Arc Voltage Torch Height Controller

XPTHC-100 Instruction Manual

Suitable for any plasma cutting machine Stand alone/DC motor

HYD CNC
http://www.hydcnc.com

Please read this manual fully before use

TABLE OF CONTENTS

1. Brief Introduction of THC 2. Specification 3. THC work process 4. Function of operation panel 5. Voltage Divide(100:1) 6. IHS(Torch Retaining Cap IHS and Proximity Switch IHS) 7. Interface Connection and Pin Definition 8. Maintenance 9. Some Advice

1Overview
1.1 XPTHC-100 is designed to support almost all plasma cutters, with full industrial THC functions such as, two models of Auto IHS (Ohmic contact IHS and Proximity Switch IHS), Set Pierce Delay Time, Freeze Auto Height Control on Receiving Corner Signal, support different HF plasmas.etc Please find details in follow chapters. 1.2Basic Functions of XPTHC-100 A Auto Initial Height Sensing(IHS) Torch Retaining Cap IHS and Proximity Switch IHS (NPN and PNP), Proximity Switch IHS is backup for Torch Retaining Cap IHS for cutting dirty/rusty workpiece, needing the Anti-Collision Fixture(breakaway kit). B Torch Anti-Collision Function: We designed Touch-Up circuit for Anti-Collision Function. No matter it is on Auto Control Model or Manual Control Model, when torch head touches the workpiece, THC would automatically lift torch up to IHS height. So with XPTHC-100, even in Manual Control Model, user doesnt need to worry about torch head crashing. C Freeze Auto Height Control on Corner Signal XPTHC-100 can recognize Corner Signal from CNC and freeze Auto Control Model on receiving this signal, and we have a unique design to backup this function. We set 30V (adjustable) as Turning Point according to our years practice. When the Actual Arc Voltage is higher than Set Arc Voltage over 30V, THC Auto Control Mode freezes to avoid torch head diving, until it goes back to 30V range. This Over Voltage protection can avoid torch diving on voltage spikes (Corner Turning, Kerf Crossing) effectively. D Lifting torch Up on IHS Disabled status. On IHS Disabled status, jogging torch head down until it reaches workpiece, when Arc Starts, torch head would lift up automatically to the Set Height set via the button SET-IHS. E Lifting Torch Up on TURN ON or Arc Off:
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When CNC is TURN ON or Plasma Arc Off, THC would lift torch up for 2 seconds, please notice this Function during commissioning, avoiding the possible damage of limit switch or lift device. F. Set Pierce Delay Time. Set Button Set-PIERE (set Pierce delay time), to delay output this signal, it is a switch signal, set to detect arc voltage lead in THC. Once THC detect arc lead in, it send arc ok signal to CNC to start cut. G. Manual Operation Many functions can be Manually operated on Operation Panel of XPTHC-100, such as, set Auto/Manual mode of THC, manually control torch Up and Down, IHS test, Arc Start test..etc. H. Arc Voltage Divide Isolation Voltage Divide detection, the Voltage Divide ratio is 100:1/50:1. Once Isolation Voltage Divide function damaged, user can also use Non-isolation Voltage Divide on our voltage divider.

2 Specification
Input PowerAC24V+5%50Hz/60H z Down/Up MotorDC24V DC MOTOR (3060W) Motor Drive: PWM ; Output Current1A-4A, Load capacity100W, Working temperature-1060 Voltage Divide ratio :100:1 Control accuracy 1V3V Size length *width *height320mm*260mm*90mm The speed of lifting 1000mm/min2000mm/min(Contact the supplier if it exceeds the range of speed

3 THC Work Flow

3.1Mode 1 :
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When CNC send out Arc Start Signal(IHS enabled), THC starts with IHS, then send Arc Start Signal to plasma, after plasma start, THC delay lead in arc voltage from plasma( set pierce delay time), THC send Arc Feedback(arc ok) Signal to CNC to start Cut after arc voltage lead in. If THC is on Auto Model, and CNC Auto Control enabled, then cutting is under THC Auto control. 3.2Mode 2 : When CNC send out Arc Start Signal (IHS disabled), THC starts without IHS, lifts torch to the set height (set via button SET-IHS), then send Arc Start Signal to plasma, after plasma start, THC delay lead in arc voltage from plasma ( set pierce delay time), THC send Arc Feedback(arc ok) Signal to CNC to start Cut after arc voltage lead in. If THC is on Auto Model, and CNC Auto Control enabled, then cutting is under THC Auto control.

4 Function of Operation Panel

Display AV Set Arc Voltage IHS Setting Set pierce delay Arc test

IHS-Test

Auto/Manual Switch

Manual UP/Down

Figure 1: Operation Panel

Arc Voltage: Before Arc Start it shows the Set Arc Voltage, after it shows the Actual Arc Voltage. Set Arc Voltage: Based on the thickness of steel plate being cut and cutting speed, it shall be set according to the parameter offered by Plasma, and it will be showed on operation panel. Set Arc Voltage decides the Torch Height during cut, the higher the arc is, the higher the Torch Height will be. On Auto mode, adjust the Set Voltage means adjusting the Torch Height. Set IHS Set Initial Height, turn clockwise, the height increases. IHS Test: Dial it up one time, it would check IHS one time, which is used to check whether it is a workable IHS or not. Set-PIERE: Set the Delay Time from Plasma Start to CNC starts cut (delay lead in arc voltage into THC), the Arc feedback (arc ok) signal would be sent to CNC only after arc voltage is detected by THC. Auto/Manual Set THC Auto or Manual mode. Meanwhile enables the Auto Signal between connectors of CNC and THC, (for EDGE system, the Auto Signal shall be connected as Normally Closed.) ARC Test Dial up and hold, Up/Down Manual operation button of Up and Down. It is effective on any mode. Indicator ARCON ON means Arc Start is processing. Indicator ARCON is off during IHS, if it is Arc Start with IHS enabled, and it is on after IHS completed. Indicator AUTO On means THC is on Auto Mode, four conditions has to be completed: 1, CNC Auto Height Control (THC) enables; 2, THC is on Auto Model; 3, arc voltage has been lead in THC; 4, Actual Arc Voltage not exceeds Set Arc Voltage 30V (Our unique design, we usually set as 30v; it can be adjusted through adjustable resistance RP104
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to test the Plasma Start. During test, Torch lifts up an IHS height.

according to cutting situation). Indicator TRANS On means THC has detected arc voltage, and output arc feedback (arc ok) signal to CNC.

5 Voltage Divider
Our Voltage Divider offers two modes of Voltage Divide, None Isolation Voltage Divide is backup for Isolation Voltage Divide. 5.1 None Isolation Voltage Divide
As Figure 2 shows

Figure2: None Isolation Voltage Divide circuit

Note: Plasma output positive pole is GND, negative pole connected with electrode in torch. DO NOT mis-connected, or THC will be UN-Effective. As None Isolation Voltage Divide is directly connected with Plasma Power Supply, to enable THC escape from interference caused by the HF during Plasma Arc Start, the Divided Arc Voltage guided into THC is Time-Delayed. It just needs to prolong the time of lead Arc Voltage into THC, this interference can be avoid effectively.

5.2 Isolation Voltage Dividing

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Plasma Arc Voltage is divided by Voltage Divider (offered with THC) on 100:1 via none isolate voltage divide, lead into THC after processed by Isolation Circuit. Arc voltage has little effect on THC after Isolation Circuit. This Voltage Divider can be connected as Isolation Voltage Divide or None Isolation Voltage Divide mode. AC220V Input - Actual Arc Voltage input +

100

output connector Of None Isolation Voltage Divide

Output of Isolation Voltage Divide Figure 3Voltage Divider connection.

Note: Non Isolation Voltage Divide is backup for Isolation Voltage Divide. On Non Isolation Voltage Divide, AC220V power can be unconnected; but it must be connected on Isolation Voltage Divide.

6. IHS (Torch Retaining Cap IHS and Proximity Switch IHS)

6.1 Torch Retaining Cap IHS

The Torch Retaining Cap should be metal, so the metal can be electric with steel plate. XPTHC-100 has a piece of Isolated IHS plate that can be fixed in the THC directly, the connection showed as Figure 4 below:

6.2 Proximity Switch IHS (NPN and PNP).

Under Proximity Switch IHS, user needs to use our Anti-collision fixture, introduced on Figure 12, (Anti-collision Fixture is not included in THC offer, optional to customer). Proximity Switch IHS is backup for Torch Retaining Cap IHS, for cutting dirty or rusty steel plate. It can work separately or simultaneously with Torch Retaining Cap. During cutting dirty or rusty workpiece, if the sensitivity of Torch Retaining Cap is affected, then Proximity Switch will secure cutting goes properly.

It is connected via Switch IHS on THC, refers to Figure 11 (chaptor 7.5) Once THC received Arc Start signal from CNC, torch moves down, when it reaches workpiece, Proximity Switch leaves proximity position, THC receives this signal, lifts torch to the set height, (Proximity Switch recovers during lifting). After IHS, THC drives plasma Start Arc. Proximity Switch IHS is suitable for all plasma IHS. Parallel connection can be used on Proximity Switch.

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7.

Interface Connection

TO-TORCH

TO-CNC

SWITCH-IHS

GND WORK SHIELD

POWERAC24V

TO-PLASMA

Figure 6Interface of XPTHC-100

Connection details as follow, 7.1 Power(AC 24V) (Connect JP1) XPTHC-100 works under AC 24V, usually it can be directly connected to the AC 24V Power Supply of plasma cutter, if not available, it needs Voltage Transformer (customer supplied).

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7.2 TO TORCH (Connect JP7).

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TO-PLASMA (Connect JP5)

Figure 9TO PLASMA connection (with plasma)

There are detailed wiring figure at the end of this manual ( Figure 12) shows the connection of THC control module, Plasma, CNC, Lifter, Torch Retaining Cap IHS, Proximity Switch IHS.

Attention: Please contact us if you are not sure about your connection, to avoid damage of PCB of THC, or malfunction.

7.4 TO-CNC (connected with JP6.)

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Figure 10. Connection between THC and CNC

The interface between THC and CNC adopts Optical Isolation. TO CNC have 6 ports as below respectively, A (EXAUTO) Auto/Manual Low Level input is AUTO; High Level is Manual. (XPTHC-100 would freeze torch on receiving Corner Signal from CNC via Pin 1.EXAUTO) BUP Low Level---Torch UP. CDOWNLow Level---Torch DOWN. D(Arc Start signal IHS Enabled)IHSARCONLow Level active, IHS first, then Arc Start automatically, E(Arc Start signal IHS Disabled)EXARCONLow Level active, Arc Starts directly, torch lifts to an initial height automatically. So in this mode, the torch should reach workpiece first before Arc Start.
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FARCTRANS1ARCTRANS2Dry Contact Output(Arc OK/Arc feedback signal to CNC. If plasma has this signal, user can use Arc OK signal of plasma, it is optional.). 7.5Proximity Switch IHS (Connect JP3 for Proximity Switch IHS)

JP3 1

Figure 11Connection of Proximity Switch IHS(SWITCH IHS)

7.6 Current Feedback Circuit Setting. The relationship between adjusting the SP2 current and the ON/OFF of Switch.

Current 4A 3A 2A 1A

1-8 OFFPWM=9KHZ ONPWM=18KHZ

2-7 OFF OFF OFF ON

3-6 OFF OFF ON ON

4-5 OFF ON ON ON

8Maintenance
8.2Cancel function of Cutting Torch Lift after Arc off,( Please contact us if you are no sure about it)
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The function of Auto Lift would choke the lifting device if the Limit switch not installed yet or doesnt work properly. So if the CNC has Auto Control function for Up and Down, you can cancel the Torch Auto Lift function on control PCB. Cancel the R234 on the control PCB or Cancel the C218 on the control PCB.

We set 30V as Over Arc Voltage Protection (OAVP) according to our years practice, it is to avoid torch diving on voltage spikes; it should NOT be changed before carefully checking. THC would cancel the function of Auto Height Control if the Actual Arc Voltage is higher than Set Arc Voltage 30V. So if OAVP is too small, the Auto Height Control function can not work. OAVP can be adjusted via adjusting RP104 on PCB. Turn one round clockwise, 4v decreased, anti-clockwise, 4v increased. Some advice, 1. When Torch Retaining Cap IHS adopted, we suggest customers use Anti-Collision Fixture to fix cutting torch and lifter and connected it with Torch Retaining Cap. In practice, when the contact between Retaining Cap and workpiece is weak (especially the workpiece is Rusty or Dirty steel plate,) Proximity Switch IHS takes effect; it is more effective to protect cutting torch. If Torch Retaining Cap IHS and Proximity Switch IHS both installed, both will be active during cutting. 2. When it is using proximity switch function, we suggest try some more proximity switches, and all switched by outside circuit. 3. The cable connecting Voltage Divider and THC must be SHIELD cable, and shall be separated away from Arc Start cable. 4. When the CNC can not receive the Arc Start Enable signal, it should use Time-Delay to run the CNC. In other word, after CNC sent Arc Start signal, delay the CNC Running.

8.2Please CONTACT US if you are not sure about solution for follow situation or your supplier from whom you bought.
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Serial Number 1 No

Malfunction

Cause

Solution

display,

black

No +5V voltage on the voltage meter 1 damage of drive

Check +5V voltage VCC3

screen 2 No rotation of motor or only one direction rotates.

1replace IR2110

IR2110 2 drive voltage +15V Check drive voltage VCC4 failure 3 protection over-current of D606 D609 IRF640 is damaged blocked or mechanical

Once turn on, cutting torch keeps lifting NPN

1.Proximity switch is not installed well in the

Install the Proximity switch perfectly

open-circuit condition 2 damage of Proximity switch Replace Proximity switch

signal2mmNPN Replace Proximity switch

Can

not

Start

Arc after

1 damage of Proximity switch, no return signal 2IHS time is too short, no return signal

automatically the IHS

Prolong the IHS switch

Instability controlling voltage

of arc

1check the connection with earth 2check the water-proof 3over-sensitive Setting time of 1increase SET-PIERE time 2 adopt the arc feedback signal of Plasma itself

CNC starts to work before accomplishment Arc Start the of

SET-PIERE is too short

Plasma

Arc

Start

using

the

EXARCON

Prolong the delay time of CNC IHS

before the IHS

signal, the delay-time of CNC controlling is too short

Cutting torch can not start arc

1Confirm the working situation of Plasma power 2Check the height of IHS 3Check the cutting torch fittings

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Arc of Torch can not transfer piece to work

1Check the connection of working lead 2Check the cutting torch fittings Prolong the time of piercing hole in the CNC system

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Cutting torch move before piercing hole completed

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CNC control starts, cutting torch heads down immediately

1Increase Set Arc Voltage 2Prolong the automatic time in the CNC system 3Decrease the Over Voltage Protection No.(30V) 4Check the situation of Auto signal or Corner signal of CNC system

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Plasma arc out after the arc transferring and piercing hole

1 Delay-time is too long

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During

IHS,

the

1 Time of HIS is too short 2 Induced lead connect with protection badly

cutting torch touches the steel plate but no movement upwards.

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Cutting torch keeps heading down after touching work piece, and no Arc Start

1 Weak contact between detecting cable and retaining cap. 2 Proximity switch is damaged 3 WORK in THC is bad connection with earth 1 THC is over sensitiveturn RP501 anti-clockwise 2 THC damaged 1 THC is low sensitiveturn RP501 clockwise

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Cutting mode

torch on

move Auto

unsteadily 16

THC is too slow on tracking, auto-state on

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Arc off during the cutting, Voltage out, runs and Arc Enable still

problemTHC can not stop immediately since it works with arc voltage signal. solutionadopt the Arc OK signal of Plasma itself

signal keeps sending machine

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