Hypertherm SENSOR OHC Page 3 Manual Download

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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

Summary of Contents for SENSOR OHC

Page 1: ...HYPERTHERM SENSOR OHC AUTOMATED OXY HEIGHT CONTROL OPERATION SET UP GUIDE Making people and machines more productive through process Automation ...

Page 2: ... Hypertherm Automation assumes no responsibility for any errors that may appear TRADEMARKS Hypertherm Automation is a wholly owned subsidiary of Hypertherm Inc Sensor is a trademark of Hypertherm Automation AR 300 100W Levilator Clearance Control is a trademark of CMC Burny COPYRIGHT 2004 by Hypertherm Automation All rights Reserved Printed in USA ...

Page 3: ...s 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 ...

Page 4: ......

Page 5: ...ving 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 a...

Page 6: ...2 Sensor OHC Operation and Set Up Guide ...

Page 7: ... 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 uppe...

Page 8: ...ced 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 Sensor OHC can be used with any CNC Easy set...

Page 9: ... 100 mm outer 50 mm inner diameters Can be calibrated for others Dimensions 8 50 216mm W x 4 21 107mm D x 4 02 102mm H Control Type Digital Micro Processor based Motor Output Full H Bridge PWM with current sensing Control Interface Optically Isolated I O on D connectors Outputs Digital In Position Output Digital Error Output Digital Plate Contact Output Inputs Digital Manual Auto Select Digital Ma...

Page 10: ... OHC Operation and Set Up Guide Control Unit Front Height Set Point Adjust Set Up Calibration Access Panel Power Indicator In Position Indicator Lower Limit Indicator Error Code Indicator Upper Limit Indicator ...

Page 11: ...Section 1 Overview 7 Control Unit Bottom Power Motor Ground Limit Switches Control Interface 6 Amp Fuse Capacitive Sensor ...

Page 12: ...8 Sensor OHC Operation and Set Up Guide Sensor and Mounting Isolator Mounting Isolator Spring Breakaway Capacitive Sensor Ring ...

Page 13: ...Manual mode is activated by connecting the input on pin 3 of the 15 pin I O connector to the signal Ground on pin 2 In manual mode the unit is controlled by using the Up Down switch only The control will not respond to the Set Height and will stay fixed in the position that it was last driven to using the Up Down switch The Up Down switch has two speeds depending on how long it is held active Duri...

Page 14: ...icates that the sensor is not plugged in or the sensor cable has opened In Auto Height mode this error will disable all motion This may also indicate that re calibration is required 3 Flashes Input Voltage Low Indicates that the 24Vac power source has dropped more than 25 below nominal Check the power source and all connections 4 Flashes Input Voltage High Indicates that the 24Vac power source is ...

Page 15: ...mp that will correctly position the sensor ring with respect to the torch tip 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 ground electrical connection between the sensor mounting isolator ...

Page 16: ...n the AR300 100 style connectors does not allow for proper cable shielding Improper cable shielding can result in severe electrical interference problems Power Connections All power connections are made to the 7 pin circular connector When connecting to the motor ensure that the motor polarity is such that if pin 2 is positive with respect to pin 5 the slide will move in the UP direction The 24 Va...

Page 17: ...al external pot The optional status output signals In Position Error and plate Contact are available on pins 7 8 7 9 respectively The outputs are transistors connected to signal return and are capable of switching up to 30V at 100 mA each A source of 12V dc is available on pin 1 for use in interfacing to the output signals Care should be taken that the total 12 Vdc current drawn from pin 1 plus th...

Page 18: ...t set point pot This would allow for central control of cutting height and eliminate the possibility of accidental errors due to the unintentional changing of the control front panel height set point pot I O and Control Pot Pin out 15 Pin D Sub Pin Description 1 I O Power 12VDC at 50Ma Max 2 I O Ground 3 Manual Select Input 4 Up Input 5 Down Input 6 Second Height Select Input 7 In Position Output ...

Page 19: ...7 PIN CIRC PIN1 PIN10 SW SPDT momentary center of f IN POSITION PIN3 MANUAL PIN2 PIN13 9 PIN D SUB PIN14 MAX CAPACITIVE SENSOR SECOND HEIGHT POT HIGH PIN3 PIN5 PIN4 BNC I O GND I O GND HEIGHT PIN2 PIN5 LIFTER MOTOR SECOND HEIGHT POT WIPER PIN15 DWN 24V RET PIN1 PIN3 PIN9 UP 24V AC PIN13 Outputs are transistors to I O Gnd If using the internal V I O 12V supply do not exceed 50mA of total current lo...

Page 20: ... INPUT Transistor using External 24V C59 0 1 DSUB 15 Male 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LED using Internal 12V IO Gnd DSUB 15 Female 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SPARE INPUT 1 2 16 15 External Circuitry Opto Isolator ERROR OUTPUT ISOLATED 12V External 24V IN POS OUTPUT 0 01 DIODE LAMP 1 2 5V 475 SPARE OUTPUT MANUAL INPUT External switch Manual Input IO Gnd 1K RESISTOR Example In...

Page 21: ...ain off off Sensitivity lowest Lowest Gain Most Stable use for high speed lifters 3000 mm min on off Sensitivity medium low off on Sensitivity medium high on on Sensitivity highest Highest Gain Least Stable use for low speed lifters 750 mm min SW7 SW8 Max Motor Current off off Current lowest 2 0 Amp 50W on off Current medium low 3 0 Amps 75W off on Current medium high 4 0 Amps 100W on on Current h...

Page 22: ...icinity of the sensor ring This includes the person who is performing the calibration The CALIBRATION LED should remain flashing even when the screwdriver is removed from the CALIBRATION POT If the CALIBRATION LED is OFF then rotate the pot clockwise CW until the LED is flashing If the CALIBRATION LED is ON then rotate the pot counter clockwise CCW until the LED is flashing 5 Check the Calibration...

Page 23: ...Optional Sensor Cables Part Number Description CONN 0141 MATING CONNECTOR KIT CABL 0163 AR 300 100 CONVERSION ADAPTER CABLE CABL 0157 COAX CABLE 0 5M CABL 0158 COAX CABLE 0 8M CABL 0159 COAX CABLE 1 0M CABL 0160 COAX CABLE 1 2M CABL 0161 COAX CABLE 1 5M ...

Page 24: ...20 Sensor OHC Operation and Set Up Guide Connector Kit CONN 141 Components ...

Page 25: ......

Page 26: ...Printed in the USA MANU 0044 ...

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