AGELKOM CAP04 User manual

Agelkom CAP04 Manual
1
AGELKOM CAP04
Plasma and Oxy Fuel Torch height control
for sheet metal cutting machines
Height Sensor & Controller
Description:
SENSOR RING:
The metal sensor ring is connected to the CAP04 via a 90
cm long 75 ohms low capacitance coaxial cable. There is
a 2 size for Sensor Ring. The Plasma Ring ID is 34 mm
and OD is 47 mm. Sensing height of the ring should be
between 1,5 to 10 mm above the plate. The Fuel Ring ID
is 50 mm and OD is 69 mm . Sensing height of the oxy
ring should be between 7 to 35 mm above the plate The
ring must be insulated from all conductive parts of the
cutting torch.
ELECTRONICS:
The connection of supply and outputs to the CAP04 is via
6core screened cable. Connector can accept cable up to
6.5 mm OD diameter. The supply is nominal 24VDC and
the consumption current is less than 150mA.
Do not use same power supply with motors.
The all outputs are at normally low, 15V level during in active and drive up to 15mA.. These
outputs can directly drive LED or Opto Coupler. Touch output can be adjusted internal
trimpot as a minimum height. It allows NULLING the height, if such feature required.
GROUNDING:
The diecast box must be grounded. Usually the sensor is bolted to the housing of torch lifter
and must be connected via thick wire 10mm² to System Ground to have a sufficient ground
connection. Use STAR type grounding.
6 PIN
INTERFACE
CONNECTOR
DOWN
IN POSITION
UP
TOUCH
CABLE FAULT
HEIGHT
CONTROL
KNOB
CAP 04
CAPACITIVE HEIGHT
CONTROLLER
BNC
SENSOR
CONNECTOR

Agelkom CAP04 Manual
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ADJUSTMENT:
1. Set “Height Control Knob” to middle
position. Manually adjust the torch
lifter, so the ring is about 50 mm above
the plate.
2. Disable the drive system (e.g. electrically
or mechanically disconnect motor).
3. Activate CAP04 and monitor up and
down output. At this point DOWN
OUTPUT led must be on, if not internal
coil adjustment needed. (Refer Internal
Coil Adjustment Section).
4. Decrease the distance between sensing
ring and plate and verify that UP
OUTPUT led is ON.
5. Disconnect BNC connector and verify
that ERROR1 LED is ON. Short 0V
supply to Sensor Ring with some wire
and observe that the ERROR2 LED is
on.
6. Reconnect the drive system.
The correctly adjusted sensor should
activate outputs within +/-0.05 mm at 1.5
mm above the plate and up to +/-0.2 mm at
35 mm. with two sensor.
Internal Coil Adjustment: (if necessary)
1. Set adjustment pot to middle position.
2. In Home position of your Z axis DOWN led is ON, if not:
Remove the front panel. Use plastic screw driver. Gently adjust of the internal coil of
CAP04 sensor and observe down output is activated in your HOME position (or
sufficiently high above the plate.) If DOWN OUTPUT is activated instead of UP
readjust the core of the coil.
3. Start slowly to decrease the distance between sensing ring and the plate to the cutting
height of say 3mm and verify that UP OUTPUT led is ON. If not, readjust the coil.
4. If you change the cable between the unit to sensor ring, internal coil should be re-
adjusted. You can use 70 cm to 100 cm long sensor cable. The original cable length is
90 cm
Important:
Do not turn fully CW or CCW and do not apply force to the CORE of the
internal coil. The CORE is easily broken.
Window Adjustment:
There is small amount of GAP (window) between UP and DOWN. Also GAP could
be adjusted with internal trimpot. Turning CW of trimpot makes gap wider. Increased
cutting height will result in a wider the GAP.
Narrow
Wide
Control Box Size:
116*65*31mm
GAP
ADJUSTMENT
6 PIN
CONNECTOR
Mounting Holes
HEIGHT
CONTROL
KNOB
DOWN
IN POS
UP
TOUCH
CABLE
SENSOR HEAD
BNCCONNECTOR
SENSOR
ADJUSTMENT
COIL
TOUCH
ADJUSTMENT
MULTITURN

Agelkom CAP04 Manual
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Touch (Down Limit) Adjustment:
After all adjustment was finished, you can start to adjust Down Limit potentiometer, adjust
this multiturn potentiometer until the TOUCH led turns on. To do this, close the sensor ring
until it touches the plate or insert paper between sensor ring and plate (cutting material).
APPLICATION:
During plasma cutting, sensor ring and plasma torch are in the same height. This will allow
to use TOUCH output as a collision detection means. If any error occurs, the UP output
activate automatically.
During thick plate cutting, dross may touch the sensor ring and the torch head lifted. To
avoid this situation correct your cutting parameters for less dross.
CAP04 can be used with voltage controlled Height Control System. The two systems are
OR’ed.
67mm approx.

Agelkom CAP04 Manual
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Simplified typical connection of CAP04 sensor is shown below. We advise that using H-Bridge for
driving the motor is cost effective. Agelkom H-Bridge-9 Board now available.
SENSOR
Auto / Manual SW
BLACK 0v (GND)
4
SENSOR POWER +24VDC
SENSOR POWER 0V
6
3
2
1
MOTOR POWER + V
AGELKOM
CAPACITIVE
SENSOR
CAP04
CABLE COLORS
RED + 24v
GREEN DOWN
YELLOW UP
CONNECTOR
PIN NUMBER
USE SEPARATEPOWER SUPPLY
2 X 1N4001
H-BRIDGE 9
UP
MANUAL
UP/DOWN SW
DOWN
OPTO
COUPLER
ISOLATED
INPUTS
100W DC
MOTOR
Can be use w/Long Cable
Keep minimum Cable length
for less electrical noise and
more BRAKE torque
20-30cm
H-Bridge can be fit in Motor Box and
HEAT SINK SHOULD BE
MOUNT VERTICALLY
Wiring diagram H-Bridge 9 with BRAKE function
N.O.
N.O.
UP / DOWN Limit Switches
DC
INPUT
MOTOR
-+
MOTOR POWER 0 V
CABLE SHIELD
POWER SUPPLY / SYSTEM GROUND
1 K resistor
CAUTION !
DO NOT REMOVE THE
MOTOR CONNECTION
WHEN THE POWER
APPLIED
5
BROWN TOUCH
WHITE IN POSITION

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Internal Coil Adjustment:
Mount CAP04 and Sensor Head with Sensor Ring to your machine.
Keep Sensor Ring to Working Plate distance at maximum (at least 10cm).
Important:
Do not turn fully CW or CCW and do not apply force to the CORE of the internal coil.
The CORE is easily broken. Use plastic screw driver.
Smoothly close some metal plate (say 20cm x 20cm) to sensor ring and observe that voltage increase
(never decrease) come to closer.
1HEIGHT CONTROL KNOB
TURN FULLY CCW
2 CONNECT DVM – to
HOOK with Blue Bead
or (-) of your Supply
3CONNECT DVM +
TO TEST POINT HOOK
With Orange Bead
GAP
ADJUSTMENT
SENSOR
ADJUSTMENT
COIL
SENSOR HEAD
CONNECTOR
CW Coil
Fully CCW
Voltage
Correct Adjustment Point
4ADJUST INNER COIL
TO MINUMUM VOLTAGE
1-3 volts

Agelkom CAP04 Manual
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To System & Power Supply Box
Use STAR type Ground Connection
Use thick wire (10mm²)
GROUNDING
MOUNTING
Dimensions are in mm. Case Size 116*65*31
Two mounting holes are shown in red
Machine Chassis
CW Coil
Fully CCW
Sensig Height
Down Led is ON
Up Led is ON
Correct Adjustment Point Wrong Adjustment Point

Agelkom CAP04 Manual
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69 mm dia.
47 mm dia.
67mm approx.
Mounting Details