Hyper Therm Mech Guide

Optimize quality, productivity and operating costMechanized cutting solutions

www.hypertherm.com©Copyright 11/08 Hypertherm, Inc. Revision 2

892120

Hypertherm, Inc. Hanover, NH USA603-643-3441 Tel800-643-0030 Tel (Toll-free USA and Canada)603-643-5352 Fax [email protected]@hypertherm.com

HYPERTHERM BRASIL LTDA. Guarulhos, SP-Brasil55 11 2409-2636 Tel 55 11 2408-0462 Fax [email protected]@hypertherm.com.br

Mexico (Representative Office) 52 55 5681 8109 Tel 52 55 5683 2127 [email protected]@hypertherm.com.mx

Hypertherm Europe B.V.Roosendaal, The Nederlands31 165 596907 Tel 31 165 596901 Fax [email protected]@hypertherm.com

Hypertherm Plasmatechnik GmbHHanau-Wolfgang, Germany49 6181 58 2100 Tel 49 6181 58 2134 Fax [email protected]

Australia/New Zealand (Representative Office)61 (0) 7 3219 9010 Tel61 (0) 7 3219 9012 [email protected]

Hypertherm, LongLife, HyDefinition, HyLife, CoolCore, SilverPlus, HySpeed, Powermax, HT, HyPerformance,HPR, MAX, Auto-voltage, MicroEDGE, EDGE, Mariner, Command, Voyager, Sensor, HyperCAD and HyperNestare trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.

Hypertherm (S) Pte Ltd.Singapore65 6841 2489 Tel 65 6841 2490 Fax [email protected]

Hypertherm (Shanghai) Trading Co., Ltd.Shanghai, China86-21 5258 3330 /1 Tel 86-21 5258 3332 Fax [email protected]

Hypertherm Japan Ltd. Osaka, Japan 81 6 6170-2020 Tel 81 6 6170-2015 Fax [email protected]

GU_MechCuttingCvr_892120.qxp:GU_892120 10/23/08 1:41 PM Page 1

ContentsComparison of plasma, oxyfuel and laser 4–5The Hypertherm advantage 6–7Hypertherm technology options 8–9Hypertherm products 10–15

The world leader inthermal cutting technologySince 1968, Hypertherm has had a single goal:cut the cost of cutting metal. The company’s one and only focus is thermal cutting technology. Its single-minded mission is to provide customers throughout theworld with the best plasma cutting equipment and service in the industry. That’s why Hypertherm holdsmore major plasma cutting patents, and has more customers worldwide than any other brand. In head-to-head tests, Hypertherm systems consistently outperform the competition in the keyareas of cut quality, productivity and operating cost.Hypertherm has evolved into a thriving global entitythat serves a continually expanding customer base.

15

Also available from Hypertherm to support yourmechanized cutting needs

Plasma torch height controls:

• Integrated Sensor ™THC• Stand alone

Command®THC• Sensor PHC

Oxyfuel torch height control:

• Sensor OHC

CNC controllers (2–12 axes):

• MicroEDGE™

• EDGE®Ti• EDGE II• Voyager™III• Mariner ™

Drive packages:• 2–4 Axes 400W AC• 2–4 Axes 750W AC

Drawing and nestingsoftware:

• HyperCAD®

• HyperNest®


GU_MechCutting_892120.qxp:GU_MechCutting_892120 11/7/08 10:51 AM Page 3

4Comparison of plasma, oxyfuel and laser

Low volume Business volume High volume

Thick

Materialthickness

Thin

Plasma advantagesvs. oxyfuel

• Better cut quality

• Greater materialflexibility

• Significantly higherproductivity

• Significantly lower costper length of cut

Plasma advantagesvs. laser

• Significantly higherproductivity

• Increased flexibility tocut a wide range ofmaterial thicknessesand types

• Significantly lowercapital, operating andmaintenance costs

LaserLaser provides excellent cut quality and productivity on materialless than 6 mm (1⁄4"). Laser technology has high capital equipment,running and maintenance costs, therefore a high level of businessvolume is required to pay back the cost of the equipment.

PlasmaPlasma provides an optimal mix of cut quality, productivityand operating cost for mild steel, stainless, and aluminumacross a wide range of thicknesses at a competitive capitalequipment price.

OxyfuelOxyfuel is limited to mild steel and is not effective on stainless steelor aluminum.

50 mm(2")

6 mm(1⁄4")


Plasma provides the optimal mix of cut quality,productivity and operating cost

5

Oxyfuel Plasma Laser

Cut quality • Good angularity• Large heat-affected zone• Dross levels require rework• Not effective on stainless steel

or aluminum

• Excellent angularity• Small heat-affected zone• Virtually dross-free• Good to excellent fine-feature cutting

• Excellent angularity• Small heat-affected zone• Virtually dross-free• Good to excellent fine-feature cutting

with narrowest kerf

Productivity • Slow cutting speeds• Pre-heat time increases pierce times

• Very fast cutting speeds for all thicknesses• Very fast pierce times• Quick-disconnect torches maximize

productivity.

• Very fast on thin material (less than6 mm – 1/4"); and slower on thickermaterial.

• Long pierce times on thick material

Operating cost • Poor productivity and required reworkdrive cost per part higher than plasma.

• Long consumable life, good productivity andexcellent cut quality drive the cost per partlower than other technologies.

• High costs per part due to powerrequirements, gas consumption, highmaintenance costs and relativelylow cut speeds on thick material.

Maintenance • Simple maintenance requirementscan often be performed by in-housemaintenance groups.

• Moderate maintenance requirements:many components are serviceable byin-house maintenance groups.

• Complex maintenance tasks requirespecialized technicians.


6The Hypertherm advantage

Hypertherm plasma provides more consistentcut quality and longer consumable life thanother plasma manufacturers.

Num

ber

of s

tart

s20

sec

onds

of

cutt

ing

per

star

t

HyperthermHyPerformancePlasma (200 A)

Competitor A(200 A)

Competitor B(160 A)

Competitor C(200 A)

0

200

400

600

800

1000

1200

1400

12 mm (1/2") – Mild steel

Cut quality and consumable lifeParts cut byHypertherm remainconsistent from thefirst cut to the last.


7

Hypertherm plasma operating cost is less thanhalf of the competition’s.

Rel

ativ

e co

st o

f cu

t

HyperthermHyPerformancePlasma (200 A)

Competitor A(200 A)

Competitor B(160 A)

Competitor C(200 A)

12 mm (1/2") – Mild steel

Productivity

• Hypertherm plasma technology consistentlydelivers the optimal mix of cut speed andcut quality to minimize secondary operationsand maximize productivity.

• Simple user interface, rapid set-up andquick-disconnect torch improve productivity.

• Hypertherm plasma cuts, bevels and marksa variety of metals, thick and thin.

Operating cost

Reliability

• All Hypertherm plasma systems endurerigorous reliability and exhaustive life testingprocedures in Hypertherm laboratories.

• Testing procedures backed by four decadesof experience guarantee Hypertherm qualityyou can count on.


8Plasma capabilities chart

Air plasma Oxygen plasma LongLife oxygen plasma HyPerformance Plasma

System Powermax45®

Powermax1000®

Powermax1250®

Powermax1650®

MAX200® HSD130™HT4400®

HT2000®

HT4001®

HPR130®

HPR260®

HPR400XD®

Cut quality Good

Some secondaryoperations and dross

Better

Some secondary operationswith virtually no dross

Better

Some secondary operationswith virtually no dross

Best

Minimal to no secondaryoperations with virtuallyno dross

Mild steel weldability Nitriding can impairmild steel welding

Good mild steel welding Good mild steel welding Good mild steel welding

Productivity Good Better Better Best

Operating cost Good Good Better Best

Consumable life Good Good Better Best

Process flexibility Good Better Better Best

Features Simple bundled systemwith minimal options

Lower degree of featuresand options

Lower degree of featuresand options

Fully featured with widerange of options

Application ranges Light-duty cutting Light- to medium-duty cutting Light- to heavy-duty cutting Precision cutting, light- toheavy-duty cutting

Price Low Medium Medium to high Higher


9

Technology benefitsOxygen plasma LongLife oxygen plasma HyPerformance Plasma

Benefits of oxygen plasmavs. air plasma

• Thicker capability• 100% duty cycle• Faster cut speeds• Better cut quality, less dross• Better weldability



Benefits of LongLife oxygenplasma vs. oxygen plasma

• Significantly longer consumable life• Significantly lower operating cost• Faster cut speeds (HySpeed)• Can be used on large machine frames

• Significantly longer consumable life• Significantly lower operating cost• Faster cut speeds• Can be used on large machine frames

Benefits of HyPerformancePlasma vs. LongLife oxygenplasma

• Significantly improved cut quality• Better process resolution on low end

for maximum cut quality on thin material• Fuel-gas capability to improve stainless

steel cut quality• Mark and cut with same consumables• Longest consumable life• Highest cut speeds• Auto gas console• Quick-disconnect torch• Bevel capability up to 45°• Significantly improved marking quality


10Air plasma: Powermax

* Note: Take care in comparison: competitors often show maximum cutting speeds rather than speeds that deliver the bestcuts, as shown above. Cut speeds listed above deliver best cut quality, but cut speeds can be up to 50% faster.

** ISO 9013 is a standard that defines cut quality of thermally cut parts. The lower the range (range 1 is the lowest), thesmaller the angle on the cut face. Cut angle in range 4 is better than in range 5.

Entry-level single gas (air or nitrogen)cutting systems, great for duct cutting, pipecut-off, beveling and robotic 3-D cutting.

Powermax

Powermax45 Powermax1000 Powermax1250 Powermax1650

CapacityMild steel

Stainless steel

Aluminum

Dross freeMaximum pierce capacity

n/a10 mm (3/8")

n/a12 mm (1/2")

n/a16 mm (5/8")

n/a19 mm (3/4")

Maximum pierce capacity 10 mm (3/8") 12 mm (1/2") 16 mm (5/8") 19 mm (3/4")

Maximum pierce capacity 10 mm (3/8") 12 mm (1/2") 16 mm (5/8") 19 mm (3/4")

Speed*(Mild steel)

At maximum piercecapacity

10 mm (3/8")810 mm/m(32 ipm)

12 mm (1/2")686 mm/m

(27 ipm)

16 mm (5/8")660 mm/m

(26 ipm)

19 mm (3/4")660 mm/m

(26 ipm)

Cut angle ISO 9013 range** 5 5 5 5

Weldability Preparation required

Preparation required



Process gasesby material

(Plasma/shield)

Mild steel Air Air Air Air

Stainless steel Air, N2 Air, N2 Air, N2 Air, N2

Aluminum Air, N2 Air, N2 Air, N2 Air, N2

Process amps Not all processesavailable for all materials

20 – 45 20 – 60 25 – 80 30 – 100


11

Oxygen plasma: MAX200

* Note: Take care in comparison: competitors often show maximum cutting speeds rather than speedsthat deliver the best cuts, as shown above. Cut speeds listed above deliver best cut quality, but cutspeeds can be up to 50% faster.

** ISO 9013 is a standard that defines cut quality of thermally cut parts. The lower the range (range 1is the lowest), the smaller the angle on the cut face. Cut angle in range 4 is better than in range 5.

Entry-level oxygen cutting system, great foroften-changing cutting requirements and production schedules. A proven production cutting system withan attractive initial capital cost.

MAX200

MAX200

CapacityMild steel

Stainless steel

Aluminum

Dross freeProduction (pierce)Severance (edge starts)

25 mm (1")25 mm (1")50 mm (2")

Production (pierce)Severance (edge starts)

25 mm (1")50 mm (2")


25 mm (1")50 mm (2")

Speed*(Mild steel)

Optimum quality 12 mm (1/2")2159 mm/m

(85 ipm)

Cut angle ISO 9013 range** 4 – 5

Weldability Ready to weld


(Plasma/shield)

Mild steel Air/Air, O2/Air,N2, CO2

Stainless steel Air/Air, N2/Air,N2/CO2, H35/N2

Aluminum Air/Air, N2/Air,N2/CO2, H35/N2


40 – 200beveling (200)


12LongLife O2 plasma: HySpeed HSD130, HT2000, HT4400

and HT4001

Heavy-duty production tools withcost-reducing LongLife technologyfor dramatically longer consumablelife and much lower operating costs.Ideal for production environments cutting mild steel, stainless and aluminum up to 75 mm (3") thick.

HySpeed HSD130, HT2000,HT4400 and HT4001

HySpeed HSD130 HySpeed HT2000 HySpeed HT4400 HT4001

CapacityMild steel

Stainless steel

Aluminum


16 mm (5/8")25 mm (1")

38 mm (1-1/2")

25 mm (1")32 mm (1-1/4")

50 mm (2")

32 mm (1-1/4")32 mm (1-1/4")

50 mm (2")

32 mm (1-1/4")32 mm (1-1/4")

75 mm (3")


20 mm (3/4")25 mm (1")

25 mm (1")50 mm (2")

32 mm (1-1/4")50 mm (2")

32 mm (1-1/4")75 mm (3")


20 mm (3/4")25 mm (1")

25 mm (1")50 mm (2")

32 mm (1-1/4")50 mm (2")

32 mm (1-1/4")75 mm (3")

Speed*(Mild steel)


(80 ipm)

12 mm (1/2")3050 mm/m

(120 ipm)

12 mm (1/2")4301 mm/m(160 ipm)

12 mm (1/2")2540 mm/m

(100 ipm)

Cut angle ISO 9013 range** 4 4 – 5 4 5

Weldability Ready to weld Ready to weld Ready to weld Preparation required


(Plasma/shield)

Mild steel O2/Air, Air/Air O2/Air, O2/O2,Air/Air, N2/CO2

O2/Air O2/H2O

Stainless steel Air/Air, N2/N2,F5/N2, H35/N2

Air/Air, N2/Air,N2/CO2, H35/N2

N2/O2-N2,N2/N2

N2/H2O

Aluminum Air/Air, H35/N2 Air/Air, N2/Air,N2/CO2, H35/N2

N2/O2-N2,N2/N2

N2/H2O


45 – 130 40 – 200beveling (200)

100 – 400beveling (400)

260 – 760beveling (all)

* Note: Take care in comparison: competitors often show maximum cutting speeds rather than speeds that deliver the best cuts, as shown above.Cut speeds listed above deliver best cut quality, but cut speeds can be up to 50% faster.

** ISO 9013 is a standard that defines cut quality of thermally cut parts. The lower the range (range 1 is the lowest), the smaller the angle on the cutface. Cut angle in range 4 is better than in range 5.


13

HyPerformance Plasma: HPR130, HPR260 and HPR400XD

HyPerformance Plasma mechanized systems deliver incomparable HyDefinitioncut quality at half the operating costs. By incorporating Hypertherm’s provenHyDefinition, LongLife and PowerPiercetechnologies, HyPerformance Plasmaboosts overall performance, productivityand profitability. The systems offerunmatched process flexibility to cut, beveland mark metals up to 80 mm (3.2") thick.

HyPerformance HPR130, HPR260 and HPR400XD

* Note: Take care in comparison: competitors often show maximum cutting speeds rather than speeds that deliver the bestcuts, as shown above. Cut speeds listed above deliver best cut quality for a given process, but cut speeds can be up to50% faster.

** ISO 9013 is a standard that defines cut quality of thermally cut parts. The lower the range (range 1 is the lowest), the smaller the angle on the cut face. Cut angle in range 4 is better than in range 5.

HPR130 HPR260 HPR400XD

CapacityMild steel

Stainless steel

Aluminum


16 mm (5/8")25 mm (1")

38 mm (1-1/2")

32 mm (1-1/4")32 mm (1-1/4")64 mm (2-1/2")

38 mm (1-1/2")50 mm (2")

80 mm (3.2")


20 mm (3/4")25 mm (1")

32 mm (1-1/4")50 mm (2")

45 mm (1-3/4")80 mm (3.2")


20 mm (3/4")25 mm (1")

25 mm (1")50 mm (2")

45 mm (1-3/4")80 mm (3.2")

Speed*(Mild steel)


(80 ipm)

20 mm (3/4")2286 mm/m

(90 ipm)

25 mm (1")2159 mm/m

(85 ipm)

Cut angle ISO 9013 range** 2 – 4 2 – 4 2 – 4

Weldability Ready to weld Ready to weld Ready to weld


(Plasma/shield)

Mild steel O2/Air, O2/O2 O2/Air, O2/O2 O2/Air, O2/O2,Ar/Air

Stainless steel H35/N2, N2/N2,H35-N2/N2, F5/N2

H35/N2, N2/N2,H35-N2/N2, F5/N2

H35/N2, N2/N2,H35-N2/N2, F5/N2,

Ar/Air, Ar/N2

Aluminum H35/N2, Air/Air,H35-N2/N2

H35/N2, Air/Air,H35-N2/N2

H35/N2, Air/Air,H35-N2/N2,Ar/Air, Ar/N2


30 – 130 30 – 260 30 – 400


14Consumables

Use genuine Hypertherm consumables to ensure optimal performance of your Hypertherm plasma cutting system. It is the only way to guarantee that you are using the latest performance-enhancing consumable technologies, machined to the highest quality standards and backed by the combined service resources of Hypertherm and itsworldwide network of channel partners.

Technology• Superior cut quality and reduced or eliminated secondary operations• Faster cutting speeds and greater thickness capabilities• Dramatically longer consumable life• Lower operating cost and higher productivity

Quality• ISO 9001:2000 registration ensures consistent manufacturing excellence• Six-sigma manufacturing processes guarantee repeatable machining of

critical-to-function dimensions for consistent consumable performance• Manufactured with state-of-the-art, precision equipment that

consistently maintains the high tolerances required by Hypertherm’shigh-performance consumable parts

Service• Worldwide product support provided in conjunction with our

network of channel partners• Customized process/system application solutions• Preventive maintenance, world-class service and operator training


ContentsComparison of plasma, oxyfuel and laser 4–5The Hypertherm advantage 6–7Hypertherm technology options 8–9Hypertherm products 10–15

The world leader inthermal cutting technologySince 1968, Hypertherm has had a single goal:cut the cost of cutting metal. The company’s one and only focus is thermal cutting technology. Its single-minded mission is to provide customers throughout theworld with the best plasma cutting equipment and service in the industry. That’s why Hypertherm holdsmore major plasma cutting patents, and has more customers worldwide than any other brand. In head-to-head tests, Hypertherm systems consistently outperform the competition in the keyareas of cut quality, productivity and operating cost.Hypertherm has evolved into a thriving global entitythat serves a continually expanding customer base.

15

Also available from Hypertherm to support yourmechanized cutting needs

Plasma torch height controls:

• Integrated Sensor ™THC• Stand alone

Command®THC• Sensor PHC

Oxyfuel torch height control:

• Sensor OHC

CNC controllers (2–12 axes):

• MicroEDGE™

• EDGE®Ti• EDGE II• Voyager™III• Mariner ™

Drive packages:• 2–4 Axes 400W AC• 2–4 Axes 750W AC

Drawing and nestingsoftware:

• HyperCAD®

• HyperNest®


Optimize quality, productivity and operating costMechanized cutting solutions

www.hypertherm.com©Copyright 11/08 Hypertherm, Inc. Revision 2

892120

Hypertherm, Inc. Hanover, NH USA603-643-3441 Tel800-643-0030 Tel (Toll-free USA and Canada)603-643-5352 Fax [email protected]@hypertherm.com

HYPERTHERM BRASIL LTDA. Guarulhos, SP-Brasil55 11 2409-2636 Tel 55 11 2408-0462 Fax [email protected]@hypertherm.com.br

Mexico (Representative Office) 52 55 5681 8109 Tel 52 55 5683 2127 [email protected]@hypertherm.com.mx

Hypertherm Europe B.V.Roosendaal, The Nederlands31 165 596907 Tel 31 165 596901 Fax [email protected]@hypertherm.com

Hypertherm Plasmatechnik GmbHHanau-Wolfgang, Germany49 6181 58 2100 Tel 49 6181 58 2134 Fax [email protected]

Australia/New Zealand (Representative Office)61 (0) 7 3219 9010 Tel61 (0) 7 3219 9012 [email protected]

Hypertherm, LongLife, HyDefinition, HyLife, CoolCore, SilverPlus, HySpeed, Powermax, HT, HyPerformance, HPR,MAX, Auto-voltage, PowerPierce, MicroEDGE, EDGE, Mariner, Command, Voyager, Sensor, HyperCAD andHyperNest are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.

Hypertherm (S) Pte Ltd.Singapore65 6841 2489 Tel 65 6841 2490 Fax [email protected]

Hypertherm (Shanghai) Trading Co., Ltd.Shanghai, China86-21 5258 3330 /1 Tel 86-21 5258 3332 Fax [email protected]

Hypertherm Japan Ltd. Osaka, Japan 81 6 6170-2020 Tel 81 6 6170-2015 Fax [email protected]


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Hyper Therm Mech Guide