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HyDefinition HD3070
Hypertherm HyDefinition HD3070 User Manual
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Plasma Arc Cutting System
with Automa
tic Gas Console
Instruction Manual
8021
80 – Revision 1
9
HyDefinition
®
HD
3
0
7
0
™
The world leader in
plasma cutting technology
2
Table of Contents
English
18
Electromagnetic Compatibility (EMC
16
Warranty
17
Table of Contents
18
Recognize Safety Information
25
Follow Safety Instructions
25
Cutting Can Cause Fire or Explosion
25
Electric Shock Can Kill
26
Cutting Can Produce Toxic Fumes
26
A Plasma Arc Can Cause Injury and Burns
27
Arc Rays Can Burn Eyes and Skin
27
Grounding Safety
27
Compressed Gas Equipment Safety
28
Gas Cylinders Can Explode if Damaged
28
Noise Can Damage Hearing
28
Pacemaker and Hearing Aid Operation
28
A Plasma Arc Can Damage Frozen Pipes
28
Additional Safety Information
28
Warning Label
29
Français
30
Section 1A
30
Sécurité
30
Danger Avertissement Précaution
31
Risque D'explosion Argon-Hydrogène Et Méthane
31
Détonation de L'hydrogène Lors du Coupage de L'aluminium
31
Les Chocs Électriques Peuvent Être Fatals
32
Le Coupage Peut Produire des Vapeurs Toxiques
32
Prévention des Chocs Électriques
32
L'arc Plasma Peut Provoquer des Blessures Ou des Brûlures
33
Mise À la Masse Et À la Terre
33
Les Rayons de L'arc Peuvent Brûler Les Yeux Et la Peau
33
Torches À Allumage Instantané
33
Sécurité des Bouteilles de Gaz Comprimé
34
Les Bouteilles de Gaz Comprimé Peuvent Exploser en Cas de Dommages
34
Le Bruit Peut Provoquer des Problèmes Auditifs
34
Pacemakers Et Prothéses Auditives
34
Identifier Les Consignes de Sécurité
31
Le Coupage Peut Provoquer un Incendie Ou Une Explosion
31
Suivre Les Instructions de Sécurité
31
Pacemakers Et Prothèses Auditives
34
Un Arc Plasma Peut Endommager Les Tuyaux Gelés
34
Étiquette de Sécurité
35
Specifications
36
Section 2 SPECIFICATIONS
36
Description
37
General
37
Power Supply
37
Automatic Gas Console
37
RHF Console
38
PAC184 Machine Torch Assemblies
38
PAC186 Machine Torch Assemblies
38
45° Torch Quick Disconnect Assembly
38
Straight Torch Quick Disconnect Assembly
39
Off-Valve Assemblies
39
Optional Units
39
Timer-Counter
39
Remote Current Control
39
Specifications
40
Automatic Gas Console
41
RHF Console
43
PAC184 Machine Torch Assemblies
44
PAC186 Machine Torch Assemblies
45
45° Torch Quick Disconnect Assembly
46
Straight Torch Quick Disconnect Assembly
46
Off-Valve Assemblies
47
Optional Units
47
Timer-Counter
47
Remote Current Control (RCC) (078050
47
IEC Symbols Used
48
Installation
49
Section 3 INSTALLATION
49
Pre-Installation
50
Upon Receipt
50
HD3070 System Components
50
Claims
50
Gas Requirements
51
Oxygen
51
Nitrogen
51
Methane
51
Air
51
Argon-Hydrogen
52
Power Supply Placement
52
Power Requirements
54
Line Disconnect Switch
54
Power Cable
54
240/480V Power Supply Lineboard Configurations
56
220/380/415V Power Supply Linkboard Configurations
56
Work Table Grounding
57
Equipment Grounding
57
Connect Power Cable
58
Power Supply
58
Line Voltage Disconnect Box
58
Local/External Pierce Delay Function
59
Local/External Current Set Function
59
Torch Lifter Requirement
59
Installation
60
System Units Placement
60
Remote High Frequency Console
60
Automatic Gas Console
60
Torch Quick Disconnect Assemblies/Off-Valve Assembly
60
Cable, Hose & Lead Set Interconnections
64
Power Supply to RHF Console and Work Table Interconnections
66
Power Supply to Automatic Gas Console Interconnections
70
Power Supply to Machine Interface/Timer-Counter Interconnection
73
Power Supply to Machine Interface Interconnection
73
Power Supply to Machine Interface/Rcc Interconnection
73
Gas Console to Machine Interface Interconnection
73
RHF to Torch Quick Disconnect Interconnections
79
Gas Console to Off-Valve Assembly Interconnections
81
Off-Valve Assembly to Torch Quick Disconnect Interconnections
82
Gas Supply Hose Connections
84
PE Ground Cable Connections
84
Hold Signal Connections
85
Mount PAC184/PAC186 Torch to Quick Disconnect
85
Torch Coolant Requirements
86
Filling Torch Coolant System
88
Post Installation
88
Operation
90
Section 4 OPERATION
90
Controls and Indicators
91
Power Supply Control Panel
91
Automatic Gas Console Front Panel
93
LCD Display Error Messages
96
Gas System (GS-ERR)
97
Automatic Gas Console Rear Panel
98
Plasma System (PS-ERR)
98
Daily Operating Procedure
99
Local Mode
99
Remote Mode
100
Changing Consumable Parts
101
Removal and Inspection
101
Replacement
102
Blow Back Option to Purge Coolant Hoses
105
How to Optimize Cut Quality
106
Tips for Table and Torch
106
Plasma Set-Up Tips
106
Maximize the Life of Consumable Parts
106
Additional Factors of Cut Quality
107
Additional Improvements
108
Technical Questions
109
Operating Data (Cut) Charts
110
Section 5 MAINTENANCE
126
Maintenance
127
Introduction
127
Routine Maintenance
128
Power Supply
128
RHF Console
128
Torch, Quick Disconnect/Off-Valve and Torch Leads Inspection
129
Gas Console
129
Starting Sequence of HD3070
130
Initial Checks
132
Troubleshooting
135
STATUS LED Troubleshooting
140
Status LED Troubleshooting Flow Diagrams
144
Error Codes and Messages
153
Power Supply Control Board Error Codes
153
Gas Console Error Messages
155
Power Supply System
155
Gas System
157
Power Supply System Error Message Flow Diagrams
158
Gas System Error Message Flow Diagrams
173
Relay Board LED Status Indicators
183
Power Supply
183
Gas Console
189
Gas Console
190
Control Board LED Status Indicators
191
Power Supply
191
Gas Console
192
Gas System Back Pressure Checks
193
CH130 Chopper Module Test Procedure
196
Torch Maintenance
199
PAC186 Water Tube Removal and Replacement
199
Bullet Connector Removal and Replacement
201
High Current Contact Removal and Replacement
201
Parts List
202
Section 6 PARTS LIST
202
Introduction
203
Power Supplies
203
Front Exterior
205
Front Interior-Right and Left Sides
206
CH130 Chopper SA
207
Linkboard Subassemblies
208
Center Panel and Bottom-Right Side
210
Center Panel and Bottom-Left Side
211
Rear Interior-Right and Left Sides
212
HF I/O Panel SA
213
Rear Exterior
214
RHF Console
216
Automatic Gas Console
218
Enclosure, Front Panel and Interior
218
PAC184 Machine Torch Assemblies
222
PAC186 Machine Torch Assemblies
222
PAC186 Machine Torch Assemblies
223
45° Torch Quick Disconnect Assembly, Mounting Sleeve and Torch Vent Hose
224
Straight Torch Quick Disconnect Assembly, Mounting Sleeve, Spacer and Torch Vent Hose
224
Off-Valve Assemblies
225
PAC184 Torch Consumable Parts
226
PAC184 Consumable Parts Kits
226
PAC186 Torch Consumable Parts
227
PAC186 Consumable Parts Kits
228
Wiring Diagrams
229
Section 7 WIRING DIAGRAMS
229
Appendix A HD3070 CNC SIGNAL INTERFACE LIST
247
Power Supply CNC Interface Signals
247
Power Supply Connector 1X1 Standard Interface
247
Power Supply Connector 1X2 Standard Interface
249
Gas Console CNC Interface Signals
250
Gas Console Connector 3X4 CNC Interface
250
Gas Control Board Dip Switch Functions
252
Appendix B GAS CONTROL BOARD DIP SWITCH FUNCTIONS
254
Propylene Glycol Safety Data
254
Benzotriazole Safety Data
254
Appendix C PROPYLENE GLYCOL SAFETY DATA
264
Appendix D TIMER-COUNTER
264
Introduction
265
Installation
265
Operation
265
Timer-Counter Internal Wiring
267
Timer-Counter Wiring
267
Parts List
268
Timer-Counter
264
Remote Current Control (Rcc
269
Appendix E REMOTE CURRENT CONTROL (RCC)
270
Introduction
270
Installation
270
RCC 1X2 to Thumbwheel Switch Wiring Interface
271
Operation
271
Parts List
272
Electromagnetic Compatibility (Emc
273
Appendix F ELECTROMAGNETIC COMPATIBILITY (EMC)
274
EMC Introduction
274
General
275
Power Cable
275
Connect Power Cable
275
EMI Filter Parts List
277
Appendix G SYSTEM GROUNDING
278
Work Table Grounding
279
System Grounding
278
System Grounding Requirements
278
Suggested Ground Cable Routing
278
Power Supply
278
Equipment Grounding
278
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Hypertherm HyDefinition HD3070 Specifications
General
Brand
Hypertherm
Model
HyDefinition HD3070
Category
Cutter
Language
English
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