Hypertherm HyDefinition HD4070 Instruction sheet

4070.97
HyDefinition
®
HD4070
Plasma Arc Cutting / Marking System
Product Configuration Manual
803770 – Revision 1

HD4070
Product Configuration Manual
(P/N 803770)
Revision 1 – December, 2002
© Copyright 2002 Hypertherm, Inc.
All Rights Reserved
Hypertherm, HyDefinition and HT are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com

Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
800-643-9878 Tel (Technical Service)
800-737-2978 Tel (Customer Service)
Hypertherm Automation, LLC
5 Technology Drive
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik, GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 6 841 2489 Tel
65 6 841 2490 Fax
65 6 841 2489 (Technical Service)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
Hypertherm UK, Ltd
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
00 800 3324 9737 Tel
00 800 4973 7329 Fax
Hypertherm S.r.l.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm Europe B.V.
Vaartveld 9
4704 SE Roosendaal, Nederland
31 165 596908 Tel
31 165 596901 Fax
Technical Service:
00 800 49 73 7843 – toll-free in Europe
31 165 596900 Tel
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax
3/27/03

0
HD4070 Product Configuration Manual 1-1
Section 1
SPECIFICATIONS
In this section:
Description................................................................................................................................................................1-2
General ............................................................................................................................................................1-2
Power Supply ..................................................................................................................................................1-2
Machine Torch..................................................................................................................................................1-2
Off-Valve Assembly..........................................................................................................................................1-2
Gas Console ....................................................................................................................................................1-2
Ignition Console ...............................................................................................................................................1-2
Options.............................................................................................................................................................1-3
Specifications............................................................................................................................................................1-7
System Requirements......................................................................................................................................1-7
Power Supply...................................................................................................................................................1-8
Gas Console Assembly – 078085..................................................................................................................1-10
Ignition Console Assembly – 078088 .............................................................................................................1-11
Off-Valve Assembly – 129563........................................................................................................................1-12
Machine Torch Assembly with Leads .............................................................................................................1-13

0
1-2 HD4070 Product Configuration Manual
SPECIFICATIONS
Description
General
The HD4070 is a fully automated 200 amp HyDefinition plasma cutting/marking 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 type and gas flow rates.
Power Supply
The power supply houses two 100-amp, 15 kHz choppers to produce up to 200A of constant current DC output.
The HD4070 power supply provides the torch the energy to cut 1/2" (12.7 mm) mild steel at up to 90 ipm
(2286 mm/min.).
Machine Torch
The machine torch can cut 1/2 inch (12.7mm) mild steel at 90 ipm (2286 mm/min.). The maximum production
cutting capability of the torch is 1 inch (25 mm). To achieve consumable long life, all cuts must begin and end
on the plate surface.
Off-Valve Assembly
The off-valve assembly consists of 5 solenoid valves, a manifold block and a wiring harness with connector. The
assembly interfaces with the machine torch, the ignition console and the gas console.
Gas Console
The gas console manages all incoming gasses for selection and flow rates and is controlled by the HD4070 power
supply. The gas console includes motor valves, solenoid valves, check valves and pressure trans-ducers all
mounted on a single manifold assembly. The manifold significantly reduces gas leaks by eliminating the use of
flexible hose. The gas console also houses 2 relay PC boards and a control PC board.
Ignition Console
The ignition console generates a high voltage, high frequency signal and couples it to the cathode lead and pilot
arc lead. The ignition console is fully electronic eliminating the need for periodic maintenance.

0
HD4070 Product Configuration Manual 1-3
SPECIFICATIONS
4070.97
HD4070 System with 2-Torch Option
Options
• 2-Torch Option –The HD4070 plasma cutting/marking system has the ability to support 2 torches operated
from a single power supply and gas console. When one torch is selected for cutting the second torch is in
the off mode. This allows the operator to configure the system for two different processes (i.e. 100 amp
consumables installed in one torch and 200 amp consumables installed in the second torch). The operator
selects torch number-1 or torch number-2 from the HD4070 display (or CNC).
Note: A torch receptacle plug must be used if a two torch system is running in single torch mode.
Single torch mode is when a table is loaded with plate material and one torch is doing all the
cutting or marking.
Dual torch mode is when one torch is performing one operation and the second torch is
performing another operation on the same plate material.

0
1-4 HD4070 Product Configuration Manual
SPECIFICATIONS
•Integrated Command THC Option –The Hypertherm Integrated Command THC takes full advantage of
the HD4070 automated capabilities. When the operator enters the material and thickness to be cut into the
HD4070 display touch screen (or CNC), the Integrated Command THC automatically adjusts the torch
settings required for the specific process, including arc volts, torch standoff, initial pierce height and pierce
time delay. The Integrated Command THC system uses the plasma arc voltage to control the physical
stand-off (distance) between the torch and workpiece during plasma arc cutting. Initial height sensing (IHS)
is accomplished by ohmic contact sensing or by limited force stall detection.
HD4070 power supplies that are equipped with the Integrated Command THC option include the THC motor
drive board, the THC control PC board and THC power supply required for torch lifter operation and control.
One or two Command THC options can be specified, depending on how many torches are installed with the
system.
Power Supply with Command THC Option for 2-Torch System
4070.48
THC Control
PC Boards THC Power
Supplies
THC Motor
Drive Boards

0
HD4070 Product Configuration Manual 1-5
SPECIFICATIONS
The Integrated Command THC option includes the X-Y lifter, torch mounting block and the related cables.
A torch breakaway (collision sensor) is also available to protect the torch, lifter and X-Y table. Adjustable air
pressure locks the torch to the THC lifter assembly. Upon side impact, the breakaway releases from the lock
position and allows the torch to float.
THC Cables
THC X-Y Lifter
THC Torch
Breakaway Option
4070.45A
Integrated Command THC Lifter, Cables and Breakaway

0
1-6 HD4070 Product Configuration Manual
SPECIFICATIONS
• Touch Screen Display Option –The HD4070 display is a touch screen interface, providing all system
control functions and plasma process information at a single location. The power supply may be ordered
with the display mounted in the front panel. Kits are also available for mounting the display remotely.
4070.23B
13
TORCH1
NOPILOTARC
STAINLESSSTEEL
NEW
PROCES
NEXT
AUTO
MAN
THC
ARC
VOLT
ARC
VOLT
OVERRIDEVOLTS:144.5V
SETARCVOLTS:142.0V
INLETGAS:H35N2
CUTTINGSPEED:65IPM
3/4IN
200AMPSSTANDOFF:0.050IN
++__
CNC
TORCH 1
READY
STAINLESS STEEL
NEW
PROCESS
NEXT
AUTO
MAN
THC
OVERRIDE VOLTS: 144.5 V
SET ARC VOLTS: 142.0 V
INLET GAS: H35 N2
CUTTING SPEED: 65 IPM
3/4 IN
200 AMPS STANDOFF: 0.050 IN
ARC
VOLT
++
ARC
VOLT
_ _
13
HELP
Display Touch Screen Option
Warning: The HD4070 system can only support one touch screen display, either local or remote. The
installation of two displays on one system may cause malfunctions or damage.

1
HD4070 Product Configuration Manual 1-7
SPECIFICATIONS
Specifications
System Requirements
Gas Quality and Pressure Requirements
Quality Pressure + 5% Flow Rate
O2Oxygen 99.5% pure (liquid gas recommended) 120 psi 133 scfh (3780 l/h)
Clean, dry, oil-free 8.3 bar / 827 kPa
N2Nitrogen 99.99% pure (liquid gas recommended) 120 psi 142 scfh 4020 l/h
Clean, dry, oil-free 8.3 bar / 827 kPa
Air Clean, dry, oil-free 120 psi 140 scfh 3960 l/h
8.3 bar / 827 kPa
CH4Methane 93% pure 120 psi 188 scfh 5340 l/h
8.3 bar / 827 kPa
H5 Argon-Hydrogen 99.995% pure (liquid gas recommended) 120 psi 122 scfh 3420 l/h
(H5=5% Hydrogen, 95% Argon) 8.3 bar / 827 kPa
H35 Argon-Hydrogen 99.995% pure (liquid gas recommended) 120 psi 146 scfh 4140 l/h
(H35=35% Hydrogen, 65% Argon) 8.3 bar / 827 kPa
*CO2Carbon-Dioxide 99.5% pure 120 psi 113 scfh 3180 l/h
8.3 bar / 827 kPa
Mild Steel Stainless Steel Aluminum
Gas Types Plasma Shield Plasma Shield Plasma Shield
Marking N2N2H5 N2H5 N2
Cutting 30 A O2O2& N2Air Air Air Air
Cutting 70 A O2O2& N2H35 & N2N2Air CH4& Air
Cutting 100 A to 200 A O2O2& N2H35 & N2N2H35 & N2N2
*CO2is not currently used on the HD4070 and there is no need to install the gas line.

1
1-8 HD4070 Product Configuration Manual
SPECIFICATIONS
Power Supply
•Place the power supply in an area that is free of excessive moisture, has proper ventilation, and is relatively
clean. Allow room at the sides and rear of the power supply for servicing.
•Cooling air is drawn in through the front panel grating and is exhausted through the rear of the unit by a
cooling fan. Allow a minimum of 12 inches (305 mm) for air flow.
•Maximum distance to the ignition console = 150 feet (46 m).
•Maximum distance to the gas console = 150 feet (46 m).
General
Maximum OCV (U0) 311 VDC
Maximum Output Current (I2) 200 amps
Output Voltage (U2) 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
Cooling Forced Air (Class F)
Input Power (Input Voltage (U1) X Input Current (I1X 1.73)
200 VAC, 3ph, 50-60 Hz, 125A
220 VAC, 3ph, 50-60 Hz, 113A
240 VAC, 3ph, 60 Hz, 103A
400 VAC CE, 3ph, 50-60 Hz, 62A
440 VAC, 3ph, 50-60 Hz, 56A
480 VAC, 3ph, 60 Hz, 52A
600 VAC, 3ph, 60 Hz, 41A

0
HD4070 Product Configuration Manual 1-9
SPECIFICATIONS
4070.42
50.5"
1283 mm
39.4"
1001 mm
24.25"
616 mm
1068 lb
484.9 kg
34.4"
874 mm
5"
127 mm
34.9"
886 mm
15.6"
396 mm

0
1-10 HD4070 Product Configuration Manual
94 lb
42.7 kg
11.625"
295 mm
18.75"
476 mm 24.75"
629 mm
1/4-20
22.75" / 578 mm
17.0"
432 mm
4070.20A
SPECIFICATIONS
Gas Console Assembly – 078085
•Position the gas console near the cutting table. Allow room to open the hinged 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 = 150 feet (46 m).
•Maximum distance to the off-valve assembly = 100 feet (31 m).

0
HD4070 Product Configuration Manual 1-11
4070.19A
0
01.25" / 32 mm
11.0"
279 mm
9.75"
248 mm
0.28"
7 mm
1.25"
32 mm
10.63" / 270 mm
4070.21
6.25"
159 mm
11.25"
286 mm
12"
305 mm
20.5 lb
9.3 kg
Horizontal Mounting Vertical Mounting
SPECIFICATIONS
Ignition Console Assembly – 078088
•Mount the ignition console near the torch. Allow room to remove the top for servicing.
•Mount the ignition console in the horizontal or the vertical position as shown below.
•Maximum distance to the torch = 15 feet (4.5 m).

0
1-12 HD4070 Product Configuration Manual
4070.18A
A
A
A - A
6.18"
157 mm
1.18"
30 mm
0.187"
4.7 mm
0.75"
19 mm
6.5"
165 mm
3"
76 mm
2.75"
70 mm
2.5 lb
1.1 kg
SPECIFICATIONS
Off-Valve Assembly – 129563
•Mount the off-valve assembly near the torch.
•Maximum distance from the torch = 4 feet (1.2 m).

0
HD4070 Product Configuration Manual 1-13
SPECIFICATIONS
Machine Torch Assembly with Leads
•Assembly includes leads, torch and consumables.
•128500 6 ft / 2 m
128501 10 ft / 3 m
128502 15 ft / 4.5 m
2.25"
(57 mm)
4070.44
4 ft / 1.2 m
2 lb
0.9 kg
14.7 lb
6.7 kg
15 ft / 4.5 m
10.86"
(276 mm)
2"
(51 mm)
1.05"
(27
mm)
4.65"
(118 mm)
1.88"
(48 mm)
1.98"
(50 mm)
3.5"
(89 mm)
Without Coolant
To off-valve
assembly
Plasma Gas
Vent

0
1-14 HD4070 Product Configuration Manual
SPECIFICATIONS

0
HD4070 Product Configuration Manual 2-1
Section 2
ORDERING
In this section:
Ordering the HD4070 System...................................................................................................................................2-2
HD4070 Power Supply with NO Integrated Command THC Option Order Form A ..................................................2-3
HD4070 Power Supply with ONE Integrated Command THC Option Order Form B................................................2-5
HD4070 Power Supply with TWO Integrated Command THC Option Order Form C...............................................2-7
HD4070 Components, Cables and Hoses for 1-Torch Option Order Form D...........................................................2-9
HD4070 Components, Cables and Hoses for 2-Torch Option Order Form E .........................................................2-11
HD4070 Supply Gas Hoses, Regulators & Upgrade Kits Order form F..................................................................2-12

0
2-2 HD4070 Product Configuration Manual
ORDERING
Ordering the HD4070 System
Ordering a system can be a complex procedure. The following components are required to operate the HD4070
system:
•Power supply
•Ignition console and connecting cables and hoses
•Gas console and connecting cables and hoses
•Off-Valve Assembly and connecting cables and hoses
•Torch and Lead Assembly
•Machine interface I/O cable to start and control the system from the CNC
Hypertherm offers three major options for the HD4070 system:
•Integrated command Torch Height Control (THC) Option
•2-Torch option
•Touch screen display
Use the following order forms as required:
Order the HD4070 power supply using Order Form , or . Touch screen display and voltage choices are
found on each of these forms.
When using order Form use Form or to order Components, Cables & Hoses
When using order Form use Form to order Components, Cables & Hoses
When using order Form use Form to order Components, Cables & Hoses
Use order form to order Supply Gas Hoses, Regulators & Upgrade Kits. The upgrade kits are for use with
previously purchased power supplies.
F
E
C
D
B
E
D
A
C
B
A
HD4070 System Configuration
Order Forms
C
Power Supply with 2-THC Option
Use Order Form
B
Power Supply with 1-THC Option
Use Order Form
A
Power Supply with NoTHC Option
Use Order Form
D
Components, Cables & Hoses for 1-Torch Option
Use Order Form
Components, Cables & Hoses for 2-Torch Option
Use Order Form E
- OR -
- OR -
Supply Gas Hoses, Regulators & Upgrade Kits
Use Order Form F

Distributor Information:
Customer Information:
480V 240V 400V 200V 440V 220V 600V
60 HZ 60 HZ 50-60 HZ 50-60 HZ 50-60 HZ 50-60 HZ 60 HZ
078087 X–––––– No Display Installed
078134 –X–––––
078089 ––X––––
078135 –––X–––
078095 ––––X––
078141 –––––X–
078106 ––––––X
078103 X–––––– With Display Installed
078149 –X–––––
078092 ––X––––
078138 –––X–––
078098 ––––X––
078144 –––––X–
078109 ––––––X
Voltage
3
SETUP
REPEAT
PREVIOUS
PROCESS
NEW
PROCESS
1
128526 10 ft.(3 m)
128527 20 ft.(6.1 m)
128528 25 ft.(7.6 m)
128529 30 ft.(9.1 m)
128530 40 ft.(12.2 m)
128531 50 ft.(15.2 m)
128532 75 ft.(22.9 m)
128533 100 ft.(30.5 m)
128534 150 ft.(45.7 m)
Remote Display Option Kit
Installed Display can be removed
and mounted at a remote location
with a remote cable kit. See Order
form or instruction manual
parts list for kit numbers.
- Use Order Form or
218
through
Warning: Each power supply can only support one display.
Installation of two displays with one power supply may result in
malfunction or damage.
19 Use Order Form F
ED
F
HYPERTHERM –HD4070 Power Supply with NO Integrated Command THC Option –Order Form
A
1
0