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

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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.