INSTALLATION & OPERATION MANUAL - MASSO CNC ......The system uses the raw plasma arc voltage to...

PLASMA THC 1.4

INSTALLATION & OPERATION MANUAL

1 | P a g e w w w . n t e n g i n e e r s . i n

Standalone Plasma Torch Height Controller

Model: THC 1.4

INSTALLATION & OPERATION

MANUAL RELEASE 1 – OCT 2015

Nasik, India

www.ntengineers.in

PLASMA THC 1.4



SAFETY ADVISE / WARNING

WHEN THE DEVICE IS IN OPERATION, HAZARDOUS VOLTAGES WHICH CAN BE

FATAL TO HUMAN LIFE ARE PRESENT INSIDE THE ENCLOSURES AND AT THE

CONNECTION TERMINALS. PLEASE FOLLOW PROPER SAFETY WHILE

HANDLINE AND INSTALLING THE EQUIPMENT.

Touching live electrical parts can cause a fatal shock or severe burn. Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit. Never touch the torch body, workpiece or the water in a water table when the plasma system is operating. Install and ground this equipment according to the instruction manual and in accordance with national and local codes. Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge. Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard. When making input connections, attach proper grounding conductor first.

PLASMA THC 1.4



Overview

DigiCut THC is a automatic plasma torch height control/initial height sensing system designed for

conventional plasma cutting applications on an X-Y cutting table. The system uses the raw plasma arc

voltage to control the physical stand-off (distance) between the torch and work piece during plasma arc

cutting. Initial Height Sense (IHS) is accomplished by ohmic contact sensing or by a floating switch method. The THC has been designed and optimised for conventional air plasma systems. DigiCut THC systems includes the following components MAIN THC UNIT The Main THC Unit houses a microcontroller, a HMI with a Backlit Graphic LCD Display, LED's for Status and buttons. The Main THC unit is the heart and control centre of the entire THC operation. The Main THC unit interfaces with the CNC Machine, Plasma Power Supply, Voltage Divider Unit, Ohmic IHS Unit through discrete IO connectors. VOLTAGE DIVIDER UNIT The voltage divider unit provides a filtered and isolated low voltage signal which is derived from the actual ARC voltage of the Plasma Arc voltage. The unit receives raw arc voltage from the plasma power source. Special care and safety precautions should be taken and the unit must not be touched or handled while the plasma is in operation. The unit enclosure must be properly grounded to ensure personnel safety. The unit can be mounted near to the plasma power supply. OHMIC IHS UNIT The unit provides Ohmic sensing (contact sensing) capability with isolation to the Main THC Unit. The unit has connections to AC power, Main THC Unit and the Work (Job) and the Shield (Torch). Special care and safety precautions should be taken and the unit must not be touched or handled while the plasma is in operation. The unit enclosure must be properly grounded to ensure personnel safety. The unit can be mounted near to the plasma power supply.

OPTIONS (NOT INCLUDED IN STANDARD ORDER)

1. LIFTER ASSEMBLY WITH MOTOR & DRIVER

2. FLOATING SWITCH BASED TORCH HOLDER ASSEMBLY

PLASMA THC 1.4



Features

DigiCut THC Plasma Height Control is an automated height control system for automated plasma cutting applications. This product uses microprocessor technology to automatically detect the plate and adjust torch position to an arc voltage set point during plasma cutting operations. This reduces operator input, improves accuracy and increases productivity. Features

• DigiCut THC is Fully standalone and can be used with any CNC Controller

• Easy setup and Operation

• Automatic & Manual Operation Modes

• Microprocessor based for increased sensitivity and control

• Graphic LCD display for set/actual voltage display, parameter settings

• Stepper / Servo motor based Z Axis control for higher precision & accuracy.

• Provides ISOLATED STEP & DIRECTION signals for Stepper / Servo Driver. (Driver Not included)

• Dual Speed IHS (Initial Height Sensing) for both Ohmic and Floating.

• Adjustable pierce height and cut height in 0.1 mm intervals

• Adjustable pierce delay in 0.1 sec intervals

• LED outputs for easy status indication for Cut, Up, Down, Plasma start, Motion Start, and Auto / Manual.

• Host of Settings for fine tuning system operation.

PLASMA THC 1.4



Specifications

Compatible Motors Stepper or AC/DC Servo based on position mode of operation (Step & Direction Signal)

Operating Voltage Main THC: 24V DC ±5% Voltage Divider: 240V AC ±5% Ohmic IHS: 240V AC ±5%

Standard lifter range: Based on lifter design

Motor output: STEP & DIRECTION PNP +5V SIGNAL and GND Outputs

MAX OUTPUT RESOLUTION 0.01mm

ACCURACY ±1 Volt

Voltage control range 45 to 220 VDC

Pierce Height 1.5 to 9.9 mm (User Adjustable)

Operator switches: UP / Down Auto / Manual IHS Auto / Manual HIS Test / Arc Test Pierce Delay Pierce Height Cut Height Settings

LED Status Indication: POWER CUT PLASMA MOTION UP / DOWN AUTO / MANUAL IHS AUTO / MANUAL

Operating environment: 0 to 50C; 95% relative humidity (non-condensing)

PLASMA THC 1.4



Physical Dimensions: Main THC Unit 192mm width 96mm height 100mm depth

PLASMA THC 1.4



Panel Cut-out Details & Dimenions

Front View of Fitting with Dimensions

PLASMA THC 1.4



Side View of Fitting with Dimensions & Clearance Details

PLASMA THC 1.4



MAIN THC Unit – Front Panel

Pierce Height

Control from

1.5 to 9.9mm

Pierce Delay

time from 0.1 to

3 Seconds

Cut Height

Adjustment

Interface buttons

for Up/Down,

Auto/Manual,

Settings and

HIS/ArcTest and

LED Indications

LCD Display for displaying the Currently

set values and various status displays

during operation.

PLASMA THC 1.4



Connections

MAIN THC UNIT

1. DC Supply Port 2Pin 24V DC Supply should be connected through an external SMPS. SMPS of minimum current rating of 2A should be used for 100% duty cycle of the THC. To Avoid interference use a sepeate SMPS for THC operation only. Do not share this SMPS with any other loads. PLEASE DO NOT CONNECT REVERSE POLARITY TO AVOID DAMAGE. 2. Motor Outputs: 3 Pin (GND, DIRECTION+,PULSE+) This is 5V Signal output for driving Stepper or Servo Motor for the Z axis operation. 3. PLASMA INTERFACE CONNECTION (4 Pin) PREFLOW PREFLOW This is the switch (DRY CONTACT) output for starting the Plasma Preflow operation before pierce. If you plasma power supply does not support preflow then please leave this unconnected. ARC START ARC START This is the switch (DRY CONTACT) output for starting the ARC of your Plasma Cutter. Please refer your plasma power source manual for more information of connection to your power supply.

4. CNC IO Connector This contains all the signals required for interfacing with your CNC Controller. All the signals are isolated and operated with 24V signal. CNC-COMMON can be set as + or – by setting the jumpers inside the main THC Unit. The 4 CNC signals CNC-CUT, CNC-CORNER, CNC-UP, CNC-DOWN are used with CNC-COMMON input. Default setting of CNC-COMMON is +, so the 4 signals are operational when –24V is supplied to each one of them. OK TO MOVE (2 Nos) is a dry contact switch output for starting the motion of your CNC Controller. Please refer manual of your CNC Controller for interfacing this signal with your system. All other signals are switched by +24V. (Down Limit, Up Limit, Collision, Plasma Arc Transfer) +24V and GND is also available at the CNC IO Connector.

PLASMA THC 1.4



5. OHMIC IHS Connector This connector is used to interface the OHMIC IHS Box with the Main THC Unit using the supplied cable. 6. Power Switch This switch is used to Power On / Off the main THC Unit. 7. DC Supply Port 2Pin (3 PIN) Middle pin should be left unconnected. Please loop the power supply given on (1) with this Port. PLEASE DO NOT CONNECT REVERSE POLARITY TO AVOID DAMAGE. 8. USB Port This port is used to update the software of the THC Unit. 9. ARC Voltage INPUT This port if used to connect the divided and isolated ARC Voltage with the Voltage Divider Box using the supplied cable.

10. Ground (Earth)

Please supply ground / earth on this screw. Earth resistance should be ideally be less than <1 Ohm for smooth

and trouble free operation.

PLASMA THC 1.4



VOLTAGE DIVIDER UNIT

1. AC 230 V (Round Circular 3 pin connector)

2. DB9 – Divided voltage output. Connect to main THC unit using supplied cable.

3. Screw Terminal for + and – raw arc voltage

PLASMA THC 1.4



OHMIC IHS UNIT

1. AC 230 V (Round Circular 3 pin connector)

2. DB9 – OHMIC IHS Signals

3. Screw Terminal for GROUDN and SHIELD

WARNING! For safety and proper operation all three units must be connected

to the star ground on the work table.

PLASMA THC 1.4



LED Diagnosis OF Ohmic IHS Unit.

Cut D8 D7-IHS D4 Description

On If D8 turns on that means IHS board is getting 24V from

THC, if NOT check 24V supply to THC DB25 Pin 18,19,20

Off On If D4 turns on when Work&Shield Shorted means 230V

present on IHS Board, CUT led should be OFF to test this

Off On On On

If D4 and IHS Turns on when Work&Shield shorted means

230V & 24V Present and board working Ok, Ohmic=1 shold

show in diagnosison THC

On On Off Off

If Cut LED is ON then Ohmic will not work even when

Work&Shield is shorted. This is for protection. Press down

momentarily or IHS to disable this LED and enable ohmic

again. L15/Ohmic LED inside the THC should glow when

Work&Shield is shorted

PLASMA THC 1.4



MAIN THC SIGNALS

I/O Connector – DB15 Female

All signals to and from the CNC are connected to the DB15 Female connector on

the MAIN THC Unit.

Inputs from CNC

CMC-Common CNC-Start Signal CNC-Corner Signal CNC-Up Signal CNC-Down Signal CNC-COMMON can be set as + or – by setting the jumpers inside the main THC Unit. The 4 CNC signals CNC-CUT, CNC-CORNER, CNC-UP, CNC-DOWN are used with CNC-COMMON input. Default setting of CNC-COMMON is +, so the 4 signals are operational when –24V is supplied to each one of them.

[All above inputs are isolated and are driven using 24v (+ or -) signals from CNC] To change the CNC-COMMON from + to – please set the jumpers inside the THC box as given below

PLASMA THC 1.4



Outputs to CNC

Ok to Move (Motion) [Ok to Move is a dry contact relay output signal. Any voltages that the CNC required should be supplied externally]

Other Signals

Floating Switch Input (Float+ and Float-) Up Limit Input+ Down Limit Input+ Collision Input+ Plasma Arc Transfer+ +24V (Supplied from Input) GND (24V) (Supplied from Input) [All inputs are opto-isolated and are driven using 24V DC Signals]

MOTOR OUTPUT – 3 Pin Screw Type Terminal

GND Step/Pulse + Direction + [Motor output is isolated PNP type and voltage level is 5v DC to be connected to suitable Stepper/Servo Driver]

PLASMA THC 1.4



MAIN THC SETTINGS

QUICK ADJUST SETTINGS

Buttons

1. Pierce Height This button lets you adjust the pierce height by turning the knob. You can press the IHS button to see the height adjusted.

2. Pierce Delay

This button lets you adjust the pierce delay by turning the know. The THC will wait for this delay before issuing motion signal to the CNC for starting the cutting operation.

3. Cut Height This button lets you adjust the cut height. This is the distance the torch would move down after pierce is complete and then the arc voltage height control kicks into action.

BUTTONS

Up / Down

This lets you JOG the Z axis during idle. The Z DRO on the LCD would update giving you the precise location of the Z axis. During cutting in Auto Mode this lets you dynamically adjust the Target Set Voltage. During cutting in manual mode this lets you JOG the torch in fixed intervals of 0.5mm for each press.

Auto / Manual

This lets you change the THC mode of operation from Manual to Auto and vice versa. In Auto mode the THC works by maintaining the voltage by continuously adjusting the Z Axis. If the THC does not read sufficient voltage after pierce it would not start the cut and show ARC ERROR. Also UP/Down pressed during the cutting operation would adjust the SET voltage dynamically and the operator would hence see the maintained height change proportionally.

PLASMA THC 1.4



This feature is particularly useful when the operator does not have knowledge of the exact voltage to be set for the Plasma source and can adjust the voltage by observing the distance and adjusting it during cutting. In Manual Mode the THC does not correct the height of the torch during cutting. It merely displays the actual ARC voltage for reference. This could be used to see the ARC voltage for sample cutting on straight surfaces. Also UP/DOWN pressed during cutting in manual mode will JOG the torch up and down for fixed distance of 0.25mm for each press. The THC would also issue motion signal even if the valid ARC voltage is not available from plasma.

IHS / Arc Test

IHS The IHS button performs initial height sensing. This is used to reconfirm the pierce height at this the plasma would be turned on. Plasma manufactures specify this height. Pressing the HIS button again when the torch is at pierce height retracts the torch to the retract height specified in the settings. ARC TEST Pressing the HIS button for 3 seconds continuously enables you issue PLASMA START signal to the Plasms Power Source. The signal is issued for as long as the button is pressed. This enables you to verify the plasma start wiring and the arc voltage connections. The LCD would display the actual arc voltage when the plasma is started.

SET

The THC allows various parameters to be tunes. The SET button enables uses to enter the settings menu to fine tune these various settings. Pressing the SET and the IHS buttons in the settings menu allow you to move to difference settings available in the system. Pressing the SET button while in settings saves the changes made and exits to the Main Screen Of the THC. The brief of all the settings available in the THC is given below.

1. Cut Voltage This is the target voltage the THC maintains by moving the torch up/down on a continuous basis. This can be adjusted by the UP / DOWN button in 0.5 V increments.

2. Deadband The system allows you to adjust the dead band between 1v to 15v. This is basically the voltage band for which the THC will not take corrective action. For example: If the target voltage is

PLASMA THC 1.4



140v and the dead band is set to 2 volts then the THC would not move the torch when the actual voltage is between 139 to 141 volts. Only once the voltage cross this band the correction would take place. This is used to avoid over corrections in the THC. 3. AVC Response time This is the time in milliseconds that the THC averages the ARC voltages and then takes action. If the cutting speed is high then this time should be kept low for quick actions. If the cutting speed is slow this should be kept higher. This setting can also be fine tuned by observing the THC during a cut and then increasing or decreasing the THC response time accordingly.

4. Float Sw Offset When the Initial height sensing is done by floating switch instead of ohmic, most lifter designs over travel a bit after the torch touches and before the floating switch triggers. This over travel can be compensated by raising the torch by the Float Sw Offset + Pierce height when the IHS operation is done using the floating switch. This ensures the same pierce height is maintained irrespective of the HIS being done by Ohmic Sensing or the floating switch mechanism.

5. Float Input Logic The floating input connection logic can be changed from Active High to Active Low using this setting. This setting is available to accommodate different lifter designs and floating mechanisms being used by difference manufactures.

6. Float as Collision The floating switch can be used as a collision signals when this setting is enabled. The THC would withdraw the Plasma Start and Ok to Move (Motion) Signal to stop the cutting if this setting is enabled and the floating switch is triggered during the cutting operation.

PLASMA THC 1.4



7. LCD Update Time This setting lets you adjust the time frequency in milliseconds that the data on the LCD is refreshed on the THC LCD Graphic display.

8. Z Speed This settings lets the user adjust the Z axis speed in mm/ second.

9. Z Acceleration This settings lets the user adjust the Z axis acceleration in mm/ second/second. This can be kept high or low as per the lifter design.

10. Slow IHS at

The system supports dual speed IHS. This helps prevent damage to the torch by hitting the plate at the full speed of the Z axis. This settings lets you adjust the distance at which the slow HIS is started. The THC assumes the last IHS location to be the 0 point. For example: if this setting is set to 15mm and the slow IHS speed is set to 50% the torch would slow down at 15mm to 50% of the set speed.

11. Slow IHS Speed

This is the speed in percentage of the main THC speed that the THC would slow down to during performing the IHS operation in dual speed.

12. Enable Ohmic HIS This settings is used to ENABLE / DISABLE the ohmic based IHS.

13. Partial Raise Ht

This is the distance in mm that the torch is raised after each cut is over. This helps to avoid the torch hit the cut parts during traversing to the next cut location.

14. Full Retract Dly

This is the time in seconds that the torch would be retracted fully till the up limit is triggered if no activity is performed (Idle).

PLASMA THC 1.4



15. Correction Speed This is the maximum correction speed in mm/second that the THC will allow corrections to happed during the Automatic Mode of operation. This speed is only affected during the actual cutting operation.

16. Correction Acceleration

This is the correction acceleration setting in mm/second/second that will be effected during the actual cutting operation.

17. Z Pulses per mm This is setting of the Z axis resolution in terms of pulses per mm. For example: If the lifter has a ball screw with a pitch of 5mm and the stepper driver is set to 200 pulses per rotation this setting would be 200/5=40 pulses per mm.

18. Voltage Divider Ratio This is the setting of the voltage divider ratio of the VOLTAGE DIVIDER CARD that is supplied to you. Please confirm that value of this setting as per the card supplied to you from the supplier.

19. Dynamic Pierce Ht Adj

When this setting is enabled and the user is adjusting and testing the pierce height by pressing the HIS button, the THC would make rapid and immediate changes in height if the Pierce Height POT is turned within 5 seconds of pressing the IHS button. This enables the user to dynamically see the height adjustment without needing to do IHS again and again.

20. Cut Speed Siml

This option is implemented for our Service Personnel only and is not to be used by the user.

21. Move Fixed Dist This option is implemented for our Service Personnel only and is not to be used by the user.

22. ArcOk Relay Tst

This is used to check and confirm the wiring of the Ok to Move (Motion) signal that is output to the CNC from the THC by pressing the Up / Down buttons. This is only for diagnosis and initial

PLASMA THC 1.4



testing of the writing.

23. INPUT SIGNALS STATUS

This screen lists all the input signal of the THC and their real-time status. This is used to check and verify the connection of the signals between the CNC and the THC.

PLASMA THC 1.4



Sequence of Operation 1. The THC waits for the CUT signal from the CNC to begin the cutting cycle. When the THC received the CUT signal it begins the cutting cycle by starting the IHS Operation. 2. After IHS is completed the torch is at the Pierce Height that is set by the user (POT). The THC then issues the PLASMA START signal to start the arcing of the Plasma Torch. 3. The THC then waits for the Pierce Delay time that is set by the user (POT). 4. After the pierce delay is completed the THC lowers the torch by the Cut height distance set by the user (POT). 5. The THC then reads and confirms the actual arc voltage of the plasma Arc and if sufficient issues the OK to MOVE signal to the CNC controller to start motion of the plasma torch in X,Y direction to begin the cutting process. 6. The THC continuously corrects the height of the torch based on the Actual Arv Voltage and the set voltage. The THC raises the torch is the Actual arc voltage is less than the set arc voltage and lowers the torch if the actual arc voltage is higher than the set voltage. The USER can press UP and DOWN during the cutting operation to dynamically change the Set Arc Voltage. The THC does not perform any correction movement during the time the CORNER signal is issued from the CNC to prevent the torch diving into the job as the speed is reduced around corners and kerfs. If the Float as Collision setting is set to enabled and the floating switch if triggered during cutting which signified the torch crashing or hitting an obstacle the THC stops the PLASMA START signal and the OK to MOVE signal and displays a collision warning. The user can resolve the condition and resume cutting by issuing a CUT signal again. 7. Once the cut signal is withdrawn the THC raises the torch by the Partial Raise Ht distance. [Available in settings] and waits for the next CUT signal. 8. If no activity or signal is issued for Full Retract Dly then the THC retracts fully upward till the up limit is triggered.

PLASMA THC 1.4



WIRING DIAGRAM Please contact our support teams to obtain wiring diagrams for your CNC Models.

PLASMA THC 1.4



Trouble Shooting Please contact our phone support for real time and quick trouble shooting.

PLASMA THC 1.4



WARRANTY POLICY

NT Engineers warrants that its Products shall be free from defects in materials and workmanship, if NT Engineers is notified of a defect within a period of one (1) year from the date of its delivery to you,

NT Engineers does not warranty systems that have been damaged as a result of poor power quality, whether from phase converters or incoming line power. This warranty shall not apply to any Product which has been incorrectly installed, modified, or otherwise damaged. NT Engineers, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with NT Engineers’s prior authorization (which shall not be unreasonably withheld), properly packed, to NT Engineers place of business in Nasik, India or to our authorized repair facility, all costs, insurance and freight prepaid. NT Engineers shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with NT Engineers’s prior written consent. The warranty above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by NT Engineers of its warranty.

INSTALLATION & OPERATION MANUAL - MASSO CNC ......The system uses the raw plasma arc voltage to...

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