HEAVTH HP103 User manual

HP103Focuson NC cutting heightcontrolfield
PortableCNC
Plasma Torch Height Control
Operation Manual
VISION 1211
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--2--
1.IMPORTANT INFORMATION
1.1SERVICEASSISTANCEAND CONTACTINFORMATION
For serviceassistance, havethefollowing informationavailable:
HP103model,part andserialnumberlocatedonalabel
Type ofcuttingapplicationyou are using
You can contact ourat:
TEL:[phone]
FOX:086-0519-89183619
1.2RECEIVINGAND UNPACKING
Afterreceiving theHP103 you should:
Carefully, unpackand inspectthe equipment.
Compare the received shipmentwiththe packing list.
Report anydamage tothe carrier andyour representative.
Storeequipmentthat will not beusedin aclean, drylocation.
Takeappropriateprecautionstopreventmoisture,dustand
dirtfromaccumulating instorageandinstallationareas.
1.3SAFETYCONSIDERATIONS
Safety practicesshould notbe anafterthought. Before installing
or servicingthecontroller,reviewand followapplicablepoliciesand
procedurestoensure workersafety.Machinerymust beinasafe
stateandyou mustbeaware ofanyadditionalhazardsthatcan
arise.
1.4PRE-INSTALLATIONCONSIDERATIONS
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--3--
BeforeinstallingtheHP103:
Check tobesure that you haveall ofthe required parts.
Familiarizeyourself withtheparts ofthe HP103.
Checktobe surethatthe torchlifter motorsyou are using with
the HP103 arewithintheacceptablerange.
Reviewthe instructionsforConfiguring theLifterMechanics.
1.5CONFIGURINGTHELIFTERMECHANICS
Properconfiguration ofthetorchliftermechanismisan
importantfactor for establishingtheaccuracyofyour cuttingsystem.
Be sure that:
Gearreductionisselectedon thetorchliftersothatthe
maximumsuspension speed doesnotexceed 3000mm/min (120
IPM).Ifhigheraccuracyisrequired,maximumsuspension speed
shouldbesetto1500 mm/min(60IPM).
Gears,racks andspindles haveminimal backlash.
Oversizing isavoided.The massofmoving parts,including
armatureinertia mustbe assmallaspossible.Motorswithlow
nominal RPMare preferred.
OnlyDC motorswiththefollowing ratings areused:
MOTORRATINGS：DC MOTOR
MOTORVOLTAGE：DC24V
MAX CURRENT：4A
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--4--
2. BriefIntro
2.1Summarize
HP103 plasmaarcvoltage heightcontrollerisequippedwith
constantcurrentplasma.Duringcuttingcourse,thecurrent
alwaysequalsthegiven current.Andthe cutting arcvoltage will
be changedwiththefixed speedbeingtheheightoftorchchanging.
When the distancegetsfarther，thearcvoltage increases; On
opposite,thearcvoltage will decrease.HP103 plasmaarcvoltage
heightcontroller will inspectthevoltage change,then control the
distancebetween cuttingtorchandmaterialvia theliftmotor.So
that the arcvoltage isfixed,the sameistheheight ofcutting torch.
Generally,theinstruction will listallthecuttingparametersfor
sometype ofplasma.Theusercanrefertotheseparameters.
Adjustthe voltage in arcvoltage heightcontroller tomatchthe
selectedcurrent.The torchheightwill keepconstantunder regular
speed.Infact,theusershouldsetthearcvoltage according tothe
heightof the cutting torch.
Inthestatusofautomation,thearcvoltage morehigh,thenthe
heightof the cutting torchmorehigh
2.2Technical parameter
lWorkingvoltage:DC24 orAC24±5%，50Hz/60Hz，Please
prepareaisolated power,donotshared withotherssuchas
electronic valve. Especial Paymore attentiontheAC24V
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--5--
lLiftmotor:DC24V DC motor
lDrivemode: PWM
lOutputcurrent：1A-4A.
lOutput power: 100W.
lWorkingtemperature: Heightcontroller - ∽℃10 60
lIHSstyle:SwitchinspectingIHS(suitableforallplasma
bothabove-water and under-water cutting)，PlasmaShield
Protector IHS(suitableforabove-water cutting’stouch
leading arcvoltage plasma)
lRunning transfer:AlternativeArctransfer andpiercetransfer
lDivided voltage ratio:100:1
l∽Accuracy: ±1V ±5V，adjustable
lOuterDimension:LengthXWidthXHeight:
272mmX225mmX80mm
2.3Application
HP103 Supportsalmostallplasmacuttersonmarketlike
Hypertherm, Kjellberg,ThermalDynamics...
And itsupportsallCNC cuttingcontrollerson marketlike
Hypertherm,Burnyindustrial level controllersorMach3suchDIY
controllers.
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--6--
2.4Operationpanel
ArcVoltage
BeforeArcStartitshowstheSetArcVoltage.afteritshowsthe
ActualArcVoltage
3. INSTALLATION
3.1workingprocess:
Mode 1:WhentheArc-ONsignalwith “IAON”(theArc-On signal
withIHS)isavailable ,theheightcontrollershouldprocess theIHS
firstly;Secondlyauto-controltheArc-on,the heightcontrollerwill
send the signalof arctransferand piercetransfertotheNC system
afterproducingthetransfer arc.Atthemean time,thecontroller
delaytimetoputthearcvoltage intothesingle chipsystem.If “Auto
Permitted isavailable in heightcontroller and NC systemhassent
outAUTOheightadjusted signal,thecontrollerison statusof
“HeightAutoadjusted”
HIS Height Piercing Delay
IHS TEST Arc Test
Arc Voltage Up
DownSet Voltage
Down
Up
Arc On
Auto Trans
Collision
Auto/Manual
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--7--
Mode 2：WhentheArc-ONsignalwith “EAON”(theArc-On
signalwithoutIHS) isavailable, theheightcontrollerwill notprocess
theIHSbutcontrol theplasmatoArc-ondirectly;theheight
controller will send the signal ofarctransferand piercetransfer to
the NC systemafterproducing thetransferarc.Atthe mean time,
thecontrollerdelaytimetoputthearcvoltage intothesingle chip
system. If “AutoPermittedisavailableinheightcontroller andNC
systemhassentoutAUTOheightadjustedsignal,the controlleris
on statusof “HeightAutoadjusted
ATTN:When the NCsystemthatyou usecan notreceivethe
signalofarc-onandpierce,pleasedelaythe timetocontrol the NC
system’srunning.Itjustmeansthatthe NC systemsendarc-on
signaltothe heightcontroller,delaytimetorunthe NC system.
3.2INSTALLATIONCONTROLER
The following section providesyou withtheproceduretofollow
when installingthe HP103.Someofthe stepsdirectyou toother
sectionsin thismanual thatprovide you withmoredetailed
instruction.
1.Determine amountinglocationfortheHP103.Keepthe
following pointsin mind:
Toavoid overheating and potentialdamage tothe control box
fromcuttingprocessfumes,DONOTchooseamountinglocation
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--8--
directlyabovethetorch.Findamounting locationawayfromthe
torchlifterunit.
2.AttachthewiresfromtheCNC,the plasma,thelifter motorand
lifterlimitswitches toaconnectorandthen tothecontrolboxatthe
receptacle.Toreducenoiseemission, 20 AWG(0.5mm2)shielded
cableisrecommended.Filtersconsisting ofaresistorandcapacitor
can be connected onlydirectlytothemotor.
3.Connect a12 AWG(2.5mm2) ground wire totheground
screwlocatedonthe control boxand then,tothemachineground
rail of your cuttingsystem.
3.3Dividedvoltageboard
Controllingthearcvoltage mustinspectthechangingofplasma
arcvoltage.The plasmaarcvoltage equalsthe voltagethatis
between the poleand ground.The anticathodewhichputoutthe
plasmapower isconnected totheground.The Cathodeconnects
tothe polewhichisinthecutting gun.Sothevoltage in the
electrode isnegative.Whenprocess thecutting,the arcvoltage
absolutevalue isusuallyhigher than 100V.If so,the voltage must
be divided in ordertoprocessthecontrol inthecontrollingcircuit.
ATTN:the voltage thatputintothe heightcontroller isnegative.
Ifthepolarityisconnectedinreverse,theHeightAuto-adjustedis
not available.
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--9--
Our company’sisolateddivided voltage ratiois100:1.The
divided voltage ratioissetupas100:1beforeourcompany’sheight
controllerleavefactory.
3.4IHSintroduction
Twotypes ofIHSstyle of heightcontroller
1. PlasmaShieldprotectorIHSinspecting style
The materialoftheprotectorshouldbemetallic. Theycan
transmiteachotherwhen itgetstothematerial.
ATTN：The cuttingtorchprotector IHSinspectingstyle is
suitableforabover-water cuttingonly.
Single
Working process: After the heightcontroller receivesthe arc-on
signalwhichissentoutfromNC system,the cuttingtorchwill fall
downimmediately.Whentheprotector gettothematerial,the
Workpiece
Shield GND
Torch
Shield
IHS spring
Hoop
HISWiring
Magnetismring
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--10--
heightcontrollerwillreceivethissignal,and thencontrolthecutting
torchtorisetothe given HeightofIHS.Theheightcontroller will
control theplasmatoarc onafterIHS.
2.inductiveproximityswitchIHSstyle(switchmode:NPN
Mode,2mm, outer diameter Ф12,the distanceofscrew
thread:1.0mm)
Whenthisstyle isadopted,theclientshoulddesignthetongs
accordingtheIHScuttingtorchtongssketchmap whichisprovided
byour company.All theplasmaIHS,whatever over-water cutting
and under-water cutting,can adoptthisIHSstyle. Pleaseadoptthe
approachswitchIHSstyle ifyou usethe high frequencyinputarc
plasmaand under-water cutting.
The tongssketchmap:Pleaseseetheappendix
BeforeIHS,theapproachswitchisonapproachingstatus.The
cuttingtorchwill riseoncetheswitchisbroken away.
Working process: After the heightcontroller receivesthe arc-on
signalwhichissentoutfromNC system,the cuttingtorchwill fall
downimmediately.When the cutting torchgetstothe material,the
approachswitchwill breakawayfromtheapproachingspot.The
heightcontroller receivesthissignal,and then controlsthe cutting
torchtorisetothegiven HeightofIHS(theapproachswitchwill
reposition automaticallyduring the rising).Theheightcontrollerwill
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--11--
control theplasmatoarconautomaticallyafter IHS.ThisIHSstyle
issuitable forallplasmaIHS.
The approachswitchisconnectedtotheheightcontroller via
the SWITCH-IHSaviation socket.
3.5Socket
1、Thepower portsofarc voltage heightcontroller
The power ofarcvoltageheightcontroller isAC24V,connectsto
the height controllerJP2.
2、Theportconnectedtotheplasmacuttingtorch.
The motoroutputport:
The positionlimitedportsforLiftup anddropdown:
TO LIFTER TO CNC TO PLASMA
Workpiece Shield
inductive proximity
GND
AC24V
THCinside
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--12--
ATTN:Position limited switchshouldmeetthe cutting –offspot
usually. setJP2,JP3canusethecutting –nospotusually。
3、Theportconnectedtoplasma
CON-PLASMAwith4core socketconnectstothe portJP6 in
main board.
PlasmaArc onsignal iscontrolledbymain board relayinheight
controller.Thearcvoltage will be postponed toenter intothe main
board.
4、TheportstotheNC system,theportcircuitbetween height
controllerandNC system.
Up
Down
Microcontroller
Arcrelay
Inputdelayrelay
Tomicrocontroller
Inputvoltage
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--13--
There are 6portswithphotoelectricityinsulated style between
singlechipandNC system
A、AUTO/MANUALsignal(EXAUTO):AUTOdependsonhigh
electricitylevel,HAND withlowelectricitylevel.Can usetheJP7
set totheoppositestate
B、UP：It will risewhen lowelectricitylevel isavailable.
C、DOWN: It will drop when lowelectricitylevel isavailable.
D、IHSArc-onsignal (IHSARCON):Itisavailable forlow
electricitylevel.IHSshouldbeprocessed before working.The
arc-onwill be automaticallyonceIHSfinished.
E、The arc-on signal withoutIHS(EXARC ON):Itisavailable
for lowelectricitylevel.Arc-on directly.
F、Arctransfer1andPiercetransfer2 （ARCTRANS1、
ARCTRANS2）:
Signal type :relay
5、InductiveProximityswitchIHSport
Microcontroller
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--14--
6.Isolated divided voltage board wiring diagram.
ATTN:
1.Toreducenoiseemission,20AWG(0.5mm2) shielded
cableisrecommended.
2.The arclead inTHC isnegative,ifthepole mis-connected,
THC can notwork.
3.HF plasmamustuseisolationvoltage divide.Theactualarc
outputshould be connected atplasma’srectifier output,better
notconnectdirectlytoElectrodeand workwhere haveserious
HF interferenceduring arcstartingtime.
4.Non IsolationVoltage Divide isbackupforIsolationvoltage
divide.On non isolation voltage divide.AC220V power can be
unconnected.
Proximity switch
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--15--
Electrical Schematic
Chat 2
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--16--
Chat3
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--17--
Chart 4
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--18--
Chart 5
AC220VPOWER Voltage- Voltage+
Out- Out+
Isolate vol-div out
100:1None
isolation
vol-divide
output
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--19--
3.4Parameter adjusted:
Clockwiserotation becomesbigger,counterclockwiserotation
becomessmaller.
RP402:Inputarc voltage amplifyset.
RP401:Internalimitationarc voltage set.
RP104:Arc maxerror setup.Initialization:030
Duringthe cuttingcourse,thecuttingtorchhavethe cuttingcrack (out-inline),
the arcvoltagewillbe raised immediately.IfnoARC_MAX_ERROR,the
cuttingtorchwill bumptothematerialwithhighspeed.Thetorchwillbe
damaged.So setupthisparametercanprotect thecuttingtorch.
RP501:AutoPWM amp.
Thisparameterisusedforsettingup thePWMspeedadjustedcoefficient
when the arcvoltageischanging.The parameterisbigger,moresensitivefor
theheightcontroller.Buttherunningstabilityofthecuttingtorchwillgetlower.
RP401RP402 JP1
RP104
RP31
JP2 JP3
RP501 RP102
RP225
JP8
JP5JP6
JP7 SP2
R6012
RP403
Created in Master PDF Editor

HP103PlasmaTorchHeightController
--20--
Onopposite,the parameterissmaller,sensitivewill be lowerand the running
stabilitywillbe higher.Soaappropriatecoefficientselectedcangetagood
balancebetween the sensitiveand stability.
RP102: Controlvoltage zeroadjustment
RP31:Arcvoltage displayvalue adjustment
RP225:Arc voltage delayinput timesetup.
Thearcvoltagewill beaffected seriouslyduringthe leadingarc.So the arc
voltagewill be delaytoput inthecircuit.
RP403:Torchcutting end,torchrisetime.
JP1:Set downinputtheexternal arc voltage.
Setup inputthe internal imitationarc voltage.
JP2:Selectthetype ofUplimitedswitch.
SetdownusetheNormallyopen spot.
Setup usetheNormallyclosedspot.
JP3:Selectthetype ofDownlimitedswitch.
SetdownusetheNormallyopen spot.
Setup usetheNormallyclosedspot.
JP5:Selectthetype ofproximityswitch.
Setup useNPNnormallyclosed.
SetdownusePNPnormallyopen.
JP6:Set isolationshielddelay.
JP7:AUTO/MANUALsignal(EXAUTO)
SetupAUTOwithlowelectricitylevel.
SetdownAUTOwithhighelectricitylevel.
Created in Master PDF Editor