Leader F1620 User manual


PortablePlasmaTorch
HeightController
Manual

（Type：F1620）



JiaXing Leader NC technology Co., LTD.
2014-12


Portable Plasma Torch Height Controller Manual (F1620)
ii
Portable Plasma Torch
Height Controller
Manual
(Type：F1620)
JiaXing Leader NC technology Co., LTD.
2014-12

Portable Plasma Torch Height Controller Manual (F1620)
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Version Date Page Description
V1.0 2012/10/10 All The new version created
V1.1 2014/09/12 iv MAX range: 21.6VDC-26.4VDC

Portable Plasma Torch Height Controller Manual (F1620)
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User Guide
Read this Manual
This manual is used to the Plasma Torch Height Controller (F1620) produced by
JiaXing Leader NC technology Co., Ltd.. Read and understand this munual, the
cutting machine manuals and local security regulation before use carefully.
Note: This product is not designed to be field serviceable. Please return back to the
after-sales (service) center for any required service.
Address: Room 711, NO.955, Rd. Jianchuan, Woxiangwojia mansion, MinHang,
Shanghai, China
Tel: [phone]
After-sales: 021-34121295 Fax: [phone]
E-mail: [email protected]; [email protected]
Website: www.flcnc.com
Work condition
zWorking Temperature, 0℃~50℃. Relative Humidity, 5~95%.
zOperation Voltage: 24VDC. MAX range: 21.6VDC-26.4VDC.
zThe THC should be installed in a cab which can provide protection from powder.
zThe THC should be better used in the situation without high electromagnetic
radiation.
Maintenance
zThis controller should only be operated by trained service person.
zDo not open the controller unless obtaining the authorization.
zDo not let any acid or alkalescency substance to corrode the controller and the
divide board.
zPlease turn off power supply if the controller does not need to work.

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Safety notice
zThis THC will switch in high electromagnetic，it can hurt me if we get to touch
with high electromagnetic . Do not touch shield cable and wire when power
supply is turning on.
zPacking pieces must be installed in accordance with the provisions and
requirements of step.
zGND must follow THC instruction.
Installation note
zTHC first check on electrical safety : Before THC first power,making all port of
wiring connected, then unplug motor cable, in other words, do not connect lifting
motor cable temporarily. Then powering on. (warning: Motor cable must be
unplug before powering on, otherwise, the reason why the lift motor has
been rising (declining) is that may be received collision signal , it can injury
lifting motor)
zCheck whether the collision function is normal: After THC power on, check
whether the collision detection function is normal, by observing the collision
indicator light to determine whether the normal. Of the following circumstances:
1)If the collision indicator light is turning on, really need to check whether a
collision, for example, whether proximity switch is divorce, whether torch
retaining cap and steel is touching.
If we only use torch retaining cap to detect collisions, separated from the
protective cap and cutting steel. Because there is no contact with torch retaining
cap and steel, the meaning that the collision have not take place, the collision
indicator light should be take off.
If we only use proximity switch to detect collisions, parameter P13 should
be set to 1, the meaning that allow the use of proximity switch detects a collision
signal. Under normal circumstances, the collision indicator light is turning on
when proximity switch is divorce; the collision indicator light is breaking down
when proximity switch is not divorce. If we use in scene, the collision indicator
light is breaking down when proximity switch is divorce, or the collision
indicator light is turning on when proximity switch is not divorce, it explain that
the description of the received signal and the normal, L09 need to set the value of
the inverse. After parameter is set correctly, proximity switch can accurately
reflect the situation of collision.
If we use proximity switch and torch retaining cap to detect collisions at

Portable Plasma Torch Height Controller Manual (F1620)
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the same time, need to check respectively each set whether can accurately reflect
the situation of collision. If a certain way is failing, please use their method by
alone to troubleshoot and fix, until it can accurately reflect the situation of
collision.
2) If the collision indicator light is breaking off, please make some
collision conditions by man, check whether the collision indicator light can be
turned on. For example, when we use torch retaining cap to detect collisions, if
we make torch retaining cap and cutting steel short circuit by metal screwdriver,
the collision indicator light should be turned on. Or when we use proximity
switch, if we make torch connector crooked by hand, make proximity switch
take off, the THC collision indicator light should be turned on. If make visible
collision conditions by man and the collision indicator light cannot be turned on,
we need to check whether the parameters can be set orderly.
zSwitching in lift motor safely: After the detection of THC collision have debug
and used normally, please remove all conditions which can made collision, at the
same time, THC collision indicator light should be broken off . Then turning off
power source of THC and connecting the lift motor cable.
zCheck whether direction of lift move is true: After motor cable have been
linked, power-on ,when check whether the button named 【▲】in THC faceplate
is pressed, observe whether the lift body is rising; when the button named【▼】is
pressed, observe whether the lift body is declining. If the button named【▲】is
pressed, the lift body is declining rather than rising, or if the button named【▼】is
pressed, the lift body is rising rather than declining, it means that direction of
motor rotation is not true. Please enabling the value of P12, or exchange two
cable of lifting motor. It is best that ensure the button【▲】and【▼】in THC
faceplate is consistent with direction of the lift body move.
zCheck arc start and used for IHS(initial height sensing): check whether start
arc by pushing button of【text arc start】and check whether accomplish the initial
positioning by pushing button of 【text used for IHS】.
zPutting in Arc voltage cable true: The wire of plasma arc voltage and cable of
checking collision must be access to the corresponding port true, otherwise, it can
lead to danger.
zDemand that torch retaining cap used for IHS wiring: After the cable of
plasma anode must be received a work piece, the action that detects the torch
retaining cap collision and the initial positioning can work.
zUsing shielded cable wiring: In order to protect equipment work, please use
shielded cable in our equipment. You can connect shielding layer in Shielded
cable to THC side and use single point grounding.
zVoltage divide board and voltage divide ratio: The ratio in THC is 100:1. And

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effective measuring voltage in THC is 0~660V DC.

Portable Plasma Torch Height Controller Manual (F1620)
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Catalogue
User Guide....................................................................................................................................iv
Read this Manual .....................................................................................................................iv
Work condition.........................................................................................................................iv
Maintenance.............................................................................................................................iv
Safety notice..............................................................................................................................v
Installation note.........................................................................................................................v
Chapter 1 overview ........................................................................................................................1
1.1 equipment presentation .......................................................................................................1
1.2 Features of equipment .........................................................................................................1
1.3 Function of equipment ........................................................................................................2
1.4 Technique parameter ...........................................................................................................5
1.5 THC Installation size...........................................................................................................5
Chapter 2 system operation............................................................................................................7
2.1 Operation panel button of explaining..................................................................................7
2.2 operation panel of explaining..............................................................................................8
2.3 Menu operation explain.....................................................................................................10
2.4 Motor drive current ...........................................................................................................17
2.5 Working process................................................................................................................17
Chapter 3 Port connection............................................................................................................19
3.1 The case view....................................................................................................................19
3.2 Chassis port .......................................................................................................................20
3.2.1 CNC port ................................................................................................................20
3.2.2 Power supply, motor and motor limit port .............................................................22
3.2.3Arc start port and proximity switch position port ...................................................24
3.2.4 USB port ................................................................................................................27
3.3 voltage divide port.............................................................................................................29
3.3.1 arc voltage port.......................................................................................................29
3.3.2 torch retaining cap detection circuit port................................................................30
Chapter 4 common problems .......................................................................................................35

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Portable Plasma Torch Height Controller Manual (F1620)
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Chapter 1 overview
1.1 equipment presentation
Portable Plasma Torch Height Controller type F1620 is a product which have
such advantage as operate simply, stabilize property, full function and high
performance ratio. It is made on basis of condition that used in plasma power source
scene, and it absorb a lot of advantage of THC all around the world. Our equipment
make use of peculiarity that plasma power source have constant current, check
alteration of plasma torch height by checking alteration of plasma torch height,
control height between torch and workpiece on time. It suit to control height of
plasma power source torch which have peculiarity of constant current, or control
height of plasma power source torch which have peculiarity of constant current within
limit. It especially suit to torch height control of portable cutting machine.
Our equipment have such advantage as operate simply, use easily, light and
portable, all buttons and knobs design by humanization, comfort and convenience.
Figure 1.1 the front panel in host(type F1620E)
1.2 Features of equipment
¾Our equipment use nixie tube and LED as arc voltage and signal display, clear
display, stabilization and anti-interference, long serve life.
¾The parameter is able to alter by button and rotary knob in our equipment, easy
to use.
¾Our equipment use the installed way which have 60 degree of slope, it suit to
use portable cutting machine
¾Our equipment have voltage divide and make all angle shield by metal, smaller
volume, better anti-interference.
¾It have simple and convenient parameter which can be set, change operation
parameter flexibly, suit complex working conditions.

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¾It can suit external working conditions by changing parameter, so we need not
change hardware within equipment.
¾It can change the electrical level of input signal which is useful. The input
signal acquiesce in low electrical level is useful. The high electrical level is
useful when we change it.
¾Input and output is insulated by optocoupler, it is useful to protect equipment
from damage when voltage is bigger and electromagnetism pulse is disturbed.
¾The arc start relay and the arc start prosperity relay is omron power relay, so it
is reliable when it work.
¾It can observe the electrical level in work process.
¾The different work process is mutual seal, it can avoid operate fault.
¾When THC have a delay of boring a hole, it can use function which it can
dynamic bore a hole after arc start is start.
¾It can monitor whether arc start have been start in torch process, if it detect that
arc is breaking off, the THC can inform CNC in time and turn off the arc start
relay, it can avoid to cite arc for empty when arc is breaking off.
¾When auto height control is proceeding, it can ensure that practical arc voltage
follow setting arc voltage is closely, it hardly have error.
¾When auto height control is proceeding, it also can change the arc voltage
setting value, it is easy to change torch height slightly when torch is working.
¾When auto height control is proceeding, collision signal can feedback for
numerical control system, it can avoid that numerical control system is
marching after collision.
¾When auto height control is proceeding, it can use function which arc voltage
can be adjusted by machine auto control
¾After torch have accomplished, THC can automatic promote torch height, and
height which we promote can setting casually.
1.3 Function of equipment
1）Auto initial height sensing(IHS)
The way of IHS have the detection way of proximity switch and the detection
way of torch retaining cap collision.
¾Proximity switch location detection
Our equipment use NPN model proximity switch (or PNP model proximity
switch), proximity switch is contacting when it do not work. When down testing or
arc down initially, if torch collide workpiece(or if collide workpiece make torch tilt),
proximity switch will break away from, then detection voltage can check this signal, it
can promote the touch height which down initially(height can change by the panel

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spin button named “down height”). When proximity switch is breaking away from for
long time, torch can keep straight rise until it collide upper limit of motor.
¾Torch retaining cap collision detection
When we test collision by torch retaining cap, if torch retaining cap connect
with work piece, detection voltage can be start and promote the touch height which
down initially(height can change by the panel spin button named “down height”).
After torch rise, torch retaining cap depart from work piece and collision signal reset
at once. If torch retaining cap signal is keeping for long time, torch can keep straight
rise until it collide upper limit of motor.
¾Dual speed of IHS
After down initially, torch can descend 6 second at fastest speed (the time can
change by menu), then it descend at lowest speed (the lowest speed= the fastest/4)
until torch collide work piece. Two kinds of speed down can promote work
efficiency, descend in appropriate height, reduce collision impact, and extend serve
life of torch retaining cap.
2）Auto arc voltage height control
When it fit to start auto height control, if arc voltage do not exceed 30V which
we have been set up(parameter can change by menu), the THC will start auto height
control.
3）Auto torch promote after collision
When collision happen in a condition which torch and down is not working,
torch can automatic promote, the time named urgency collision rise spear time.
When down initially detection is working, or when collision happen within torching,
auto torch promote, the time named down height time.
4）Auto torch promote after torch is accomplished
After torch is accomplished，auto torch promote, height can change by setting
parameter.
5）Manual operation
Many functions can be manual operated on operation panel of THC, such as,
set auto/manual mode of THC, manually control torch up and down, IHS test arc start
test.......etc.
6）Auto operate
After numerical control system send arc start signal, THC can automatic
accomplish down initially—arc start—arc start feedback success, after CNC receive
signal which arc start feedback is successful, machine tool start to motion and incise.
7）The function of displaying and monitoring
THC display arc voltage value by using two nixie tube, the green nixie tube
above equipment is used for display arc voltage setting value, the red nixie tube
under equipment is used for display actual value of arc voltage. It is convenience for

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user to monitor arc voltage value in incising.
8）Menu Operation
When torch is not working, parameters can be changed by panel button. Users
can flexibly change speed, working way and so on.
9）Spin button operation
The panel has three spin buttons; it can change arc voltage, initial height and
delay time for piercing.
10）High and low level control
Input switch can choose using low level or high level, it can suit complicated
applied environment. The default level is low. Also it can be changed by menu.
11）The function of avoiding collision
When torch is working, if the lower arc voltage setting value(or nozzle loss)
lead to torch collide work piece, THC can send rise signal , it can avoid torch collide
work piece continually and damage work piece. When collision happen in a
condition which torch is working, if collide have happened several times, we can
make numerical control stop work. Before equipment leave factory, if collision is
happening, CNC will make torch stop work. If user do not make collision input
signal connect with CNC, so when collision happen a condition which torch is
working, CNC cannot receive the collision signal, it make torch continue to work.
Whatever numerical control system whether have stopped torch, when collision
happened, THC can promote torch height automatically until down height initially.
When torch is not working, if torch collide steel plate, torch will automatic
promote a height named urgency collision rise spear height(in general, this height is
higher than down height, and this parameter can be change).
12）Intelligent arc voltage adjust
When intelligent arc voltage adjust is been use and torch is working, if torch
collide continuously steel plate twice, arc voltage can increase automatically a value
which we have set (this parameter can be change, it is 5V that we set), for example,
if arc voltage setting value is 110V, after torch collide continuously steel plate twice,
arc voltage setting value increase automatically 5V, arc voltage setting value is 115V
now, it can promote torch height to avoid collide work piece when torch is working.
13）Dynamic pierce function
During torch is working, if set-pierce have delay, torch can promote a height
when arc start work at the moment. Before delay time of piercing have
accomplished, torch can descend a height which it is the same with promoting
height. It can be named dynamic pierce function similarly. When piercing is
working, torch need promote a height, it can avoid dress get into torch head. If
dynamic pierce lifting times that we set is 0, torch cannot promote when arc start is
working.

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14）Collision signal feedback
THC can make numerical control system receive collision feedback signal, it
can avoid that torch is working after collision have happened. THC make CNC
receive collision feedback signal after collision happened several times, it can keep
coherent torch.
1.4 Technique parameter
¾Work voltage：Rated DC 24V （The scope is 21.6VDC-26.4VDC）。
¾Lifting motor：DC 24V.
¾Motor drive：PWM.
¾Output current：0A-3A (the electric current that motor can input is 5A).
¾Load capacity：100W.
¾Working temperature：0 ~50 .℃℃
¾IHS：proximity switch of IHS.
Torch retaining cap of IHS.
¾Voltage divide ratio：100:1
¾The precision of arc voltage sampling：0.2V
¾The precision of arc voltage adjust：1V
¾The speed of lifting：It determines by highest speed of lifting.
¾Setting scope of arc voltage：30V~600V, it can change by panel spin button.
¾The biggest torch following speed：It determines by highest speed of lifting.
¾Overload protect：auto overload、overheating、lack of voltage protect，making
power source connect adversely to protect itself.
1.5 THC Installation size
¾THC installation size：width 271mm ， depth 190mm （ it can not contain line and
port in back) ， height 70mm 。
¾THC installation screw of IHS：

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Portable Plasma Torch Height Controller Manual (F1620)
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Chapter 2 system operation
2.1 Operation panel button of explaining
Figure 2.1 panel and button explain
【▲】： torch up button. Rising is earlier than declining.
【▼】： torch down button.
【MENU】： it is also named as【MENU】. Menu function button of choosing, and
different condition have different function.
【OK】： it is also named as【OK】. After entering into menu, if this button have
been pressed at the first time, the parameters are able to be modified,
After modified, the parameter will be confirmed when the button is
pressed at the second time.
【＋】： when parameter is switching, the button can increase the parameter
number progressively. When parameter is amending, the button can increase the
parameter value.
【－】： when parameter is switching, the button can decrease the parameter
number progressively. When parameter is amending, the button can decrease the
parameter value.
【AUTO】： it is also named as【AUTO】, it is used for switching the condition which
allow auto height control. Whenever the button have pressed, the light
above the button can change condition. If the light is lighted, THC can
start auto height control during torch is working. If the light is gone out,
auto height control will stop work. The light is lighted when THC is

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start.
【ARCON TEST】： it is also named as 【ARCON TEST】. During torch do not work
and menu operation do not use, plasma can start arc(arc start relay is
closed) when button have been pressed, and it can stop start arc(arc relay
is opened) when button have been loosened. If arc start button of testing
is loosened, torch will lift up an height which named torch
accomplishment height of putting the spear.
【IHS TEST】：
it is also named as 【IHS TEST】.IHS button of testing. During torch do
not work and menu operation do not use, if the button is pressed first,
THC will start IHS until down is accomplished. If the button is pressed
again during down is working, or【▲】is pressed, down will stop work.
The light above the button is lighted during IHS test. If IHS test finish,
the light will go out.
2.2 operation panel of explaining
1.Displaying with Nixie tube ：Arc voltage value is displayed by two nixie tubes
in the front operation panel. During torch do not work and menu operation do not
been used, it can display arc voltage 、IHS 、pierce delay value and so on. The green
nixie tube is used to display arc voltage setting value; the red nixie tube is used for
display actual value of arc voltage. Arc voltage setting value can be changed by
turning the button named【ARC SET】(【ARC SET】)，and the value displayed with green
nixie tube will be changed at the same time. The red nixie tube display 0 when plasma
do not been working. The value displayed with red nixie tube is actual arc voltage
value during plasma is working.
2.Parameter spin button of setting：
There have three spin button of spin encoding in panel.
The spin button named“ARC SET”：When menu operation do not use, arc voltage
value can change by turning this spin button. If it turn clockwise, arc voltage value
will increase. If it turn anticlockwise, arc voltage value will decrease. Arc voltage
setting value is displayed in yellow nixe tube. When we change arc voltage setting
value, it should on the basis of workpiece thickness and torch speed, it also need use
parameter which offer by plasma power source. Torch height depend on Arc voltage
value when torch is working.
During torch is working, arc voltage setting value also can change by spin button,
and it can adjust torch height. This operation suit to adjust slightly torch height when
torch is working.
The spin button named“Piercing Delay” ：When menu operation do not use,
turning the button can change the value of piercing delay time. If it turn clockwise, the

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value of piercing delay time will increase. If it turn anticlockwise, the value of
piercing delay time will decrease. When the spin button is turned, the yellow nixie
tube display“Dly”, the red nixie tube display piercing delay time, the unit is second.
When THC use the piercing delay time which user set, it can send arc OK signal
to CNC after piercing delay is finishing and arc voltage by sampling is effective.
Some CNC have piercing delay time, but this delay is calculated when CNC receive
arc OK signal. The authentic piercing delay time is the sum of piercing delay time of
THC and piercing delay time of CNC. If user do not want to use the piercing delay
time of THC, user can set it as zero.
The spin button named“IHS Height”：When menu operation do not use, turning
the button can change height of IHS. If it turn clockwise, the height of IHS will
increase. If it turn anticlockwise, the height of IHS will decrease. When the spin
button is turned, the green nixie tube display“IHS”, the red nixie tube display the
height of IHS. The height of IHS set by delay, the unit is second.
When menu operation do not use, two nixie tube is display arc voltage setting
value. If user turn the spin button named “Piercing Delay”or the spin button named
“IHS Height”, it will display corresponding character. If the spin button is not turned
for a long time, the nixie tube will display arc voltage setting value.
3. Working condition indicator：
The panel have 8 LED light：
¾UP indicator：This LED light is turned on when torch lift up.
¾AUTO THC indicator：This LED light will be truned on when the THC is
working in auto height controlling processing. If it satisfy four conditions
below, the indicator will turn on：
1）The indicator named“AUTO”is turned on.
2）CNC Auto height control enables.
3）THC have sampled valid arc voltage.
4）The sampling arc voltage do not exceed the value added
between arc setting voltage and arc protecting voltage(in general, the value is 30V and
can been changed).
¾TRANS indicator：The indicator is lighted, it means system have detected the
effective arc voltage value and piercing have competed. (it is piercing delay
time of THC over, it is not contain the piercing delay time of CNC)
¾ARC ON indicator：Turn on when THC send arc start signal out. If IHS
completed, this indicator is lighted when THC send arc start signal. During
arc start test, the indicator is lighted.
¾DOWN indicator：Turn on when torch lift down.
¾COLLISION indicator：Turn on when torch touch workpiece or proximity
switch effective.

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¾AUTO indicator：The indicator up the button named【AUTO】is indicated
whether allowed auto height control. If the indicator is lighted, THC will
allow auto height control. If the indicator is extinguish, THC will not allow
auto height control. The indicator is lighted after starting up. The indicator
condition will change when the button named【AUTO】is pressed.
¾IHS TEST indicator：The indicator up the button named【IHS TEST】is lighted
during IHS test, it means IHS test is working. The indicator is extinguish
during other condition.
2.3 Menu operation explain
THC have concise menu, it can set some parameter and adopt to different work
condition. Menu operation use the button named【MENU】、【OK】、【+】、【-】and so on.
It also use two nixie tube to display parameter, the green nixie tube display parameter
number and the red nixie tube display parameter value.
When user use it on the scene, parameter number and meaning can refer to
concise parameter grid up the chassis.
During torch do not work, when arc start and IHS test do not work, user press the
button named【MENU】can enter into the menu operation model. After it enter into the
menu model, the button named【IHS TEST】、【ARCON TEST】
is trashy. Only the button
named【▲】、【▼】and the signal named THC_UP、THC_DN that CNC send is useful.
If THC enter into the menu model, it will not test and cut.
When THC enter into the menu model, it mean THC enter into first submenu
named “Pxx”（xx is parameter number），if the button named【MENU】is pressed again，
THC will enter into second submenu named“Hxx”. When the button named【MENU】
is pressed, THC can switch the next submenu. When it have switched the last
submenu, if the button named 【MENU】is pressed, it will exit the menu model. THC
can test and cut until it exit the menu model. So user need exit the menu model in time
after parameter have changed.
When THC switch submenu, the submenu is in a view model, it display first
parameter of submenu. For example, the first parameter of first submenu is named
“recover factory parameter”. The yellow LED display“P00”，the red LED display“ 1”.
When the submenu is in view model, pressing the button named【+】can switch the
next parameter in same submenu. For example, the yellow LED display“P01”, when
the button named【+】is pressed, it can display“P02”. The red LED display value of
P02. When the button named【+】is pressed again, it can display“P02”, by parity of
reasoning. Similarly, pressing the button named【-】can go back the last parameter
successively.
When the submenu is in view model, pressing the button named【OK】can enter

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into the parameter modification model. Then the red LED start flicker, it means this
parameter is waiting for changing. Pressing the button named 【+】/【-】can
increase/decrease parameter, the value which user change will display in the
parameter. After parameter have changed, user can save it by pressing the button
named【OK】and cancel it by pressing the button named【MENU】.
If user save it by pressing the 【OK】button, the red LED will stop flicker and
display the value which user have change. If the parameter have be changed and user
cancel it by pressing the 【MENU】button, the red led will stop flicker and display the
value which the parameter is not changed。
THC have“Pxx”“Hxx”“Lxx” three submenu.With the addition of non-menu
model, it have four condition. When the button named【MENU】is pressed, THC can
switch in four condition circularly. Warning: During the non-menu model, if THC
is testing or auto height control is working, THC will not enter into the menu
model and change parameter. Similaryly, if THC have entered into menu model,
it will not start test and auto height control. After the parameter have changed,
user must be remember to exit menu model in time.
“Pxx”submenu contain 21 parameters, they are“P00”~“P20”and contain sundry
quantification parameter. The sundry parameter can change in this submenu.
“Hxx”submenu contain 9 parameters, they are“H01”~“H09”. It is used to check
input signal is high level or low level. The sundry parameter can not change in this
submenu. Warning : During torch start to work, pressing the button named
【MENU】can look up the level condition of input port.
“Lxx”submenu contain 9 parameters, they are“L01”~“L09”. It can be set the
input signal as high level effective or low level effective. The sundry parameter can
change in this submenu.
“Pxx”submenu listing
Para
meter
numb
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Settin
g
scope
step
and
lengt
h
adju
st
Initial
para
meter
Yel l
ow
LED
Red
LED
Remark
P00 0-1 1 1 P00 1 Recovering factory parameter/
amending parameter interval
P01 0-50 1 50 P01 50 Setting manual lift speed of torch, the
minimum speed is 0, the maximum
speed is 50. CNC_THC_UP also use
this speed.