Hypertherm SensorOHC User Manual

HYPERTHERM SENSOR™ OHC

A

UTOMATED OXY HEIGHT CONTROL

PERATION & SET UP GUIDE

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Making people and machines more productive through process Automation

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ISCLAIMER The information in this document is subject to change without notice and should not

be construed as a commitment by Hypertherm Automation
Automation

®

assumes no responsibility for any errors that may appear.

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RADEMARKS Hypertherm Automation is a wholly owned subsidiary of Hypertherm

®

. Hypertherm

®

, Inc.

Sensor™ is a trademark of Hypertherm Automation.

AR-300/100W Levilator Clearance Control is a trademark of CMC Burny.

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OPYRIGHT ©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 shunt, 24Vdc, 2 Amps to 6 Amps

Max Power Output 150 Watts

4 Sensor OHC Operation and Set Up Guide

Description and Features

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

¾ Sensor OHC 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 diagnostic and fault detection features
¾ Auto retract on plate contact
¾ Optional second height set point input for preheat or pierce
¾ Indicator lights for operation including:

⇒ Power On
⇒ Upper Limit Switch
⇒ Lower Limit Switch

Options

¾ Five Cable Lengths from 19.7” (500mm) to 59” (1500mm)
¾ Adapter cables allowing direct replacement for existing AR-300/100W Levilator Clearance

Controls

⇒ In Position Indicator
⇒ Attention / Error indicator

System Features*

Compatible Motors DC shunt 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