemblies
The PAC184 machine torch is a dual gas (plasma and shield) plasma arc cutting torch. The slimmer design allows
it to be used primarily in robotic cutting applications. The torch assembly includes the torch main body and
consumables. The torch is cooled by a closed-loop system which distributes the coolant to and from the torch by
way of the quick disconnect assembly, RHF console and the cooling subassemblies in the power supply. There are
two torch assemblies: one torch assembly comes without an IHS tab on the shield cap; the other torch assembly
comes with an IHS tab on the shield cap. See Figure 2-3.
PAC186 Machine Torch Assemblies
The PAC186 machine torch is a dual gas (plasma and shield) plasma arc cutting torch designed for X-Y table
cutting applications. The torch assembly includes the torch main body and consumables. The torch is cooled by a
closed-loop system which distributes the coolant to and from the torch by way of the quick disconnect assembly,
RHF console and the cooling subassemblies in the power supply. There are two torch assemblies: one torch
assembly comes without an IHS tab on the shield cap; the other torch assembly comes with an IHS tab on the
shield cap. See Figure 2-3.
45° Torch Quick Disconnect Assembly
The torch quick disconnect assembly is primarily used for robotic cutting applications. Inputs from the RHF console
using the torch lead set are: electrode cooling water supply and return, power, and pilot arc. Inputs from the offvalve assembly are for torch blow back and plasma and shield gases. The quick disconnect also includes a 10 inch
strain relief, which clamps on the end of the torch sleeve, to prevent damage to the leads and hoses.
Straight Torch Quick Disconnect Assembly
The torch quick disconnect assembly allows mechanized changing of torches by the cutting machine. Inputs from
the RHF console using the torch lead set are: electrode cooling water supply and return, power, and pilot arc.
Inputs from the off-valve assembly are for torch blow back and plasma and shield gases.
Off-Valve Assemblies
Two off-valve assemblies are offered: one with a blow back solenoid valve and the other without a blow back
solenoid valve. Both off-valve assemblies provide on/off control between the preflow and operate gas flows. This
2-4 HD3070 with Manual Gas Console Instruction Manual
15
SPECIFICATIONS
assembly consists of three solenoid valves which provide inlet and outlet gas connections. The inlet connections
(plasma gas, shield gas and preflow gas) are input from the gas console using the gas lead set. The outlet
connections (blow back [if desired], plasma gas and shield gas) are output to the torch quick disconnect assembly.
Optional Units
Timer-Counter
The timer/counter allows the operator to monitor the number of arc starts, the cumulative time that the arc is on in
hours, and the number of arc blow outs. The arc starts and arc errors LCD counters can be reset. This unit
connects with the power supply.Refer to Appendix B for installation, operation and parts information.
Remote Current Control (RCC)
The RCC allows the operator the ability to select the cutting current from a remote location. This unit connects with
the power supply. Refer to Appendix C for installation, operation and parts information.
HD3070 with Manual Gas Console Instruction Manual 2-5
15
SPECIFICATIONS
*Gantry
Cutting
Machine
Straight Torch
Quick Disconnect
* Non Hypertherm Components
Figure 2-1 HD3070 System Components with Gantry Cutting Machine
Input
Power
Input
Supply
Gases
Power
Supply
Timer-Counter
(Optional)
Remote Current
Control (RCC)
(Optional)
Gas
Console
*CNC
Controller
RHF
Console
Off-Valve
Assembly
PAC186
Machine Torch
2-6 HD3070 with Manual Gas Console Instruction Manual
15
SPECIFICATIONS
*Robotic
Cutting
Machine
Power
Supply
Input
Power
Input
Supply
Gases
RHF
Console
Remote Current
Control (RCC)
(Optional)
Timer-Counter
(Optional)
Off-Valve
Assembly
45° Torch
Quick Disconnect
PAC184
Machine Torch
Gas
Console
Workpiece
*Robotic
Controller
Figure 2-2 HD3070 System Components with Robotic Cutting Machine
* Non Hypertherm Components
HD3070 with Manual Gas Console Instruction Manual 2-7
15
SPECIFICATIONS
Specifications
Power Supply (078019, 078023, 078024, 078025, 078030)
Maximum OCV (U0) ..........................................................280 VDC
Output Current (I2).............................................................15 to 100 amps
Output Voltage (U2) ..........................................................150 VDC
Duty Cycle Rating (X) .......................................................80% at 100 amps
Cooling..............................................................................Forced Air (Class F)
Ambient temperatures/duty cycle......................................Power supplies will operate between +14° and
104° F (-10° and +40° C). Power supplies
operated in an ambient temperature above 86° F
(30° C) may show some decrease in duty cycle.
Input Power (U1Input Voltage, I1Input Current):
078019 ..............................................................................240/480 VAC, 3 Ph, 60 Hz, 50/25 amps
078023 .............................................................................208 VAC, 3 Ph, 60 Hz, 58 amps
078024 ..............................................................................220/380/415 VAC, 3 Ph, 50/60 Hz, 54/30/28 amps
(see Appendix D)
078025 .............................................................................600 VAC, 3 Ph, 60 Hz, 20 amps
078030 ..............................................................................200 VAC, 3 Ph, 50/60 Hz, 60 amps
Torch Cooling Requirements:
Coolant Tank Capacity ......................................................2.9 gallons (11 liters)
Coolant..............................................................................Propylene glycol/deionized water/benzotriazole
(refer to Section 3, Torch Coolant Requirements
for specifications, warning, and caution).
Flow Rate..........................................................................≈ 1 gallon/minute (3.8 liters/minute)
Pressure ...........................................................................150 psi (10.2 bar)
Dimensions and Weight:
Width.................................................................................24.25 inches (616 mm)
Height................................................................................36 inches (914 mm)
Depth.................................................................................38.25 inches (972 mm)
Weight...............................................................................545 pounds (247 kg)
Gas Console (078059)
Input power from power supply (intrlk'd) ...........................120 VAC
Output power to off-valve assembly..................................120 VAC
Output to CNC...................................................................Active (low or closed)
Dimensions and Weight:
Width.................................................................................12.5 inches (318 mm) w/o hardware; 15 inches
(381 mm) w/hardware
Height................................................................................15 inches (381 mm)
Depth.................................................................................10 inches (254 mm) w/o hardware; 11.5 inches
(292 mm) w/hardware
Weight...............................................................................35 pounds (16 kg)
2-8 HD3070 with Manual Gas Console Instruction Manual
15
SPECIFICATIONS
Gas Supply Requirements:
Plasma Gas Type .............................................................Oxygen (O2 ) (15, 30, 50, 70 or 100 amp mild
steel cutting) Air (30, 50, or 70 amp stainless
steel cutting; 70 amp aluminum cutting)
Argon/Hydrogen (H35 = 35% Hydrogen/65%
Argon) and Nitrogen (N2) mixture (100 amp
stainless steel cutting)
Shield Gas Type ...............................................................Oxygen (O2) and Nitrogen (N2) mixture (15, 30,
50, 70 or 100 amp mild steel cutting) Methane
(CH4) and Air mixture (70 amp stainless steel
cutting) Air (30 and 50 amp stainless steel
cutting) Methane (CH4) (70 amp aluminum
cutting) Nitrogen (N2) (100 amp aluminum and
stainless steel cutting)
Oxygen Gas Quality..........................................................99.95 % pure (liquid gas recommended)
Nitrogen Gas Quality.........................................................99.995 % pure (liquid gas recommended)
H35 Quality (35% Hydrogen/65% Argon)..........................99.995 % pure (liquid gas recommended)
Air Quality..........................................................................Clean, dry and oil-free
Methane Quality................................................................93 % pure (commercial grade)
All Gas and Air Inlet Pressures .........................................120 psi (8.2 bar)
Air Flowrate.......................................................................81.7 scfh (2313 l/hr) at fullscale
Oxygen Flowrate ..............................................................77.8 scfh (2203 l/hr) at fullscale
H35 Flowrate ....................................................................85 scfh (2407 l/hr) at fullscale
Nitrogen Flowrate .............................................................83.1 scfh (2353 l/hr) at fullscale
Methane Flowrate .............................................................110 scfh (3114 l/hr) at fullscale
RHF Console (078010)
Input power from power supply (intrlk'd) ...........................120 VAC
Output power ....................................................................2700 VAC
High frequency spark gap .................................................0.020 ± 0.001 inch (0.51 ± 0.03 mm)
Dimensions and Weight:
Width.................................................................................12.63 inches (321 mm)
Height................................................................................13.5 inches (343 mm)
Depth................................................................................. 6.5 inches (165 mm)
Weight...............................................................................20 pounds (9 kg)
PAC184 Machine Torch Assemblies (028839, 128199)
Maximum cutting thickness...............................................1/4 inch (6.4 mm)
Maximum current at 100% duty cycle ...............................30 amps
HD3070 with Manual Gas Console Instruction Manual 2-9
15
SPECIFICATIONS
Torch Cooling Requirements:
Coolant..............................................................................Propylene glycol/deionized water/benzotriazole
(refer to Section 3, Torch Coolant Requirements
for specifications, warning, and caution).
Flow Rate..........................................................................≈ 1 gallon/minute (3.8 liters/minute)
Pressure ...........................................................................150 psi (10.2 bar)
Dimensions and Weight (see Figure 2-3):
Diameter............................................................................1.75 inches (44 mm)
Length ...............................................................................3.44 inches (88 mm)
Weight...............................................................................1 pound (0.45 kg)
PAC184.02
0.059 - 0.79"
(1.5 - 2.0 mm)
0.0355"
(9.0 mm)
PAC184 Torch Assembly
0.41" (1.04 mm)
0.20" (0.51 mm)
1.05"
(2.67 mm)
70
90
PAC184.01
0.02" (0.05 mm)
2-10 HD3070 with Manual Gas Console Instruction Manual
17
SPECIFICATIONS
PAC186 Machine Torch Assemblies (128101, 128102)
Maximum cutting thickness...............................................1/2 inch (12.7 mm)
Maximum current at 80% duty cycle .................................100 amps
Torch Cooling Requirements:
Coolant..............................................................................Propylene glycol/deionized water/benzotriazole
(refer to Section 3, Torch Coolant Requirements
for specifications, warning, and caution).
Flow Rate..........................................................................≈ 1 gallon/minute (3.8 liters/minute)
Pressure ...........................................................................150 psi (10.2 bar)
Dimensions and Weight (see Figure 2-3):
Diameter............................................................................1.75 inches (44 mm)
Length ...............................................................................3.44 inches (88 mm)
Weight...............................................................................1 pound (0.45 kg)
0.20" (0.5 mm)
0.18" (0.46 mm)
1.06"
(2.69 mm)
80
PAC186.01
0.04" (0.1 mm)
0.58"
(1.47 mm)
PAC186 Torch Assembly
HD3070 with Manual Gas Console Instruction Manual 2-11
17
SPECIFICATIONS
45° Torch Quick Disconnect Assembly (028840)
Dimensions and Weight:
Width.................................................................................2.13 inches (54 mm)
Length ...............................................................................4.19 inches (107 mm)
Depth.................................................................................4.56 inches (117 mm)
Weight...............................................................................1 pound (0.45 kg)
Straight Torch Quick Disconnect Assembly (028855)
Dimensions and Weight:
Diameter (outer)................................................................2 inches (51 mm)
Length ...............................................................................2.5 inches (63 mm)
Weight...............................................................................1 pound (0.45 kg)
2.00"
(5.08 mm)
6.50"
(16.50 mm)
9.57"
(24.31 mm)
O
45
4.83"
(12.27 mm)
10.00"
(25.40 mm)
1.73"
(4.39 mm)
(4.37 mm)
1.72"
4.39"
(11.15 mm)
8.25"
(21.00 mm)
5.82"
(14.78 mm)
2.00"
(5.08 mm)
1.73"
(4.39 mm)
2-12 HD3070 with Manual Gas Console Instruction Manual
17
SPECIFICATIONS
Off-Valve Assemblies (129239, 129281)
Input Power from Gas Console ........................................120 VAC
Dimensions and Weight:
Diameter (side to side)......................................................5.75 inches (146 mm)
Diameter (front to back) ....................................................4.25 inches (108 mm)
Weight...............................................................................4 pounds (1.8 kg)
Motion Control System (Customer Supplied)
Travel Speed (maximum)..................................................200 ipm (5.08 m/min)
Braking..............................................................................Positive (drifting through stop point not
acceptable)
Weight...............................................................................Must be able to handle combined weight of
PAC184/PAC186 torch, torch quick disconnect
assembly, off-valve assembly, and lead sets.
Optional Units
Timer-Counter (078049)
Receives error signals and ...............................................Dry contacts
machine arc time and machine
start signals from power supply
Dimensions and Weight:
Width.................................................................................6.5 inches (165 mm)
Height................................................................................2.5 inches (64 mm)
Depth.................................................................................8.5 inches (216 mm)
Weight...............................................................................3 pounds (1.4 kg)
Refer to Appendix B for installation, operation and parts information.
Remote Current Control (RCC) (078050)
Receives current setpoint signals from power supply
Dimensions and Weight:
Width.................................................................................6.5 inches (165 mm)
Height................................................................................2.37 inches (61 mm)
Depth.................................................................................8.5 inches (216 mm)
Weight...............................................................................3 pounds (1.4 kg)
Refer to Appendix C for installation, operation and parts information.
HD3070 with Manual Gas Console Instruction Manual 2-13
17
SPECIFICATIONS
IEC Symbols Used
Direct Current (DC).
Alternating current (AC).
Plasma cutting torch.
AC input power connection.
The terminal for the external protective (earthed) conductor.
A chopper-based power source.
Anode (+) work clamp.
Temperature switch.
Pressure switch.
Plasma torch in the TEST position (cooling and cutting gas exiting nozzle).
The power is on.
The power is off.
Volt/amp curve.
HD3070 with Manual Gas Console Instruction Manual 3-1
16
Section 3
INSTALLATION
In this section:
Pre-Installation..........................................................................................................................................................3-2
Upon Receipt ...................................................................................................................................................3-2
HD3070 System Components..........................................................................................................................3-2
Claims ..............................................................................................................................................................3-2
Gas Requirements ...........................................................................................................................................3-3
Oxygen.........................................................................................................................................................3-3
Nitrogen .......................................................................................................................................................3-3
Air.................................................................................................................................................................3-3
Methane.......................................................................................................................................................3-3
Argon-Hydrogen (H35).................................................................................................................................3-4
Power Supply Placement .................................................................................................................................3-4
Power Requirements........................................................................................................................................3-6
Line Disconnect Switch................................................................................................................................3-6
Power Cable ................................................................................................................................................3-6
240/480V Power Supply Linkboard Configurations .....................................................................................3-8
220/380/415V Power Supply Linkboard Configurations ..............................................................................3-8
Work Table Grounding ................................................................................................................................3-8
Equipment Grounding..................................................................................................................................3-8
Connect Power Cable................................................................................................................................3-10
Power Supply.............................................................................................................................................3-10
Line Voltage Disconnect Box.....................................................................................................................3-10
Local/External Pierce Delay Function ............................................................................................................3-11
Local/External Current Set Function ..............................................................................................................3-11
Torch Lifter Requirement................................................................................................................................3-11
Installation...............................................................................................................................................................3-12
System Units Placement ................................................................................................................................3-12
Remote High Frequency Console..............................................................................................................3-12
Gas Console .............................................................................................................................................3-12
Torch Quick Disconnect Assemblies/Off-Valve Assembly..........................................................................3-12
Cable, Hose & Lead Set Interconnections .....................................................................................................3-16
Power Supply to RHF Console and Work Table Interconnections.............................................................3-18
Power Supply to Gas Console Interconnections........................................................................................3-22
Power Supply to Machine Interface/Timer-Counter/RCC Interconnections...............................................3-25
RHF to Torch Quick Disconnect Interconnections .....................................................................................3-28
Gas Console to Off-Valve Assembly Interconnections...............................................................................3-30
Off-Valve Assembly to Torch Quick Disconnect Interconnections..............................................................3-32
Gas Supply Hose Connections..................................................................................................................3-34
PE Ground Cable Connections..................................................................................................................3-34
Mount PAC184/PAC186 Torch to Quick Disconnect ......................................................................................3-35
Torch Coolant Requirements..........................................................................................................................3-36
Filling the System...........................................................................................................................................3-38
Post Installation ......................................................................................................................................................3-38
3-2 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Pre-Installation
Prior to the installation of the HD3070 plasma cutting system, the components must be unpacked and the following
requirements must be fulfilled. Their purpose is to aid you in the installation of your plasma cutting system and to
allow maximum performance.
Installation and service of the electrical and plumbing systems must conform to national or local electrical
and plumbing codes. Have this work performed only by qualified, licensed personnel.
If questions arise at any time, call Technical Service listed in the front of this manual or your authorized Hypertherm
distributor.
Upon Receipt
Before unpacking the HD3070 System, inspect the box(es) for evidence of damage during shipment. If there is
evidence of damage, refer to Claims for Damage During Shipment below for details. Remove all packing material
and remove the units and items from the box(es). Verify that the components listed below are included. Alert
Hypertherm if any of the items are damaged or missing. All communications regarding this equipment must include
the model number and serial number (located on the back of the units). Refer to Claims below for details.
HD3070 System Components
• Power Supply (078019, 078023, 0768024, 078025 or 078030)
• Gas Console (078059)
• Remote High Frequency Console (RHF) (078010)
• PAC184 Torch Assembly (028839 or 128199)
PAC186 Torch Assembly (128101 or 128102)
• 45° Torch Quick Disconnect Assembly (028840) or
Straight Torch Quick Disconnect Assembly (028855)
• Off-Valve Assembly (129239 or 129281)
• PAC184 Consumable Parts Kit (028842 or 028900)
• PAC186 Consumable Parts Kit (128097 or 128098)
• Power Supply Service Parts Kit (028724)
• System Interconnecting Cables & Hoses
• HD3070 with Manual Gas Console Instruction Manual (802170)
Optional Units
• Timer/Counter( 078049)
• Remote Current Control (RCC) (078050)
Claims
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance,
call Customer Service listed in the front of this manual or your authorized Hypertherm distributor.
Claims for defective or missing merchandise – If any of the merchandise is defective or missing, call your
authorized Hypertherm distributor. If you need additional assistance, call Customer Service listed in the front of this
manual or your authorized Hypertherm distributor.
HD3070 with Manual Gas Console Instruction Manual 3-3
15
INSTALLATION
Gas Requirements
The following gases required by the HD3070 plasma system for cutting are provided by the customer. Bottled
liquid gas is recommended. If the purity level of the gas is too low or if there are leaks in the supply hoses or
connections:
• System can be contaminated
• Cut speeds can decrease
• Cut quality can deteriorate
• Cutting thickness capability can decrease
• Parts life can shorten
If making hard plumbing connections, avoid using iron pipe. Never use PTFE tape on any joint preparation. After
installation, pressurize the entire system and check for leaks.
Oxygen (O2)
The customer must provide a regulated oxygen supply to the gas console at 99.95 % purity, at a pressure of
120 psi (8.2 bar) and at a flowrate of 77.8 scfh (2203 l/hr). Connect the oxygen supply with a 3/8-inch ID hose to
the O
2
input adapter (1/4 NPT right handed 'B', 9/16-inch 18 thread, male) on the gas console.
Nitrogen (N2)
The customer must provide a regulated nitrogen supply to the gas console at 99.995 % purity, at a pressure of
120 psi (8.2 bar) and at a flowrate of 83.1 scfh (2353 l/hr). Connect the nitrogen supply with a 3/8-inch ID hose to
the N2input adapter (1/4 NPT right handed ʻBʼ, 9/16-inch 18 thread, inert female) on the gas console.
Air
Either cylinder compressed air or shop compressed air can be used to supply the plasma and shield gas
requirements. Air supplied to the gas console must be clean, dry and oil-free, at a pressure of 120 psi (8.2 bar)
and at a flowrate of 81.7 scfh (2313 l/hr). Connect the air supply to the AIR input adapter with a 3/8-inch ID hose
(1/4 NPT #6, 9/16-inch 18 thread, male flare).
Methane (CH4)
WARNING
FIRE HAZARD
Oxygen can cause a potential fire hazard. Install an exhaust ventilation system when using oxygen
gas.
The customer must provide a regulated commercial grade methane supply to the gas console at 93 % purity, at a
pressure of 120 psi (8.2 bar) and at a flowrate of 110 scfh (3114 l/hr). Bottled liquid gas is recommended. Connect
the methane supply with a 3/8-inch ID hose to the CH4input adapter (1/4 NPT, left handed ʻBʼ, 9/16-inch 18 thread,
male) on the gas console.
WARNING
EXPLOSION HAZARD
Methane is a combustible gas and can be an explosion hazard. Keep open flames away from the
methane cylinders and gas hoses.
3-4 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
WARNING
EXPLOSION HAZARD
H35 is a combustible gas and can be an explosion hazard. Keep open flames away from the gas
cylinders and gas hoses.
Argon-Hydrogen (H35)
The customer must provide a regulated H35 supply to the gas console at 99.995 % purity, at a pressure of 120 psi
(8.2 bar) and at a flowrate of 85 scfh (2407 l/hr). Connect the H35 supply with a 3/8-inch ID hose to the H35 input
adapter (1/4 NPT left handed ‘B’, 9/16-inch 18 thread, male) on the gas console.
Power Supply Placement
Place the power supply according to the criteria below and the dimensions called out in Figure 3-1. Once the power
supply has been placed, locate the line disconnect box on a wall near the power supply, so that the power supply
can be quickly turned off in an emergency situation.
Note: A lifting eye is provided for moving the power supply into place with a crane or hoist. To access the lifting
eye, remove the 6 screws from the top cover and remove cover. It may also be moved by forklift if the forks
are long enough to extend more than half way the length of the base. Care should be used when lifting with
the forks so that the underside of the power supply is not damaged.
• Place the units in an area that is free of excessive moisture, has proper ventilation, and is relatively
clean. Allow room for accessing the sides of the power supply for servicing.
• Place the power supply so that air flow is not blocked in any way. (Cooling air is drawn in through the
front panel grating, and is exhausted through the rear of the unit by a cooling fan.) Do not place any filter
device over the air intake locations. This reduces cooling efficiency and VOIDS THE WARRANTY.
HD3070 with Manual Gas Console Instruction Manual 3-5
15
INSTALLATION
38-1/4 Inch (972 mm)
24-1/4 Inch (616 mm)
Figure 3-1 HD3070 Power Supply Dimensions
36 Inch
(972 mm)
3-6 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Power Requirements
All switches, slow-blow fuses and power cables are customer supplied and must be chosen as directed by
applicable national and/or local electrical codes.
Use a separate primary line disconnect switch for each HD3070 power supply and slave.
Note: Input voltage must not drop below 15% of the values listed below. The power supply will go into an idle
mode and display an error on the control board if the input voltage is too low.
Size the disconnect box(es) to Table 3-1 requirements for the HD3070 power supply.
Line Disconnect Switch
The line disconnect switch serves as the supply voltage disconnecting (isolating) device. Install this switch on a
wall near the power supply for easy accessibility by the operator. The line disconnect switch must be installed by
qualified personnel following all applicable local and national codes. The switch should:
• Isolate the electrical equipment and disconnect all live conductors from the supply voltage when in the
OFF position
• Have one OFF and one ON position clearly marked with “0 (OFF)” and “I (ON)”
• Have an external operating handle capable of being locked in the OFF position
• Contain a power operated mechanism that serves as an emergency stop
• Have slow-blow fuses installed for the proper breaking capacity (Table 3-1)
Power Cable
The power cable is customer supplied. Use an 8-4 conductor Type SO input power cable with a conductor
temperature rating of 140°F (60°C).
WARNING
Electrical installation must be performed by qualified personnel only.
HD3070 with Manual Gas Console Instruction Manual 3-7
15
INSTALLATION
Table 3-1 Line Voltage Disconnect Box Fusing Requirements
Input Rated Input Current @ Recommended
Voltage 15 kw Output Slow- Blow Fuse Sizes
(VAC) Phase/Hz (amps) (amps)
200 3/50-60 60 70
208 3/60 58 70
220 3/50-60 54 70
240 3/60 50 60
380 3/50-60 30 40
415 3/50-60 28 35
480 3/60 25 30
600 3/60 20 25
3-8 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
240/480V Power Supply Linkboard Configurations
• The 240/480-volt power supplies (078019) are shipped configured for 480-volt operation. The links must be
moved for 240-volt operation (Figure 3-2).
220/380/415V Power Supply Linkboard Configurations
• The 220/380/415-volt, 3PH, 50 Hz power supplies (078024) are normally shipped from the factory set up for
380-volt operation, unless otherwise specified. To change the power supply to a different voltage (220 or
415 volts), the links must be moved (Figure 3-3).
Work Table Grounding
• The work table must be grounded properly to ensure personal safety, and to reduce the emission of radiofrequency interference.
• See Appendix E for important grounding instructions.
Equipment Grounding
• The power supply, RHF console and gas console provide connections for protective earth (PE) grounding.
• See Appendix E for important grounding instructions.
HD3070 with Manual Gas Console Instruction Manual 3-9
15
INSTALLATION
220-Volt
415-Volt
380-Volt
Figure 3-3 220/380/415V Linkboard Configurations
240-Volt
Figure 3-2 Dual Voltage 240/480-Volt Linkboard Configurations
480-Volt
3-10 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Connect Power Cable
After the power supply and line disconnect switch have been placed, connect the power cable to the power supply
first and then connect it to the line disconnect switch.
Power Supply
To connect the power cable to a 220/380/415V power supply (078024), refer to Appendix D.
For other power supply voltages use the procedure below.
1. Insert the power cable through the strain relief at the lower right rear of the power supply. Connect the power
cable leads to TB1 the rear center panel of the right side (see Figure 3-4).
2. Connect the power leads to the L1 (U), L2 (V), and L3 (W) terminals of TB1. Make sure that all electrical
connections are tight to avoid excessive heating.
3. Connect the ground lead to the ground stud.
Line Voltage Disconnect Box
Connecting the power cable to the disconnect box must conform to national and local electrical codes. This work
should be performed only by qualified, licensed personnel.
Figure 3-4 Power Supply Power Cable Connections
Power Cable
Ground Stud
(PE)
Power Supply
TB1
L1
(U)
L2
(V)
L3
(W)
Ground
L1 (U)
L2 (V)
L3 (W)
Connect to Line Voltage
Disconnect Box
HD3070 with Manual Gas Console Instruction Manual 3-11
15
INSTALLATION
Local/External Pierce Delay Function
The power supply is shipped with the PIERCE DELAY potentiometer on the power supply control panel enabled.
Perform the steps below to enable the external pierce complete function. Refer to Section 6, Figure 6-2, item 5 to
locate control board 1XPCB3 and power supply (power unit) wiring diagram for wiring information.
1. Remove the power supply front panel and locate control board 1XPCB3.
2. Disconnect PL10 from REC5 on 1XPCB3.
3. Locate the blue jumper wire connected to PL10 pin 7. Connect the free end of the jumper to PL10 pin 5.
4. Reconnect PL10 to REC5.
To reestablish local control, remove jumper wire from PL10 pin 5.
Local/External Current Set Function
The power supply is shipped with the AMPS thumbwheel switch on the power supply control panel enabled.
Perform the steps below to enable the external current set function. Refer to Section 6, Figure 6-2, item 5 to locate
control board 1XPCB3 and power supply (power unit) wiring diagram for wiring information.
1. Remove the power supply front panel and locate control board 1XPCB3.
2. Disconnect PL27-B (thumbwheel switch connector) from REC27 and then connect PL27-A (external current set)
to REC27.
3. Connect the current setpoint cable (Figure 3-22) between 1X2 (rear of power supply) and CNC Interface.
To reestablish local control, disconnect PL27-A from REC27 and connect PL27-B to REC27. Then disconnect
current setpoint cable between 1X2 and CNC Interface.
Torch Lifter Requirement
The HD3070 requires a motorized torch lifter with sufficient vertical travel to cut all required metal thicknesses.
Vertical travel must be in increments of 0.010 inch (0.25 mm) and have a travel speed of 200 ipm (5.08 m/min)
maximum and braking should be positive. A unit which drifts through the stop point is not acceptable.
3-12 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Installation
This section provides the user with the necessary information to install the HD3070 system. Installation of the
HD3070 System should not be undertaken unless all of the pre-installation requirements presented in front of this
section have been completed. This section includes the following:
• Placing and mounting the system units.
• Interconnecting the units with the electrical control cables, cooling hoses and torch and gas lead sets.
• Mounting the PAC184 or PAC186 torch to the torch quick disconnect.
• Adding the torch coolant.
System Units Placement
Position the RHF console and gas console prior to making electrical, gas, and coolant connections. Also mount the
torch quick disconnect and off-valve assembly. Note that power supply placement information is presented in Pre-
Installation in the front of this section.
Remote High Frequency Console
Place the RHF console in a convenient location to allow easy routing and connection of the torch lead set. Bolt the
unit to the mounting surface. See Figure 3-5.
Gas Console
Place the gas console in a convenient location near the operator for easy plasma gas and injection water
monitoring adjustment. The gas console must be located within 100 feet of the torch. Bolt the unit to the mounting
surface. See Figure 3-6.
Torch Quick Disconnect Assemblies/Off-Valve Assembly
The torch quick disconnect assemblies and off-valve assembly are shipped loose. The 45° quick disconnect,
generally used with the PAC184 torch, is normally mounted onto a robotic arm using the four 1/4-20 mounting
holes. See Figure 3-7 for torch quick disconnect mounting hole dimensions.
The straight quick disconnect assembly, generally used with the PAC186 torch, is normally mounted onto a torch
lifter on a x-y cutting table.
The off-valve assembly may be mounted up to a distance of four feet from either of the torch quick disconnects.
HD3070 with Manual Gas Console Instruction Manual 3-13
15
INSTALLATION
Figure 3-5 RHF Console Mounting Dimensions
13.5 Inch (343 mm)
6.5 Inch
(165 mm)
14.5 Inch (368 mm)
10 Inch (254 mm)
Drain holes down in
this position
12.75 Inch
(324 mm)
Hole Size
0.30 Inch
(7.6 mm)
Typ.
3-14 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
3.0 inch
73.5 mm
9.0 inch
220.5 mm
2.5 inch
61 mm
10 inch
24.5 mm
3070.11
1/4-20
Figure 3-6 Gas Console Mounting Dimensions
15 Inch (381 mm)
15 Inch
(381 mm)
12.5 Inch (318 mm)
10 Inch (254 mm)
11.5 Inch (292 mm)
HD3070 with Manual Gas Console Instruction Manual 3-15
15
INSTALLATION
1.400 Inch
(35.56 mm)
1.625 Inch
(41.275 mm)
1/4-20
screws
Figure 3-7 45° Torch Quick Disconnect Mounting Hole Dimensions
3-16 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Cable, Hose & Lead Set Interconnections
The following cable, hose and lead set interconnecting procedures are supported by the system interconnection
diagram, Figure 3-8. Also provided are illustrations of each unit showing where the connections are to be made and
illustrations of the cables, hoses and lead sets.
Note that these procedures and supporting illustrations are cross referenced (, , etc.) to ensure a safe and
correct installation. Also note that the cross referencing numbers do not indicate a sequence for interconnecting.
It is assumed that in most cases the interconnections will be routed through a power track or festoon system from
one point to the other.
IMPORTANT
When interfacing with the CNC, optically isolated I/Os or ground floating interfaces are recommended
to avoid ground shift and make the system more immune to EMI noises.
HD3070 with Manual Gas Console Instruction Manual 3-17
15
INSTALLATION
Off-Valve
Assys
Figure 3-8 HD3070 System with Manual Gas Console Interconnect Diagram
SHIELD
PLASMA
PREFLOW
3X3
3X3
Gas Lead Set –
Plasma, Shield &
Preflow Hoses &
Gas/Torch Control
Cable
Ground Rod
Cutting Table
1X4
1X4
3X1
3X1
3X2
3X2
1X3
1X1
1X1
Machine Interface Cable
Control
Machine
Interface
Work Cable (++)
Timer-
Counter
078049
PE
4X1
4X1
Plasma,
Shield &
Back Flow
Hoses
PAC186**
Torch Assy
128101/128102
Pilot Arc
Negative (-)
OUTPUT
INPUT
Cooling Hose (Rtn-Red)
Cooling Hose (Supply-Grn)
2X1
1X5
PS/RHF
Control
PS/Gas
Control
PS/Gas
Control
PA
(-)
Green
Fitting
Red
Fitting
PE
TORCH
Torch Lead Set –
Cooling Supply/Power (-) and Return Hoses,&
Pilot Arc (+) Lead
Input Gases
PE
RHF
Console
078010
Gas
Console
078059
(++)
Power Supply
078019 – 240/480V
078023 – 208V
078024 – 220/380/415V
078025 – 600V
078030 – 200V
2X1
1X5
POWER (-)
PILOT ARC (+)
3-Phase
Input Power
Torch QDisc
Assy
028855
Notes:
* PAC184 torch used for robotic cutting
applications.
** PAC186 torch used for X - Y cutting
table applications.
1X1
PE
Torch QDisc
Assy
028840
129239/
129281
1X6
1X6
PS/Timer-Counter
Control
5X1
5X1
1X2
1X2
Machine Interface
Cable
Current Setpoint
Remote Current
Control (RCC)
078050
1X2
1X2
TB3
Hold Signal to
Power Supplies
PAC184*
Torch Assy
028839/128199
O
2 N2
AIR CH
4
H35
1X3
3-18 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Power Supply to RHF Console and Work Table Interconnections (Figure 3-9)
Pilot Arc Lead (+) (Figure 3-10)
1. Route one end of the lead through the feed-thru on the rear of the power supply and connect to the pilot arc
terminal.
2. Route the other end of the lead through the PILOT ARC strain relief on the RHF Console and connect to the
pilot arc terminal on the I/O PC BD Assy.
Negative Lead (-) (Figure 3-11)
1. Route one end of the lead through the feed-thru on the rear of the power supply and connect to the negative
terminal.
2. Route the other end of the lead through the POWER (-) strain relief on the RHF Console and connect to the
negative terminal on the I/O PC BD Assy.
Cooling Water Supply Hose /Power Lead (-) (Green) (Figure 3-12)
1. At the rear of the power supply connect the coolant supply hose (green band) to the check valve connector
painted green.
2. Route the other end of the hose through the IN feed-thru on the RHF Console and connect to the manifold
adapter painted green.
Cooling Water Return Hose (Red) (Figure 3-13)
1. At the rear of the power supply connect the coolant return hose (red band) to the check valve connector painted
red.
2. Route the other end of the hose through the OUT feed-thru on the RHF Console and connect to the manifold
adapter painted red.
Control Cable (Figure 3-14)
1. Connect the cable plug marked 1X5 to the receptacle marked 1X5 on the rear of the power supply.
2. Connect the other end of the cable marked 2X1 to the receptacle marked 2X1 on the RHF Console.
Work Cable (Figure 3-15)
1. Route one end of the cable through the feed-thru on the rear of the power supply and connect to the work (++)
terminal (Figure 3-8).
2. Connect the other end of the cable to the work table ground rod or to the work table. Make sure that good metalto-metal contact has been made (Figure 3-8).
654
3
2
1
HD3070 with Manual Gas Console Instruction Manual 3-19
15
INSTALLATION
Pilot Arc Lead
1
Figure 3-9 Power Supply to RHF Console Interconnections
Cooling water supply
hose/power lead (-)
3
Cooling water
return hose
4
Pilot arc lead (+)
1
Pilot arc lead (+)
2
2X1 Control cable
5
RHF Console
RHF Console
Terminal
1
Terminal
2
1X5 RHF Control cable
5
(+) Work Cable
6
Cooling water supply hose/power lead (-)
(green)
3
Cooling water return hose
(red)
4
EMI Filter used
on 220/380/415V
CE units only
Negative Lead (-)
2
Power Supply
Rear
Connection
(green band)
3
Connection
(red band)
4
Caution
Remove the foam block used to support the
cathode block during shipment in order to
make the cooling water return hose
connections.
435
2
1
18
18
3-20 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
RHF Console
Power Supply
Part Number Length
023924 4 ft (1.2 m)
023569 15 ft (4.6 m)
023526 25 ft (7.6 m)
023527 50 ft (15.2 m)
023528 75 ft (23 m)
023529 100 ft (30.5m)
023730 115 ft (35 m)
023746 125 ft (38 m)
Figure 3-10 Pilot Arc Lead (+)
Part Number Length
023925 4 ft (1.2 m)
023530 15 ft (4.6 m)
023531 25 ft (7.6 m)
023532 50 ft (15.2 m)
023533 75 ft (23 m)
023534 100 ft (30.5 m)
023731 115 ft (35 m)
023747 125 ft (38 m)
RHF Console
Power Supply
Figure 3-11 Negative Lead (-)
Part Number Length
024421 4 ft (1.2 m)
024290 15 ft (4.6 m)
024291 25 ft (7.6 m)
024263 50 ft (15.2 m)
024264 75 ft (23 m)
024265 100 ft (30.5 m)
024385 115 ft (35 m)
024396 125 ft (38 m)
024459 150 ft (46 m)
Figure 3-12 Cooling Supply Hose/Power Lead (-)
RHF ConsolePower Supply
Green
Green
1
2
3
HD3070 with Manual Gas Console Instruction Manual 3-21
15
INSTALLATION
Part Number Length
024422 4 ft (1.2 m)
024266 15 ft (4.6 m)
024267 25 ft (7.6 m)
024012 50 ft (15.2 m)
024269 75 ft (23 m)
024270 100 ft (30.5 m)
024386 115 ft (35 m)
024397 125 ft (38 m)
024460 150 ft (46 m)
Figure 3-13 Cooling Return Hose
Red
Red
RHF Console
Power Supply
2X1
1X5
RHF Console
Power Supply
RUN LIST
SIGNAL PLUG 1X5 COLOR PLUG 2X1
Door Interlock 1 Black 1
2 Red 2
Ground 5 Shield Cut
HV Transformer 6 Red 6
7 Black 7
Ground 3 Shield Cut
Figure 3-14 PS/RHF Control Cable
Part Number Length
023535 15 ft (4.6 m)
023536 25 ft (7.6 m)
023828 39.4 ft (12 m)
023537 50 ft (15.2 m)
023538 75 ft (23 m)
023539 100 ft (30.5 m)
Figure 3-15 Work Cable (+)
+
+
Part Number Length
023926 4 ft (1.2 m)
023470 15 ft (4.6 m)
023562 25 ft (7.6 m)
023563 50 ft (15.2 m)
023564 75 ft (23 m)
023565 100 ft (30.5 m)
023732 115 ft (35 m)
023748 125 ft (38 m)
Cutting TablePower Supply
4
5
6
3-22 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Power Supply to Gas Console Interconnections (Figure 3-16)
Gas Console Cable (Figure 3-17)
1. Connect the cable plug marked 1X4 to the receptacle marked 1X4 on the rear of the power supply.
2. Connect the other end of the cable marked 3X1 to the receptacle marked 3X1 on the gas console.
Gas Console Control Cable (Figure 3-18)
1. Connect the cable plug marked 1X3 to the receptacle marked 1X3 on the rear of the power supply.
2. Connect the other end of the cable marked 3X2 to the receptacle marked 3X2 on the gas console.
8
7
1X3
Gas Console
Control cable
8
1X4
Gas Console
Control cable
7
3X2
Gas Console
Control cable
8
3X1
Gas Console
Control cable
7
Figure 3-16 Power Supply to Gas Console Interconnections
EMI Filter used
on 220/380/415V
CE units only
Power Supply
Gas Console
HD3070 with Manual Gas Console Instruction Manual 3-23
15
INSTALLATION
3X1
1X4
Gas Console
Power Supply
RUN LIST
SIGNAL PLUG 1X4 COLOR PLUG 3X1
Spare Valve # 1 14 Black 14
15 Green 15
Gnd 9 Shield 9
Shield Operate 12 Black 12
13 Yellow 13
Gnd 7 Shield 7
Air and CH
4
23 Black 23
24 Blue 24
Gnd 29 Shield 29
Shield Preflow 10 Black 10
11 Orange 11
Gnd 5 Shield 5
H35 and N
2
25 Black 25
26 White 26
Gnd 31 Shield 31
Plasma On & Off 1 Black 1
2 Brown 2
Gnd 6 Shield 6
O
2
and N
2
27 Red 27
28 Brown 28
Gnd 33 Shield 33
Unassigned 3 Black 3
4 Red 4
Gnd 8 Shield 8
Gas System Power 36 Red 36
37 Brown 37
Gnd 32 Shield 32
Unassigned 34 Black 34
35 Red 35
Gnd 30 Shield 30
Key N/A N/A 16
Part Number Length
023673 6 ft (1.8 m)
023558 10 ft (3 m)
023472 25 ft (7.6 m)
023556 50 ft 15 m)
023557 75 ft (23 m)
023760 100 ft (30.5 m)
023744 125 ft (38 m)
023733 150 ft (45.6 m)
7
Figure 3-17 Gas Console Cable
3-24 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
3X2
1X3
Gas Console
Power Supply
RUN LIST
SIGNAL PLUG 1X3 COLOR PLUG 3X2
DC On Light 23 White 23
24 Black 24
Gnd 19 Shield Cut & Key
O
2
Plasma Select 21 Blue 21
22 Black 22
Gnd 17 Shield Cut & Key
Test Preflow 12 Yellow 12
13 Black 13
Gnd 7 Shield Cut & Key
Test Operate 14 Green 14
15 Black 15
Gnd 9 Shield Cut & Key
H35 & N
2
Plasma Select 10 Red 10
11 Brown 11
Gnd 5 Shield Cut & Key
Jumper 3 Black 3
4 Red 4
Gnd 8 Shield Cut & Key
Gas Pressure 1 Gray N/A
2 Gray N/A
Part Number Length
023927 10 ft (3 m)
023672 25 ft (7.6 m)
023928 50 ft 15 m)
023929 75 ft (23 m)
023930 100 ft (30.5 m)
023931 125 ft (38 m)
023932 150 ft (45.6 m)
8
Figure 3-18 Gas Console Control Cable
HD3070 with Manual Gas Console Instruction Manual 3-25
15
INSTALLATION
Power Supply to Machine Interface /Timer Counter/RCC Interconnections (Figure 3-19)
Timer-Counter Control Cable (Figure 3-20)
1. Connect the cable plug marked 1X6 to the receptacle marked 1X6 on the rear of the power supply.
2. Connect the other end of the cable to the machine interface or receptacle marked 5X1 on the rear of the timercounter. (Figure 3-8)
Machine Interface Control Cable (Figure 3-21)
1. Connect the cable plug marked 1X1 to the receptacle marked 1X1 on the rear of the power supply.
2. Connect the other end of the cable to the machine interface. (Figure 3-8)
Machine Interface Current Setpoint Cable (Figure 3-22)
Do not connect this cable unless the external current set function is going to be initiated from the CNC or
RCC.
1. Connect the cable plug marked 1X2 to the receptacle marked 1X2 on the rear of the power supply.
2. Connect the other end of the cable to the machine interface or receptacle marked 1X2 on the rear of the RCC.
(Figure 3-8)
11
10
9
1X6
Machine interface/
timer-counter
control cable
EMI Filter used
on 220/380/415V
CE units only
Figure 3-19 Power Supply to Machine Interface/Timer-Counter/RCC Interconnections
1X1
Machine interface
control cable
10
1X2
Machine interface/
RCC current
setpoint cable
11
9
1X1
1X1
3-26 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
RUN LIST
MACHINE INTERFACE/
SIGNAL PLUG 1X3 COLOR TIMER-COUNTER
DC On Light 23 White 23
Starts & Arc Time 2 White 1
Starts & Arc Time 3 Black 2
Drain 4 Drain Cut
Error Counter 5 Red 15
Error Counter 6 Black 16
Drain 7 Drain Cut
Part Number Length
023946 3.5 ft (1.1 m)
023947 5.5 ft (1.7 m)
023948 6 ft (1.8 m)
023949 25 ft (7.6 m)
023721 28.3 ft (8.6 m)
023950 38 ft (11.6 m)
123111 50 ft (15.2 m)
123100 75 ft (23 m)
123328 100 ft (30.5 m)
123186 150 ft (45.7 m)
9
Figure 3-20 PS/Machine Interface or Timer/Counter Control Cable
Power Supply
1X6
Machine Interface/
Timer Counter
5X1
RUN LIST
SIGNAL PLUG 1X1 COLOR MACHINE INTERFACE/
Hold (Dry) 1 Black 1
Hold (Dry) 5 Red 5
- 10 Drain 10
Pierce Comp (Dry) 2 Black 2
Pierce Comp (Dry) 6 White 6
- 11 Drain 11
Part Number Length
023707 25 ft (7.6 m)
023829 28.2 ft (8.6 m)
023933 50 ft (15.2 m)
023934 75 ft (23 m)
023935 100 ft (30.5 m)
023936 125 ft (38 m)
023937 150 ft (45.6 m)
10
Power Supply
Machine Interface
HD3070 with Manual Gas Console Instruction Manual 3-27
15
INSTALLATION
Torch Ignition Out (Dry) 3 Black 3
Torch Ignition Out (Dry) 7 Green 7
- 12 Drain 12
Power Off - 4 Black 4
Power Off + 8 Blue 8
- 13 Drain 13
Plasma On (Dry) 9 Black 9
Plasma On (Dry) 15 Yellow 15
- 14 Drain 14
Ext Inter CC (Dry) 16 Red 16
Ext Inter CC (Dry) 17 Blue 17
- 18 Drain 18
Power On Input + 29 Black 29
Power On Input - 34 Brown 34
- 23 Drain 23
1/50 Arc Voltage - 33 Red 33
1/50 Arc Voltage + 28 Green 28
- 27 Drain 27
Power Interlocks (Dry) 35 Red 35
Power Interlocks (Dry) 30 White 30
- 24 Drain 24
Transfer Out (Dry) 37 Black 37
Transfer Out (Dry) 32 Orange 32
- 26 Drain 26
Figure 3-21 PS/Machine Interface Control Cable
RUN LIST
SIGNAL PLUG 1X2 COLOR MACHINE INTERFACE/RCC
Shield 10 N/A NC
1 Amp BCD 2 White 2
2 Amp BCD 3 Red 3
4 Amp BCD 4 Green 4
8 Amp BCD 5 Brown 5
10 Amp BCD 6 Blue 6
20 Amp BCD 7 Orange 7
40 Amp BCD 8 Yellow 8
80 Amp BCD 12 Gray 12
100 Amp BCD 13 Violet 13
Common 11 Black 11
Part Number Length
023708 25 ft (7.6 m)
023830 28.2 ft (8.6 m)
023943 38 ft (11.6)
023709 50 ft 15 m)
023710 75 ft (23 m)
023711 100 ft (30.5 m)
023944 125 ft (38 m)
023945 150 ft (45.6 m)
11
Figure 3-22 PS/Machine Interface or RCC Current Setpoint Cable
1X2
Power Supply
Machine Interface/RCC
1X2
RHF Console to Torch Quick Disconnect Interconnections (Figure 3-23)
The torch lead set interconnections include connecting the torch lead set between the RHF console and the
torch quick disconnect.
Torch Lead Set to RHF Console
Route the pilot arc lead and water hoses from the torch lead set through the brass feed-through on the RHF
console marked TORCH.
Pilot Arc Lead (+)
• Route the ring end of the cable through the hole in the center section and connect to the pilot arc terminal
on the I/O PC BD Assy.
Cooling Water Hose Supply Hose /Power Lead (-) (Green)
• Connect cooling supply hose (green band) to the manifold adapter (green).
Cooling Water Return Hose (Red)
• Connect cooling return hose (red band) to the manifold adapter (red).
Torch Lead Set to Torch Quick Disconnect
Route the other end of the torch lead set through the power track or festoon to connect to the torch quick
disconnect. Wrap the hose and lead ends together with electrical tape, so that the ends do not catch while routing.
Route torch lead set through strain relief and torch mounting sleeve.
Caution: Make sure the vent tube from the torch head is vented to atmosphere. If the vent
tube is routed into a protective sleeve or power track a build up of Oxygen will
occur. This build up can cause burning or explosion.
Pilot Arc Lead (+)
• Connect the pilot arc cable to the pilot pin fitting.
Cooling Water Supply Hose /Power Lead (-) (Green)
• Connect the cooling supply hose (green band) to the water inlet fitting (RH) at the center of the torch.
Caution: Hold hex fitting on inlet tube with wrench, the tube may snap.
Turn fitting on torch lead set only.
Cooling Water Return Hose (Red)
• Connect the cooling return hose (red band) to the water outlet fitting (RH).
12
3-28 HD3070 with Manual Gas Console Instruction Manual
17
INSTALLATION
12 A
12 B
12 C
12 A
12 B
12 C
GREENGREEN
REDRED
HD3070 with Manual Gas Console Instruction Manual 3-29
15
INSTALLATION
Cooling Return Hose
(Red Band)
Pilot Arc Lead (+)
Pilot Arc Lead (+)
Blow Back
Hose (installed)
Figure 3-24
Torch Lead Set
Cooling Return Hose (Red
Band not shown this end)
RHF Console
45° Quick
Disconnect
CAUTION
Hold hex fittings on quick
disconnect. Do not turn.
Tubing may snap. To
install and remove hoses
and leads, turn fittings on
hoses and leads only.
CAUTION
Remove the foam block used to support the
cathode block during shipment in order to make
the cooling water return hose connections.
Shield Hose
Figs 3-24
& 3-26
Torch Lead Set
with blow back option (shown)
Part Number Length
028866 15 ft (4.6 m)
028867 20 ft (6.1 m)
028868 25 ft (7.6 m)
028869 30 ft (9.1 m)
028695 35 ft (10.6 m)
028870 40 ft (12.2 m)
128001 50 ft (15.2 m)
128083 75 ft (23 m)
128084 100 ft (30.5 m)
Figure 3-23 RHF Console to Torch Quick Disconnect Interconnections
Cooling Return
Hose (Red Band)
Pilot Arc Lead (+)
Cooling Supply
Hose/Power Lead (-)
(Green Band)
Part Number Length
028498 15 ft (4.6 m)
028499 20 ft (6.1 m)
028500 25 ft (7.6 m)
028501 30 ft (9.1 m)
028502 35 ft (10.6 m)
028503 40 ft (12.2 m)
128132 50 ft (15.2 m)
128133 75 ft (23 m)
128134 100 ft (30.5 m)
Torch Lead Set
without blow back option (not shown)
Straight Quick
Disconnect
Plasma Hose
Figs 3-24
& 3-27
Torch Vent
Hose
Shield Hose
Figs 3-24
& 3-26
Torch Vent
Hose
Plasma Hose
Figs 3-24
& 3-27
Cooling Supply Hose/
Power Lead (-)
(Green Band)
Cooling Supply Hose/
Power Lead (-)
(Green Band)
12 B
15141212151616
12 A
12 C
12 B
12 C
12 B
12 A
12 B
12 C
12 A
12 C
12 A
12 A
12 B
12 C
3-30 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Gas Console to Off-Valve Assembly Interconnections (Figure 3-24)
The gas lead set interconnections include connecting the torch lead set between the gas console and the offvalve assembly.
Gas Lead Set to Gas Console
Connect the gas lead set to the three fittings and receptacle on the gas console marked TORCH.
Plasma Gas Hose
• Connect the hose (clear) to the blue PLASMA fitting (LH).
Shield Gas Hose
• Connect the hose (gray) to the green SHIELD fitting (RH).
Preflow Gas Hose
• Connect the hose (red) to the red PREFLOW fitting (RH).
Control Cable
• Connect the cable plug marked 3X3 to the receptacle marked 3X3.
Gas Lead Set to Off Valve Assembly
Route the other end of the gas lead set through the power track or festoon to connect to the off-valve assembly.
Wrap the hose and lead ends together with electrical tape, so that the ends do not catch while routing.
Plasma Gas Hose
• Connect the hose (clear) to the plasma gas inlet fitting (blue) (LH).
Shield Gas Hose
• Connect the hose (gray) to the shield gas inlet fitting (green) (RH).
Preflow Gas Hose
• Connect the hose (red) to the preflow gas inlet fitting (red) (RH).
Control Cable
• Connect the cable plug marked 4X1 to the receptacle marked 4X1.
13
3A
1
3B
1
3C
1
3D
1
3A
1
3B
1
3C
1
3D
1
HD3070 with Manual Gas Console Instruction Manual 3-31
15
INSTALLATION
Control Cable
4X1
Preflow Gas Hose
(Red Band)
Shield Gas Hose
(Green Band)
Plasma Gas Hose
(Blue Band)
Control Cable
3X3
Preflow Gas Hose
(Red Band)
Plasma Gas Hose
(Blue Band)
Gas Console
Shield Gas Hose
(Green Band)
Off-Valve Assy
Gas Lead Set
Figure 3-24 Gas Console to Off-Valve Assembly Interconnections
*Disregard these items, if system was
ordered without the blow back option.
Off-Valve Cable Assy
*Blow Back Solenoid
(End user 120 VAC required.)
SV16
SV14 SV15
Plasma Hose
Figs 3-23 & 3-27
Shield Hose
Figs 3-23 & 3-26
*Blow Back Hose
Figure 3-23
SV16
SV15
SV14
13B13C1
3B
13
13
141516
Part Number Length
128175 15 ft (4.6 m)
128176 20 ft (6.1 m)
128177 25 ft (7.6 m)
128178 30 ft (9.1 m)
128179 35 ft (10.6 m)
Part Number Length
128180 40 ft (12.2 m)
128181 50 ft (15.2 m)
128182 75 ft (23 m)
128183 100 ft (30.5 m)
3D
1
3A
1
3C
1
3B
1
3A
3D
1
1
1
3A
1
3B
3C
1
1
3D
3C
1
3A
1
3D
1
3-32 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Off-Valve Assembly to Torch Quick Disconnect Interconnections (Figures 3-23 and 3-24)
After the torch lead set and gas lead set have been connected, connect the plasma and shield gas hoses and blow
back hose between the off-valve assembly and torch quick disconnect. Route plasma and shield gas hoses and
blow back hose through strain relief and torch mounting sleeve.
Off-Valve Assembly
*Blow Back Hose (Figure 3-24)
• Connect the blow back hose (from torch lead set) to blow back solenoid.
Shield Gas Hose (Figure 3-26)
• Connect the gray hose to the shield inlet fitting (RH).
Plasma Gas Hose (Figure 3-27)
• Connect the clear hose to the plasma inlet fitting (LH).
Torch Quick Disconnect
Slide the other hose ends through the torch sleeve and connect to torch quick disconnect.
Shield Gas Hose
• Connect the hose (gray) to the shield inlet fitting (RH).
Plasma Gas Hose
• Connect the hose (clear) to the plasma inlet fitting (LH).
Slide the torch sleeve to the torch quick disconnect, mate threaded ends and tighten.
1615161514
* Not used, if system was ordered without the blow back option.
HD3070 with Manual Gas Console Instruction Manual 3-33
15
INSTALLATION
Part Number Length
128491 43 in (1.1 m)
Torch Lead Set
Off-Valve
Assembly
14
*Figure 3-25 Blow Back Hose Replacement Kit
Part Number Length
024429 4 ft (1.2 m)
Torch Quick
Disconnect
Torch Quick
Disconnect
Off-Valve
Assembly
15
Figure 3-26 Shield Gas Hose Assembly, 3/16 Inch Gray RH “A”
Part Number Length
024430 4 ft (1.2 m)
Off-Valve
Assembly
16
Figure 3-27 Plasma Gas Hose Assembly, LH “A”
* Not used, if system was ordered without the blow back option.
3-34 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Figure 3-28 Gas Supply Hose and PE Ground Connections
Gas Supply Hose Connections (Figure 3-28)
Gas Supply Hoses
The gas supply hoses are customer supplied.
• Connect the oxygen (O2) and nitrogen (N2) gas supplies from the high pressure regulators to the gas
console fittings marked O2 and N2.
The gas console fittings marked AIR, CH4, and H35 are for other required cutting gases.
17
PE Ground Cable Connections (Figures 3-8, 3-9 and 3-28)
PE Ground Cables
The PE ground cables are customer supplied. The power supply, RHF console and gas console provide
connections for protective earth (PE) grounding. Each cable should be connected to the worktable earth ground.
Refer to Pre-Installation, Equipment Grounding for cable specifications in the front of this section.
18
18
17
HD3070 with Manual Gas Console Instruction Manual 3-35
15
INSTALLATION
Hold Signal Connections (Figures 3-8 and 3-30)
Hold Signal Terminal Block TB3
The hold signal is used to synchronize the starting of two or more systems. The hold signal is available at TB3 or at
the CNC through cable 1X1. Dry contact start. The hold signal cable is customer supplied.
19
Figure 3-30 PAC184/PAC186 Torch Gas, Coolant and Pilot Arc Port Locations
Plasma
Vent Out
Pilot
Arc
Water
Out
Water In
and Power
Plasma
In
Shield
In
Mount PAC184/PAC186 Torch to Quick Disconnect
1. Align the PAC184 or PAC186 torch ports to the torch quick disconnect receptacle, then push into place. See
Figure 3-30.
2. Turn the securing ring clockwise (cw) to lock torch into place.
Hold Signal
TB3
TB2
Reference
Rear Panel Interior,
Right Side
Figure 3-29 TB3 Hold Signal Connection Location
3-36 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Torch Coolant Requirements
The power supply is shipped without any coolant in the tank. A standard mixture of propylene glycol (30%),
deionized water (69.9%) and benzotriazole (0.1%) is recommended. This mixture resists freezing to +10° F (-12° C)
and contains a corrosion inhibitor (benzotriazole) to protect copper surfaces in the coolant loop. This mixture is
available in 1-gallon containers by ordering 028872. 100% propylene glycol is available by ordering 028873.
Freezing torch coolant can result in a cracked torch head, leads, or other damage to the torch cooling system. For
operating temperatures colder than +10° F (-12° C), the percentage of propylene glycol must be increased. See
Figure 3-31.
Coolant will become more conductive the longer it is in service. If the conductivity of the coolant becomes too high,
the coolant may conduct torch voltage, resulting in the torch misfiring and can be a shock hazard. Check coolant
conductivity whenever the cooling system is serviced.
Conductivity of new coolant mixture should not exceed 10 µ Siemens/cm at 77° F (25° C). Every 6 months, flush
the power supply of its torch coolant and replace with new coolant.
Observe the warning and caution below. Refer to the Material Safety Data Sheets in Appendix A for data on
safety, handling, storage and disposal of propylene glycol and benzotriazole.
Caution: Always use propylene glycol in the coolant mixture. Do not use anti- freeze in
place of propylene glycol. Antifreeze contains corrosion inhibitors which will
damage the torch coolant system.
Always use purified water in the coolant mixture in order to prevent corrosion
in the torch coolant system. The hardness of purified water should be between
0.206 and 8.5 ppm. If using a conductivity meter to measure water purity, the
recommended level is between 0.5 and 18 µ Siemens/cm at 77° F (25° C).
WARNING
Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if swallowed. Upon
contact, flush skin or eyes with water. If swallowed drink water and call a physician immediately. Do not
induce vomiting.
HD3070 with Manual Gas Console Instruction Manual 3-37
15
INSTALLATION
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
0 102030405060
Temperature ° F
Propylene Glycol (%)
32 °F (0 °C)
Figure 3-31 Freezing Points of a Mixture of Propylene Glycol (%) and Deionized Water
10 °F (-12 °C)
(Standard mixture resists
freezing to this temperature)
3-38 HD3070 with Manual Gas Console Instruction Manual
15
INSTALLATION
Filling Torch Coolant System
1. Before proceeding with filling the system with coolant:
• Ensure that your cutting environment and clothing meet the safety requirements.
Refer to Safety, Section 1 in this manual.
• Ensure that all installation requirements in this manual have been met.
Caution: Never turn the power supply on before filling the tank.
2. Turn on the inlet gas supplies to the gas console. Ensure the gases are available at 120 psi (8.2 bar).
3. At the rear of the power supply, ensure the coolant shutoff valve (1, Figure 3-32) is open and unscrew the
filler/vent cap (3) on coolant tank (2). Fill tank with 8.5 quarts (8 liters) of coolant.
Caution: Do not over fill the tank.
4. At the line voltage disconnect box, set the switch to On.
5. Turn on the power supply by depressing and holding the POWER ON (I) pushbutton switch/ indicator (PB1/LT1).
The COOLANT FLOW LED will remain out until the coolant has pushed all of the air out of the torch cooling
hoses and the coolant returns to the tank. This process may take up to 60 seconds.
6. Locate the red button (5, Figure 3-32) on top of the coolant filter (4) at the rear of the power supply. Press the
button until a little coolant comes out and no air bubbles are seen in the clear filter housing.
7. When the COOLANT FLOW LED illuminates, release the POWER ON (I) pushbutton (PB1). The green
POWER ON indicator (LT1) should light, indicating that the system is operating normally.
8. Observe that the coolant gauge indicates F (Full). Refill the tank when the gauge indicates 1/2 or a little under.
Do not allow the coolant to get too low. Low coolant will overheat and cause shorter consumable life.
9. Check for coolant leaks at hose connections at the power supply, RHF console, and torch quick disconnect.
Post Installation
To checkout system operation, refer to Section 4 Operation.
HD3070 with Manual Gas Console Instruction Manual 3-39
15
INSTALLATION
Figure 3-32 Filling Coolant System
LEGEND
(1) Shutoff Valve
(2) Coolant Tank
(3) Filler/Vent Cap
(4) Filter
(5) Pressure Release Button
32154
HD3070 with Manual Gas Console Instruction Manual 4-1
17
Section 4
OPERATION
In this section:
Controls and Indicators.............................................................................................................................................4-2
Power Supply ...................................................................................................................................................4-2
Gas Console ....................................................................................................................................................4-4
Daily Start-Up Procedure..........................................................................................................................................4-7
Changing Consumable Parts....................................................................................................................................4-9
Removal and Inspection...................................................................................................................................4-9
Replacement ....................................................................................................................................................4-9
Blow Back Option to Purge Coolant Hoses ............................................................................................................4-12
How to Optimize Cut Quality...................................................................................................................................4-14
Tips for Table and Torch.................................................................................................................................4-14
Plasma Set-up Tips........................................................................................................................................4-14
Maximize the Life of Consumable Parts.........................................................................................................4-14
Additional Factors of Cut Quality....................................................................................................................4-15
Additional Improvements................................................................................................................................4-16
Technical Questions.......................................................................................................................................4-17
Operating Data (Cut) Charts...................................................................................................................................4-18
4-2 HD3070 with Manual Gas Console Instruction Manual
15
OPERATION
Controls and Indicators
Power Supply Control Panel (Fig. 4-1)
POWER
• ON ( I ) Pushbutton/indicator switch (PB1/LT1)
Activates the power supply and its control circuits. Indicator lights when power up is complete.
• OFF ( O ) Pushbutton switch (PB2)
Shuts the power supply down.
• DC POWER ON Indicator (LT2)
Illuminates when main contactor closes, indicating DC power is being supplied to the torch.
STATUS*
• RHF INTERLOCK LED (LT3)
Illuminates when RHF Console door is closed. Remains extinguished when door is open.
• OVERTEMP LED (LT4)
Illuminates when power supply main transformer or chopper has overheated. Remains extinguished when
transformer and chopper are operating within limits.
• EXT INTERLOCK LED (LT5)
Illuminates when customer machine interlock (optional) is closed. Remains extinguished when interlock is
open. If not used, the external interlock option must be jumpered (connector 1X1, pins 16 and 17), so that
the plasma system will operate.
• GAS SYSTEM LED (LT6)
Illuminates when gas system is operational. Remains extinguished due to gas system error.
• GAS PRESSURE LED (LT7)
Illuminates when plasma and shield gas pressures are above the low level limit of 105 psi (7.2 bar).
Remains extinguished when either the plasma or shield gas is below the limit.
• COOLANT TEMP LED (LT8)
Illuminates when coolant temperature is normal. Remains extinguished when coolant temperature is too
high.
• COOLANT FLOW LED (LT9)
Illuminates when coolant flow is adequate. Remains extinguished when coolant flow is inadequate.
HD3070 with Manual Gas Console Instruction Manual 4-3
15
OPERATION
* All STATUS LEDs extinguish (except for OVERTEMP which illuminates) when the associated fault condition
occurs. Most fault conditions will cause the system to shut down causing all STATUS LEDs to extinguish (except
for OVERTEMP which illuminates). When this occurs the operator must depress and hold in the POWER ON (1)
switch. The first STATUS LED that does not illuminate (except for OVERTEMP which illuminates) indicates the
fault condition.
AMPS thumbwheel switch (S1)
Selects the desired cutting current.
PIERCE DELAY potentiometer (P1)
Delays ramp up of current.
Figure 4-1 HD3070 Power Supply Controls and Indicators
RHF INTERLOCK
OVER TEMP
EXT INTERLOCK
GAS SYSTEM
GAS PRESSURE
COOLANT TEMP
COOLANT FLOW
STATUS
3070STAT.0 8
4-4 HD3070 with Manual Gas Console Instruction Manual
15
OPERATION
Gas Console (Figure 4-2)
• PLASMA GAS, SHIELD GAS, and H35 PLASMA GAS pressure gauges
PG1 gauge indicates the H35 gas inlet supply pressure.
PG2 gauge indicates the O2/AIR gas inlet supply pressure.
PG3 gauge indicates the N2 /CH4gas inlet supply pressure.
• PROCESS SELECTION/INLET GAS toggle switch (S1)
This switch is used to set test preflow and test cut flowrates using the controls described below. Test preflow and
test cut flowrates are specified in Cut Charts at the end of the section.
TEST CUT FLOW
• PLASMA metering valve (MV1) and PLASMA flowmeter (FM1) are used to set the test cut flowrates for
H35 gases.
• PLASMA metering valve (MV2) and PLASMA flowmeter (FM2) are used to set the test cut flowrates for O
2
,
air, or N2gases.
• PLASMA pressure gauge (PG4) indicates the pressure of the set plasma gas test cut flowrate. If correct
flowrate values cannot be obtained, check gauge and refer to Section 5, Maintenance to perform gas
system back pressure checks.
• SHIELD metering valve (MV3) and flowmeter (FM3) are used to set the test cut flowrates for O2, air, or N
2
gases.
• SHIELD metering valve (MV4) and flowmeter (FM4) are used to set the test cut flowrates for N2or CH
4
gases.
• TEST PRE/RUN/TEST CUT toggle switch (S2)
S2 SWITCH
POSITION
Yes No
No Yes
Yes No
S1 SWITCH SELECTED SELECTED
POSITION PLASMA SHIELD
O
2
O2/N
2
Air Air/CH
4
H35/N
2
N
2
O2 PLASMA
AIR PLASMA
H35 & N2 PLASMA
TEST
CUTFLOW
RUN
TEST
PREFLOW
The contactor is disabled, current
is not delivered to the electrode
and the arc cannot be fired.
Enables normal operation after
the test preflow and test cut
flowrates have been set.
HD3070 with Manual Gas Console Instruction Manual 4-5
15
OPERATION
• SHIELD pressure gauge (PG5) indicates the pressure of the set shield gas test cut flowrates. If correct
flowrate values cannot be obtained, check gauge and refer to Section 5, Maintenance to perform gas
system back pressure checks.
TEST PRE FLOW
• PREFLOW metering valve (MV5) and flowmeter (FM3) are used to set the test preflow flowrates for O2, air,
or N2gases.
• PREFLOW metering valve (MV6) and flowmeter (FM4) are used to set the test preflow flowrates for N2gas.
• PREFLOW pressure gauge (PG6) indicates the pressure of the set test preflow flowrates. If correct flowrate
values cannot be obtained, check gauge and refer to Section 5, Maintenance to perform gas system back
pressure checks.
Figure 4-2 Gas Console Controls and Indicators (1 of 2)
Front
(FM3)
(MV6)
(S2)
(MV3)
(MV5)
(MV4)
(MV1)
(MV2)
(FM4)
(FM1) (FM2)
4-6 HD3070 with Manual Gas Console Instruction Manual
15
OPERATION
Figure 4-2 Gas Console Controls and Indicators (2 of 2)
Right Side
Left Side
(S1)
(PG1)
(PG2)
(PG4)
(PG5)
(PG6)
(PG3)
HD3070 with Manual Gas Console Instruction Manual 4-7
15
OPERATION
Daily Start-Up Procedure
Prior to start-up, ensure that your cutting environment and that your clothing meet the safety requirements outlined
in Section 1, Safety. If problems occur during start-up, refer to Section 3, Installation to check installation
requirements and procedures. The daily start-up procedure involves setting up the system for cutting as follows:
1. Check that the consumable parts are not worn or damaged. Refer to Changing Consumable Parts in this
section.
2. Select cutting current at the AMPS thumbwheel (S1).
Always use the cutting current for which the consumables are rated. For example, do not select 25 or 35 amps
for 30 amp consumables. Cutting at a current other than the rated current will cause excessive consumable
wear and unpredictable cutting performance. It will also be more difficult to troubleshoot cutting faults, since
baseline data does not exist for other than the 30 amp current.
3. Check that the torch is perpendicular to the workpiece to get a clean, vertical cut. Use a square to align the
torch. The torch should be aligned at 0° and 90°.
4. Set initial torch height using the suggested initial height data from the Cut Charts.
Torch initial height sensing should be accurate and consistent for good electrode and nozzle life. When the
initial height is too high, the pilot arc is prevented or prolonged from transferring to the cutting arc. When the
initial height is too low, pierce slag can build up on the shield increasing the chance for a double- arc on
subsequent starts. If a pierce is made with the shield touching the workpiece, the molten slag will be forced
between the nozzle and shield, rendering the shield gas useless and probably ruining the shield and nozzle.
5. Set arc voltage on torch height control unit (THC) using the suggested arc voltage data from the Cut Charts.
One (1) arc volt equals approximately .005 inch (.127 mm).
Arc voltage is typically how the torch height is maintained above the workpiece during a cut. A higher arc
voltage will maintain a higher standoff between the torch and workpiece. The arc voltage potential is between
the tip of the electrode (actually the bottom of the pit in the hafnium element) and the workpiece being cut. As
the electrode tip wears, a pit is formed and the arc voltage may have to be increased to compensate for the
longer distance that now exists between the bottom of the pit and the workpiece. For example, after a few
hundred starts, the torch will ride closer to the workpiece causing an undercut cut edge. To correct the
undercut, simply increase the arc voltage setting by a couple of arc volts. The torch standoff distance will
increase, and cut quality will return.
6. Set the PIERCE DELAY potentiometer (P1) to the suggested pierce delay data on the Cut Charts.
7. Select the plasma gas with the PROCESS SELECTION toggle switch (S1) on the gas console right side panel.
8. Check that the gas inlet supplies are connected and available at 120 psi (8.2 bar) on the inlet gas pressure
gauges (PG1, PG2, and PG3). It is important to keep equal values of the pressures to obtain the correct
mixtures of the gases.
9. Set the main disconnect switch for the power supply to On.
10. Turn on the power supply by depressing the POWER ON (1) switch (PB1). Check that the green POWER ON
indicator (LT1) lights. If not, check the STATUS LEDs. Refer to Front Panel Controls and Indicators in this
section.
4-8 HD3070 with Manual Gas Console Instruction Manual
15
OPERATION
11. Establish plasma and shield gas flows for cutting as follows.
• Set TEST PRE/RUN/TEST CUT toggle switch (S2) on the gas console to TEST CUTFLOW.
Note: The metering valves normally turn hard. Do not loosen the packing nut around the valve stems to make
the valves turn more easily. Loosening the packing nuts breaks the seals and allows gases to leak out
around the valve stems.
• Turn the PLASMA metering valves (MV1 and MV2) to set required flowrates on flowmeters (FM1 and FM2).
See Cut Charts for required flowrates.
• Turn the SHIELD metering valves (MV3 and MV4) to set required flowrates on flowmeters (FM3 and FM4).
See Cut Charts for required flowrates.
12. Establish preflow gas flows as follows.
• Set TEST PRE/RUN/TEST CUT toggle switch (S2) on the gas console to TEST PREFLOW.
• Turn the PREFLOW metering valves (MV5 and MV6) to set the required flowrates on flowmeters (FM3 and
FM4). See Cut Charts for required flowrates.
13. If correct flowrate values cannot be obtained, check the associated pressure gauges on the left side of the gas
console to check the back pressure. Refer to the Section 5, Maintenance, to perform the gas system back
pressure check.
14. Purge the gas lines by positioning the TEST PRE/RUN/TEST CUT toggle switch (S2) on the gas console to
TEST CUTFLOW for 20 seconds and then position the switch to TEST PREFLOW for 20 seconds. After
purging the gas lines, set the switch to RUN.
15. The system is now ready for operation.
HD3070 with Manual Gas Console Instruction Manual 4-9
15
OPERATION
Changing Consumable Parts
Inspect torch consumable parts before cutting for wear and damage, and replaced when needed. The PAC184 and
PAC186 torch consumable parts kits (refer to Section 6, Parts List contain tools for removal and inspection of the
consumable parts. To remove, inspect and replace the consumables, proceed as follows. See Figures 4-3 – 4-6.
Removal and Inspection
1. Remove the shield cap and inspect shield for plugged holes or damage. To remove the shield, push on it until it
releases. Check the O-ring for wear and damage.
2. Remove the inner cap and inspect for plugged holes or damage.
3. Remove the nozzle using the removal tool. Check for wear and arcing. Also check the O-rings for wear and
damage.
4. Remove the electrode using the removal tool. The electrode should be inspected and replaced if there is a pit
.040 inch (1 mm) deep. See Figure 4-6 in order to check the pit depth. Check the O-ring for wear and damage.
5. Remove the swirl ring using the removal tool. Insert the tool into the swirl ring until it catches on the lip and then
pull back to remove swirl ring. Inspect the swirl ring for plugged holes or damage. Check the O-rings for wear
and damage.
Replacement
Do not use an excessive amount of silicone grease when applying to any of the consumable O-rings.
Excess grease can easily plug ports and holes, causing improper gas flow during operation. Only apply a
light coat of silicone grease.
Avoid touching the tip of the electrode during installation as grease or dirt may affect starting reliability.
Check the electrode tip and wipe clean if necessary.
1. Apply silicone to the electrode O-ring and then to both O-rings on the swirl ring.
2. Insert the electrode into the small diameter end of the swirl ring, then insert the swirl ring (large diameter end)
into the nozzle. Apply silicone to the nozzle O-rings, then insert the nozzle into the torch and push it into place.
3. Inspect the threads on the torch main body, and clean threads if necessary. Apply silicone to the O-rings on the
torch main body.
WARNING
Always disconnect the power supply from the main power source before inspecting or changing the
torch parts.
(Continued on page 4-12)
4-10 HD3070 with Manual Gas Console Instruction Manual
15
OPERATION
Figure 4-3 PAC186 Torch Consumable Parts
020633
120111
020644
020670
120113
020940
020941
120112
020646
020671
30A
Mild Steel
120112
020647
PAC186 Torch
120349
020634/
020687
Shield
Cap
020789
Shield
Nozzle
Retaining
Cap
Swirl
Ring
020637
Electrode
120111
020671
020645
020937
020938
020637
020633
020949
020948
020947
120113
020795
020796
120273
120266 120272 020637
120410
15A
Mild Steel
30A
Stainless
Steel
50A
Mild Steel
50A
Stainless
Steel/
Copper
70A
Mild Steel/
Stainless
Steel/
Aluminum/
Copper
100A
Mild Steel
120594
120592
120591
120590
120589
100A
Stainless
Steel/
Aluminum
120623
(ccw)
120626
(ccw)
120622 (ccw) 120626 (ccw)
120623 (ccw)
120626 (ccw)
120617 (ccw) 120624 (ccw)
120237 (ccw)120238 (ccw)
120626 (ccw)
120621 (ccw)
120616 (ccw)
CCW (counter clockwise) consumables are available for mirror image cutting.
HD3070 with Manual Gas Console Instruction Manual 4-11
15
OPERATION
This tool is used to check the electrode pit depth. To use,
proceed as follows:
1. Loosen height adjust and insert electrode as shown.
Tighten height adjust.
2. Ensure the point touches the flat surface next to the pit.
3. Loosen the dial indicator locking screw, zero indicator
and retighten locking screw.
4. Lower point into pit and read indicator for pit depth.
5. Replace electrodes with indicated pit depths greater
than 0.040 inch (1.0 mm).
Nozzle
Electrode
Electrode
120209
Shield Cap
120221/120543
Shield
120222
Inner Cap
120219
Nozzle
120277
15 Amp
Swirl
Ring
120212
120218
30 Amp
PAC184 Torch
120208
Figure 4-4 PAC184 Torch 15 and 30 Amp Mild Steel Consumable Parts
Figure 4-5 Consumable Removal Tools
PAC184 Tool (004670)
All Electrodes
& 100 Amp
Nozzles
15, 30 & 50 Amp
Mild Steel and 30
Amp Stainless Steel
Nozzles
PAC186 Tool (004555)
50 Amp Stainless
Steel & 70 Amp
Nozzle/Shields
PAC186 Swirl Ring Tool
(004745)
Figure 4-6 Electrode Pit Depth Gauge (004630)
Locking
Screw
Point (004629)
Raises and lowers
point
Electrode
Dial Indicator
Height Adjust
4-12 HD3070 with Manual Gas Console Instruction Manual
15
OPERATION
4. Install the inner cap on to the torch main body. Hand tighten the inner cap snugly to ensure good electrical
contact. Do not overtighten.
5. Install the shield cap with the shield in place on to the torch main body. If the shield is not in place, apply
silicone to the O-ring and insert the shield into the shield cap and push into place. Hand tighten the shield cap
snugly. Failure to tighten the shield cap snugly could result in poor electrical contact and water and gas
leaks which will impair cut quality.
Blow Back Option to Purge Coolant Hoses
Before removing the PAC184 or PAC186 torch, the operator may want to purge the torch coolant from the coolant
hoses back into the coolant tank to minimize the coolant dripping when the torch is disconnected from the quick
disconnect. After replacing the torch, the coolant hoses should be refilled with coolant. Refer to the procedures
below.
Purge Coolant Hoses (Blow Back)
1. Shut the power supply down at the control panel or CNC.
2. At off-valve assembly (Fig. 4-7) connect 1/4-inch air hose to air inlet.
3. Connect 120 VAC power cable from CNC or other source to blow back solenoid valve.
4. Apply air at approximately 20 psi (1.4 bar) to the air inlet. Air supply should be clean, dry and oil free in
order not to contaminate the coolant.
5. Apply 120 VAC signal for about 3 seconds to open the solenoid valve in order to purge the coolant from the
hoses. It is not necessary to purge longer than 3 seconds.
6. After the coolant hoses have been purged, disconnect the torch from the torch quick disconnect.
blow back
solenoid valve
120 VAC
(Ref.)
air inlet
off-valve
assembly
Figure 4-7 Coolant Purging Setup
HD3070 with Manual Gas Console Instruction Manual 4-13
17
OPERATION
Refill Coolant Hoses
1. Reconnect torch to the torch quick disconnect.
2. Apply power to the power supply at the control panel or from CNC.
If at the power supply, depress and hold the POWER ON pushbutton switch until the COOLANT FLOW LED
lights. If at the CNC, maintain the Power On signal until the COOLANT FLOW LED lights.
When the COOLANT FLOW LED lights, release the POWER ON switch at the power supply or the Power On
signal at the CNC. The green POWER ON indicator should remain on, indicating that the system is operating
normally.
(The COOLANT FLOW LED will remain out until the coolant has pushed all of the air out of the torch cooling
hoses and the coolant returns to the tank. However, coolant hoses with too many bends can have air pockets
even though the COOLANT FLOW LED lights and the system appears ready for operation. The trapped air
can cause the torch to lose cooling momentarily and potentially cause damage to the torch.)
4-14 HD3070 with Manual Gas Console Instruction Manual
17
OPERATION
How to Optimize Cut Quality
The following tips and procedures will help produce square, straight, smooth and dross-free cuts.
Tips for Table and Torch
• Use a square to align the torch at right angles to the workpiece.
• The torch may travel more smoothly if you clean, check and “tune” the rails and drive system on the cutting
table. Unsteady machine motion can cause a regular, wavy pattern on the cut surface.
• The torch must not touch the workpiece during cutting. Contact can damage the shield and nozzle, and
affect the cut surface.
Plasma Set-Up Tips
Follow carefully each step in the Daily Start-Up procedure described earlier in this section.
Purge the gas lines before cutting.
Maximize the Life of Consumable Parts
Hypertherm’s LongLife®process automatically “ramps up” the gas and current flows at the start and ramps them
down at the end of each cut, to minimize erosion of the electrode’s center surface. The LongLife process also
requires that cuts start and stop on the workpiece.
• The torch should never fire into the air.
– Starting the cut at the edge of the workpiece is acceptable, as long as the arc is not fired in the air.
–
To start with a pierce, use a pierce height that is 1.5 to 2 times the torch-to-work distance. See Cut Charts.
• Each cut should end with the arc still attached to the workpiece, to avoid arc blow-outs (ramp-down errors).
– When cutting drop parts (small parts that drop down after being cut from the workpiece), check that the
arc stays attached to the edge of the workpiece, for proper ramp-down.
• If arc blow-outs occur, try one or more of the following:
– Reduce the cutting speed during the final part of the cut.
– Stop the arc before the part is completely cut, to allow completion of the cut during the ramp-down.
– Program the path of the torch into the scrap area for ramp-down.
Note: Use a “chain cut” if possible, so the path of the torch can lead directly from one cut part into
the next, without stopping and starting the arc. However, do not allow the path to lead off
the workpiece and back on, and remember that a chain cut of long duration will cause
electrode wear.
Note: It may be difficult to achieve the full benefits of the LongLife process in some conditions.
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