Hypertherm Hrt User manual

Duramax™ Retrofit Torch

HRT, HRTs, MRT

Operator Manual – 807190

Revision 1

Operator Manual

(P/N 807190)

Revision 1 – May 2011

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

email: [email protected]

Hypertherm, Powermax, and Duramax are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries.

Duramax™ Retrofit Torch

HRT, HRTs, MRT

Hypertherm, Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

603-643-3441 Tel (Main Office)

603-643-5352 Fax (All Departments)

[email protected] (Main Office Email)

800-643-9878 Tel (Technical Service)

[email protected] (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.ser[email protected] (Customer Service Email)

Hypertherm Automation

5 Technology Drive, Suite 300

West Lebanon, NH 03784 USA

603-298-7970 Tel

603-298-7977 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

D-63457 Hanau-Wolfgang, Deutschland

49 6181 58 2100 Tel

49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane

Media Centre

Annexe Block #A01-01

Singapore 349567, Republic of Singapore

65 6841 2489 Tel

65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit A, 5th Floor, Careri Building

432 West Huai Hai Road

Shanghai, 200052

PR China

86-21 5258 3330/1 Tel

86-21 5258 3332 Fax

Hypertherm Europe B.V.

Vaartveld 9

4704 SE

Roosendaal, Nederland

31 165 596907 Tel

31 165 596901 Fax

31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service)

00 800 4973 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building

2-1-1 Edobori, Nishi-ku

Osaka 550-0002 Japan

81 6 6225 1183 Tel

81 6 6225 1184 Fax

Hypertherm Brasil Ltda.

Avenida Doutor Renato de

Andrade Maia 350

Parque Renato Maia

CEP 07114-000

Guarulhos, SP Brasil

55 11 2409 2636 Tel

55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1,

Colonia Olivar de los Padres

Delegación Álvaro Obregón

México, D.F. C.P. 01780

52 55 5681 8109 Tel

52 55 5683 2127 Fax

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D,

1514 Woo-dong, Haeundae-gu, Busan

Korea, 612-889

82 51 747 0358 Tel

82 51 701 0358 Fax

03/08/11

9/10

Compliance Information EMC-1

Introduction

Hypertherm’s CE-marked equipment is built

in compliance with standard EN60974-10.

The equipment should be in stalled and used

in accordance with the information be low to

achieve elec tro mag net ic com pat i bil i ty.

The limits required by EN60974-10 may

not beadequate to com plete ly eliminate

interference whenthe affected equip ment

is in close proximity orhas a high degree of

sen sitivity. Insuch cases itmay be nec essary

to use other mea sures to furtherre duce

interference.

This cutting equipment is designed for use

onlyin an in dus tri al environment.

Installation and use

The user is responsible for installing and

usingtheplasma equipment according to the

manufacturer’s instructions. If elec tromagnet ic

disturbances are de tect ed then it shall be

the respon si bil i ty of the user to re solve the

situation withthe technical as sis tance of the

man u fac tur er. Insome cases this remedial

action may be as sim ple as earthing the

cuttingcircuit, see Earthingof Workpiece.

Inother cas es it could involve constructing an

electromag net ic screen enclosing the pow er

source and the work complete with associated

input filters. In all cases elec tro mag net ic

disturbanc es must be reduced to the point

where they are no longer trou ble some.

Assessment of area

Before installing the equipment the user

shall make an assessment of po ten tial

electromagnet ic problems in the sur round ing

area. The following shall be taken into account:

a. Other supply cables, control cables,

signalling and telephone ca bles; above,

below and adjacent to the cutting equipment.

b. Radio and television transmitters and

receivers.

c. Computer and other control equip ment.

d. Safety critical equipment, for example

guarding of industrial equipment.

e. Health of the people around, for example the

use of pacemakers and hear ing 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 com pat i ble. This may require ad di tion al

protection measures.

h. Time of day that cutting or other ac tiv i ties

are to be carried out.

The size of the sur round ing area to be

considered will depend on the structure of

the building and other activities that are taking

place. The surrounding area may ex tend

beyond the bound aries of the pre mises.

Methods of reducing

emissions

Mains supply

Cutting equipment must be con nect ed to the

mains supply according to the man u fac tur er’s

recom men da tions. If in ter fer ence occurs, it may

ELECTROMAGNETIC COMPATIBILITY EMC

9/10

EMC-2 Compliance Information

be necessary to take addi tional precautions

such as fil ter ing of the mains supply.

Consideration should be given to shield ing the

supply cable of per ma nent ly installed cutting

equip ment, in metallic conduit or equiv a lent.

Shielding should beelec tri cal ly continuous

through out its length. The shielding should

becon nect ed to the cutting mains supply

so that good electrical contact is maintained

between the conduit and the cutting pow er

source enclosure.

Maintenance of cutting equipment

The cutting equipment must be rou tine ly

maintained according to the man u fac tur er’s

recom men da tions. All ac cess and service doors

and covers should be closed and properly

fastened when the cutting equip ment is in

operation. The cutting equipment should not be

modified in any way except as set forth in and

in accordance with the manufacturer’s written

instructions. For example, the spark gaps of

arc striking and sta bi liz ing devices should be

adjusted and maintained according to the

manu fac tur er’s recommendations.

Cutting cables

The cutting cables should be kept as short

aspossible and should be po si tioned 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 com po nents

bonded to the workpiece will increase the risk

that the op er a tor could receive a shock by

touch ing these metallic compo nents and the

electrode (nozzle for laser heads) at the same

time. The op er a tor should be in su lat ed from all

such bonded metallic components.

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 ex-

ample, ship’s hull or building steel work, a

con nec tion bonding the work piece to earth

may reduce emis sions in some, but not all

instances. Careshould be takento prevent the

earthing ofthe work piece increasing the risk

of injury to users, or damage to other elec tri cal

equipment. Where necessary, the con nec tion

of the workpiece to earth should be made by

a direct connection to the work piece, but in

some countries where direct connection is not

permitted, the bonding should be achieved by

suit able capacitances se lect ed 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 com pe tent to

assess whether the chang es will in crease the

risk of injury, for example, by al low ing parallel

cutting cur rent return paths which may damage

the earth cir cuits of other equipment. Further

guid ance is provided in IEC 60974-9, Arc

Welding Equip ment, Part 9: Installation and

Use.

Screening and shielding

Selective screening and shielding of other

cables and equipment in the surrounding

area may alleviate problems of in ter ference.

Screening of the entire plas ma cutting

installation may be con sid ered for special

applications.

9/10

Compliance Information W-1

Attention

Genuine Hypertherm parts are the factory-

recommended replacement parts for your

Hypertherm system. Any damage or injury

caused by the use of other than genuine

Hypertherm parts may not be covered by the

Hypertherm warranty, and will constitute misuse

of the Hypertherm Product.

You are solely 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 for the specific periods of time

set forth herein and as follows: 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 Powermax brand 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,

and with respect to torch lifter assemblies

within a period of one (1) year from its date of

delivery to you, and with respect to laser heads

within a period of one (1) year from its date of

delivery to you, and with respect to Automation

products one (1) year from its date of delivery

to you, with the exception of the EDGE Pro

CNC and ArcGlide THC, which shall be within

a period of two (2) years from the date of

delivery to you.

This warranty shall not apply to any Powermax

brand power supplies that have been used with

phase converters. In addition, Hypertherm does

not warranty systems that have been damaged

as a result of poor power quality, whether from

phase converters or incoming line power. This

warranty shall not apply to any Product which

has been incorrectly installed, modified, or

otherwise damaged.

Hypertherm provides repair, replacement or

adjustment of the Product as the sole and

exclusive remedy, if and only if the warranty

set forth herein properly is invoked and

applies. 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 pre paid by

the customer. Hypertherm shall not be liable

for any repairs, replacement, or adjustments

of Products covered by this warranty, except

those made pursuant to this paragraph and

with Hypertherm’s prior written consent.

The warranty set forth 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.

WARRANTY

9/10

W-2 Compliance Information

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.

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 have the right to 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 in any event

no longer than fourteen (14) days after

learning of any action or threat of action), and

Hypertherm’s obligation to defend 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 direct, indirect, punitive

or exemplary damages (including but

not limited to lost profits) regardless of

whether such liability is based on breach

of contract, tort, strict liability, breach of

warranty, failure of essential purpose,

or otherwise, and even if advised of the

possibility of such damages.

National and local codes

National and local codes governing plumbing

and electrical installation shall take precedence

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.

Liability cap

In no event shall Hypertherm’s liability,

if any, whether such liability is based on

breach of contract, tort, strict liability,

breach of warranties, failure of essential

purpose or otherwise, for any claim,

action, suit or proceeding (whether in

court, arbitration, regulatory proceeding

or otherwise) arising out of or relating

to the use of the Products exceed in

the aggregate the amount paid for the

Products that gave rise to such claim.

Insurance

At all times you will have and maintain

insurance in such quantities and types, and

with coverage sufficient and appropriate to

defend and to hold Hypertherm harmless in the

event of any cause of action arising from the

use of the products.

WARRANTY

9/10

Compliance Information W-3

Transfer of rights

You may transfer any remaining rights you may

have hereunder only in connection with the

sale of all or substantially all of your assets or

capital stock to a successor in interest who

agrees to be bound by all of the terms and

conditions of this Warranty. Within thirty (30)

days before any such transfer occurs, you

agree to notify in writing Hypertherm, which

reserves the right of approval. Should you

fail timely to notify Hypertherm and seek its

approval as set forth herein, the Warranty set

forth herein shall be null and void and you will

have no further recourse against Hypertherm

under the Warranty or otherwise.

WARRANTY

9/10

W-4 Compliance Information

TABLE OF CONTENTS

Duramax Retrofit Torch Operator Manual xi

Electromagnetic compatibility .................................................................................................................. EMC-1

Warranty............................................................................................................................................................. W-1

Section 1

Specifications

Component weights .......................................................................................................................................... 1-2

Duramax HRT hand torch dimensions .......................................................................................................... 1-2

Duramax HRTs hand torch dimensions ........................................................................................................ 1-2

Duramax MRT full-length machine torch dimensions ................................................................................ 1-3

Duramax MRT without positioning sleeve (mini torch) .............................................................................. 1-3

Section 2

Torch Setup

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

Consumable life .................................................................................................................................................. 2-2

Hand torch setup ............................................................................................................................................... 2-3

Choose the hand torch consumables ................................................................................................ 2-3

Hand torch consumables ...................................................................................................................... 2-4

Install the hand torch consumables ..................................................................................................... 2-5

Machine torch setup.......................................................................................................................................... 2-6

Converting a Duramax retrofit machine torch into a mini torch .................................................... 2-7

Mount the torch ........................................................................................................................................ 2-9

Choose the machine torch consumables ........................................................................................2-12

Machine torch consumables ...............................................................................................................2-12

Install the machine torch consumables ............................................................................................2-15

Aligning the torch ..................................................................................................................................2-15

Torch installation ..............................................................................................................................................2-16

Section 3

Operation

Using the cut charts .......................................................................................................................................... 3-3

Estimated kerf-width compensation .................................................................................................... 3-3

100 amp mechanized shielded cutting for Powermax1650.......................................................... 3-6

85 amp mechanized shielded cutting for Powermax1650 ............................................................ 3-8

80 amp mechanized shielded cutting for Powermax1250/1650 ..............................................3-12

65 amp mechanized shielded cutting for Powermax1250/1650 ..............................................3-14

60 amp mechanized shielded cutting for Powermax1000/1250/1650 ...................................3-18

TABLE OF CONTENTS

xii Duramax Retrofit Torch Operator Manual

45 amp mechanized shielded cutting for Powermax1000/1250/1650 ...................................3-20

100 amp mechanized unshielded cutting for Powermax1650 ...................................................3-24

85 amp mechanized unshielded cutting for Powermax1650......................................................3-26

65 amp mechanized unshielded cutting for Powermax1250/1650 ..........................................3-30

45 amp mechanized unshielded cutting for Powermax1000/1250/1650 ..............................3-34

FineCut® consumables for Powermax1000/1250/1650 ............................................................3-38

Using the hand torch .......................................................................................................................................3-41

Operate the safety trigger ...................................................................................................................3-41

Hand torch cutting hints ......................................................................................................................3-42

Start a cut from the edge of the workpiece.....................................................................................3-43

Pierce a workpiece ................................................................................................................................3-44

Gouge a workpiece ..............................................................................................................................3-45

Common hand-cutting faults ..............................................................................................................3-48

Using the machine torch ................................................................................................................................3-49

Ensure the torch and table are set up correctly .............................................................................3-49

Understand and optimize cut quality .................................................................................................3-49

To pierce a workpiece using the machine torch ............................................................................3-52

Common machine-cutting faults ........................................................................................................3-52

Section 4

Maintenance and parts

Perform routine maintenance .......................................................................................................................... 4-2

Inspect the consumables ................................................................................................................................. 4-3

Hand torch replacement parts ........................................................................................................................ 4-4

Machine torch replacement parts .................................................................................................................. 4-6

Accessory parts.................................................................................................................................................. 4-7

Duramax Retrofit Torch Operator Manual 1-1

Section 1

SPECIFICATIONS

In this section:

Component weights .......................................................................................................................................... 1-2

Duramax HRT hand torch dimensions .......................................................................................................... 1-2

Duramax HRTs hand torch dimensions ........................................................................................................ 1-2

Duramax MRT full-length machine torch dimensions ................................................................................ 1-3

Duramax MRT without positioning sleeve (mini torch) .............................................................................. 1-3

SPECIFICATIONS

1-2 Duramax Retrofit Torch Operator Manual

Duramax HRT hand torch dimensions

Duramax HRTs hand torch dimensions

9.9 in (25.2 cm)

3.8 in

(9.8 cm)

75°

angle 2.6 in

(6.6 cm)

1.0 in

(2.5 cm)

Component weights

Torch type Weight – lbs (kg)

Hand torch 25 ft (7.6 m) 7.1 (3.2)

Hand torch 50 ft (15 m) 12.5 (5.7)

Machine torch 25 ft (7.6 m) 7.6 (3.4)

Machine torch 50 ft (15 m) 13.2 (6.0)

10.2 in (25.9 cm)

1.9 in

(4.7 cm)

15°

angle 2.6 in

(6.6 cm)

1.0 in

(2.5 cm)

SPECIFICATIONS

Duramax Retrofit Torch Operator Manual 1-3

Duramax MRT full-length machine torch dimensions

15.6 in

(39.6 cm)

1.0 in

(2.5 cm)

1.4 in (3.6 cm) outer

dimension, 1.3 in

(3.3cm) flat sides

12.3 in

(31.3 cm)

8.1 in

(20.6 cm)

1.4 in

(3.5 cm)

1.0 in

(2.5 cm)

1.4 in (3.6 cm) outer

dimension, 1.3 in

(3.3cm) flat sides

1.4 in

(3.5 cm)

Duramax MRT without positioning sleeve (mini torch)

6.6 in

(16.8 cm)

3.3 in

(8.4 cm)

SPECIFICATIONS

1-4 Duramax Retrofit Torch Operator Manual

Duramax Retrofit Torch Operator Manual 2-1

Section 2

TORCH SETUP