Hypertherm THC2 User Manual
THC-2
Torch Height Control
Instruction Manual
800200 Rev. 6
THC-2
Torch Height Control
Instruction Manual
P/N 800200
Revision 6 September, 2002
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© Hypertherm, Inc., 2002
All Rights Reserved
HYPERTHERM is a trademark of Hypertherm, Inc. and is
registered in the United States; International registration is pending.
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
800-643-9878 Tel (Technical Service)
800-737-2978 Tel (Customer Service)
Hypertherm Automation
5 Technology Drive
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm Singapore Pte Ltd
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 841 2489 Tel
65 841 2490 Fax
65 841 2489 (Technical Service)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
Hypertherm UK Ltd
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
0805 050 111 Tel
0805 050 222 Fax
Hypertherm S.r.L.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm B.V.
Burg. Haverkampstraat 13
7091 CN Dinxperlo, Nederland
31 315 655866 Tel
31 315 655886 Fax
Hypertherm B.V. (ETSO)
Vaartveld 9
4704 SE Roosendaal, Nederland
00 800 49 73 7843 – toll-free in Europa
31 165 596900 Tel
31 165 596901 Fax
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax
10/30/01
ELECTROMAGNETIC COMPATIBILITY (EMC)
EMC INTRODUCTION
Hypertherm's CE-marked equipment is built
in compliance with standard EN50199. The
equipment should be installed and used in
accordance with the information below to
achieve electromagnetic compatibility.
The limits required by EN50199 may not be
adequate to completely eliminate interference when the affected equipment is in
close proximity or has a high degree of
sensitivity. In such cases it may be necessary to use other measures to further
reduce interference.
This plasma equipment is designed for use
only in an industrial environment.
INSTALLATION AND USE
The user is responsible for installing and
using the plasma equipment according to
the manufacturer's instructions. If electromagnetic disturbances are detected then it
shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as
earthing the cutting circuit, see Earthing of
Workpiece. In other cases it could involve
constructing an electromagnetic screen
enclosing the power source and the work
complete with associated input filters. In all
cases electromagnetic disturbances must
be reduced to the point where they are no
longer troublesome.
ASSESSMENT OF AREA
Before installing the equipment the user
shall make an assessment of potential electromagnetic problems in the surrounding
area. The following shall be taken into
account:
a. Other supply cables, control cables,
signalling and telephone cables; above,
below and adjacent to the cutting equipment.
b. Radio and television transmitters and
receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example
guarding of industrial equipment.
e. Health of the people around, for
example the use of pacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User shall ensure that other
equipment being used in the environment is
compatible. This may require additional
protection measures.
h. Time of day that cutting or other activities
are to be carried out.
Earthing of Workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth
because of its size and position, for example,
ship's hull or building steelwork, a connection
bonding the workpiece to earth may reduce
emissions in some, but not all instances.
Care should be taken to prevent the earthing
of the workpiece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary, the connection of
the workpiece to earth should be made by a
direct connection to the workpiece, but in
some countries where direct connection is
not permitted, the bonding should be
achieved by suitable capacitances selected
according to national regulations.
Note. The cutting circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be authorized by a person who is competent to
assess whether the changes will increase
the risk of injury, for example, by allowing
parallel cutting current return paths which
may damage the earth circuits of other
equipment. Further guidance is given in IEC
TC26 (sec)94 and IEC TC26/108A/CD Arc
Welding Equipment Installation and Use.
Screening and Shielding
Selective screening and shielding of other
cables and equipment in the surrounding
area may alleviate problems of interference.
Screening of the entire plasma cutting
installation may be considered for special
applications
The size of the surrounding area to be
considered will depend on the structure of
the building and other activities that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
METHODS OF REDUCING EMISSIONS
Mains Supply
Cutting equipment must be connected to the
mains supply according to the manufacturer's recommendations. If interference
occurs, it may be necessary to take
additional precautions such as filtering of
the mains supply. Consideration should be
given to shielding the supply cable of permanently installed cutting equipment, in
metallic conduit or equivalent. Shielding
should be electrically continuous throughout
its length. The shielding should be connected to the cutting mains supply so that good
electrical contact is maintained between the
conduit and the cutting power source
enclosure
Maintenance of Cutting Equipment
The cutting equipment must be routinely
maintained according to the manufacturer's
recommendations. All access and service
doors and covers should be closed and
properly fastened when the cutting
equipment is in operation. The cutting
equipment should not be modified in any
way except for those changes and adjustments covered in the manufacturer's
instructions. In particular, the spark gaps of
arc striking and stabilizing devices should
be adjusted and maintained according to
the manufacturer's recommendations.
Cutting Cables
The cutting cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor
level.
Equipotential Bonding
Bonding of all metallic components in the
cutting installation and adjacent to it should
be considered. However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a
shock by touching these metallic
components and the electrode at the same
time. The operator should be insulated from
all such bonded metallic components.
Hypertherm Plasma Systems i
WARRANTY
ii Hypertherm Plasma Systems
9-01
WARNING
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any damage
caused by the use of other than genuine Hypertherm parts may
not be covered by the Hypertherm warranty.
WARNING
You are responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
warranty regarding the safe use of the Product in your
environment.
GENERAL
Hypertherm, Inc. warrants that its Products shall be free from
defects in materials and workmanship, if Hypertherm is notified
of a defect (i) with respect to the power supply within a period
of two (2) years from the date of its delivery to you, with the
exception of G3 Series power supplies, which shall be within a
period of three (3) years from the date of delivery to you, and
(ii) with respect to the torch and leads within a period of one (1)
year from its date of delivery to you. This warranty shall not
apply to any Product which has been incorrectly installed,
modified, or otherwise damaged. Hypertherm, at its sole
option, shall repair, replace, or adjust, free of charge, any
defective Products covered by this warranty which shall be
returned with Hypertherm’s prior authorization (which shall not
be unreasonably withheld), properly packed, to Hypertherm’s
place of business in Hanover, New Hampshire, or to an
authorized Hypertherm repair facility, all costs, insurance and
freight prepaid. Hypertherm shall not be liable for any repairs,
replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph or with
Hypertherm’s prior written consent. The warranty above is
exclusive and is in lieu of all other warranties, express,
implied, statutory, or otherwise with respect to the
Products or as to the results which may be obtained
therefrom, and all implied warranties or conditions of
quality or of merchantability or fitness for a particular
purpose or against infringement. The foregoing shall
constitute the sole and exclusive remedy for any breach
by Hypertherm of its warranty. Distributors/OEMs may offer
different or additional warranties, but Distributors/OEMs are
not authorized to give any additional warranty protection to you
or make any representation to you purporting to be binding
upon Hypertherm.
PATENT INDEMNITY
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’s
specifications and in cases of designs, processes, formulae, or
combinations not developed or purported to be developed by
Hypertherm, Hypertherm will defend or settle, at its own
expense, any suit or proceeding brought against you alleging
that the use of the Hypertherm product, alone and not in
combination with any other product not supplied by
Hypertherm, infringes any patent of any third party. You shall
notify Hypertherm promptly upon learning of any action or
threatened action in connection with any such alleged
infringement, and Hypertherm’s obligation to indemnify shall be
conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the defense
of the claim.
LIMITATION OF LIABILITY
In no event shall Hypertherm be liable to any person or
entity for any incidental, consequential, indirect, or
punitive damages (including but not limited to lost profits)
regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranties, failure of
essential purpose or otherwise and even if advised of the
possibility of such damages.
LIABILITY CAP
In no event shall Hypertherm’s liability, whether such
liability is based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or
otherwise, for any claim action suit or proceeding arising
out of or relating to the use of the Products exceed in the
aggregate the amount paid for the Products that gave rise
to such claim.
INSURANCE
At all times you will have and maintain insurance in such
quantities and types, and with coverage sufficient and
appropriate to defend and to hold Hypertherm harmless in
the event of any cause of action arising from the use of the
Products.
NATIONAL AND LOCAL CODES
National and Local codes governing plumbing and electrical
installation shall take precedent over any instructions
contained in this manual. In no event shall Hypertherm be
liable for injury to persons or property damage by reason of any
code violation or poor work practices.
TRANSFER OF RIGHTS
You may transfer any remaining rights you may have
hereunder only in connection with the sale of all or substantially
all of your assets or capital stock to a successor in interest who
agrees to be bound by all of the terms and conditions of this
Warranty.
TABLE OF CONTENTS
DESCRIPTION AND SPECIFICATIONS .................................................................. v
SECTION 1 INSTALLATION - To Cutting Machine and Torch Lifter ..................1-1
Install the THC-2 Control Module ...........................................................................1-2
Mount the THC-2 Control Module .....................................................................1-2
Connect the THC-2 Control Module to the Cutting Machine
Computer Interface and Torch Lifter Motor .......................................................1-3
SECTION 1a INSTALLATION - MAX100 or MAX100D ...................................... 1a-1
Mount the Voltage Divider to MAX100 or MAX100D ............................................ 1a-2
Install Interconnect Cable to MAX100 or MAX100D .............................................1a-2
SECTION 1b INSTALLATION - MAX200 ...........................................................1b-1
Mount the Voltage Divider to MAX200 .................................................................1b-2
Install Interconnect Cable to MAX200 ..................................................................1b-4
SECTION 1c INSTALLATION - PAC-500 .......................................................... 1c-1
Mount the Voltage Divider to PAC-500................................................................. 1c-2
Install Interconnect Cable to PAC-500 .................................................................1c-3
SECTION 2 OPERATION ..................................................................................2-1
Description of Controls and Indicators ...................................................................2-2
Operating Instructions ............................................................................................2-3
Notes on Operation...........................................................................................2-3
SECTION 3 PARTS LIST...................................................................................3-1
THC-2 Torch Height Control Systems ....................................................................3-2
Torch Height Control System for MAX100, MAX100D, MAX200....................... 3-2
Torch Height Control System for PAC-500 .......................................................3-2
THC-2 Interconnect Cable - #023264 ....................................................................3-3
THC-2 Control Module - #053005 ..........................................................................3-5
THC-2 Torch Height Control
Page iii
TABLE OF CONTENTS
List of Figures
Figure 1-1 THC-2 Control Module Mounting Dimensions....................................................... 1-2
Figure 1-2 THC-2 Control Module Front and Rear Views ...................................................... 1-3
Figure 1-3 Wiring Diagram -
THC-2 to Cutting Machine Interface and Lifter Motor ........................................... 1-4
Figure 1-4 Typical DC Lifter Wiring ........................................................................................ 1-5
Figure 1a-1 Connections to MAX100 or MAX100D ................................................................. 1a-3
Figure 1b-1 Voltage Divider Template Location -
MAX200 Center Wall Right Rear ........................................................................ 1b-3
Figure 1b-2 Voltage Divider Mounting Location -
MAX200 Center Wall Left Rear ........................................................................... 1b-3
Figure 1b-3 Inside Rear of MAX200 Power Supply ................................................................ 1b-4
Figure 1b-4 Wiring Diagram - THC-2 to MAX200 ................................................................... 1b-5
Figure 1c-1 PAC-500 Plasma Control Console Plumbing Compartment ................................ 1c-2
Figure 1c-2 PAC-500/500L Plasma Control Consoles ............................................................ 1c-3
Figure 1c-3 PAC-500/500L Plasma Control Consoles - 1TB Location .................................... 1c-4
Figure 1c-4 HF Compartment - PAC-500 Console .................................................................. 1c-5
Figure 1c-5 Top Rear View of THC-2 ......................................................................................1c-6
Figure 1c-6 Inside View of THC-2 ........................................................................................... 1c-7
Figure 2-1 THC-2 Front Panel ................................................................................................ 2-2
Figure 3-1 THC-2 Control Cable - MAX100/100D/200 ............................................................ 3-3
Figure 3-2 THC-2 Front and Rear Panels .............................................................................. 3-4
Figure 3-3 THC-2 Interior ....................................................................................................... 3-6
FIgure 3-4 Voltage Divider - 041007 - .................................................................................... 3-8
Page iv
THC-2 Torch Height Control
DESCRIPTION AND SPECIFICATIONS
DESCRIPTION
he THC-2 Torch Height Control automatically controls torch height while plasma cutting. After
setting the arc voltage with the thumbwheel on the front panel, the THC-2 controls the torch
T
the workpiece. If the torch is too high from the workpiece, the actual arc voltage will be greater than
the reference voltage. The Arc Voltage Control will then activate the torch suspension motor to move
the torch downward. If the torch is too close to the workpiece, the arc voltage will be less than the
reference voltage. In this case, the Arc Voltage Control will activate the torch suspension motor to
move the torch upward.
The THC-2 comes with a voltage divider that mounts in the MAX100 , MAX100D and MAX200 power
supplies, or in the PAC-500/500L Plasma Control Console. The voltage divider reduces the arc
voltage by a ratio of 25:1.
Section 1 of this manual - Installation - describes mounting the THC-2 module and connecting it to
the cutting machine computer and the torch lifter. Sub-sections 1a, 1b etc. describe hooking the
THC-2 to Hypertherm products that utilize this type of torch-height control. Section 2 is a brief
operation section, and Section 3 is a parts list. A wiring diagram follows the parts list.
suspension motor by comparing this reference voltage with the voltage between the torch and
SPECIFICATIONS
THC-2 Control Module - #053005*
Power Input .........................................................115 VAC, 50/60 Hz
Operating Environment ....................................... 32°F (0°C) to 122°F (50°C)
Height .................................................................. 6 inches (152 mm)
Width ...................................................................8 inches (203 mm)
Depth................................................................... 17 inches (432 mm)
Weight .................................................................15 pounds (6.8 kg)
Arc Voltage Setting Range .................................. 100-250 V
Control Accuracy ................................................. +/- 2 V
* For a parts list breakdown of the THC-2 systems see Section 3 - Parts List
THC-2 Torch Height Control
Page v
Section 1 INSTALLATION - To Cutting Machine and
Torch Lifter
In this section:
Install the THC-2 Control Module........................................................1-2
Mount the THC-2 Control Module...................................................1-2
Connect the THC-2 Control Module to the Cutting Machine
Computer Interface and Torch Lifter Motor.....................................1-3
THC-2 Torch Height Control
Page 1-1
INSTALLATION - To Cutting Machine & Torch Lifter
INSTALL THE THC-2 CONTROL MODULE
Before installing the THC-2 system, verify the following components after unpacking:
• Voltage Divider
• THC-2 Control Module
• Interconnecting cable #023264 (Cable not available for PAC-500 systems)
Mount the THC-2 Control Module
1. Mount the THC-2 Control Module in a convenient location for the operator. See Fig.1-1
for mounting dimensions. Note the length of the control cable (5 feet) that will connect
from the THC-2 to the inside of the MAX100, MAX100D, or MAX200 and make certain
that the cable will reach before mounting. Customers must supply and fabricate cables
for the PAC-500 systems.
8-32
Tapped
Hole (3)
Page 1-2
Bottom
View
FRONT
6-3/4"
8"
Figure 1-1 THC-2 Control Module Mounting Dimensions
17-3/32"
15-5/8"
5/8"
THC-2 Torch Height Control
INSTALLATION - To Cutting Machine & Torch Lifter
2. To ensure proper grounding at the THC-2, run a #10 gauge copper cable from the ground
stud on the rear of the THC-2 (Fig. 1-2) to a common earth ground. To correctly operate
the THC-2 system, it must be grounded properly.
Connect the THC-2 Control Module to the Cutting Machine Computer Interface
and Torch Lifter Motor
A cable running from the THC-2 control module to the cutting machine interface and torch
lifter must be fabricated. Hypertherm recommends a 7-conductor 24-gauge shielded cable.
3. Remove the eight screws on the THC-2 Control Module and take off the top
panel - Fig. 1-2.
Remove Screws
Figure 1-2 THC-2 Control Module Front and Rear Views
THC-2 Torch Height Control
Remove Screws
RECP2
Ground
Stud
Strain
Reliefs
Page 1-3
INSTALLATION - To Cutting Machine & Torch Lifter
4. Feed the cable through one of the strain reliefs located on the THC-2 rear panel (Fig.
1-2). See Figure 1-3 for cable connections. Consult your cutting machine schematics, or
call the cutting machine manufacturer for actual connections on the cutting machine
interface.
Note: The THC-2 normally operates AC lifter motors. See Figure 1-4 and refer to THC-2
schematic for DC lifter connections.
This completes installation of THC-2 to the cutting machine interface and torch lifter. For
installation of voltage divider and cable to: MAX100 or MAX100D - go to Section 1a;
MAX200 - go to Section 1b; PAC-500 - go to Section 1c.
1TB
Cutting Machine
Interface
Start*
Machine Motion**
AVC***
AC Lift Motor
UP
120
Common
DOWN
120 VAC Hot for
AC Lift Motor
Notes: * Not used for the PAC-500 system
** Dry contacts to CNC control. Closed = Motion; Open = No Motion
*** Dry contacts to CNC control. Closed = AVC allowed; Open = No AVC
127
128
129
130
131
132
133
126
119
THC-2
Figure 1-3 Wiring Diagram - THC-2 to Cutting Machine Interface and Lift Motor
Page 1-4
THC-2 Torch Height Control
INSTALLATION - To Cutting Machine & Torch Lifter
UP
DOWN
DN
MAN
+
UP
DC
Power
_
AUTO
MAN
AUTO
Double pole, single throw
toggle switch - Mount in
operator station
Jump to wire 106
on DC Power Supply
1PS in THC-2
UP
115VAC
DN
115VAC
UP
DOWN
UP
Quantity (2), 2 pole, N/O relays,
115 VAC coils - Mount in the THC-2
1TB-131
1TB-133
DN
Lifter
Motor
Jump to wire 107
on DC Power Supply
1PS in THC-2
Add jumper and relays to THC-2
Figure 1-4 Typical DC Lifter Wiring
THC-2 Torch Height Control
JUMPER
1TB-132
Page 1-5
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