Hypertherm PHC Sensor User Manual

Hypertherm Automation 5 Technology Drive, Suite 300 W. Lebanon, NH 03784 USA Phone: 603-298-7970 Fax: 603-298-7977 HYPE

10 Sensor™ PHC Operation and Setup Guide Features Sensor™ PHC Plasma Height Control is an automated height control system for plasma shape cutting

Section 1: Overview 11 System Specifications* Compatible motors: DC PM 24Vdc, 2 Amps to 6 Amps Max power output: 150W Standard lifter range: Linea

12 Sensor™ PHC Operation and Setup Guide Connections All connections to the Sensor™ PHC are made through four connectors on the bottom of the contro

Section 1: Overview 13 PHC to CNC Signals All signals to the CNC are connected through the 25-pin D subconnector on the control unit. For detailed

14 Sensor™ PHC Operation and Setup Guide Sensor™ PHC Front Panel Indicators Green Power Yellow Upper Limit Green In Position Yellow Lower

Section 1: Overview 15 Control Module Electrical Input power (switch selected dual range)... 115 VAC or 230 VAC, 1 Pha

16 Sensor™ PHC Operation and Setup Guide Plasma Interface Assembly The plasma interface module is shown in Figure 3. Electrical Parallel digital I

Section 1: Overview 17 Standard Lifter Assembly Electrical Motor ...

18 Sensor™ PHC Operation and Setup Guide

Section 2: Installation and Setup 19 Section 2: Installation and Setup The standard PHC system includes the following components: Standard componen

DISCLAIMER The information in this document is subject to change without notice and should not be construed a

20 Sensor™ PHC Operation and Setup Guide Power Requirements The PHC can be connected to either 115 Vac or 230 Vac 50/60 Hz. Depending on the input

Section 2: Installation and Setup 21 Control Unit Mounting Before interconnecting the PHC system, mount the units as required, using customer-suppli

22 Sensor™ PHC Operation and Setup Guide Control Unit Mounting from Front Mount the PHC control unit close to the machine operator console for easy

Section 2: Installation and Setup 23 Plasma Interface Assembly Mounting Mount the plasma interface assembly close to the plasma power supply for easy

24 Sensor™ PHC Operation and Setup Guide Lifter Assembly Mounting Mount the lifter assembly on the cutting table to take maximum advantage of the ve

Section 2: Installation and Setup 25 Torch Breakaway Assembly The torch breakaway (229164) should be mounted to the lifter as shown in Figure 10.

26 Sensor™ PHC Operation and Setup Guide Torch Mounting Block Kit Mount the torch mounting block kit to the lifter torch breakaway assembly. See Fi

Section 2: Installation and Setup 27 System Cables Install system cables as shown in Figure 12. All cables should be properly shielded with shield c

28 Sensor™ PHC Operation and Setup Guide Grounding Requirements WARNING! To ensure personal safety and reduce electromagnetic interference (EMI),

Section 2: Installation and Setup 29 PHC Interface Signals Most of the PHC interface signals are through optoisolators. Figure 14 shows the details

iii Table of Contents Making people and machines more productive through process Automation ... ISAFETY

30 Sensor™ PHC Operation and Setup Guide CNC Interface Signals See Figure 14 on page 29 for an illustration. CNC Interface Signals 25-pin D Sub

Section 2: Installation and Setup 31 IHS Sync This optional CNC output is used to synchronize torches in a multiple torch installation. The CNC is

32 Sensor™ PHC Operation and Setup Guide RELAYStart OutputStart InputMotion OutputInterlockMotion InputSensor PHC I/OCNC I/OInterlock Output+++11231

Section 2: Installation and Setup 33 Plasma Interface Signals WARNING: HAZARDOUS VOLTAGE & ENERGY The plasma interface signals from plasma cu

34 Sensor™ PHC Operation and Setup Guide Plasma Interface Signals Name 15-pin D Subconnector Pin #s Plasma Interface Signal Type Plasma start

Section 2: Installation and Setup 35 Figure 17: Plasma Interface Connection to star ground on work table Connect negative electrode voltage

36 Sensor™ PHC Operation and Setup Guide WARNING! For safety and proper operation this unit must be connected to positive ground. WorkPositive Gro

Section 2: Installation and Setup 37 Plasma Start This signal is a relay contact output from the PHC and an input the plasma power supply. The PHC

38 Sensor™ PHC Operation and Setup Guide Lifter Interface Signals These signals can be directly connected to a Sensor™ PHC standard lifter using th

Section 2: Installation and Setup 39 Lifter Power Connections These connections can be made directly to a Sensor™ PHC standard lifter using the supp

iv Plasma Start ...

40 Sensor™ PHC Operation and Setup Guide DIP Switch Setup Figure 20: Setup DIP Switches Switch Settings Switch settings for control module

Section 2: Installation and Setup 41 SW3 SW4 Voltage Control Response / Gain on on Gain = Low = +/- 4V In Position Range on off Gain

42 Sensor™ PHC Operation and Setup Guide SW9 SW10 End of Cut Retract Time on on Retract = Low = 0.25 Sec @ Max Speed (0.8” std lif

Section 2: Installation and Setup 43 SW15 Torch Breakaway Switch on (Sw NO) Open on Breakaway – Use normally open switch input * off (Sw

44 Sensor™ PHC Operation and Setup Guide Calibration Pot Setup ARC - Arc Voltage Calibration This trim pot is used to calibrate the actual arc volt

Section 3: Operation 45 Section 3: Operation Automated torch height control (THC) systems used in mechanized plasma cutting are used to provide the

46 Sensor™ PHC Operation and Setup Guide Automatic Operation Automatic voltage control operation is selected by placing the lower center toggle swit

Section 3: Operation 47 Manual Operation Manual lifter operation is selected by placing the lower center toggle switch in the lower manual position.

48 Sensor™ PHC Operation and Setup Guide

Section 4: Troubleshooting 49 Section 4: Troubleshooting Error Codes Figure 21: Error Indications The red ERROR LED indicates abnormal condition

v Table of Figures Figure 1: Connections ...

50 Sensor™ PHC Operation and Setup Guide • A coolant leak on a liquid cooled torch. Solution: This error is reset on the next CYCLE_START. E.03 L

Section 4: Troubleshooting 51 E.09 Low Input Power Error Reason: The PHC input power is 20% below the nominal voltage. Solution: increase the input

52 Sensor™ PHC Operation and Setup Guide Troubleshooting Guide Problem Solution The Error LED and Error code are displayed. ¾ Note the error code

Section 4: Troubleshooting 53 Problem Solution Arc extinguishes after Transfer with large pierce hole ¾ Check that the pierce delay is not too long.

54 Sensor™ PHC Operation and Setup Guide 4. Test the connection by attaching a jumper between pins 7 and 8 on the 9-pin D subconnector. If th

Section 4: Troubleshooting 55 Parts and Kits Kit Number Description Configured PHC Kits 228214 Sensor PHC with control module, lifter, and 50-f

56 Sensor™ PHC Operation and Setup Guide Lubricant For the linear bearing carriage and ball screw, the bearing manufacturer suggests grease with the

Appendix A: Interfacing to a Custom Lifter 57 Appendix A: Interfacing to a Custom Lifter The performance of the Sensor™ PHC is tightly coupled to th

Printed in the USA 806150 -- Revision 1

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Safety 1 Safety Read this Manual Readandunderstandthismanual,thecuttingmachinemanuals,andyouremployer’ssafetypractices.Note:Thisp

8 Sensor™ PHC Operation and Setup Guide

Section 1: Overview 9 Section 1: Overview Hypertherm’s Sensor™ PHC (228214) is a plasma torch height control/initial height sensing (THC/IHS) system