Hypertherm HyDefinition HD3070 Instruction sheet

HD3070
PlasmaArcCuttingSystem
with Automatic Gas Console
Product Configuration Manual
802310 - Revision 4

Revision 4 - January 2000
HD3070
Plasma Arc Cutting System
with Automatic Gas Console
Product Configuration Manual
PM-231
© Copyright 2000 Hypertherm, Inc.
All Rights Reserved
Htpertherm and HyDefinition are trademarks of Hypertherm, Inc. and may be
registered in the United States and/or other countries
Hypertherm, Inc.
Hanover, NH USA
http://www.hypertherm.com
email: [email protected]

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Tel.: [phone] (Customer Service – toll-free in USA and Canada)
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email: [email protected] (Technical/Customer Services)
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Technologiepark Hanau
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D–63457 Hanau-Wolfgang, Germany
Tel.: [phone]
Fax: [phone]
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No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847
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Runcorn, Cheshire, England WA7 1TQ
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95610 Eragny, France
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Via Torino 2
20123 Milan, Italy
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81 03 5326 3142 Tel
81 03 5326 3001 Fax
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1-1HD3070 w/Automatic Gas Console
1 Ordering Procedure
In this section:
Introduction ............................................................................................................... 1-2
Torches ................................................................................................................ 1-2
Cutting Machines ................................................................................................. 1-2
Multi-Torch Systems ................................................................................................. 1-3
Layout of Cutting Machine and HD3070 System ...................................................... 1-4
Ordering Information ................................................................................................. 1-5
Single-System Ordering Procedure .......................................................................... 1-6
Customized Ordering For HD3070 w/Automatic Gas Console ................................. 1-8
1 Power Supply ................................................................................................. 1-8
2 Automatic Gas Console.................................................................................. 1-8
3 RHF Console .................................................................................................. 1-8
4 Leads Between Power Supply and the RHF Console .................................... 1-8
5 Work Cable Between Power Supply and Work Table .................................... 1-10
6 Leads Between Power Supply and Gas Console........................................... 1-10
Torch Configuration................................................................................................... 1-12
13 Leads Between RHF Console and Torch ....................................................... 1-14
14 Off-Valve Assembly ........................................................................................ 1-14
15 Shield Hose .................................................................................................... 1-14
16 Plasma Hose .................................................................................................. 1-14
17 Leads Between Gas Console and Off-Valve Assembly ................................. 1-14
18 Control Cable Between Gas Console and Cutting Machine Interface............ 1-16
19 Control Cable Between Power Supply and Cutting Machine Interface .......... 1-16
20 Current Setpoint Cable ................................................................................... 1-18
21 Timer Counter Cable ...................................................................................... 1-18
22 Remote Current Control (RCC) ...................................................................... 1-18
23 Timer-Counter ................................................................................................ 1-18
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1-2 HD3070 w/Automatic Gas Console
INTRODUCTION
Hypertherm’s HD3070 HyDefinition® plasma cutting system is a precision cutting dual gas
machine-torch system. The microprocessor-controlled system helps to provide extended life
for the torch consumables parts. To achieve consumable long life, all cuts must begin and
end on the plate surface; this allows for the proper ramping of gases and DC current to
extend the life of the nozzle and electrode. The HD3070 system consists of a power supply,
remote high frequency (RHF) console, gas console, off-valve assembly and torch. Optional
units include a timer-counter and a remote current control.
The HD3070 can be configured for either robotic applications or X-Y cutting tables. To
accommodate the different needs of these two types of systems, two different torches are
offered.
TORCHES
PAC184
If ordering for a robotic system, the PAC184 torch with 45°quick disconnect is recom-
mended. This torch, with a pointed front end, is designed to cut in a robotic environment.
PAC186
The PAC186 torch with the straight quick disconnect is more suitable for X-Y cutting tables.
A unique feature to the PAC184 and PAC186 torches is that the torch bodies, quick discon-
nects and mounting sleeves are all interchangeable.
CUTTING MACHINES
If cutting on an X-Y machine, it is extremely critical that the torch drive system has very
accurate vibration-free control of the X, Y, and Z axes. Placing a precision-cutting plasma
system on a cutting machine with poor positioning or poor contouring tolerance, or with
inadequate acceleration and deceleration characteristics will clearly show the effects on the
cut face. The Z-axis of the cutting machine must be controlled to +/-.005 in. Initial height
sensing (IHS) for plate piercing must also be accurate and repeatable to ensure long
consumable life.
Hypertherm recommends HD3070 units be installed on new, high-precision X-Y machines.
For robotic and hard tooling applications, any system that is laser compatible will generally
perform well with the HD3070 system.
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1-3HD3070 w/Automatic Gas Console
MULTI-TORCH SYSTEMS
If more than one torch is required, increase the quantity of each component by the number
of torches to be used.
To specify the correct components for each application, follow the guidelines in this section.

1-4 HD3070 w/Automatic Gas Console
LAYOUT OF CUTTING MACHINE AND HD-3070 SYSTEM
When configuring an HD3070 system(s), it is important to know where each major compo-
nent will be placed. This will vary with the cutting machine manufacturer and with the particu-
lar installation. After the location of the major components has been determined, the inter-
connecting leads and cable lengths can be specified.
It is critical to follow the path that the interconnecting leads will follow and allow for some
slack when specifying their lengths. Do not try to get by with the next shorter length!
Pictured below is a diagram showing an overhead view of a typical precision cutting X-Y
machine. Installations vary, so use this figure as a guide.
Rail Water
Table
Torch
Rail
Bridge
* Cables are usually in a power track or
festoon system. Cable, lead and hose lengths
must allow for routing through the system.
Figure 1-1 Gantry (Bridge) Layout)*

1-5HD3070 w/Automatic Gas Console
ORDERING INFORMATION
The figure below represents an HD3070 plasma system with automatic gas console mounted in a
robotic environment. A complete robotic system is also represented in block diagram form on page
1-7. See pages 1-20 and 1-21 for representations of an HD3070 plasma system with automatic gas
console mounted on an X-Y cutting table.
Notes: • Block diagrams are offered to clarify connection points and do not necessarily
reflect relative sizes or distances between components.
• If the cutting system has a power track for cabling and hosing, be certain to see the
Specifications section to check hose, cable and connector diameters.
Figure 1-2 HD3070 System in Robotic Environment
2
3
4
5
61
19 21
1HD3070 Power Supply, Auto
2 HD3070 Automatic Gas Console
3 Remote High Frequency (RHF) Console
4 Leads Between Power Supply and RHF Console
5 Work Cable Between Power Supply and Work Table
6 Leads Between Power Supply and Auto Gas Console
7 PAC186 Torch (not shown)
8 Quick Disconnect Assembly - Straight (not shown)
9 10 Inch Torch Mounting Sleeve (not shown)
10 PAC184 Torch
11 Quick Disconnect Assembly - 45°
12 8 Inch Torch Mounting Sleeve
13a Shielded Leads Between RHF Console and Torch (with Blow
Down Check Valve & Hose)
13b Shielded Leads Between RHF Console and Torch (without Blow
Down Check Valve & Hose)
14a Off-Valve Assembly (with Blow Down Solenoid Valve)
14b Off-Valve Assembly (without Blow Down Solenoid Valve)
15 48 Inch Shield Gas Hose Between Off-Valve Assy and Torch
16 48 Inch Plasma Gas Hose Between Off-Valve Assy and Torch
17 Leads Between Gas Console and Off-Valve Assy
18 Cable Between Gas Console and Cutting Machine Interface
19 Control Cable Between Power Supply and Cutting Machine Interface
20 Current Setpoint Cable Between Power Supply and Cutting Machine
Interface or Between Power Supply and RCC
21 Timer-Counter Cable Between Power Supply and Cutting Machine
Interface or Between Power Supply and Timer-Counter
22 Remote Current Control (RCC)
23 Timer-Counter
11
10
12
14
22
23
17
13
15 16
18
20
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1-6 HD3070 w/Automatic Gas Console
1 HD3070 Power Supply, Auto
2 HD3070 Automatic Gas Console
3 Remote High Frequency (RHF) Console
4 15 Ft Leads Between Power Supply and RHF Console
5 39.4 Ft Work Cable Between Power Supply and Work Table
6 6 Ft Leads Between Power Supply and Auto Gas Console
7 PAC184 Machine Torch Assy
8 PAC184 Machine Torch Quick Disconnect Assembly and Leads:
8a PAC184 45°Quick Disconnect
8b 8 Inch Torch Mounting Sleeve
8c Off-Valve Assy (Off-Valve comes with or without Blow Down Solenoid Valve)
8d 4 Ft Hoses from Off-Valve Assy to Torch
8e 35 Ft Leads from Gas Console to Off-Valve Assy
8f 19.7 Ft Leads from RHF Console to Torch (Leads come with or without Blow Down
Check Valve & Hose)
9 28.2 Ft Cable Between Gas Console and Cutting Machine Interface
10 28.2 Ft Control Cable Between Power Supply and Cutting Machine Interface
11 28.2 Ft Current Setpoint Cable Between Power Supply and Cutting Machine Interface
12 28.2 Ft Timer-Counter Cable Between Power Supply and Cutting Machine Interface
If this exact configuration will work for your particular site, simply order by using the
appropriate system number listed directly below.
078067 HD3070 Plasma System w/Auto Gas Console, 200V, 50/60 Hz, 3Ø
078068 HD3070 Plasma System w/Auto Gas Console, 208V, 60 Hz, 3Ø
078069 HD3070 Plasma System w/Auto Gas Console, 220/380/415V, 50/60 Hz, 3Ø
078070 HD3070 Plasma System w/Auto Gas Console, 240/480V, 60 Hz, 3Ø
078071 HD3070 Plasma System w/Auto Gas Console, 600V, 60 Hz, 3Ø
To customize a system, begin on page 1-8 and use the order form.
SINGLE-SYSTEM ORDERING PROCEDURE
SYSTEM ORDERING FOR HD3070 w/AUTOMATIC GAS CONSOLE -
ROBOTIC APPLICATIONS
Special numbers have been established for ordering an entire HD3070 system. Under these
numbers, all cables, hoses and leads are at fixed lengths. Refer to the list below and Figure
1-3 on the following page for clarification of the system.
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1-7HD3070 w/Automatic Gas Console
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RHF
Console
3
4
5
Work Table
7
8a
8b
8c 8d
8f
Automatic
Gas
Console
2
Cutting
Machine
Interface
11
Power
Supply
1
8e
69
Standard HD-3070 Plasma System w/Automatic Gas Console - Robotic
(Use Single System Number on This Sheet)
Ground Rod
Figure 1-3 HD3070 w/Automatic Gas Console Single Order Number System Configuration
10
12
Plasma Gas
Shield Gas
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