Hypertherm SENSOR OHC User manual

HYPERTHERM SENSOR™OHC
AUTOMATED OXY HEIGHT CONTROL
OPERATION &SET UP GUIDE
Making people and machines more productive through process Automation

DISCLAIMER The information in this document is subject to change without notice and should not
be construed as a commitment by Hypertherm Automation®. Hypertherm
Automation®assumes no responsibility for any errors that may appear.
TRADEMARKS Hypertherm Automation is a wholly owned subsidiary of Hypertherm®, Inc.
Sensor™ is a trademark of Hypertherm Automation.
AR-300/100W Levilator Clearance Control is a trademark of CMC Burny.
COPYRIGHT ©2004 by Hypertherm Automation. All rights Reserved
Printed in USA

Table of Contents
SAFETY ................................................................................................................................................ 1
Read This Manual ............................................................................................................................. 1
Dangerous Machinery ....................................................................................................................... 1
High Voltages..................................................................................................................................... 1
SECTION 1: OVERVIEW .................................................................................................................. 3
Introduction ....................................................................................................................................... 3
Description and Features.................................................................................................................. 4
Hardware Specifications................................................................................................................ 5
Control Unit Front ............................................................................................................................ 6
Control Unit Bottom.......................................................................................................................... 7
Sensor and Mounting Isolator .......................................................................................................... 8
SECTION 2: OPERATION ................................................................................................................ 9
Operation Modes................................................................................................................................ 9
Automatic Operation ..................................................................................................................... 9
Manual Operation.......................................................................................................................... 9
Errors.............................................................................................................................................. 9
Error Conditions.............................................................................................................................. 10
SECTION 3: INSTALLATION AND SET UP .............................................................................. 11
Installation....................................................................................................................................... 11
Sensor Mounting .......................................................................................................................... 11
Sensor Position to Torch.............................................................................................................. 11
Connectors.................................................................................................................................... 12
Power Connections....................................................................................................................... 12
Limit Switch................................................................................................................................. 13
Digital I/O..................................................................................................................................... 13
Optional External Height Set Pot............................................................................................... 13
Optional External Second Height Set Pot.................................................................................. 13
Standard Wiring Installation...................................................................................................... 15
IO Interfacing .................................................................................................................................. 16
IO Interfacing Examples ............................................................................................................. 16
DIP Switch Setup ............................................................................................................................ 17
Calibration Procedure ..................................................................................................................... 18
Component List ............................................................................................................................... 19
Optional Sensor Cables ............................................................................................................... 19

Safety 1
Safety
Read This Manual
Read and understand this instructional manual, the cutting machine manuals, and your
employer’s safety practices. Note: This product is not designed to be field serviceable. Please
return to an authorized repair center for any required service.
Dangerous Machinery
Operation and maintenance of automated equipment involves potential hazards. Personnel
should take precautions to avoid injury.
Injury and entanglement may occur if hands and limbs come in contact with moving machinery.
KEEP HANDS CLEAR of dangerous moving machinery. All control, including manual, can be
affected using the remote interface.
Loose fitting clothing or ties may become entangled in the machinery. These items should not be
worn while operating or servicing the machine.
High Voltages
Electric shock can kill. Be sure this equipment is safely installed in accordance with the enclosed
procedures and specifications.
Avoid contact with electrical wires and cabling while power is on.
This equipment should only be opened by trained service personnel.
Please refer to the appropriate appendix in the Installation Guide provided with your control for
details on safety certification for that product.

2 Sensor OHC Operation and Set Up Guide

Section 1: Overview 3
Section 1: Overview
Introduction
One of the most important parameters in Oxy Torch cutting is consistent torch tip to plate standoff
distance. The Hypertherm Sensor OHC uses a capacitive sensor to measure the torch to plate
distance. The unit will drive a DC motor on the torch lifter to automatically maintain a user
selected torch to plate distance. This automatic closed loop control of the torch height will
dramatically improve the cutting speed, quality and consistency.
The Sensor OHC includes the control unit, the capacitive sensor, sensor mounting isolator,
sensor spring style breakaway, and standard 1 meter coax cable. A connector kit is available for
the standard mating connectors. For demonstration purposes, a connector conversion kit is
available that will make the unit plug compatible with the Burny AR 300/100 “Levitator Clearance
Controller”.
It is the installer’s responsibility to provide a compatible lifter mechanism. A compatible lifter will
utilize a 24Vdc motor between 2 Amps, 50 Watts and 6 Amps 150 Watts. The full speed
operation must be geared to produce a linear full speed of between 20 in/ min (500 mm/min) and
140 in/min (3500 mm/min). The tradeoff being between a low speed extremely high accuracy lifter
and a high speed lower accuracy lifter. The lifter should have adequate rigidity and very little
backlash and moving inertia. The lifter should also have normally closed upper and lower limit
switches mounted at the extremes of travel.
The installer must also provide an appropriate mounting clamp that will attach the 20 mm
diameter sensor mounting isolator to the torch. The mounting clamp should be designed for a
center of torch to center of isolator distance of 2 inches or 50mm so that that the sensor ring will
be properly centered and positioned around the torch tip. Additionally, the mounting clamp
should provide a good electrical ground connection to the overall machine frame and to the metal
plate being sensed. Failure to provide an adequate ground connection to the plate will have a
negative effect on the height measurement and control accuracy.
Main Power Supply: 24Vac +/- 10%, 50, 60 Hz
Compatible Lifter Motors DC permanent magnet, 24Vdc, 2 Amps to 6 Amps
Max Power Output 150 Watts

4 Sensor OHC Operation and Set Up Guide
Description and Features
System Features*
Compatible Motors DC permanent magnet 24VDC, 2 Amps to 6 Amps
(customer supplied)
Max Power Output 150W
Control Range Linear 0.1” (2.5mm ) to 1.0” (25mm)
Motor Output Full “H” bridge PWM with current sensing
Accuracy .01” (.25mm )**
Operator controls Easy to use control set point knob and easy read indicators
Calibration Easy access calibration pot on front Panel
Measuring Technology Capacitive Ring with Coax Cable
Dimensions 8.50” (216mm ) W x 4.21” (107mm) D x 4.02” (102mm) H
Inputs/ Outputs 3 outputs and 6 inputs optically isolated on “D” connectors
Weight 2.4 lbs
Operating Environment 0 to 50C; 95% relative humidity (non-condensing)
Power 24VAC +/- 10% 50/60 Hz
*Information subject to change without notice.
** Dependent on customer supplied lifter mechanics
SENSOR™ OHC - Oxy Height Control is an advanced automated height control system for
oxy fuel shape cutting applications. This product utilizes advanced capacitive sensing and
microprocessor technology to automatically detect the plate and adjust torch position to a
desired set point during oxy fuel cutting operations. This reduces operator input, improves
accuracy and increases productivity.
Features
¾Sensor OHC can be used with any CNC
¾Easy setup & operation
¾Both manual & automatic operation modes
¾Microprocessor control for increased sensitivity and control
¾High positioning speeds possible with up to 6 amps continuous current and linear
adjustment over full range
¾Built-in diagnostic and fault detection features
¾Auto retract on plate contact
¾Optional second height set point input for preheat or pierce
¾Indicator lights for operation including:
⇒Power On
⇒Upper Limit Switch
⇒Lower Limit Switch
Options
¾Five Cable Lengths from 19.7” (500mm) to 59” (1500mm)
¾Adapter cables allowing direct replacement for existing AR-300/100W Levilator Clearance
Controls
⇒In Position Indicator
⇒Attention / Error indicator

Section 1: Overview 5
Hardware Specifications
Main Power Supply: 24 VAC +/- 10%, 50/60 Hz
Compatible Lifter Motors: DC permanent magnet motor 24Vdc, 2 Amps to 6 Amps
Operating Temperature: 0 to +50 deg C
Control Range: Linear 0.1 inch to 1.0 inch (2.5 to 25 mm)
(standard sensor & cable)
Height Measuring Technology: Capacitive Ring with Coax Cable
Accuracy: 0.01 inch (0.25 mm) w/ representative Lifter
(dependent on lifter mechanics)
HF Coax Cable: 500 mm to 1500 mm (1000 mm standard)
Standard Sensor: Stainless Steel Ring 100 mm outer & 50 mm inner
diameters. Can be calibrated for others
Dimensions:
8.50” (216mm) W x 4.21” (107mm) D x 4.02” (102mm) H
Control Type: Digital Micro Processor based
Motor Output: Full “H” Bridge PWM with current sensing
Control Interface: Optically Isolated I/O on “D” connectors
Outputs: Digital In-Position Output
Digital Error Output
Digital Plate Contact Output
Inputs: Digital Manual/Auto Select
DigitalManualUp
DigitalManualDown
Digital Upper Limit Switch
Digital Lower Limit Switch
Digital Second Height Select
Remote Height Set-point Pot
Second Height Set-point Pot
Front Panel Indicators green Power
yellow UpperLimitSwitch
green InPosition
yellow Lower Limit Switch
red Attention/Error Code

6 Sensor OHC Operation and Set Up Guide
Control Unit Front
Hei
g
ht Set Point Ad
j
us
t
Set Up & Calibration
Access Panel
Power Indicator
In Position Indicator
Lower Limit Indicator
Error Code Indicator
U
pp
er Limit Indicator