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
Automation
HYPERTHERM SENSOR™ PHC
LASMA HEIGHT CONTROL
P
PERATION & SET UP GUIDE
O
Making people and machines more productive through process Automation
D
ISCLAIMER 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 appear.
T
RADEMARKS Hypertherm Automation is a wholly owned subsidiary of Hypertherm
Sensor™ is a trademark of Hypertherm Automation.
HyDefinition
®
Plasma is a reg. trademark of Hypertherm®, Inc.
®
, Inc.
HyPerformance™ Plasma is a trademark of Hypertherm Automation.
Other trademarks are properties of their respective owners.
C
OPYRIGHT 2008 by Hypertherm Automation. All rights Reserved
Printed in USA
iii
Table of Contents
Making people and machines more productive through process Automation .............................................. I
SAFETY ............................................................................................................................................................... 1
SECTION 1: OVERVIEW ................................................................................................................................. 9
PHC Control Module ......................................................................................................................................... 9
Plasma Interface Assembly .............................................................................................................................. 9
Lifter Assembly ................................................................................................................................................. 9
Sensor PHC Models .......................................................................................................................................... 9
Features ........................................................................................................................................................... 10
Features ....................................................................................................................................................... 10
Options ......................................................................................................................................................... 10
System Specifications* ................................................................................................................................... 11
Connections ..................................................................................................................................................... 12
PHC to CNC Signals ................................................................................................................................... 13
PHC to Plasma Signals ............................................................................................................................... 13
PHC to Lifter Signals .................................................................................................................................. 13
Sensor™ PHC Front Panel Indicators ....................................................................................................... 14
Sensor™ PHC Front Panel Controls .......................................................................................................... 14
Control Module ................................................................................................................................................ 15
Plasma Interface Assembly ............................................................................................................................ 16
Standard Lifter Assembly .............................................................................................................................. 17
SECTION 2: INSTALLATION AND SETUP .............................................................................................. 19
Standard components ..................................................................................................................................... 19
PHC Control Module ................................................................................................................................... 19
Optional components ...................................................................................................................................... 19
Claims .............................................................................................................................................................. 19
Claims for damage during shipment .......................................................................................................... 19
Claims for defective or missing merchandise ............................................................................................ 19
Power Requirements ....................................................................................................................................... 20
Control Unit Mounting ................................................................................................................................... 21
Control Unit Mounting from Rear ............................................................................................................. 21
Control Unit Mounting from Front ............................................................................................................ 22
Plasma Interface Assembly Mounting ........................................................................................................... 23
Lifter Assembly Mounting .............................................................................................................................. 24
Torch Breakaway Assembly ........................................................................................................................... 25
Torch Mounting Block Kit .............................................................................................................................. 26
System Cables ................................................................................................................................................. 27
Grounding Requirements ............................................................................................................................... 28
Grounding Requirements ............................................................................................................................... 28
PHC Interface Signals .................................................................................................................................... 29
CNC Interface Signals .................................................................................................................................... 30
CNC Signal Descriptions ................................................................................................................................ 30
Cycle Start ................................................................................................................................................... 30
Auto Disable / Corner Hold ......................................................................................................................... 30
IHS Sync ...................................................................................................................................................... 31
IHS Complete .............................................................................................................................................. 31
Motion .......................................................................................................................................................... 31
Retract Complete ......................................................................................................................................... 31
Error ............................................................................................................................................................. 31
Interlock ....................................................................................................................................................... 31
Plasma Interface Signals ................................................................................................................................ 33
iv
Plasma Start ................................................................................................................................................ 37
Hold Ignition ................................................................................................................................................ 37
Transfer ........................................................................................................................................................ 37
Lifter Interface Signals ................................................................................................................................... 38
Lower Limit Switch ..................................................................................................................................... 38
Upper Limit Switch ..................................................................................................................................... 38
Breakaway Switch ....................................................................................................................................... 38
Lifter Power Connections ............................................................................................................................... 39
Motor Power ................................................................................................................................................. 39
Lifter Brake ................................................................................................................................................. 39
DIP Switch Setup ............................................................................................................................................ 40
Switch Settings ............................................................................................................................................ 40
Calibration Pot Setup ..................................................................................................................................... 44
ARC - Arc Voltage Calibration ................................................................................................................... 44
KERF - Auto Kerf Detection Level ............................................................................................................. 44
STALL - IHS Stall Sensing Level ............................................................................................................... 44
SECTION 3: OPERATION ............................................................................................................................ 45
Automatic Operation ...................................................................................................................................... 46
Manual Operation ........................................................................................................................................... 47
SECTION 4: TROUBLESHOOTING ........................................................................................................... 49
Error Codes ..................................................................................................................................................... 49
E.01 CYCLE_START at power up Error ................................................................................................... 49
E.02 Plate Contact at Home Error ............................................................................................................. 49
E.03 Lifter Timeout Error ........................................................................................................................... 50
E.04 Limit Reached during Auto Operation .............................................................................................. 50
E.05 IHS SYNC Timeout ............................................................................................................................ 50
E.06 Transfer Timeout Error ...................................................................................................................... 50
E.07 Lost Plasma Arc Error ........................................................................................................................ 50
E.08 Torch Breakaway Error ...................................................................................................................... 50
E.09 Low Input Power Error ...................................................................................................................... 51
E.10 High Input Voltage Error ................................................................................................................... 51
E.11 Over-Temperature Error .................................................................................................................... 51
E.12 Interlock Tripped Error ...................................................................................................................... 51
E.13 Excess Plate Contact Error ................................................................................................................ 51
E.99 Internal Software Error ..................................................................................................................... 51
Troubleshooting Guide ................................................................................................................................... 52
Parts and Kits ................................................................................................................................................. 55
Recommended THC Slide Maintenance ........................................................................................................ 55
Interval......................................................................................................................................................... 55
Lubricant...................................................................................................................................................... 56
APPENDIX A: INTERFACING TO A CUSTOM LIFTER ....................................................................... 57
Requirements .................................................................................................................................................. 57
v
Table of Figures
Figure 1: Connections ......................................................................................................................................... 12
Figure 2: Control Module ................................................................................................................................... 15
Figure 3: Plasma Interface (Cover Removed) ................................................................................................... 16
Figure 4: Lifter Assembly .................................................................................................................................. 17
Figure 5: Power Connection and Fuse .............................................................................................................. 20
Figure 6: Control Unit Rear Mounting ............................................................................................................. 21
Figure 7: Control Unit Front Mounting ............................................................................................................ 22
Figure 8: Plasma Interface Mounting ............................................................................................................... 23
Figure 9: Lifter Mounting .................................................................................................................................. 24
Figure 10: Torch Breakaway ............................................................................................................................. 25
Figure 11: Torch Mounting Clamp .................................................................................................................... 26
Figure 12: System Cables................................................................................................................................... 27
Figure 13: System Grounding ............................................................................................................................ 28
Figure 14: General Interfacing Examples ......................................................................................................... 29
Figure 15: Basic CNC Interface ......................................................................................................................... 32
Figure 16: Powermax Connections using Plasma Interface Unit ................................................................... 34
Figure 17: Plasma Interface............................................................................................................................... 35
Figure 18: Plasma Interface Connections ......................................................................................................... 36
Figure 19: Interfacing to Older Plasma Systems (MAX100 or MAX200) ....................................................... 37
Figure 20: Setup DIP Switches .......................................................................................................................... 40
Figure 21: Error Indications .............................................................................................................................. 49
vi
Safety 1
Safety
Read this Manual
Readandunderstandthismanual,thecuttingmachinemanuals,andyouremployer’ssafetypractices.
Note:Thisproductisnotdesignedtobefieldserviceable.Returnthisproducttoanauthorizedrepaircenter
forservice.
Sensor PHC Safety Listing
Note: This product has been designed and manufactured in a c cordance with CE and UL Safety Standards.
UL has successfully tested and listed this product in accordance with the applicable U.S. and Canadian Safety
Standards. File number E307226.
Additional markings:
1) Useminimum75
0
Ccopperwireonly.
2) Usecopperconductorsonly.
3) Suitableforuseonacircuitcapableofdeliveringnotmorethan5000rmssymmetricalamperes,
230voltsmaximum.
4) Integralsolidstateshortcircuitprotectiondoesnotprovidebranchcircuitprotection.Branch
circuitprotectionprovidedbyintegralLISTEDbranchcircuitprotection
fuse.
5) “Solidstatemotoroverloadprotectionisprovidedat145%offullloadcurrent”,ortheequivalent.
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
designed for conventional plasma cutting applications on an X-Y cutting table. The system uses the plasma
arc voltage to control the physical stand-off (distance) between the torch and work piece during plasma arc
cutting. Initial Height Sense (IHS) is accomplished by ohmic contact sensing or by a limited force stall
detection method. The Sensor™ PHC has been optimized for conventional plasma at or below 200 amps.
Note: Sensor™ PHC is not recommended for HyDefinition
applications. The system is not recommended for use on a water table.
A complete Sensor™ PHC system includes the following components:
PHC Control Module
The PHC control module (228116) houses a microcontroller, an operator control panel, and a Lifter motor drive.
This unit provides initial height sensing, arc voltage control. The PHC control module interfaces with the torch
lifter, the CNC machine, and the plasma power supply through standard discrete I/O interfaces. The operator
interface includes an LED display for set and actual arc voltage as well as error codes. The control unit ma in
functions are: arc voltage control/manual position mode, end of cut retract, IHS test, pierce height, voltage
controlled cut height, pierce delay; and access to setup and calibration adjustments. See Figure 2 on page 15.
Plasma Interface Assembly
®
or HyPerformance™ cutting or for higher power
The plasma interface (228256) provides a clean, standardized connection between the PHC control module
and the plasma power supply. The assembly can be mounted either to the back of or inside the plasma power
supply. The voltage divider provides a filtered low voltage signal which is derived from the cutting arc voltage.
The interface also provides an enclosed terminal block for easy connection to the interface signals. See Figure
3 on page 16.
Lifter Assembly
The torch lifter station (228117) positions a torch head vertically above the work piece and is controlled by the
PHC control module. Its maximum standard stroke is 6 inches (152 mm) between home and the lower limit. It
is driven by a DC motor attached to a lead screw. The control module interfaces with an optional lower limit
switch to detect maximum travel downward. The control also interfaces with an optional home switch to detect
when the lifter is in the highest position. The standard lifter does not use limit switches but has been designed
to allow for hard stop limit detection. A power-off brake disables power off motion of the torch. A torch
breakaway is an integral part of the lifter and provides a level of protection for the torch, lifter and X-Y table.
Upon impact, the breakaway releases from the locked position and allows the torch to float. A breakaway
switch detects when this protection has tripped and signals both the PHC control and the CNC machine. See
Figure 4 on page 17.
Sensor PHC Models
Kit Number Description
228214 Sensor PHC with control module, lifter, and 50-foot cables
228123 Sensor PHC (with 123896) for Powermax bundle
228242 Sensor PHC without lifter station
228243 Sensor PHC without lifter or 123895
228244 Sensor PHC without control module
228245 Sensor HPC without plasma interface
10 Sensor™ PHC Operation and Setup Guide
Features
Sensor™ PHC Plasma Height Control is an automated height control system for plasma shape cutting
applications. This product uses microprocessor technology to automatically detect the plate and adjust torch
position to an arc voltage set point during plasma cutting operations. This reduces operator input, improves
accuracy and increases productivity. The design of the Sensor™ PHC has been optimized for lower power
conventional plasma operation.
Features
¾ Sensor™ PHC can be used with any CNC
¾ Easy setup & operation
¾ Both manual & automatic operation modes
¾ Microprocessor control for increased sensitivity and control
¾ High positioning speeds possible with up to 6 amps continuous current and linear adjustment over
full range
¾ Built-in torch breakaway protection
¾ Built-in diagnostic and fault detection features
¾ Auto retract on plate contact
¾ 7 Segment LED display for set/actual arc voltage & error displays
¾ Power on indicator
¾ Upper and lower limit indicators
¾ In Position Indicator
¾ Attention / error indicator
¾ Torch position hold indicator
¾ Plate contact indicator
Options
¾ Interface cables
¾ Torch mounting clamps -1 3/8”, 1 3/4” and 2” diameters available.
Section 1: Overview 11
System Specifications*
Compatible motors:
DC PM 24Vdc, 2 Amps to 6 Amps
Max power output:
Standard lifter range:
Motor output:
Accuracy:
Voltage control range:
IHS range:
Operator controls:
Operator switches:
Operator display:
Calibration adjustments:
Setup DIP switches:
Measuring technology:
Interface inputs/ outputs:
150W
Linear 6” (152mm)
Full “H” bridge PWM with current & voltage sensing
0.01” (.25mm ) or 0.5 Volt **
50 Vdc to 210 Vdc
0.05 inches (1.2 mm) to 0.5 inches (12 mm) **
Arc voltage, IHS height, & pierce delay control knobs
IHS test, auto / manual, & manual up / down
3 digit 7 segment display for set volts, actual volts, & error
Arc voltage, stall force, auto kerf detect level
Max motor current, arc voltage response, IHS speed, auto delay,
int/ext pierce delay, end of cut retract height, auto kerf detect,
preflow during IHS, limit switches, breakaway switch, arc voltage
calibration
Arc voltage feedback & ohmic contact sensing
8 outputs and 6 inputs optically isolated on “D” connectors
Control dimensions:
Control weight:
Control power:
Standard lifter dimensions:
Standard lifter weight:
Operating environment:
*Information subject to change without notice.
** With Standard supplied lifter mechanics
6.2”(157mm)W x 4.3”(1.9mm)D x 10.4”(264mm)H
9 lbs
115VAC 0r 230VAC +/- 10% 50/60 Hz –selectable
6”(152mm)W x 3.15”(80mm)D x 21.5”(546mm) **
19 lbs **
0 to 50C; 95% relative humidity (non-condensing)
12 Sensor™ PHC Operation and Setup Guide
Connections
All connections to the Sensor™ PHC are made through four connectors on the bottom of the control unit. See
Figure 1.
Lifter signal
connections
Computer
controller I/O
Input power
115/230 Vac
Figure 1: Connections
table.
Fuse and voltage
selector w/ switch
WARNING! For safety and proper operation this unit must be connected to the star ground o n the work
Lifter motor &
brake power
Plasma
system I/O
Ground
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
interfacing information, see PHC Interface Signals on page 29 and CNC Interface Signals on page 30.
Outputs to CNC:
Digital IHS complete output
Digital motion output
Digital retract complete output
Digital error output/torch collision
Inputs from CNC:
Digital cycle start input
Digital corner hold input
Digital IHS sync input
Interlock
PHC to Plasma Signals
All signals to the plasma interface are connected through the 15-pin D subconnector on the control unit. These
signals are easily connected through the plasma interface unit or d irectly to a Powermax
®
G3 supply using a
G3 interface cable. For more detailed information, see Plasma Interface Assembly on page 16.
Outputs to plasma:
Digital plasma start output
Digital hold ignition output
Inputs from plasma:
Digital transfer input
Analog attenuated arc voltage
PHC to Lifter Signals
All signals to the lifter are connected through the 9-pin D subconnector on the control unit. For more detailed
information, see Standard Lifter Assembly on page 17.
Inputs from lifter:
Digital upper limit switch
Digital lower limit switch
Digital breakaway switch
Analog tip touch sense
PHC to Lifter Power Connections
All power connections to the lifter are coupled through the 7-pin circular connector on the control unit. For
more detailed information, see Standard Lifter Assembly on page 17.
Outputs to Lifter:
Motor drive 24V PWM
Power off brake 24Vdc
14 Sensor™ PHC Operation and Setup Guide
Sensor™ PHC Front Panel Indicators
Green Power
Yellow Upper Limit
Green In Position
Yellow Lower Limit
Red Attention / Error Code
Yellow Corner / Kerf Hold
Red Plate Contact
Red 3 digit Set / Actual Arc Voltage – Error Number – Set Pierce Height & Delay
Sensor™ PHC Front Panel Controls
Multiturn Rotary Pot Set Arc Voltage
Rotary Pot Pierce Height Retract
Rotary Pot Pierce Delay Time
Momentary Toggle Switch IHS Test
Toggle Switch Auto / Manual
Momentary 3 pos Toggle Manual Up / Down
Section 1: Overview 15
Control Module
Electrical
Input power (switch selected dual range)................................ 115 VAC or 230 VAC, 1 Phase, 50/60 Hz
Parallel digital I/O ................................................................... + 12 Vdc
Motor drive output voltage ……………………….....................24 Vdc
Motor drive output current ……………………….....................2,3,4,6 Amps max DIP switch selectable
Motor brake output ………………………………......................+24 Vdc ½ Amp
The features of the control module are highlighted in Figure 2.
Power
Upper limit
Torch position hold
Display actual /
set arc voltage &
errors
Voltage in
control
Lower limit
Error
Set IHS
height
IHS test
Manual / auto
Plate contact LED
Set arc voltage
Set pierce
delay time
Manual up / down
for torch
Figure 2: Control Module
Calibration
and setup
16 Sensor™ PHC Operation and Setup Guide
Plasma Interface Assembly
The plasma interface module is shown in Figure 3.
Electrical
Parallel digital I/O.....................................................................+12 Vdc to +24 Vdc
Interface signals……………………………………................... Plasma start, hold ignition, transfer
Voltage divider function............................................................Arc voltage (attenuated and filtered)
Plasma interface
signals
Electrode voltage
(negative)
Connection for ground
to the star ground on
the work table
Figure 3: Plasma Interface (Cover Removed)
If you are using a Sensor PHC 228245 with an HSD 130, select plasma interface assembly 22824 7 (25-foot
cable) or 228248 (50-foot cable). Refer to Field Service Bulletin 805740 for installation information.
Section 1: Overview 17
Standard Lifter Assembly
Electrical
Motor .......................................................................................+ 24 Vdc, 3 Amps
Motor brake …………………………………………...................+ 24 Vdc ½ Amp
Limit switches...........................................................................not used – hard stop limit detection
Breakaway switch ……..……………………………..................+ 12 Vdc proximity
Lifter Control Function
Motordrive...............................................................................DC full bridge, PWM chopped current source
Lifter speed feedback.............................................................Motor voltage
Maximum lifter speed..............................................................200 inches (508 cm) per minute
Maximum lifter stroke..............................................................6- inches (152 mm)
Maximum lifter load 10 pounds
All cable connections
exit top cover
Torch magnetic
breakaway
All lifter components, including
motor and brake, are fully
enclosed
Figure 4: Lifter Assembly
18 Sensor™ PHC Operation and Setup Guide
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