Adtech HCA1002 User manual

HCA1002
PLASMA HEIGHT TORCH CONTROLLER

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1、Introduction
1.1、Product Name & Model：
HCA1002（upgrade）CNC Plasma Torch Height Controller
1.2、Basic Parameter
yWorking Voltage：AC24V+5%，50Hz/60Hz
yLifter motor- up/down：DC24V motor
yDriver mode: PWM
yOutput Current：1A-4A, Max.:6A, Load Capacity: 100W,
yWorking Temperature: -10 ∽60℃
yDivide-voltage ratio: 100:1
yControl Accuracy：±1V∽±3V
ySize：Length * Width * Height：320mm*260mm*90mm
yThe speed of lifting: 1000M/S ∽4000M/S（Contact the supplier if it exceeds the range of
speed）
1.3、Application：
HCA1002 supports mostly all plasma cutting machine on worldwide market like
Hypertherm, Thermal Dynamics etc. It includes HD Plasmas like HPR130, 260,
Ultra-cut series…. And it supports all CNC cutting controllers also. Like Hypertherm,
Burny, and industrial level controller or MACH3 such DIY controllers, because it can
start Auto Height Control with or without auto enable signal from CNC. But with Auto
enable/disable signal from CNC, THC would be work better.
1.4、Components
HCA1002 includes follow parts:
A. HCA1002 Control module;
B. Voltage Divider;
C. All related connectors.

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1.5、Basic Functions：
A、Automatic Initial Height Sensing (IHS)：
Torch Retaining Cap HIS and Proximity Switch HIS (NPN and PNP),
Proximity Switch HIS is backup for Torch Retaining Cap HIS 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 HIS height, so with HCA1002, even in
Manual Control Model, user doesn’t need to worry about torch head crashing.
C、Freeze Auto Height Control on Corner Signal
It 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 Tuning, Kerf Crossing) Effectively.
D、Lifter Torch Up on HIS Disabled Status
On HIS 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-HIS.
E、Lifter Torch Up on TURN ON or ARC Off
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
SetButtonSet-PIERE(setPiercedelay time), to delay output this signal, it is a

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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.
Dynamic Pierce works by receiving plasma’s Dynamic Pierce signal (Kjellbery plasma
has this signal) or plasma’s arc feedback signal. After HIS, THC controls plasma start
arc, and it lifts torch up when arc strikes. It is to protect the torch tip and electrode;
consumables can work longer in this way.
G、Manual Operation
Many functions can be Manually operated on Operation Panel of ADT-HC1002,
Such as, Set Auto/Manual Mode of THC, manually control torch Up and Down, HIS test,
Arc Start test etc.,
H、Arc Voltage Divide
Isolation Voltage Divide, the voltage divide ratio is 100:1 or 50:0. Once Isolation
voltage divide function damaged, user can also use Non-Isolation Voltage Divide on your
voltage divider.
1.1、Basic Functions：
1.6.1 Work with HIS
When CNC send out Arc Start Signal(HIS enabled), THC starts with HIS, 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, the cutting is under
THC Auto control.
We don’t recommend work without IHS

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2、Commission & Set
2.1、Operation Panel Introduction
Arc Voltage
Before Arc Start it shows the Set Arc voltage, after it shows the Actual Arc Voltage.
Arc-Voltage Setting
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.
Pierce HEIGHT
Increase on clock –wise turn, decrease on anto-clockwise. Pierce height means torch lift up
height after receiving dynamic pierce signal from plasma or arc feedback signal from plasma.
It is used on cutting thick material. If the dynamic pierce signal is disconnected, this function
is disabled.

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HIS HEIGHT
Set Initial Height, Turn clockwise, the height increase
PIERCING DELAY
Set the Delay Time from plasma start to CNC start 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.
HIS –Test
Press one time, it would check HIS on time, which is used to check whether it is a workable
HIS or not.
AUTO
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).
ARCON TEST
Press and hold, to test the Plasma Start, during test, Torch lifts up and HIS height.
Up and Down
Manual operation button of Up and Down, It is effective on any mode.
Indicators
Down Indicator: Turn on when torch lift down.
Collision Indicator: Turn on when torch touch workpiece or proximity switch effective.
TRANS Indicator: Turn when THC receives arc feedback signal, and sent out Arc OK
signal to CNC.
AUTO Indicator: On means THC is on Auto Mode, Four Conditions have to be completed:
1. CNC Auto Height Control (THC) enables;

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2. THC is on Auto Model;
3. Arc voltage has been lead in THC;
4. Actual Arc Voltage not higher than Set Arc Voltage over 30V.
Note:
A. When THC on Auto Mode, the 5 indicators all should be ON, if anyone is OFF, that
means Auto Mode failed, please check the reason according to indicators.
B. There are 6 indicators on Operation panel, demo THC from Torch down - Touch
workpierce - arc start-arc feedback - Auto on, please check the failure reason from
the one by one step.
2.2、Voltage divider
Our Voltage Divider offers tow modes of Voltage Divide; None Isolation Voltage
Divide is backup for Isolation Voltage Divide.
2.2.1 None Isolation Voltage Divide
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 Divide
Arc Voltage guided into THC is Time-Delayed.
It just needs to prolong the time of lead Arc Voltage into THC, the interference can be
avoid effectively.
As shoed in figure 2-2

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2.2.1 None Isolation Voltage Divide
Plasma Arc Voltage is divided by Voltage Divider (offered with THC) on 100:1 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 Divider or Non Isolation Voltage Divide mode.
As showed in figure 2-3

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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.
2.3 HIS
2.3.1 None Isolation Voltage Divide

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The Torch Retaining Cap should be metal, so the metal can be electric conducted with
steel plate. It has a piece of Isolated HIS plate that can be fixed in the THC directly, the
connection showed as Figure 2-4 below:
Torch Retaining Cap HIS
THC receives arc start signal from CNC, lift torch down, when torch retaining cap
torches steel, THC lift torch up to set HIS height, After HIS, THC control plasma to start
arc.
Note:
A. The cable from SHIELD (marked as shield on THC) to torch retaining cap.

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B. The GND must be well grounded WORK must connected with ground, and
the grounding cable must be > 4mm2
C. The cable connected to retaining cap must be Height Voltage cable.
2.3.2 Proximity Switch HIS
HCA1002 supports torch retaining cap HIS and proximity switch HIS both. We
recommend proximity switch HIS, which can be HIS and anti-collision function job both,
especially cutting rusty/painted steel,
Proximity switches HIS uses 3-pin connector, named on THC “Switch HIS”, Pin
definition as follow:
It uses 2 Proximity switch connected as above drawing, any one of then effective, THC
can receive this signal, as figure 2-6 shows:
Note: In side THC, a 250mA Recoverable Fuse is installed at the power supply of
proximity switch, to avoid damage of power when proximity switch failed.
Work Process: Once THC received Arc Start signal from CNC, torch moves down, when
it reaches workpiece, Proximity Switch leaves proximity position, THC receives the
signal, lifts torch to the set height,( proximity Switch recovers during lifting). After HIS,
THC drives plasma Start Arc.
Proximity Switch HIS is suitable for all plasma
HIS

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3、Wiring Introduction:
Introduction HCA1002 Connector’s wiring details,

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3.1、Power
HCA1002 works under AC24V
Socket as right picture Power
3.2 Motor Port
HCA1002 use DC24V motor as drive output,

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Socket shows as right picture TO TORCH
3.2.1 TO TORCH
3.2.2 Drive Current & Set
The relationship between adjusting the SP2 current and the ON/OFF of Switch

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3.3 To CNC
HCA1002 connect to CNC via a 10-pin socket
Shows as right picture To CNC

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3.4 To plasma
HCA1002 Connects to Plasma via 4-pin socket,
Marked as TO PLASMA

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3.5 Proximity Switch HIS Port
HCA1002 Proximity switch HIS port is 3-pin socket,
Marked as SWITCH HIS,
4、THC wiring diagram

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HCA1002 Wiring Diagram

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5、Maintenance

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