Hypertherm HyDefinition HD4070 Instruction Manual
Plasma arc cutting / marking system
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Also See for HyDefinition HD4070:
- Product configuration manual (88 pages) ,
- Field service bulletin (8 pages)
Related Manuals for Hypertherm HyDefinition HD4070
Summary of Contents for Hypertherm HyDefinition HD4070
- Page 1 HyDefinition ® HD4070 Plasma Arc Cutting / Marking System Instruction Manual 803760 – Revision 2 4070.97...
- Page 2 Changed Page Description Rev 1 to 2 12/17/01 Changed dimension from 2.4" to 2.8". 2 rail lifter change. 2.12 3.6 & .12, 3A.2 &. 23, Updated art to show off-valve cover 3B.2,.12 & .21, 5.3 4.14 & 6.13 Added CCW consumables for 200A M.S. Text changed to match figure change in Rev1 (P2 Jumper for 265V is now for 5.35 211V block position changed from 265V to 211V)
- Page 3 Changed Page Description IM376 Rev 0 to 1 4/26/01 Cover Added HyDefinition to title H35 percentages corrected to H35 = 35% Hydrogren, 65% Argon 2.11 Updated dimension from 2.25" to 3.5" and metric equivalent iv &3.1 Correction to table of contents: 3-19 canged to 3-20, 3-20 to 3-21 Caution box text realigned 3.14 Note added under power requirements table (Pg still says 0 not 1.1)
- Page 4 Revision 2 – December, 2001 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2001 Hypertherm, Inc. All Rights Reserved Hypertherm, HyDefinition and Command THC are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries...
- Page 5 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...
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Page 6: Electromagnetic Compatibility (Emc
The size of the surrounding area to be Earthing of Workpiece considered will depend on the structure of Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth the building and other activities that are tak- in compliance with standard EN50199. The for electrical safety, nor connected to earth ing place. -
Page 7: Warranty
Hypertherm system. Any damage infringement, and Hypertherm’s obligation to indemnify shall be caused by the use of other than genuine Hypertherm parts may conditioned upon Hypertherm’s sole control of, and the not be covered by the Hypertherm warranty. -
Page 8: Table Of Contents
TABLE OF CONTENTS Electromagnetic Compatibility (EMC) ...........................i Warranty ..................................ii General ................................ii Patent Indemnity..............................ii Limitation of Liability ............................ii Liability Cap .................................ii Insurance ................................ii National and Local Codes............................ii Transfer of Rights ..............................ii Section 1 Safety ..............................1-1 Recognize Safety Information...........................1-2 Follow Safety Instructions ............................1-2 Cutting Can Cause Fire or Explosion ........................1-2 Electric Shock Can Kill..............................1-3 Cutting Can Produce Toxic Fumes ...........................1-3... - Page 9 TABLE OF CONTENTS System Gas Requirements ..........................2-5 Power Supply ..............................2-6 Gas Console Assembly ...........................2-8 Ignition Console Assembly ..........................2-9 Off-Valve Assembly ............................2-10 Torch Specifications ............................2-11 X-Y Lifter Assembly ............................2-12 Torch Breakaway Kit ............................2-13 Section 3 Installation ............................3-1 Upon Receipt ................................3-2 Claims ..................................3-2 Installation Requirements ............................3-2 Gas Requirements ..............................3-2 Torch Coolant Requirements ............................3-3...
- Page 10 TABLE OF CONTENTS Install the Work Lead .............................3A-6 Pilot Arc Lead..............................3A-7 Negative Lead..............................3A-7 Work Lead ..............................3A-7 Install the Gas Console to Ignition Console Cable ..................3A-8 Cable – Gas Console to Ignition Console......................3A-9 Install the Ignition Console to Off-Valve Cable and Gas Hose Assembly ............3A-10 Hoses –...
- Page 11 TABLE OF CONTENTS Torch Connections..............................3B-19 Connecting the Torch to Torch Leads ......................3B-19 Torch Mounting and Alignment ........................3B-20 Install the Torch and Lead Assembly ........................3B-21 Torch and Lead Assembly..........................3B-21 Fill the Power Supply with Coolant ........................3B-22 Section 4 Operation .............................4-1 Power Supply Controls and Indicators........................4-2 General ................................4-2 Power Switch ..............................4-2 Power Indicators ..............................4-2...
- Page 12 TABLE OF CONTENTS Error Code Troubleshooting- 3 of 4........................5-18 Error Code Troubleshooting- 4 of 4........................5-19 Electrical PC Boards and Power Supplies ......................5-20 Plasma Interface Board PCB5 status Indicators ....................5-21 Breakout Board PCB6 status Indicators......................5-22 Control Board PCB3 status Indicators ......................5-26 Power Distribution Board PCB4 Status Indicators ..................5-27 Start Circuit Assembly Board PCB2 .......................5-28 Pilot Arc Current Levels..........................5-28...
- Page 13 TABLE OF CONTENTS Appendix A System Grounding ..........................a-1 System Grounding Requirements..........................a-1 Suggested Ground Cable Routing..........................a-1 Power Supply ..............................a-1 Equipment Grounding ............................a-1 Work Table Grounding............................a-2 Appendix B Propylene Glycol Safety Data......................b-1 Benzotriazole Safety Data......................b-1 Appendix C Gas Regulators ..........................c-1 Appendix D Service Screen (#18) Status Table ....................d-1 Appendix E Integrated Command THC Supplemental Information ..............e-1 Command THC serial protocol..........................e-2...
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Page 14: Safety
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 Hypertherm Plasma Systems... -
Page 15: Recognize Safety Information
• Install an aeration manifold on the floor of the water closed container. table to eliminate the possibility of hydrogen • Do not cut containers that have held combustible detonation. Refer to the Appendix section of this materials. manual for aeration manifold details. Hypertherm Plasma Systems 11-98... -
Page 16: Electric Shock Can Kill
• Provide a disconnect switch close to the power grounding conductor first. supply with properly sized fuses. This switch allows • Each Hypertherm plasma system is designed to be the operator to turn off the power supply quickly in used only with specific Hypertherm torches. Do not an emergency situation. -
Page 17: A Plasma Arc Can Cause Injury And Burns
Work Table Connect the work table to an earth power cord ground. Fasten the retaining nut tightly. ground, in accordance with appropriate national or • Tighten all electrical connections to avoid excessive local electrical codes. heating. Hypertherm Plasma Systems 4-99... -
Page 18: Compressed Gas Equipment Safety
Protection Association, 470 Atlantic Avenue, Boston, MA 02210 Hazardous Substances, American Welding Society 10. OSHA, Safety and Health Standards, 29FR 1910 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 U.S. Government Printing Office, Washington, D.C. 20402 Hypertherm Plasma Systems 11-98... -
Page 19: Warning Label
Use welding helmet with correct shade of filter. Wear complete body protection. Become trained and read the instructions before working on the machine or cutting. Do not remove or paint over (cover) warning labels. Hypertherm Plasma Systems 8-99... -
Page 20: Section 1A
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 Hypertherm Systèmes plasma 1a-1 2/12/01... -
Page 21: Identifier Les Consignes De Sécurité
• Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de combustibles. renseignements sur les collecteurs d’aération. 1a-2 Hypertherm Systèmes plasma 2/12/01... -
Page 22: Les Chocs Électriques Peuvent Être Fatals
• Installer un sectionneur avec fusibles appropriés, à la prise de terre appropriée. proximité de la source de courant. Ce dispositif permet à • Chaque système plasma Hypertherm est conçu pour être l’opérateur d’arrêter rapidement la source de courant en utilisé uniquement avec des torches Hypertherm cas d’urgence. -
Page 23: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures
Bien serrer l’écrou de retenue. Table de travail Raccorder la table de travail à la terre, • S’assurer que toutes les connexions sont bien serrées conformément aux codes de sécurité locaux ou nationaux pour éviter la surchauffe. appropriés. 1a-4 Hypertherm Systèmes plasma 2/12/01... -
Page 24: Sécurité Des Bouteilles De Gaz Comprimé
LES TUYAUX GELÉS • Se tenir le plus loin possible de la source de courant. Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. Hypertherm Systèmes plasma 1a-5 2/12/01... -
Page 25: Étiquette De Sécurité
6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. 7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité. 1a-6 Hypertherm Systèmes plasma 2/12/01... -
Page 26: Specifications
Section 2 SPECIFICATIONS In this section: System Description ............................2-2 General..............................2-2 Power Supply ............................2-2 Machine Torch ............................2-2 Off-Valve Assembly ..........................2-3 Gas Console............................2-3 Ignition Console............................2-3 Options ..............................2-3 Options - continued ..........................2-4 Specifications ..............................2-5 System Gas Requirements........................2-5 Power Supply ............................2-6 Gas Console Assembly - 078085 ......................2-8 Ignition Console Assembly - 078088 ......................2-9 Off-Valve Assembly - 129563 .......................2-10 Torch Specifications..........................2-11... -
Page 27: System Description
SPECIFICATIONS System Description General The HD4070 is a fully automated 200-amp plasma cutting system that requires minimal input and adjustment by the operator. Using the HD4070 display touch screen (or CNC), the operator enters the material and thickness to be cut. The HD4070 system automatically selects and adjusts the power and gas required to optimize cutting, including amperage, gas and gas flow rate. -
Page 28: Off-Valve Assembly
200-amp consumables installed in the second torch), and to select one torch or the other from the HD4070 display (or CNC). • Integrated Command THC Option - The Hypertherm Integrated Command THC takes full advantage of the HD4070's automated capabilities. When the operator enters the material and thickness to be cut, using... -
Page 29: Options - Continued
SPECIFICATIONS Options - continued • Touch Screen Display Option - The HD4070 display is a touch screen that provides all system control functions and plasma process information at a single location. The torch consumables that are required for the selected process are also listed. The power supply may be ordered in three configurations. •... -
Page 30: Specifications
SPECIFICATIONS Specifications System gas requirements Gas Quality and Pressure Requirements Quality Pressure + 5% Flow Rate Oxygen 99.5% pure (liquid gas recommended) 120 psi 133 scfh (3780 l/h) Clean, dry, oil-free 8.3 bar / 827 kPa Nitrogen 99.99% pure (liquid gas recommended) 120 psi 142 scfh 4020 l/h Clean, dry, oil-free... -
Page 31: Power Supply
SPECIFICATIONS Power Supply General Maximum OCV (U 311 VDC Maximum Output Current (I 200 amps Output Voltage (U 85 - 200 VDC Duty Cycle Rating (X) 100% @ 40 kw, 104°F (40°C) Ambient Temperature/Duty Cycle Power supplies will operate between +14° and 104°F ( -10°C and +40°C) Power Factor(cosϕ) 0.98 @ 200A DC output... - Page 32 SPECIFICATIONS Voltage Options 480V 240V 400V 200V 440V 220V 600V Display 1 THC 2 THC Power Supply Part Number 60 HZ 60 HZ 50-60 HZ 50-60 HZ 50-60 HZ 50-60 HZ 60 HZ 078087 – – – – – – 078101 –...
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Page 33: Gas Console Assembly
SPECIFICATIONS Gas console assembly - 078085 Position the gas console near the cutting table. Allow room to open the top for servicing. Venting air is drawn in through fans on both sides and is exhausted through the front of the unit. Maximum distance from the power supply should not exceed 150 feet (46 m). -
Page 34: Ignition Console Assembly
SPECIFICATIONS Ignition console assembly - 078088 • Mount the ignition console up to 15 feet (4.5 m) from the torch lifter station. Allow room to remove the top for servicing. • The ignition console may be mounted in the horizontal or the vertical position as shown below. Horizontal Mounting Vertical Mounting 12"... -
Page 35: Off-Valve Assembly
SPECIFICATIONS Off-valve assembly - 129563 • Mount the off-valve assembly up to 4 feet (1.5 m) from the torch lifter station. 2.75" 70 mm 0.75" 19 mm 2.5 lb 1.1 kg 6.18" 157 mm 0.187" 4.7 mm 1.18" 3" 30 mm 76 mm 6.5"... -
Page 36: Torch Specifications
SPECIFICATIONS Torch Specifications 4 ft / 1.2 m 1.05" 4.65" 10.86" (118 mm) (276 mm) 2" 2.25" (51 mm) (57 mm) 1.98" 1.88" 3.5" (48 mm) (50 mm) (89 mm) 14.7 lb 2 lb 6.7 kg 0.9 kg 15 ft / 4.5 m 4070.44 HD4070 Instruction Manual 2-11... -
Page 37: X-Y Lifter Assembly
SPECIFICATIONS X-Y Lifter Assembly Electrical Motor .................+ 2.48 VDC, 2-phase (3.3 amp per ph.) Limit switches..............+ 24 VDC Lifter Control Function Motor .................Stepper Motor Drive................Stepper, chopped constant current Lifter Feedback ..............Encoder Lifter Limit Switches ............Home switch and lower limit switch Maximum Z Axis Speed ............200 inches (508 cm) per minute Maximum Z Axis Stroke ............8 inches (203 mm) Torch Mounting Dimensions... -
Page 38: Torch Breakaway Kit
SPECIFICATIONS Torch Breakaway Kit - 128281 Electrical Pressure switch..............CNC emergency stop circuit voltage Breakaway Control Function Shop air pressure..............100 psi (6.9 bar) maximum Size Breakaway width ...............3.8 inches (97 mm) Breakaway height (thickness) ...........2.25 inches (57 mm) Air filter/regulator height ............7.06 inches (179 mm) Air filter/regulator width .............1.56 inches (40 mm) Air filter/regulator depth (from gauge to back)....3.125 inches (79 mm) Weight... -
Page 39: Installation
Section 3 INSTALLATION In this section: Upon Receipt ..............................3-2 Claims ................................3-2 Installation Requirements..........................3-2 Gas Requirements ............................3-2 Torch Coolant Requirements...........................3-3 Water Purity Requirements ..........................3-4 Noise levels..............................3-4 Torch Lifter Requirement..........................3-4 Placement of System Components.........................3-5 HD4070 Installation - Basic Requirements .....................3-6 Place System Components: ........................3-7 Customer-Supplied Cables and Hoses: ....................3-7 Install Cables and Hoses:........................3-7 Remote Display Option ...........................3-7... -
Page 40: Upon Receipt
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. -
Page 41: Torch Coolant Requirements
INSTALLATION Torch Coolant Requirements The power supply is shipped without any coolant in the tank. Hypertherm recommends a mixture of 30% propylene glycol, 69.9% deionized water, and 0.1% benzotriazole. This mixture resists freezing to +10° F (-12° C) and contains a corrosion inhibitor to protect copper surfaces in the coolant loop. This mixture is available in 1-gallon containers by ordering 028872. -
Page 42: Water Purity Requirements
INSTALLATION Water Purity Requirements It is critical to maintain a low level of calcium carbonate in the coolant to avoid reduced performance of the torch or cooling system. Water purity should meet the requirements defined below. Water Purity Conductivity Resistivity Dissolved Grains per Water Purity... -
Page 43: Placement Of System Components
INSTALLATION Placement of System Components • Place all system components in position prior to making electrical, gas and interface connections. Use the diagram on the following page for component placement guidelines. • Ground all system components to earth. See Grounding Requirements in this section for details. •... -
Page 44: Hd4070 Installation - Basic Requirements
INSTALLATION HD4070 Installation – Basic Requirements 4070.99B HD4070 Instruction Manual... -
Page 45: Place System Components
INSTALLATION Place system components: Power supply; see page 3-8. Gas console; see page 3-9. Ignition console; see page 3-10. Off-valve assembly; see page 3-11. Customer-supplied cables and hoses: Grounding cable; see page 3-12. Gas supply plumbing; see page 3-13. Power cable; see page 3-14/15. Install cables and hoses Gas console signal cable;... -
Page 46: Placement Of The Power Supply
INSTALLATION Placement of the power supply WARNING ELECTRICAL SHOCK CAN KILL Remove all electrical connections to power supply before moving or positioning. Transporting unit can cause personal injury and equipment damage. The power supply can be moved by forklift but the forks must be long enough to extend the entire length of the base. -
Page 47: Placement Of The Gas Console Assembly
INSTALLATION Placement of the gas console assembly • Position the gas console near the cutting table. Allow room to open the hinged top for servicing. Preferred orientation is shown in the figure below. The maximum length of cables between the power supply and gas console is 150 feet (45 m). -
Page 48: Mount The Ignition Console Assembly
INSTALLATION Mount the ignition console assembly • Mount the ignition console on the gantry (bridge). Allow room to remove the top for servicing. Maximum length of the leads between the ignition console and the torch is 15 feet (4.5 m). •... -
Page 49: Install The Off-Valve Assembly
INSTALLATION Install the Off-valve assembly • Mount the off-valve assembly near the torch lifter station. The maximum length of the gas hoses between the off-valve assembly and the torch is 4 feet (1.2 m). • 2-Torch systems: 2 off-valve assemblies are required for a 2-torch system. 4070.18 6.18"... -
Page 50: Grounding Requirements
INSTALLATION Grounding Requirements Proper grounding is essential for personal safety and to prevent emission of high-frequency interference. See Grounding Safety in Section 1 and Appendix A for system grounding requirements. Connect the worktable to a high-quality earth ground, not more than 20 feet (6 m) from the table. -
Page 51: Supply Gas Plumbing
CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen-enriched atmosphere that it creates. As a precaution, Hypertherm recommends that an exhaust ventilation system be installed when cutting with oxygen. -
Page 52: Power Requirements
INSTALLATION Power Requirements General All switches, slow-blow fuses and power cables are customer supplied and must be chosen as outlined by applicable national or local electrical codes. Installation must be performed by a licensed electrician. Use a separate primary line disconnect switch for the power supply. -
Page 53: Connect The Power
INSTALLATION Connect the power WARNING ELECTRICAL SHOCK CAN KILL The line disconnect switch must be in the OFF position before making the power cable connections. In the U.S., use a "lock-out/tag-out" procedure until installation is complete. In other countries, follow appropriate national or local safety procedures. -
Page 54: Install The Power Supply To Gas Console And Cnc Cables
INSTALLATION Install the Power Supply to Gas Installation Note Console and CNC Cables Mark the identification number on the ends of each cable. Gas Console 4070.08 Male Ends (Pins) Signal IGN CSL 1 Input Power IGN CSL 2 Connect to the CNC 4070.09 3-16 HD4070 Instruction Manual... -
Page 55: Signal Cable - Power Supply To Gas Console
INSTALLATION Signal cable – Power supply to gas console Part No. Length Part No. Length 123428 10 ft (3 m) 123433 50 ft (15 m) 123429 20 ft (6 m) 123434 75 ft (23 m) 123430 25 ft (7.5 m) 123435 100 ft (30.5 m) 123431... -
Page 56: Cnc Interface Cable - Power Supply To Cnc
INSTALLATION CNC interface cable - Power supply to CNC Part No. Length Part No. Length 123437 10 ft (3 m) 123442 50 ft (15 m) 123438 20 ft (6 m) 123443 75 ft (23 m) 123439 25 ft (7.5 m) 123444 100 ft (30.5 m) 123440... - Page 57 INSTALLATION Notes: to CNC interface cable run list Relay Note 1. Motion and Transfer Outputs. Relay Contact Closure. Output Note 2. HD4070 outputs are optically coupled Output transistors with maximum ratings of 24 VDC and 10 mA. 24 VDC maximum 10 mA maximum 12 V Return 4.7 K...
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Page 58: Install The Remote Display Cable
INSTALLATION Install the Remote Display Cable Installation Note 1 – Mark the identification number Warning: The HD4070 system can only support one on the end of the cable. touch screen display, either local or remote. Installing displays at both locations on one system 2 –... -
Page 59: Display Mounting Dimensions
INSTALLATION Display mounting dimensions Mounting Panel (Customer Supplied) 1.7"/43 mm Cut-out 5.71"/145 mm 7.835"/199 mm 4070.55 HD4070 Instruction Manual 3-21... -
Page 60: Section 3A
Section 3A 1-TORCH INSTALLATION In this section: HD4070 1-Torch Installation .........................3A-2 System Components ............................3A-3 Cables and Hoses ............................3A-3 Install the Coolant Hoses ........................3A-4 Coolant Hose Assembly - Green Supply....................3A-5 Coolant Hose Assembly - Red Return ....................3A-5 Install the Power Supply to Ignition Console Leads ................3A-6 Install the Work Lead ...........................3A-6 Pilot Arc Lead..............................3A-7 Negative Lead...............................3A-7... -
Page 61: Hd4070 1-Torch Installation
1-TORCH INSTALLATION HD4070 1-Torch Installation 4070.99C 3A-2 HD4070 Instruction Manual... -
Page 62: System Components
1-TORCH INSTALLATION System Components Cables and Hoses See section 3 for installation details. Coolant hose assembly; see page 3A-4. Power supply Coolant hose assembly; see page 3A-4. Gas console Pilot arc lead; see page 3A-6. Ignition console Negative lead; see page 3A-6. Off-valve assembly Work lead;... -
Page 63: Install The Coolant Hoses
1-TORCH INSTALLATION Install the coolant hoses Important: A jumper hose is installed in power supplies configured for 1 torch and must be in place when system is run with one torch. Coolant will flow out if the jumper hose is not in place. Jumper Green Green... -
Page 64: Coolant Hose Assembly - Green Supply
1-TORCH INSTALLATION Coolant hose assembly – Green supply Part No. Length Part No. Length 024563 10 ft (3 m) 024263 50 ft (15 m) 024564 20 ft (6 m) 024264 75 ft (23 m) 024291 25 ft (7.5 m) 024265 100 ft (30.5 m) 024503 30 ft (9 m) -
Page 65: Install The Power Supply To Ignition Console Leads
1-TORCH INSTALLATION Install the power supply to ignition console leads install the work lead CNC Interface Display 4070.03 Lower frame of work table (typical). 4070.05 3A-6 HD4070 Instruction Manual... -
Page 66: Pilot Arc Lead
1-TORCH INSTALLATION (−) (−) 4070.06 Pilot arc lead Part No. Length Part No. Length 123409 10 ft (3 m) 123414 50 ft (15 m) 123410 20 ft (6 m) 123415 75 ft (23 m) 123411 25 ft (7.5 m) 123416 100 ft (30.5 m) 123412 30 ft (9 m) -
Page 67: Install The Gas Console To Ignition Console Cable
1-TORCH INSTALLATION Install the gas console to ignition console cable Installation Note Mark the identification number on the ends of the cable. Female end (Sockets) Male end (Pins) Signal Input Power IGN CSL 2 IGN CSL 1 4070.10A 3A-8 HD4070 Instruction Manual... -
Page 68: Cable - Gas Console To Ignition Console
1-TORCH INSTALLATION Cable – Gas console to ignition console Part No. Length Part No. Length 123446 10 ft (3 m) 123512 50 ft (15m) 123447 20 ft (6 m) 123559 60 ft (18m) 123448 25 ft (7.5 m) 123513 75 ft (23m) 123449 30 ft (9 m) 123514... -
Page 69: Install The Ignition Console To Off-Valve Cable And Gas Hose Assembly
1-TORCH INSTALLATION Install the ignition console to Off-valve cable and Installation Note gas hose assembly Mark the identification number on the ends of cable 18. Make sure there are no leaks at connections. Off-Valve 1 Plasma Shield Cut Flow Preflow Cut Flow Preflow 4070.10B... -
Page 70: Hoses - Gas Console To Off-Valve
1-TORCH INSTALLATION Hoses – gas console to Off-valve Part No. Length Part No. Length 128445 15 ft (4.6 m) 128450 40 ft (12 m) 128446 20 ft (6 m) 128558 50 ft (15 m) 128447 25 ft (7.5 m) 128559 60 ft (18 m) 128448 30 ft (9 m) -
Page 71: Thc And Torch Installation
1-TORCH INSTALLATION THC and Torch Installation X-Y lifter assembly • Mount the X-Y lifter assembly on the cutting table. 1/4" (6 mm) 22.4" (570 mm) 3.5" (89 mm) 1.26" (32 mm) 3.5" 1.42" 2.12" (89 mm) (36 mm) (54 mm) 1.75"... -
Page 72: Torch Mounting Block Kit
1-TORCH INSTALLATION Torch mounting block kit • Mount the torch mounting block kit to the X-Y lifter assembly. Refer to Section 6, Parts List for a complete list of available kits. Spacer Hex screws (4) Hex screws (2) THC.44 Block X-Y Lifter Assembly Torch Mounting Block HD4070 Instruction Manual 3A-13... -
Page 73: Torch Breakaway Kit (Optional)
1-TORCH INSTALLATION Torch breakaway kit (optional) If not installing breakaway kit, go to page 3A-16 Install the torch breakaway kit as follows. Refer to Figure on next page. 1. Mount the fiberglass bracket to the X-Y lifter with 4 hex screws. 2. - Page 74 1-TORCH INSTALLATION Fiberglass bracket Spacer and 4 hex screws not Tubing connector used if breakaway is installed. 6 screws Collar Hex screws (4) Collar Breakaway Block X-Y Lifter Hex screws (2) Tubing Connect to 1-5/16 inch emergency (33.34 mm) stop circuit Blue (Not Connected) Brown...
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Page 75: Install The Torch (Without Torch Breakaway Option)
1-TORCH INSTALLATION Install the torch (without torch breakaway) Mount the torch to the lifter with the mounting block and 2 screws. See Figure below. Install the shield to the mounting block with 4 screws. THC.57 Torch Installed without Torch Breakaway Option 3A-16 HD4070 Instruction Manual... -
Page 76: Install The Torch (With Torch Breakaway Option)
1-TORCH INSTALLATION Install the torch (with torch breakaway) Install the shield to the mounting block with 4 screws. See Figure below. Mount the torch to the lifter with the mounting block and 2 screws. THC.56 Torch Installed with Torch Breakaway Option HD4070 Instruction Manual 3A-17... -
Page 77: Integrated Command Thc Option - Cable Installation
1-TORCH INSTALLATION Integrated command THC option – cable installation Installation Note Mark the identification number on the end of each cable. Lifter I/O (1) 1X6 Motor (1) 1X7 Lifter I/O (2) 1X8 Motor (2) 1X9 Female Male Torch 4070.26B 3A-18 HD4070 Instruction Manual... -
Page 78: Cable - Lifter Interface
1-TORCH INSTALLATION 4070.26C Cable – Lifter Interface Part No. Length Part No. Length See next page for signal information 123209 5 ft./1.5 m 123215 40 ft./12.2 m 123210 10 ft./3 m 123216 45 ft./13.7 m 123211 15 ft./4.6 m 123023 50 ft./15.2 m 123212 20 ft./6.1 m... -
Page 79: Lifter Interface Cable Signals
1-TORCH INSTALLATION Lifter interface cable signals Power Supply Wire Pin number Signal Name Color Function 1 Input Encoder Power - Black Encoder power Encoder Power (5V)+ 2 Input Encoder B - Black A quad B position signal. Encoder B + Green 3 Input Encoder A -... -
Page 80: Torch Connections
1-TORCH INSTALLATION Torch Connections Connecting the torch to torch leads Apply a light coat of lubricant to the threads on the Apply a thin film of silicone quick-disconnect to ease torch installation. lubricant to each O-ring Silicone Grease Torch body Torch leads 120651 128341, 128463 or 128462... -
Page 81: Torch Mounting And Alignment
1-TORCH INSTALLATION Torch Mounting and Alignment Mounting the Torch Securing screws Torch sleeve Installation Note 1. Install the torch (with torch leads attached) in the torch mounting bracket. 2. Position the torch until the torch body extends all the way through the bracket, Torch mounting bracket so that the bracket is now around the... -
Page 82: Install The Torch And Lead Assembly
1-TORCH INSTALLATION Install the torch and lead assembly Torch 0.11 Plasma gas vent Torch and lead assembly Part No. Length 128500 6 ft (2 m) 128501 10 ft (3 m) 128502 15 ft (4.5 m) HD4070 Instruction Manual 3A-23... -
Page 83: Fill The Power Supply With Coolant
1-TORCH INSTALLATION Fill the power supply with coolant Note: Hypertherm coolant, part # 028872, is recommended. For requirements see pg. 3-3, Installation section. Check that the drain valve is closed. Add coolant to the power supply until the sight gauge indicates full. - Page 84 1-TORCH INSTALLATION Turn the power supply ON. Navigate to set-up screen 5. REPEAT PREVIOUS PROCESS PROCESS SETUP LANGUAGE UNITS ˜ ESPANOL INCH/PSI ENGLISH NOTE: Torch 2 must be turned off (Not installed) FRANÇAIS ITALIANO METRIC/KPA When the system is configured for use with 1 torch.
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Page 85: Section 3B
Section 3B 2- TORCH INSTALLATION In this section: HD4070 2-Torch Installation .........................3B-2 System Components ............................3B-3 Cables and Hoses ............................3B-3 Install the Coolant Hoses ........................3B-4 Coolant Hose Assembly - Green Supply....................3B-5 Coolant Hose Assembly - Red Return ....................3B-5 Install the Pilot Arc Leads........................3B-6 Pilot Arc Lead ............................3B-7 Install the Negative and Work Leads ......................3B-8 Negative Lead...............................3B-9... -
Page 86: Hd4070 2-Torch Installation
2-TORCH INSTALLATION HD4070 2-Torch Installation 4070.99D 3B-2 HD4070 Instruction Manual... -
Page 87: System Components
2-TORCH INSTALLATION System Components Cables and Hoses See section 3 for installation details. Coolant hose assembly; see page 3B-4. Power supply Coolant hose assembly; see page 3B-4. Gas console Pilot arc lead; see page 3B-6. Ignition console Negative lead; see page 3B-8. Off-valve assembly Work lead, see page 3B-8. -
Page 88: Install The Coolant Hoses
2-TORCH INSTALLATION Install the coolant hoses Installation Note WARNING Mark hoses and ignition consoles Crossed return hoses can cause for torch number 1 and torch catastrophic torch failure number 2. Torch # 1 Torch # 2 CSL 2 CSL 1 CSL 2 CSL 1 CSL 2... -
Page 89: Coolant Hose Assembly - Green Supply
2-TORCH INSTALLATION Coolant hose assembly - Green supply Part No. Length Part No. Length 024563 10 ft (3 m) 024263 50 ft (15 m) 024564 20 ft (6 m) 024264 75 ft (23 m) 024291 25 ft (7.5 m) 024265 100 ft (30.5 m) 024503 30 ft (9 m) -
Page 90: Install The Pilot Arc Leads
2-TORCH INSTALLATION Install the pilot arc leads Installation Note Mark the pilot arc leads for torch number 1 and torch number 2. CNC Interface Display 4070.05C 3B-6 HD4070 Instruction Manual... -
Page 91: Pilot Arc Lead
2-TORCH INSTALLATION 4070.05D Pilot arc lead Part No. Length Part No. Length 123409 10 ft (3 m) 123414 50 ft (15 m) 123410 20 ft (6 m) 123415 75 ft (23 m) 123411 25 ft (7.5 m) 123416 100 ft (30.5 m) 123412 30 ft (9 m) 123417... -
Page 92: Install The Negative And Work Leads
2-TORCH INSTALLATION Install the negative and work lead Installation Note Mark negative and work leads for torch number 1 and torch number 2. CNC Interface Display 4070.05B 3B-8 HD4070 Instruction Manual... -
Page 93: Negative Lead
2-TORCH INSTALLATION Negative lead 4070.05E Part No. Length Part No. Length 123418 10 ft (3 m) 023079 50 ft (15 m) 023136 20 ft (6 m) 023124 75 ft (23 m) 023078 25 ft (7.5 m) 023080 100 ft (30.5 m) 023101 30 ft (9 m) 023081... -
Page 94: Install The Gas Console To Ignition Console Cable
2-TORCH INSTALLATION Install the gas console to ignition console cable Installation Note Mark the cable identification number and torch number on the ends of each cable. Pilot Arc Pilot Arc Female Ends (Sockets) Male ends (Pins) Signal Input Power IGN CSL 2 IGN CSL 1 4070.10C 3B-10... -
Page 95: Cable - Gas Console To Ignition Console
2-TORCH INSTALLATION Cable – Gas console to ignition console 3X3/4 Part No. Length Part No. Length 123446 10 ft (3 m) 123512 50 ft (15m) 123447 20 ft (6 m) 123559 60 ft (18m) 123448 25 ft (7.5 m) 123513 75 ft (23m) 123449 30 ft (9 m) -
Page 96: Install The Gas Hose Assembly
2-TORCH INSTALLATION Install the gas hose assembly Installation Note Mark the torch number on the ends of each gas hose assembly. Make sure there are no leaks at connections. Off-Valve 1 Plasma Shield Cut Flow Preflow Cut Flow Preflow Off-Valve 2 Plasma Shield Cut Flow... -
Page 97: Hoses - Gas Console To Off-Valve
2-TORCH INSTALLATION Hoses - Gas console to Off-valve Part No. Length Part No. Length 128445 15 ft (4.6 m) 128450 40 ft (12 m) 128446 20 ft (6 m) 128558 50 ft (15 m) 128447 25 ft (7.5 m) 128559 60 ft (18 m) 128448 30 ft (9 m) -
Page 98: Install The Ignition Console To Off-Valve Cables
2-TORCH INSTALLATION Install the ignition console to Installation Note Off-valve cables Mark the cable identification number and torch number on the ends of each cable. Pilot Arc Pilot Arc 4070.10D 3B-14 HD4070 Instruction Manual... -
Page 99: Cable - Ignition Console To Off-Valve
2-TORCH INSTALLATION ƒ CABLE RUN LIST Cable - Ignition console to Off-valve FUNCTION COLOR SHIELD PREFLOW White SHIELD Green 2 2 3 3 CUTFLOW White PLASMA Orange PREFLOW White PLASMA Blank Part No. Length Part No. Length CUTFLOW White 123451 6 ft (1.8 m) 123453 15 ft (4.6 m) -
Page 100: Install The Integrated Command Thc Option
2-TORCH INSTALLATION Install the Integrated Command Installation Note THC Option Mark the identification number See section 3A for instructions to mount X-Y and torch number on the ends of lifter, torch mounting block and torch breakaway each cable. options. Lifter I/O (1) 1X6 Motor (1) 1X7 Lifter I/O (2) 1X8 Motor (2) 1X9... -
Page 101: Cable - Lifter Interface
2-TORCH INSTALLATION 4070.26E Cable – Lifter interface Part No. Length Part No. Length See next page for signal information 123209 5 ft./1.5 m 123215 40 ft./12.2 m 123210 10 ft./3 m 123216 45 ft./13.7 m 123211 15 ft./4.6 m 123023 50 ft./15.2 m 123212 20 ft./6.1 m... -
Page 102: Lifter Interface Cable Signals
2-TORCH INSTALLATION Lifter interface cable signals Power Supply Wire Pin number Signal Name Color Function 1 Input Encoder Power - Black Encoder power Encoder Power (5V)+ 2 Input Encoder B - Black A quad B position signal. Encoder B + Green 3 Input Encoder A -... -
Page 103: Torch Connections
2-TORCH INSTALLATION Torch Connections Connecting the torch to torch leads Apply a light coat of lubricant to the threads on the Apply a thin film of silicone quick-disconnect to ease torch installation. lubricant to each O-ring Silicone Grease Torch body Torch leads 120651 128341, 128463 or 128462... -
Page 104: Torch Mounting And Alignment
2-TORCH INSTALLATION Torch Mounting and Alignment Mounting the Torch Securing screws Torch sleeve Installation Note 1. Install the torch (with torch leads attached) in the torch mounting bracket. 2. Position the torch until the torch body extends all the way through the bracket, Torch mounting bracket so that the bracket is now around the... -
Page 105: Install The Torch And Lead Assembly
2-TORCH INSTALLATION Install the Torch and Lead Installation Note Assembly Mark the torch number on the ends of each gas hose and torch lead. Torch Torch 4070.11A Plasma Gas Vent Plasma Gas Vent Torch # 2 Torch # 1 Torch and lead assembly Part No. -
Page 106: Fill The Power Supply With Coolant
2-TORCH INSTALLATION Fill the Power Supply with Coolant Note: Hypertherm coolant, part # 028872, recommended. For requirements see pg. 3-3, Installation Section. Check that the drain valve is closed. Add coolant to the power supply until the sight gauge indicates full. - Page 107 2-TORCH INSTALLATION Turn the power supply ON. Navigate to set-up screen 5. REPEAT PREVIOUS PROCESS PROCESS SETUP LANGUAGE UNITS ˜ ESPANOL INCH/PSI ENGLISH NOTE: Torch 2 must be turned off (Not installed) FRANÇAIS ITALIANO METRIC/KPA When the system is configured for use with 1 torch.
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Page 108: Section 4 Operation
Section 4 OPERATION In this section: Power Supply Controls and Indicators ......................4-2 General..............................4-2 Power Switch ............................4-2 Power Indicators ............................4-2 Power Supply Display..........................4-3 System Setup Screens navigation .........................4-4 System Operation Screens navigation ......................4-6 Daily Start-up ..............................4-7 Check Torch............................4-7 Turn Power Supply ON...........................4-8 System Setup Screens .........................4-8 System Operation Screens........................4-11 Consumables Selection ..........................4-14... -
Page 109: Power Supply Controls And Indicators
The torch consumables that are required for the selected process are also listed on the HD4070 display. If the Hypertherm Integrated Command THC option is installed, the HD4070 system will automatically adjust torch settings required for the specific process, including arc volts, torch-to-work, initial pierce height and pierce time delay. -
Page 110: Power Supply Display
Service Screens – Screens 17 and 18 are for troubleshooting only. You can not make adjustments. See Section 5 page 13 for details. Access the service screens by pressing the Hypertherm logo on screens 13 - 16. 4070.33 Warning: The HD4070 system can only support one touch screen display, either local or remote. -
Page 111: System Setup Screens Navigation
System Setup Screens – Navigation System Setup Screens - Navigation NOTE: The content of the screens in the manual may vary from the actual machine display. REPEAT PREVIOUS PROCESS PROCESS TORCH 2 TORCH 1 SETUP BACK Indicates last button selected. LANGUAGE UNITS ˜... - Page 112 MILD STEEL BEST SPEED 30 AMPS AND QUALITY MILD STEEL BEST SPEED 70 AMPS AND QUALITY MILD STEEL MORE BEST SPEED 100 AMPS AND QUALITY 1/4 IN MILD STEEL BEST SPEED BACK 200 AMPS 1/4 - 1 IN AND QUALITY SELECT THICKNESS RANGE BACK...
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Page 113: System Operation Screens Navigation
System Operation Screens – Navigation System Operation Screens - Navigation NOTE: The content of the screens in the manual may vary from the actual machine display. MACHINE ACCEL RETRACT SPEED READY 9.000 S TRAVEL SPEED: 65 IPM TORCH 1 IHS STALL PIERCE DELAY INLET GAS: H35 N2 STAINLESS STEEL... -
Page 114: Daily Start-Up
OPERATION Daily Start-up Prior to start-up, ensure that your cutting environment and that your clothing meet the safety requirements outlined in the Safety section of this manual. Check Torch WARNING Before operating this system, you must read the Safety section thoroughly! Turn OFF the power supply's main disconnect switch before proceeding with the following steps. -
Page 115: Turn Power Supply On
OPERATION Turn power supply ON 1. Move the power switch to the ON position. 2. Check that the green AC indicator is illuminated. 4070.33 System setup screens Press to return to the REPEAT Press to select : PREVIOUS last cutting process PROCESS 1. - Page 116 OPERATION System setup screens – continued Select which torch is to be used. TORCH 2 TORCH 1 This screen will be bypassed if the 2-torch option is not installed. BACK Select the material to be cut. MILD STEEL STAINLESS STEEL SELECT MATERIAL ALUMINUM BACK...
- Page 117 OPERATION System setup screens – continued STAINLESS STL BEST QUALITY 200 AMPS AND SPEED Select cutting process to be used. STAINLESS STL CUSTOM 186 AMPS A custom setting must be saved before it will be displayed. BACK NEW CONSUMABLES? BLUE/GRAY The consumables required for the process are ELECTRODE shown for reference.
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Page 118: System Operation Screens
OPERATION System operation screens PURGING When screen 13 first appears, the system will TRAVEL SPEED: 65 IPM TORCH 1 purge all gas lines. INLET GAS: H35 N2 STAINLESS STEEL STANDOFF: 0.050 IN 200 AMPS SET ARC VOLTS: 142.0 V 3/4 IN OVERRIDE VOLTS: 144.5 V AUTO VOLT... - Page 119 OPERATION System operation screens – continued Adjust arc volts Use the ARC VOLT buttons to adjust the arc volts. READY TRAVEL SPEED: 65 IPM TORCH 1 INLET GAS: H35 N2 STAINLESS STEEL STANDOFF: 0.050 IN 200 AMPS SET ARC VOLTS: 142.0 V 3/4 IN OVERRIDE VOLTS: 144.5 V AUTO...
- Page 120 OPERATION System operation screens – continued Adjust gas flows First select the gas flow that you want to adjust. Then use the ++ or -- buttons to increase or decrease the flow PRECUT SHIELD SHIELD value. Press the DEFAULT VALUES button to return all gas flows to the preset values.
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Page 121: Consumables Selection
Consumables Selection = Sets not included in parts kit Mild Steel Stainless Steel Aluminum 30/45 Amp 120678 120677 120676 120706 120705 120704 120741 120740 120739 70 Amp 120685 120684 120683 120713 120712 120711 120748 120747 120746 100 Amp 120660 120655 120654 120720 120719... -
Page 122: Install Consumables
OPERATION Install Consumables Apply a thin coat of silicone lubricant on all O-rings. Clean current ring using a cotton swab with water or 3% hydrogen Silicone Grease peroxide. Do not overtighten parts! Only tighten until mating parts are seated. Install electrode Insert swirl ring Install retaining cap Install... -
Page 123: Cut Charts
If the Hypertherm Integrated Command THC option is installed, the HD4070 system will also automatically adjust torch settings required for the specific process, including arc volts, torch standoff, initial pierce height and pierce time delay. - Page 124 OPERATION Mild Steel Plasma / O Shield 30A Cutting O-Ring Color: Black/Red (see page 4-14) 120907 120678 120677 120676 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Material Cutting work Height Pierce Thickness Speed distance Factor Delay Voltage Plasma Shield Plasma...
- Page 125 OPERATION Stainless Steel Plasma / N Shield 45A Cutting O-Ring Color: Gray/Red (see page 4-14) 120907 120706 120705 120704 Test Preflow Rate (%) Test Cutflow Rate (%) Pierce Torch-to-work Cutting Material Height Pierce distance Speed Thickness Factor Delay Voltage Plasma Shield Plasma Shield...
- Page 126 OPERATION Aluminum Air Plasma / Air Shield 30A Cutting O-Ring Color: White/Red (see page 4-14) 120907 120741 120740 120739 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Cutting work Height Pierce Material Speed Thickness distance Factor Delay Voltage Plasma Shield Plasma...
- Page 127 OPERATION Mild Steel Plasma / O Shield 70A Cutting O-Ring Color: Black/Yellow (see page 4-14) 120907 120685 120684 120683 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Material Cutting work Height Pierce Speed Thickness distance Factor Delay (gauge or Voltage Plasma Shield...
- Page 128 OPERATION Stainless Steel H35-N Plasma / N Shield 70A Cutting O-Ring Color: Gray/Yellow (see page 4-14) 120907 120713 120712 120711 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Material Cutting work Height Pierce Speed Thickness distance Factor Delay (gauge or Voltage Plasma...
- Page 129 OPERATION Aluminum Air Plasma / CH Shield 70A Cutting O-Ring Color: White/Yellow (see page 4-14) 120907 120748 120747 120746 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Material Cutting work Height Pierce Thickness Speed distance Factor Delay Voltage Plasma Shield Plasma...
- Page 130 OPERATION Mild Steel Plasma / O Shield 100A Cutting O-Ring Color: Black/Green (see page 4-14) 120907 120660 120655 120654 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Cutting Material work Height Pierce Speed Delay Thickness distance Factor Plasma Shield Plasma Shield...
- Page 131 OPERATION Stainless Steel H35-N Plasma / N Shield 100A Cutting O-Ring Color: Gray/Green (see page 4-14) 120907 120720 120719 120718 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Cutting Pierce Material work Height Speed Thickness distance Factor Delay Voltage Plasma Shield...
- Page 132 OPERATION Aluminum H35-N Plasma / N Shield 100A Cutting O-Ring Color: White/Green (see page 4-14) 120907 120755 120754 120753 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Cutting Material work Height Pierce Speed Thickness distance Factor Delay Voltage Plasma Shield Plasma...
- Page 133 OPERATION Mild Steel Plasma / O Shield 200A Cutting O-Ring Color: Black/Blue (see page 4-14) 120907 120692 120691 120690 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Cutting Material work Height Pierce Speed Thickness distance Factor Delay Plasma Shield Plasma Shield...
- Page 134 OPERATION Stainless Steel H35-N Plasma / N Shield 200A Cutting O-Ring Color: Grey/Blue (see page 4-14) 120907 120727 120726 120725 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Cutting Material work Height Pierce Speed Thickness distance Factor Delay Voltage Plasma Shield...
- Page 135 OPERATION Aluminum H35-N Plasma / N Shield 200A Cutting O-Ring Color: White/Blue (see page 4-14) 120907 120762 120761 120760 Test Preflow Rate (%) Test Cutflow Rate (%) Torch-to- Pierce Cutting Material work Height Pierce Speed Thickness distance Factor Delay Voltage Plasma Shield Plasma...
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Page 136: Changing Consumable Parts
OPERATION Changing Consumable Parts WARNING The HD4070 power supply is designed to go into an idle mode if the retaining cap is removed. However, DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE! Always disconnect power to the power supply before inspecting or changing torch consumable parts. Remove consumables Check the consumable parts daily for wear before cutting. -
Page 137: Inspect Consumables
OPERATION Inspect consumables Part Check For Action Erosion, missing material Replace cap Cracks Replace cap Burned Replace cap Nozzle Erosion or missing material Replace nozzle* Blocked gas holes Replace nozzle* Center hole 1. Must be round Replace nozzle if hole is no longer round* 2. -
Page 138: Inspect Torch
OPERATION Inspect torch Water return Plasma gas bullet bullet connector connector Water Tube Water in bullet connector Plasma vent bullet Current connector Ring Pilot arc Shield gas bullet connector bullet connector Inspect Check For Action All Surfaces Dirt or debris Clean surfaces Erosion, missing material Replace torch... -
Page 139: Inspect Electrode Pit Depth
OPERATION Inspect electrode pit depth 004147 *NOTE: See Replace Torch Water Tube later in this section. Part Check For Action Electrode Center surface Wear Replace electrode if pit is deeper than 0.040 inch (1 mm)* *NOTE: Always replace the nozzle and electrode as a set. 4-32 HD4070 Instruction Manual... -
Page 140: Replace Torch Water Tube
Turn OFF all power to the HD4070 system. Remove consumables from torch. See page 4-23 Do not overtighten parts! Only tighten until mating parts are seated. Install new water tube Remove water tube Replace consumables see page- 4-15 Hypertherm 027347 Tool 4070.37 HD4070 Instruction Manual 4-33... -
Page 141: Common Cutting Faults
OPERATION Common Cutting Faults • Torch pilot arc will initiate, but will not transfer. Causes can be: 1. Work cable connection on the cutting table is not making good contact. 2. Malfunction in the HD4070 system. See Section 3. Torch-to-work distance is too high. •... -
Page 142: Cutting Techniques
OPERATION Cutting Techniques How to get better cut quality In order to get the best cut quality, ensure the HD4070 plasma system is set up according to the Daily Start- Up procedure in this section. The 3 major components of cut quality are: cut angle, dross, and shape (flatness and smoothness) of the cut surface. - Page 143 OPERATION Dross conditions Dross can occur in the following ways: 1. Low-speed dross forms when the torch travel speed is too slow and the arc shoots ahead. It forms as a heavy, bubbly deposit at the bottom of the kerf and can be easily removed. Normally, increasing the speed will reduce the dross.
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Page 144: How To Get Longer Consumable Life
OPERATION How to get longer consumable life ® The HD4070 plasma system incorporates Hypertherm's patented LongLife process to extend the life of consumable parts. Full compliance with the LongLife operating procedures that follow, as well as the gas purity requirements listed earlier in this section, is necessary in order to optimize the useful life of consumable parts. -
Page 145: How To Get Better Pierces
Technical Questions Claims for defective merchandise -- All units shipped from Hypertherm undergo rigorous quality control testing. However, if your system does not function correctly: 1. Recheck all requirements and connections in Section 3, Installation. -
Page 146: Maintenance
Section 5 MAINTENANCE In this section: Introduction ..............................5-2 Routine Maintenance ............................5-2 HD4070 System Description ...........................5-3 Control and Signal Cables........................5-3 Power Supply Coolant System Servicing......................5-4 Torch Coolant Draining............................5-6 Power Supply Coolant Draining ........................5-6 Coolant System Filter and Strainer .........................5-7 Coolant Flow Test Procedure ..........................5-9 HD4070 Process Sequence..........................5-10 Initial Checks..............................5-12 Power Measurement ............................5-13... -
Page 147: Introduction
MAINTENANCE Introduction Hypertherm assumes that the service personnel performing the troubleshooting testing are high-level electronic service technicians who have worked with high-voltage electro-mechanical systems. Knowledge of final isolation troubleshooting techniques is also assumed. In addition to being technically qualified, maintenance personnel must perform all testing with safety in mind. -
Page 148: Hd4070 System Description
MAINTENANCE HD4070 System Description Control and Signal Cables Power Cable: Provides 120 VAC to the Gas Console. Signal Cable: Provides process and status signals between the Power Supply and the Gas Console. 4070.28 Power Cable: Provides 120 VAC to the Ignition Console and control power for the off-valve assembly. -
Page 149: Power Supply Coolant System Servicing
MAINTENANCE Power Supply Coolant System Servicing Check that the drain valve is closed. Add coolant to the power supply until the sight gage indicates full. Replace the filler cap. 4070.40A HD4070 Instruction Manual... - Page 150 MAINTENANCE Turn the power supply ON. Navigate to set-up screen 5. REPEAT PREVIOUS PROCESS PROCESS SETUP LANGUAGE UNITS ˜ ESPANOL INCH/PSI ENGLISH NOTE: Torch 2 must be turned off (Not installed) FRANÇAIS ITALIANO METRIC/KPA When the system is configured for use with 1 torch.
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Page 151: Torch Coolant Draining
MAINTENANCE Torch Coolant Draining If the torch needs to be changed or transported, follow this procedure for draining the torch coolant from the torch and torch leads. Coolant should be drained from the system every 6 months. See Preventative Maintenance Schedule at the back of this section. -
Page 152: Coolant System Filter And Strainer
MAINTENANCE Coolant System Filter and Strainer Filter replacement 1. Disconnect all power to the HD4070 system. 2. Remove cover. 3. Remove and discard filter element. 4. Install new filter element 027664. 5. Re-install cover. HD4070 Instruction Manual... - Page 153 MAINTENANCE Pump strainer cleaning 1. Disconnect all power to the HD4070 system. 2. Drain coolant. See Power Supply Coolant Draining previous page. 3. Remove nut. 4. Remove and clean strainer with a mild soap and water solution. 5. Re-insert strainer. 6.
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Page 154: Coolant Flow Test Procedure
MAINTENANCE Coolant Flow Test Procedure 1. Turn HD4070 main power OFF. 2. Remove the return coolant hose (red) from the back of the power supply for the torch you want to check. See page 3A-4 or 3B-4 for hose location. 3. -
Page 155: Hd4070 Process Sequence
MAINTENANCE HD4070 Process Sequence Turn power supply ON • Display panel cycles through Setup Screens 1 and 2. • Setup Screen 3 is displayed. State 0 – Idle • Pump, Fan and Contactor OFF. • Lifter sent to home position if present. State 1 –... - Page 156 MAINTENANCE HD4070 Process Sequence – continued Continued from previous page State 5 – Pilot Arc • Gas console set to state 2 (ignitors ON). • Waits for current. • Pilot arc will timeout in 1 second if no current is detected. Pilot Current Detected State 6 –...
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Page 157: Initial Checks
MAINTENANCE Initial Checks Before tracking down specific problems, do a visual check and verify proper voltages are present at the power source, transformers and power distribution board. WARNING SHOCK HAZARD: Always use caution when servicing a power supply when plugged in and the covers are removed. -
Page 158: Power Measurement
MAINTENANCE Power Measurement 5. Measure the voltage between the W, V and U terminals of TB1 located on the right side of the power supply. See figure above. Also refer to the wiring diagram in Section 7, if required. The voltage between any 2 of the 3 terminals should be equal to the supply voltage. -
Page 159: Service Display Screens
MAINTENANCE Service Display Screens VOLTAGE: 000.0 V AMPERAGE: 000.0 AMPS STARTS: 0000000 POWER CHECK: 000.0 VAC INLET GAS 1: 000.0 PSI ERRORS: 0000000 INLET GAS 2: 000.0 PSI HOURS: 0000000 INLET GAS 3: 000.0 PSI STATE: 0 DATA BASE REV: 0 NEXT SOFTWARE REV: 0 Screen 17 is display only. -
Page 160: Error Codes
MAINTENANCE Error Codes HD4070 Error codes Error codes are displayed at the top of screen 13. The system will clear some error codes and will then return to the READY state. Other error codes require the operator to turn off the power supply, perform corrective maintenance and then turn ON the power supply again. - Page 161 ID #'s 0-50: The sytem will continue to operate when a warning message is displayed. To clear the message, adjustments may have to be made ID # Error Code or Message Description Corrective action Supply gas pressure is 10psi (0.34 bar) under required specification. System LOW PRESSURE WARNING Adjust supply gas pressure will continue to run.
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Page 162: Electrical Pc Boards And Power Supplies
ID #'s 51-65: Adjustments or changes are required before cutting can continue. ID #'s 66-80: Operation will stop after a short delay. The system will not function until the fault is corrected. ID #'s 81 & > Operation is stopped immediately. A reset button is displayed. The fault must be corrected and reset button pressed before the sytem will operate. ID # Error Code or Message Description... - Page 163 ID # Error Code or Message Description Corrective action (1) If the plasma interface board LED D17 is ON (indicating coolant flow), check for continuity across coolant flow sensor output connections. If there is continuity across the sensor output connections, replace the sensor. If LED D17 is ON and there is no continuity across the sensor output connections, When the power supply is turned on, the system checks operation of the troubleshoot the plasma interface board.
- Page 164 ID # Error Code or Message Description Corrective action (1) Check all cables from relay PCB to motor valves. (2) Check LED for relay PCB#1, shown later in this section. (3) Check relay PCB#1 incoming signal. (4) Check relay PCB#1 output signal. (5) Switch cables to a working MV;...
- Page 165 041706 041511 THC CONT PCB THC MTR DRV PCB (THC1) (THC1) 041626 PS CPU 041613 BREAKOUT PCB (PCB6) 041509 THC 130W PS (THC1) 041664 PC-104 041610 041594 PWR DIST PCB 041657 RELAY PCB (PCB4) GAS CONS CONT PCB 041594 RELAY PCB 041616 PLZ INT PCB (PCB5)
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Page 166: Plasma Interface Board Pcb5 Status Indicators
MAINTENANCE Plasma interface board PCB5- status indicators 041 616R A .eps Plasma Interface PC Board LED List Signal Name Function +24 Volts Power indicator, Always ON Ohmic Contact Illuminates when torch is in contact with plate Transfer Illuminates when arc transfers to plate Shield #1 Relay for THC #1. -
Page 167: Breakout Board Pcb6 Status Indicators
MAINTENANCE Breakout board PCB6- status indicators J 13 J 17 J 16 J 21 0 4 1613R A .eps 5-22 HD4070 Instruction Manual... - Page 168 MAINTENANCE Breakout board LED list Signal Name Function THC1 Tx Transmits information to THC1 THC2 Tx Transmits information to THC2 THC1 Rx Receives information from THC1 THC2 Rx Receives information from THC2 Watchdog Illuminated when no errors are detected CNC Tx Transmits information to CNC Gas Tx Transmits information to gas console...
- Page 169 MAINTENANCE Breakout board LEDN list – continued LEDN3 Signal Name Function LEDN3-1 Not Used — LEDN3-2 Plasma int spare input 2 — LEDN3-3 Coolant temp switch Coolant temperature is with-in normal operating range LEDN3-4 Coolant flow switch Coolant flow is with-in normal operating range LEDN3-5 Transfer sense Arc transfer detected...
- Page 170 MAINTENANCE LEDN7 Signal Name Function LEDN7-1 CNC motion Sends start signal to THC LEDN7-2 Slave 80 Amp select — LEDN7-3 Slave 40 Amp select — LEDN7-4 Slave 20 Amp select — LEDN7-5 Slave 10 Amp select — LEDN7-6 Slave 1/10th current —...
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Page 171: Control Board Pcb3 Status Indicators
MAINTENANCE Control board PCB3- status indicators Control PC Board LED List Signal Description/ Function Chopper #1 Temp OK Interlocks OK, panels in place Transformer Temp OK Power indicator, +15 Volts Power indicator, -15 Volts DC Output ON, signals choppers to turn on Chopper #2 Temp OK Current #1, current detected from chopper #1 Current #2, current detected from chopper #2... -
Page 172: Power Distribution Board Pcb4 Status Indicators
MAINTENANCE Power distribution board PCB4- status indicators 04 1610R A .eps Power Distribution PC Board LED List Signal Description/ Function 240 VAC Out Power indicator 120 VAC Out Power indicator 24 VAC Out Power indicator Notes: When circuit breaker CB1 is switched ON, LEDs D3-D5 will illuminate and stay illuminated. To measure voltages at the power distribution board, find fuses F1, F2 and F3. -
Page 173: Start Circuit Assembly Board Pcb2
MAINTENANCE Start circuit assembly board PCB2 IGBT Output +15 VDC 041554R A .eps Pilot Arc Control PC Board LED List Signal Description/ Function Pilot Arc Active +15 Volts power indicator Operation The start circuit is a high-speed switch that quickly transfers the pilot arc current from the pilot arc load to the work load. -
Page 174: Start Circuit Functional Schematic
MAINTENANCE Start circuit functional schematic Plasma Power Supply Chopper Choke Power Resistor ALEL Caps Cutting IGBT Control Diode Logic Start Circuit Pilot Start circuit troubleshooting WARNING SHOCK HAZARD: Always use caution when servicing a power supply when plugged in and the covers are removed. -
Page 175: Gas Console Relay Board Pcb1
MAINTENANCE Gas console relay board PCB1 D 2 2 D 2 3 D 25 D 27 D 2 8 D 1 0 D 1 1 D 1 2 D 1 3 D 1 4 D 1 5 D 1 6 D 1 7 D 1 8 D 19... - Page 176 MAINTENANCE Gas console relay PC board #1: LED sequences during operation - continued H35/N Cutting Sequence H35 Plasma Shield H35 Plasma Plasma Shield LED Name Function Preflow Preflow Cutflow Cutflow Cutflow +12 VDC Power indicator SV11 Plasma operate SV18 Shield operate SV14 Plasma preflow SV12...
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Page 177: Gas Console Relay Board Pcb3
MAINTENANCE Gas console relay board PCB3 D1 0 D 1 1 D1 2 D1 3 D1 4 D1 5 D 1 6 D 1 7 D 1 8 D1 9 D 2 0 D 2 1 D 2 2 D 2 3 D 24 D 25 D 26... - Page 178 MAINTENANCE Gas console relay PC board #1: LED sequences during operation - continued H35/N Cutting Sequence H35 Plasma Shield H35 Plasma Plasma Shield LED Name Function Preflow Preflow Cutflow Cutflow Cutflow +12 VDC Power indicator Shield operate - N /Air MV6 Open Shield preflow N /Air...
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Page 179: Gas Console Control Board Pcb2
MAINTENANCE Gas console control board PCB2 U23 LCD Display Shows the following: – Revision number – Inlet gas pressures – Current operating state number – Error messages – Motor valve position – Control voltage Always ON D11 D12 D13 041657.eps Gas console control PC board LED list Signal Name Function... -
Page 180: Leak Test Procedure
MAINTENANCE Leak Test Procedure 1. Locate the off-valve assembly. It will be within 4 feet (1.2 meters) of the torch receptacle. See Installation section page 3-11. 2. Disconnect the power cable to the off-valve assembly. See Installation section page 3A-10 or 3B-14. 3. -
Page 181: Chopper Module Test Procedure
MAINTENANCE Chopper Module Test Procedure WARNING SHOCK HAZARD: Use extreme care when working near the chopper modules. The large electrolytic capacitor(s) (blue-cased cylinder(s)) store large amounts of energy in the form of electric voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks. - Page 182 MAINTENANCE 6. If a chopper does not output +311 VDC, check to see if LED1 logic power light is illuminated. If LED1 is extinguished, check if 120V is going to JP6. If there is no 120V at JP6, check wiring back to power distribution board.
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Page 183: Phase Loss Detection Board Pcb1 Status Indicators And Operation
MAINTENANCE Phase loss detection board PCB1 status indicators and operation Operation The phase-loss detection circuit checks the incoming voltage and verifies that the voltages between the 3-wire inputs are within +/- 15% of each other. • After contactor CON1 closes, opto-coupler U on PCB1 is activated, shorting pins 1&2 of PL1 together and illuminating LED1. -
Page 184: Thc Routine Maintenance
MAINTENANCE THC ROUTINE MAINTENANCE Every 3 months complete the following: WARNING ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover. Press the power supply OFF (0) pushbutton switch and set the line disconnect switch to OFF. In the U.S., use a "lock-out and tag-out"... - Page 185 MAINTENANCE VIEW 1 Retaining Block Left Side Cover Screws (5) Left Side Cover Retaining Block VIEW 2 Retainer Sealing Band VIEW 3 Figure 5-1 Sealing Band – Remove 5-40 HD4070 Instruction Manual...
- Page 186 MAINTENANCE Sealing band – Install (Figure 5-2) 1. Install the new band from the back of the lifter (View 1). 2. Route the band through the top and bottom slots. Make sure the band sits in the channel (View 1). 3.
- Page 187 MAINTENANCE VIEW 2 Retainer Retaining Block VIEW 3 Left Side Cover Screws (5) Left Side Cover Figure 5-2 Sealing Band - Install (2 of 2) 5-42 HD4070 Instruction Manual...
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Page 188: Thc Motor Drive Board
MAINTENANCE THC motor drive board Status Lights During Normal Power-up The following LEDs are located on the motor drive PCB inside the control box. THC #1 power supply (see next page) THC #2 THC #2 power supply motor drive PCB Signal Function Function Drive Active... -
Page 189: Thc Power Supply
MAINTENANCE THC power supply The following connections are located on the power supply board located inside the control box. See figure and table below. See control box figure on previous page for location. 4 PF 3 S- PWR FAIL 2 S+ 1 N/C 041509 15,16 +5V... -
Page 190: Thc Control Board
MAINTENANCE THC control board – status lights during normal power-up The following LEDs are located on the control board inside the control box. See figure below for location. LED Signal Function Status LED Signal Function Status D9 - cycle start input D41 - +24v D10 - auto height on/off D42 - -12v... - Page 191 RS-422 MACHINE INTERFACE PENDANT PLASMA INTERFACE MACHINE INTERFACE INPUTS J10 J11 PLASMA INTERFACE INPUTS 10 11 12 13 14 18 19 20 21 22 EXT INTER- LOCK OK MACHINE INTERFACE OUTPUTS 27 28 29 30 PLASMA INTERFACE OUTPUTS 34 35 36 37 ARC VOLTAGE ADJUST 041706...
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Page 192: Preventive Maintenance Schedule
Date Completed: Service 1________ Service 2________ Drain coolant system -- See Instruction Manual, Maintenance section Replace coolant filter element - See Instruction Manual, Maintenance section Replace coolant with genuine Hypertherm coolant Annually: Date Completed:________ Replace pilot arc relay Replace main contactor... -
Page 193: Parts List
Section 6 PARTS LIST In this section: Power Supply ..............................6-2 Front Panel Outside..........................6-2 Left Side Interior .............................6-3 Right Side Interior...........................6-4 PC Boards and Interlock Switches ......................6-5 I/O Panel..............................6-6 Control Box: Shown with Parts for Two THC option ................6-7 Cooling System ............................6-8 Ignition Console .............................6-9 Gas Console - 1 of 2 .............................6-10 Gas Console - 2 of 2 .............................6-11... -
Page 194: Power Supply
PARTS LIST Power Supply Front panel outside FP-06 Warning: The HD4070 system can only support 1 touch screen display, either local or remote. The installation of 2 displays on 1 system may cause malfunctions or damage. Part Item Number Description Designator Qty. -
Page 195: Left Side Interior
PARTS LIST Power Supply Left side interior Part Item Number Description Designator Qty. 041605 Control Board PCB3 108075 Fuse: 6A 250V 109004 Current Sensor 109004 Current Sensor 008317 125Amp Fuse F1,F2 003149 Relay 120VAC 003149 Relay 120VAC 129568 20kW Chopper with Fan 129568 20kW Chopper with Fan 027080... -
Page 196: Right Side Interior
PARTS LIST Power Supply Right side interior Part Item Number Description Designator Qty. 129264 Start Circuit Board Assembly PCB2 129631 Power Input Filter EMI Filter 029316 Input Power Block 003201 Main Contactor CON1 014239 Control Transformer 041610 Power Distribution Board PCB4 108075 Fuse: 6A 250V... -
Page 197: Pc Boards And Interlock Switches
PARTS LIST Power Supply PC boards and interlock switches Part Item Number Description Designator Qty. 041616 Plasma Interface Board PCB5 108075 Fuse: 6A 250V 041613 Breakout Board PCB6 005100 Door Limit Switch HD4070 Instruction Manual... -
Page 198: I/O Panel
PARTS LIST Power Supply I/O panel Part Item Number Description Designator Qty. 009622 Resistor: 10-OHM 50W 009827 Resistor: 100-OHM 50W 109205 Resistor: 20-OHM 50W 109204 Diode:600V 30A Dual 003142 Relay:120VAC 009015 Resistor: 10K-OHM 10W 009912 Capacitor: 350µf 450WV 109201 Current Sensor: Hall 500A = 4V HD4070 Instruction Manual... - Page 199 PARTS LIST Power Supply Control box: Shown with parts for 2-THC option 4070.56 Part Item Number Description Designator Qty. 041511 THC Motor Drive PCB THC1 041511 THC Motor Drive PCB THC2 128407 THC Control Board Replacement Kit THC1 027647 Floppy Drive 041509 THC Power Supply THC1...
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Page 200: Cooling System
PARTS LIST Power Supply Cooling system 14 15 4070.40c Part Item Number Description Designator Qty. 129485 Solenoid Valve SA W/ Temp Switch TMP1 SV1, SV2, SV3 1 006113 Check Valve: 3/8 FTP CHV5 024341 Hose assembly: 3/8, Blue, 10 Inches 129620 Flow Switch Assembly 011084... -
Page 201: Ignition Console
PARTS LIST Ignition Console 4070.38 Part Item Number Description Designator Qty. 078088 Ignition Console 009040 Filter: 3A, 3W 128510 Kit: Filter Capacitor Replacement 129616 Inductor: Ignition Console 027648 Ignition Module 041619 PCB Assembly: Ignition Console Interface HD4070 Instruction Manual... -
Page 202: Gas Console - 1 Of 2
PARTS LIST Gas Console – 1 of 2 Part Item Number Description Designator Qty. 078085 Gas Console 041657 Control Board PCB2 041594 Relay Board PCB1 041594 Relay Board PCB3 129633 Green Power Light 129629 Ventilation Fan 6-10 HD4070 Instruction Manual... -
Page 203: Gas Console - 2 Of 2
PARTS LIST Gas Console – 2 of 2 SV19 SV19 SV13 SV13 SV16 SV16 SV22 SV22 SV12 SV12 SV14 SV14 SV15 SV15 SV17 SV17 SV21 SV21 SV11 SV11 SV18 SV18 SV20 SV20 Part Item Number Description Designator Qty. 006117 Output Solenoid Valves SV23,24,25,26 129496 Pressure Transducers... -
Page 204: Hd4070 Torch
PARTS LIST HD4070 Torch Entire torch assemblies including leads, torch and consumables Part Number Description 128500 Torch with 6' (2 m) Leads 128501 Torch with 10' (3 m) Leads 128502 Torch with 15' (4.5 m) Leads Lead assemblies, torch and consumables Part Item Number... -
Page 205: Consumable Configurations
Consumable Configurations... -
Page 206: Consumable Parts Kit
PARTS LIST Consumable Parts Kit Part Number Description Qty. 128520 Consumable Parts Kit 001067 Box: Gray Plastic 004663 Nozzle Wrench 027102 Electrode Wrench 027347 Water Tube Replacement Tool 120025 Water Tube 026009 O-ring, .208 x .070 044028 O-ring, 1.364 x .070 027012 Lubricant: Silicon 2-Oz Tube 120690... -
Page 207: Off-Valve Assembly
PARTS LIST Off-Valve Assembly – 129563 Recommended Spare Parts Power supply Part Number Description Designator Qty. 129632 White DC Power Light 129633 Green AC Power Light 027080 Chopper Fan FAN1, FAN2 129568 20kW Chopper with Fan CH1, CH2 008317 125A Fuse F1, F2 041610 Power Distribution Board... - Page 208 PARTS LIST Recommended Spare Parts (continued) Gas console Part Number Description Designator Qty. 041657 Control Board PCB2 041594 Relay Board PCB1 Cooling system Part Number Description Designator Qty. 129485 Solenoid Valve SA with Temp Switch TMP1 SV1, SV2, SV3 027664 Filter Element 129489 Flow Switch Assembly...
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Page 209: Integrated Command Thc
PARTS LIST Integrated Command THC X-Y lifter assembly (Located under seal band) (inside) Second limit switch is located under driving block Torch mounting block kit mounting location Item Part No. Description Qty. 128606 X-Y lifter assembly 027898 Motor and encoder assembly 027550 Brake, power off 027903... -
Page 210: X-Y Lifter Torch Mounting Block Kit
PARTS LIST Integrated Command THC x-y lifter torch mounting block kit THC.54 4070.EPS Item Part No. Description Qty. 128279 Kit, Torch Mounting Block, 2-Inch Diameter Torch 004775 Spacer, Command THC Mounting Block 075127 Socket Cap, 1/4-20 X 1-1/2 Inch Hex BTN S/Z 075583 Socket Cap, 1/4-20 X 1-3/4 inch hex SST 120597... -
Page 211: X-Y Lifter Breakaway Kit - Optional
PARTS LIST Integrated Command THC x-y lifter breakaway kit – optional Spacer and hex screws are not used if breakaway is installed. Torch Mounting Block Kit THC.41 Customer Supplied Hex screws (2) 8-32 X 1-1/2 inch (4 mm x 40 mm) Item Part No. -
Page 212: Ohmic Contact Wire
PARTS LIST Integrated Command THC Ohmic contact wire Part Item Number Description Length Quantity 123542 Wire, Ohmic Contact 10 ft./3 m 123543 20 ft./6.1 m 123544 25 ft./7.6 m 123545 30 ft./9.1 m 123546 40 ft./12.2 m 123547 50 ft./15.2 m 123548 75 ft./23 m 123549... - Page 213 PARTS LIST HD4070 - Least Replacement Units Part Number Descriptions 120651 torch head with no consumables Power Supply 129568 20 kW chopper with fan 027080 Chopper Cooling Fan 041564 Phase Loss Detection PCB 129264 Pilot arc controller board (Start Circuit Board Assembly) 129566 System I/O board / surge injection 041594...
- Page 214 PARTS LIST 027664 Filter Element 006113 Check Valve :3/8 FTP 129489 flow switch SA 011084 Sight Glass 027632 Radiator 129619 pump motor assembly 078085 Gas Console 129633 Green Power Light 129629 Gas Vent Fan 129496 Pressure transducer 129546 Motor valve subassembly 041657 Gas console control board 041594...
- Page 215 PARTS LIST 024268 50 ft. (15.2 m) 024269 75 ft. (23 m) 024270 100 ft. (30.5 m) 024460 150 ft. (45.7 m) PILOT ARC LEAD ASSEMBLY: PS TO RHF 123409 10 ft. (3 m) 123410 20 ft. (6.1 m) 123411 25 ft.
- Page 216 PARTS LIST 123434 75 ft. (23 m) 123435 100 ft. (30.5 m) 123436 150 ft. (45.7 m) POWER CABLE: PS TO GAS CONSOLE 123419 10 ft. (3 m) 123420 20 ft. (6.1 m) 123421 25 ft. (7.6 m) 123422 30 ft. (9.1 m) 123423 40 ft.
- Page 217 PARTS LIST 128459 100 ft. (30.5 m) 128460 150 ft. (45.7 m) THC LIFTER I/O CABLE 123209 5 ft. (1.5 m) 123210 10 ft. (3 m) 123211 15 ft. (4.6 m) 123212 20 ft. (6.1 m) 123022 25 ft. (7.6 m) 123213 30 ft.
- Page 218 PARTS LIST SUPPLY GAS REGULATOR KITS 128544 2-Stage Oxygen 128545 2-Stage Nitrogen 128546 2-Stage Hydrogen (H5, H35 and Methane) 128547 2-Stage Air 128458 1-Stage (for use with cryogenic liquid Nitrogen or Oxygen) SUPPLY GAS HOSES Oxygen - 3/8" Blue RH "B" 024204 15 ft.
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Page 219: Wiring Diagrams
Section 7 WIRING DIAGRAMS Introduction This section contains the wiring diagrams for the HD4070 system. When tracing a signal path or referencing with the Parts List or Troubleshooting sections, please be aware of the following format to assist you in understanding the wiring diagrams' organization: •... - Page 220 Push Button, Battery Fuse Normally Open Receptacle Ground Clamp Cap, polarized Relay, Coil Ground, Chassis Cap, non-polarized Relay, Normally Closed Ground, Earth Cap, feed-thru Relay, Normally Open IGBT Circuit breaker Relay, Solid State, AC Inductor Coax shield Relay, Solid State, DC Current Sensor Relay, Solid State, Dry Light...
- Page 221 Time Delay Closed, Switch, Level, Torch Symbols NO/Off Normally Closed Switch, Pressure, Transformer Normally Closed Electrode Switch, Pressure, Transformer, Air Core Normally Open Switch, 1 Pole, 1 Throw Nozzle Transformer Coil Switch, 1 Pole, 2 Throw Triac Switch, 1 Pole, 1 Throw, Shield Center Off VAC Source...
- Page 222 POWER SUPPLY TEMP SW. FILTER CHV1 PUMP SHUT OFF VALVE TCH1 TCH2 HD4070 COOLING SYSTEM SCHEMATIC 013334 SHEET 1 OF 1...
- Page 223 SHEET 2-B2 INPUT POWER FROM FACILITY SHEET 2-D1 SHEET 2-D4 SHEET 2-B2 SHEET SHEET 2-D4 2-A3 SHEET 2-D1 (-)NEGATIVE CH1-9 CH1-6 TSW1 CHOPPER SA 129160 TSW2 SURGE INJECTION EMI FILTER 109199 CHOPPER SA CON1 129160 TSW2 TCH1 TCH2 LINE LINE SHOWN WIRED FOR 480V CH2-9 CH2-6...
- Page 224 PCB4 POWER DISTRIBUTION SHEET SHEET 041610 P4.1 1-B4 SHEET SHEET 1-B1 P5.7 FAN2 FAN3 SHEET SHEET SHIELD #1 240 VAC IN 1-D4 SHIELD #2 J4.10 SHEET SHEET 1-D1 P4.2 YEL 24VAC RED/BLK RED/BLK 25 YEL 120 VAC IN WORK 26 YEL/BLK RED 120VAC RED/BLK ELECTRODE...
- Page 225 SHEET SHEET DC POWER SUPPLY 2-C2 FLOPPY DRIVE 041626 RED/BLK RED/BLK OPTIONAL POWER SUPPLY THC1 P106 041509 CN2-3 123467 SHEET SHEET MASTER POWER SUPPLY (INTERNAL) 2-A3 CPU PCB 041620 123468 SHEET SHEET PLASMA INTERACE PCB 2-B1 SHEET SHEET 2-C1 OPTIONAL CONTROL PCB OPTIONAL MOTOR PCB 123493 123474...
- Page 226 INPUT POWER INPUT POWER FROM FACILITY FROM FACILITY WIRED FOR 480V 60HZ WIRED FOR 240V 60HZ TSW1 TSW1 A3 0 EMI FILTER EMI FILTER B3 0 CON1 CON1 B1 0 C3 0 LINE LINE LOAD LOAD INPUT POWER FROM FACILITY INPUT POWER FROM FACILITY WIRED FOR 200V 50-60HZ...
- Page 227 INPUT POWER INPUT POWER FROM FACILITY FROM FACILITY WIRED FOR 440V 50-60HZ WIRED FOR 220V 50-60HZ TSW1 TSW1 A3 0 A1 0 EMI FILTER EMI FILTER B3 0 CON1 CON1 B1 0 LINE LINE LINE LINE LOAD LOAD LOAD LOAD INPUT POWER FROM FACILITY WIRED FOR 600V 60HZ...
- Page 228 SV27 SV28 SV11 SV29 SV23 SV12 CHK1 SV30 SV13 PLASMA OPERATE SV31 SV14 SV24 OFF VALVE #1 TORCH #1 SV15 129563 128342 CHK2 SV16 PLASMA PREFLOW SV32 SV17 SV10 SV25 SV33 SV18 CHK3 SV19 SV34 SHIELD OPERATE SV35 SV20 SV26 SV36 SV21 CHK4...
- Page 229 SHEET 041594 PCB 3-D4 PCB 1 RED/BLK OUTPUT 3 OUTPUT ENABLE OUT 1 RED/BLK OUTPUT 4 RED/BLK OUT 2 OUTPUT 2 OUT 3 RED/BLK OUTPUT 5 RED/BLK OUTPUT 1 OUT 4 SV10 OUT 5 RED/BLK OUTPUT 6 RED/BLK OUT 6 RED/BLK 120VAC OUT 7...
- Page 230 SHEET 3-D1 041594 PCB SHEET 4-B1 PCB3 OUTPUT ENABLE OUTPUT 3 CLOSE VALVE OUT 1 SHEET 4-B1 OUT 2 OUTPUT 4 OPEN VALVE OUTPUT 2 CLOSE VALVE OUT 3 OUT 4 OUTPUT 5 OPEN VALVE RED/BLK IGNITOR OUTPUT 1 OUT 5 SHIELD PREFLOW SV31 RED/BLK (J3-1) SHIELD CUTFLOW SV30...
- Page 231 SHEET SHEET 2-D1 1-D1 OUTPUT ENABLE OUTPUT ENABLE P8-2 P4-2 P6-2 OUT 26 OUT 1 OUT 27 OUT 2 OUT 28 OUT 3 041657 PCB PCB 2 OUT 29 OUT 4 OUT 30 OUT 5 OUT 31 OUT 6 OUT 32 OUT 7 OUT 33 OUT 8...
- Page 232 SHEET SHEET 041327 PCB 3-2B 2-B3 PCB 11 SPAN INPUT OFFSET -2V REF SHEET SHEET 041327 PCB 2-C3 3-2B PCB 10 SPAN INPUT OFFSET -2V REF SHEET SHEET 041327 PCB 2-C3 3-2C PCB 9 SPAN INPUT OFFSET -2V REF SHEET SHEET 041327 PCB 3-2C...
- Page 233 SHARP EDGES. BREAK SHARP EDGES IF SHARP EDGES. BREAK SHARP EDGES IF SCALE SCALE MODEL MODEL SHEET SHEET FROM HYPERTHERM, INC. FROM HYPERTHERM, INC. 1 OF 1 1 OF 1 NECESSARY WITH CHAMFER OR RADIUS .015. NECESSARY WITH CHAMFER OR RADIUS .015. 7-27...
- Page 234 NOTES: 1. CABLES AND HOSES ARE AVAILABLE IN MULTIPLE LENGTHS. NUMBERS SHOWN ARE OF SOURCE DRAWING. THC LIFTER #1 LIFTER INTERFACE 123022 POWER SUPPLY MOTOR DRIVE 123020 ASSEMBLY PART NUMBER OHMIC CONTACT 123542 128433 ASSEMBLY PART NUMBER PILOT ARC 123409 078135 200V, NO THC, NO DISPLAY IGNITION CONSOLE #1...
- Page 235 129563 SHIELD PREFLOW SV31 IF USED AS OFF VALVE #1 SV36 IF USED AS OFF VALVE #2 RED/BLK SHIELD CUTFLOW SV30 IF USED AS OFF VALVE #1 RED/BLK SV35 IF USED AS OFF VALVE #2 RED/BLK PLASMA PREFLOW SV28 IF USED AS OFF VALVE #1 SV33 IF USED AS OFF VALVE #2 RED/BLK PLASMA CUTFLOW...
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Page 236: Appendix A System Grounding
Appendix A SYSTEM GROUNDING System Grounding Requirements The plasma system must be grounded for safety reasons and to suppress EMI: • Safety The entire system—power supply, accessory enclosures, and worktable—must be grounded to protect it and the operator from a ground fault. The protective earth (PE) ground connections must be installed by a licensed electrician and conform to national or local codes. -
Page 237: Work Table Grounding
The customer must furnish all conductors for equipment grounding. Grounding conductors may be purchased through Hypertherm in any length specified by the customer (Part No. 047058). The conductor may also be purchased locally, using a minimum 8 AWG UL Type MTW cable (USA specification) or the appropriate cable specified by national and local codes. - Page 238 APPENDIX A – SYSTEM GROUNDING Plasma Power Supply Ignition Console (PE) Ferrite Choke (PE) Power Cord Ground Work Table Gas Console (PE) Supplementary Grounding Rod Other Equipment receiving power from the plasma power supply (PE) Figure a-1 Recommended Ground Connection Configuration Note: Configuration may vary for each installation and may require a different ground scheme.
- Page 239 APPENDIX A – SYSTEM GROUNDING Other Equipment receiving power from the plasma power supply (PE) Gas Console (PE) Plasma Power Supply Ignition Console Ferrite Choke (PE) (PE) Power Cord Ground Work Table Supplementary Grounding Rod Figure a-2 Alternate Ground Connection Configuration The preferred cable routing for this configuration is as shown, but it is acceptable to “daisy-chain”...
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Page 240: Benzotriazole Safety Data
Appendix B PROPYLENE GLYCOL SAFETY DATA BENZOTRIAZOLE SAFETY DATA In this appendix: Propylene Glycol Safety Data Section 1 Chemical Product and Company Identification ................b-2 Section 2 Information on Ingredients ......................b-2 Section 3 Hazards Identification........................b-2 Section 4 First Aid Measures ........................b-3 Section 5 Fire Fighting Measures .........................b-3 Section 6 Accidental Release Measures.......................b-3 Section 7 Handling and Storage ........................b-3... - Page 241 HD4070 Instruction Manual...
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- Page 245 % of Propylene Glycol Figure b-1 Freezing Point of Propylene Glycol Solution HD4070 Instruction Manual...
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Page 250: Appendix C Gas Regulators
Appendix C GAS REGULATORS In this appendix: Gas Regulators ...............................c-2 HD4070 Instruction Manual... - Page 251 Use a high-quality, 2-stage, gas regulator to maintain consistent gas supply pressure from high pressure gas cylinders. The high-quality gas regulators listed below are available from Hypertherm and meet U.S. Compressed Gas Association (CGA) specifications. In other countries, select gas regulators that conform to national or local codes.
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Page 252: Appendix D Service Screen (#18) Status Table
Appendix D SERVICE SCREEN (#18) STATUS TABLE In this appendix: Input / Output Status Table..........................d-2 HD4070 Instruction Manual... - Page 253 APPENDIX D – SERVICE SCREEN STATUS TABLE Input / Output (Screen 18) Port 0 Base Addr 224H Output Port 1 Base Addr 225H Input Port 2 Base Addr 226H Output Bit 0 Select 160 amp Pin 47 Bit 0 Input power active Pin 31 Bit 0 DC output On/Off...
- Page 254 Appendix E INTEGRATED COMMAND THC SUPPLIMENTAL INFORMATION In this appendix: Command THC serial protocol........................e-2 CNC Serial Interface ............................e-4 HD4070 Instruction Manual...
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Page 255: Command Thc Serial Protocol
APPENDIX E – INTEGRATED COMMAND THC SERIAL PROTOCOL AND INTERFACE Command THC serial protocol Commands can be sent over a serial link to control the function of the torch height control. The interface is 4 wire RS422 on the Machine Interface Cable (pins (1) RX-, (20) RX+, (2) TX-, (21) TX+). The serial frame runs at 19200 baud, 8 data bits, 1 stop bit, and no parity. - Page 256 APPENDIX E – INTEGRATED COMMAND THC SERIAL PROTOCOL AND INTERFACE Application notes: To do manual movements Jog up, down and Step up, down the THC must be in manual mode (Automatic Voltage Control = 0). When the THC receives a Jog up or down command, it will move the torch up/down for 50 milliseconds. If a new command is not received after this time the motion will stop.
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Page 257: Cnc Serial Interface
HD4070 then contact Hypertherm engineering directly to get the most up-to-date and detailed information. Hypertherm has already developed a low level DLL (dynamic linked library) that will provide the basic plasma system interface to any PC based controller. - Page 258 APPENDIX E – INTEGRATED COMMAND THC SERIAL PROTOCOL AND INTERFACE LAST_ERROR – get most recent error code Response Data – error code from Chris’s list of triaged warning/error conditions REMOTE_MODE – request a change to remote mode Response Data – (none) – respond with actual mode achieved. GET_STD_PROCS, GET_CUST_PROCS –...
- Page 259 APPENDIX E – INTEGRATED COMMAND THC SERIAL PROTOCOL AND INTERFACE GET_TORCH – determine currently selected torch Response Data – (number of active torch) number: 0=neither torch, 1=first torch, 2=second torch SET_TORCH1, SET_TORCH2 – select specified torch Comment – Power supply will not allow a torch change while cutting. Response Data –...
- Page 260 APPENDIX E – INTEGRATED COMMAND THC SERIAL PROTOCOL AND INTERFACE SET_GAS_FLOW_XX_n, (XX=PreCut, CuT, PreShield, SHield), (n=1,2) – set gas flow-rate of specified gas Comment – receipt of this command will terminate any gas-flow tests in progress Command Data – gas flow-rate as a percent of full, e.g. “50” means half-flow Response Data –...
- Page 261 The following are suggestions to allow a single CNC system to interface to multiple HD4070 plasma systems using the serial interface. Contact Hypertherm Engineering for more information. If the CNC controller is a PC based controller then possibly the simplest way would be to add an expansion I/O board with the correct number of RS422 serial ports.
- Page 262 Appendix F PC-104 STACK: JUMPER POSITIONS In this appendix: PC-104 Stack: Jumper Positions ........................f-2 HD4070 Instruction Manual...
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Page 263: Appendix Fpc-104 Stack: Jumper Positions
APPENDIX F – PC-104 STACK: JUMPER POSITIONS PC104 Stack: Jumper Positions CPU Board (B1) Jumper Block Position Jumper Jumper Block Position Jumper open jumper open open open jumper open 9,10 open jumper 11,12 jumper 13,14 jumper jumper 15,16 open open 17,18 jumper jumper... - Page 264 APPENDIX F – PC-104 STACK: JUMPER POSITIONS Flash Memory Board (B2) Jumper Block Position Jumper all open Dual Serial Board (B3) Jumper Block Position Jumper jumper all open all open all open all open open open open jumper 8,10 jumper jumper open jumper...
- Page 265 APPENDIX F – PC-104 STACK: JUMPER POSITIONS 48 Channel Digital I/O #2 (B5) Jumper Block Position Jumper jumper open open jumper open jumper open open jumper open 13,14 jumper all others open 2,3,4 6,7,8 Analog Board (B6) Jumper Block Position Jumper jumper open...
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