XPTHC-Portable300 Arc Voltage Torch Height Controller · XPTHC-Portable300 Arc Voltage Torch Height Controller ... Arc voltage torch height controller XPTHC-Portable 300 ... controllers

XPTHC-Portable300

Arc Voltage Torch Height Controller

Please read this manual fully before use

HYDHYDHYDHYD 深圳市宏宇达数控技术有限公司

地址：深圳市南山区西丽留仙洞关外20号厂房6楼6-4 TEL：0755-26625800 FAX：0755-26729960

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SAFETY：：：：

Please read this manual fully before use XPTHC- Portable300

DO NOT open cabinet of THC unless trained technician.

DO NOT adjust the sealed resister.

Turn off Powersupply if when THC is unused.

DO NOT put liquid on THC.

Attention Anti-dust work, DO NOT let metal dust into THC.。

Installation Note：：：：

XPTHC- Portable300 uses AC24 Powersupply,±5%。

GND Must follow THC instruction, GND resister≤1Ω。

UP/DOWN on THC must be same to Z-axis Lifter

To avoid interference, follow cables please use shield cable( connection

between CNC controller and THC, to motor, to voltage divider, to IHS card),

especially the cable from THC to voltage divider, please use shield twisted pair

cable, and shield net connected at THC side.

To Customer：：：：

We only supply to re-seller as CNC cutting machine manufacturer,

engineering company" end-user please contact our local distributor for

product supplying.

We offer technical support to all distributors and users of our product.

。

IMPORTANT NOTE：

All our THCs have been tested on CNC cutting machine in our workshop

before delivery, all commissioning work was done. Please DO NOT change

the setting without informing your supplier.

ShenZhen HYD CNC Technology CO.,LTD


Table of Contents

1. Brief Intro ........................................................................................................................ 4

1.1 Product name and model ............................................................................................. 4

1.2 Basic parameter ........................................................................................................... 4

1.3 Application .................................................................................................................... 4

1.4 Components ................................................................................................................. 4

1.5 Installation size ...................................................................................................... 5

1.6 Basic Functions of XPTHC-Portable 300 ............................................................... 5

1.7 THC Work Flow ..................................................................................................... 6

1.7.1 Wok with IHS ............................................................................................... 6

1.7.2 Work without IHS ......................................................................................... 6

2. Voltage Divider ............................................................................................................... 7

2.2.1 None isolation voltage divide .............................................................................. 7

2.2 Isolation voltage divide .......................................................................................... 7

3. XPTHC-Portable300 Funtion and Set ............................................................................. 9

3.1 XPTHC-Portable300 operation panel .................................................................... 9

3.2 XPTHC-Portable300 inside Configuration. .......................................................... 11

3.3 XPTHC-Portable300 Setting ................................................................................ 12

3.3.1 Torch lift up after cutting（RS5） .............................................................. 12

3.3.2 IHS Speed Setting（RS6） ....................................................................... 13

3.3.3 THC Sensitive Setting（RS1） ................................................................. 13

3.3.4 Motor Drive Current Setting ....................................................................... 14

3.3.5 Motor Plug-Braking Setting ....................................................................... 14

3.4 IHS SET .............................................................................................................. 14

4 XPTHC-Portable300 Connection................................................................................ 15

4.1 POWER ............................................................................................................... 15

4.2 IHS connection .................................................................................................... 15

4.2.1 Torch retaining cap IHS ............................................................................. 15

4.2.2 Proximity switch IHS .................................................................................. 17

4.3 Plasma connection .............................................................................................. 19

4.4 TO CNC control system....................................................................................... 19

4.6 Lifter Motor Connection ....................................................................................... 21

6. Some advice .......................................................................................................... 23



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1. Brief Intro

1.1 Product name and model

Arc voltage torch height controller XPTHC-Portable 300

1.2 Basic parameter

Input Power：AC24V+5%，50Hz/60H z

Down/Up Motor：DC24V DC MOTOR

Motor Drive: PWM ;

Output Current：1A-2A, Load capacity：40W,

Working temperature：-10∽60

Voltage Divide ratio :100:1

Control accuracy ：：：：±1V∽∽∽∽±3V

Size ：length *width *height：320mm*260mm*90mm

The speed of lifting：1000mm/min∽4000mm/min(Contact the supplier if it exceeds the range

of speed）

1.3 Application

XPTHC- Portable 300 supports almost all plasma cutters on market like Hypertherm, Thermal

DynamicsI

And it supports all CNC cutting controllers on market like Hypertherm, Burny industrial level

controllers or Mach3 such DIY controllers, because XPTHC-Portable 300 can start Auto Height

control with or without Auto enable signal from CNC. But with Auto enable/disable signal from

CNC, THC would work better.

1.4 Components

XPTHC-Portable 300 includes follow parts

A、、、、XPTHC- Portable 300 Control module,

B、、、、Voltage divider,

C、、、、All related connectors.



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1.5 Installation size

Figure 1-1

1.6 Basic Functions of XPTHC-Portable 300

Auto Initial Height Sensing(IHS), Dual speed IHS。。。。

Torch Retaining Cap IHS and Proximity Switch IHS

NPN Proximity Switch IHS is backup for Torch Retaining Cap IHS for cutting dirty/rusty workpiece,

needing the Anti-Collision Fixture

Dual speed of IHS

During IHS, THC receives arc start signal from CNC, lift down z-axis lifter for 2 seconds(adjustable),

then change to another much lower speed(1/4 of previous speed) to touch the workpiece for IHS. It

effectively raises the precision of IHS and protects torch retaining cap.

Torch Anti-Collision Function

We designed Touch-Up circuit for Anti-Collision Function. No matter it is on Auto Control Model or

Manual Control Model, when torch head touches the workpiece, THC would automatically lift torch up

to IHS height. So with XPTHC-Portable 300, even in Manual Control Mode, user no needs to

worry about torch head crashing.



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Freeze Auto Height Control on Corner Signal

XPTHC- Portable300 can recognize Corner Signal from CNC and freeze Auto Control Model on

receiving this signal,

Lifting Torch Up on TURN ON or Arc Off:

When CNC is TURN ON or Plasma Arc Off, THC would lift torch up for 2 seconds, It is adjustable.

Set Pierce Delay Time

Set Button SET-PIERCE (set Pierce delay time), to delay output this signal, it is a switch signal, set

to detect arc voltage lead in THC. Once THC detects arc lead in, it sends Arc OK (Arc Trans) signal

to CNC to start cut.

Manual Operation

Many functions can be Manually operated on Operation Panel of XPTHC- Portable300, such as, set

Auto/Manual mode of THC, manually control torch Up and Down, IHS test, Arc Start testI..etc.

Voltage Divide

XPTHC- Portable300 uses voltage divider 100:1.

1.7 THC Work Flow

1.7.1 Wok with IHS

When CNC send out Arc Start Signal(IHS enabled), THC starts with IHS, then send Arc Start

Signal to plasma, after plasma start, THC delay lead in arc voltage from plasma( set pierce delay

time), THC send Arc Feedback(arc ok) Signal to CNC to start Cut after arc voltage lead in. If THC

is on Auto Model, and CNC Auto Control enabled, then cutting is under THC Auto control.

1.7.2 Work without IHS

When CNC send out Arc Start Signal (IHS disabled), THC starts without IHS, lifts torch to the set

height (set via button SET-IHS), then send Arc Start Signal to plasma, after plasma start, THC

delay lead in arc voltage from plasma ( set pierce delay time), THC send Arc Feedback(arc ok)

Signal to CNC to start Cut after arc voltage lead in. If THC is on Auto Model, and CNC Auto

Control enabled, then cutting is under THC Auto control.



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2. Voltage Divider

Our Voltage Divider offers two modes of Voltage Divide, None Isolation Voltage Divide is backup for

Isolation Voltage Divide.

2.2.1 None isolation voltage divide

Note: Plasma output positive pole is GND, negative pole connected with electrode in torch. DO

NOT mis-connected, or THC will be UN-Effective.

As None Isolation Voltage Divide is directly connected with Plasma Power Supply, to enable THC

escape from interference caused by the HF during Plasma Arc Start, the Divided Arc Voltage guided

into THC is Time-Delayed.

It just needs to prolong the time of lead Arc Voltage into THC, this interference can be avoid effectively.

As showed in figure 2-1

Figure 2-1

2.2 Isolation voltage divide

Plasma Arc Voltage is divided by Voltage Divider (offered with THC) on 100:1 via none isolate voltage

divide, lead into THC after processed by Isolation Circuit. Arc voltage has little effect on THC after

Isolation Circuit. This Voltage Divider can be connected as Isolation Voltage Divide or None Isolation

Voltage Divide mode. Connection as follow,



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AC220V input - Actual arc input +

- isolate vol-div out +

Figure 2-2

Note：：：：1、、、、The arc lead in THC is negative, if the pole mis-connected, THC can not work.

2、、、、HF plasma must use isolation voltage divide.

3、For China plasma, the Actual arc output should be connected at plasma’s rectifier

output, better not connect directly to Electrode and Work where have serious HF

interference during arc starting time.

Non Isolation Voltage Divide is backup for Isolation Voltage Divide. On Non Isolation Voltage

Divide, AC220V power can be unconnected; but it must be connected on Isolation Voltage

Divide.

100：1None

isolation

vol-divide

output



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3. XPTHC-Portable300 Funtion and Set

3.1 XPTHC-Portable300 operation panel

IHS Set pierce

Indicator Height Arc display Delay UP

Auto/manual Arc set Down

IHS Test Arc on test

Figure 3-1

Arc Voltage

Before Arc Start it shows the Set Arc Voltage, after it shows the Actual Arc Voltage.

Set Arc Voltage

Based on the thickness of steel plate being cut and cutting speed, it shall be set according to the

parameter offered by Plasma, and it will be showed on operation panel. Set Arc Voltage decides

the Torch Height during cut, the higher the arc is, the higher the Torch Height will be. On Auto

mode, adjust the Set Voltage means adjusting the Torch Height.

IHS HEIGHT

Set Initial Height, turn clockwise, the height increases.

PIERCING DELAY

Set the Delay Time from Plasma Start to CNC starts cut (delay lead in arc voltage into THC), the

Arc feedback (arc ok) signal would be sent to CNC only after arc voltage is detected by THC.

IHS Test

Press one time, it would check IHS one time, which is used to check whether it is a workable IHS

or not.



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AUTO

Set THC Auto or Manual mode. Meanwhile enables the Auto Signal between connectors of CNC

and THC.

ARC Test

Press to test the Plasma Start. During test, Torch lifts up an IHS height.

Up/Down

Manual operation button of Up and Down. It is effective on any mode.

DOWN Indicator: Turn on when torch lift down

Collision Indicator: Turn on when torch touch workpiece or proximity switch effective.

ARCON Indicator: Turn on when THC sends arc start signal out. If arc start with IHS

enable, this indicator is off until IHS completed.

TRANS Indicator: Turn when THC receives arc feedback signal, and sent out Arc OK signal to

CNC.

AUTO Indicator：：：：On means THC is on Auto Mode, four conditions have to be completed: 1, CNC

Auto Height Control (THC) enables; 2, THC is on Auto Model; 3, arc voltage has been lead in THC;

4, Actual Arc Voltage not higher than Set Arc Voltage over 30V.

Note

A、、、、When THC on Auto Mode, the 5 indicators all should be ON, if anyone is OFF,that means

Auto Mode failed, please check the reason according to indicators.

B、、、、There are 6 indicators on Operation panel, demo THC from Torch down—Touch

workpiece—arc start---arc feedback---Auto on, please check the failure reason from the

one by one steps.



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3.2 XPTHC-Portable300 inside Configuration.

Figure 3-2

Torch

retaining cap

IHS card



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3.3 XPTHC-Portable300 Setting

DO NOT adjust the sealed adjustor Figure 3-3

3.3.1 Torch lift up after cutting（（（（RS5））））

XPTHC-Portable300 can adjust the Torch Lift Up Height via setting RS-5（UP-PS-ADJ on Pcb，

clockwise increase the height, with range 10 turns.



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Before setting, all THC cables must be connected, torch Up/Down function workable, IHS is ok.

Method A：：：：

A、 Close plasma power.

B、 Press button “DOWN” on THC, lift down torch to cutting height properly.

C、 Press button “ARCON TEST” once, at least 5 second, torch lift up automatically.

D、 If torch lift up height is ok or not, increase on clockwise, decrease on counter-clockwise.

E、 Repeat A-D steps, until reach a right height.

Method B：：：：

A. Turn off plasma

B. Operation on CNC (plasma mode), CNC control THC to complete IHS and arc start, then

ARCON indicator is on.

C. Pause CNC, cutting signal missed, torch would lift up automatically.

D. If torch lift up height is ok or not, increase on clockwise, decrease on counter-clockwise

E. Repeat A-D steps, until reach a right height

3.3.2 IHS Speed Setting（（（（RS6））））

It is Dual speed IHS on XPTHC-Portable300. It can set the fast speed stroke via setting RS

（DOWN-PS-ADJ on Pcb）, The stroke increases on clockwise turn.

This setting should be done after the commissioning of Torch Lift Up after cutting, and

without Manually lift torch up/down. RS6 maximum turns 10 round.

3.3.3 THC Sensitive Setting（（（（RS1））））

XPTHC-Portable300 sensitive is adjustable via setting RS1（SEN-ADJ on Pcb）. The sensitive of

THC decides the cutting accuracy. As the difference of torch lifter design and speed, it needs to

adjust the THC sensitive for different lifters. Sensitive increases on clockwise, decrease on

counter-clockwise. RS1 maximum turns 10 Round.

Note：：：： If sensitive is too high, torch would shake, so please test it carefully.

XPTHC-Portable300 is tested on 2m/min lifter，user may take it as reference on setting

sensitive.

1. Sensitive should be set according to the difference between Actual Arc and Set

Arc, the difference is ok when it is around 1-3V, if over 3V, the sensitive needs

to be increased.

2. Sensitive set, Turn one round every time, DO NOT turn too much at one time.

3. Sensitive matters to the quality of lifter. If the motor can lift torch up/down on

below 3V start voltage, then .it is a suitable lifter for XPTHC-Portable300



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3.3.4 Motor Drive Current Setting

Motor Drive Current Setting switch is SP2，setting as follow：

Current 1-8 2-7 3-6 4-5

3A OFF：：：：PWM=9KHZ

ON：：：：PWM=18KHZ

OFF OFF OFF

2A OFF OFF ON

1A OFF ON ON

0.5A ON ON ON

3.3.5 Motor Plug-Braking Setting

XPTHC-Portable300 achieves fast braking by Plug-Braking. It can be set via Risister (Brake-ADJ) on

Pcb . It’s already set well before delivery, so user do not adjust it.

3.4 IHS SET

XPTHC-Portable300 IHS is set via SW2, as showed follow

SW2 all on OFF, Torch Retaining Cap IHS,

SW2 all are ON，it uses Proximity Switch IHS , Torch Retaining Cap IHS is workable too.

After SW2 turned ON, if proximity switch not connected, torch keep lifting up, until Signal port added

low-level voltage( short-connect with COM), So once proximity switch installed, the switch’s Signal

port should be low-level, it only changes when proximity switch is being activated.

Figure 3-5

IHS SET

SW2 position



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4 XPTHC-Portable300 Connection

XPTHC-Portable300 back side connection as Figure 4-1shows，

Torch retaining cap IHS

To Torch Lifter To CNC system To plasma Switch IHS Power

Figure 4-1

4.1 POWER

XPTHC-Portable300 uses AC 24; The power supply depends on the Motor in lifter.

Transformer ≥Motor+25W

4.2 IHS connection

XPTHC-Portable300 IHS uses torch retaining cap IHS and proximity switch IHS, as Figure 4-1

shows,

4.2.1 Torch retaining cap IHS

The Torch Retaining Cap should be metal, so the metal can be electric conducted with steel

plate.。XPTHC-portable300 has an IHS card inside the THC module, It needs to take off the cover

for wiring, as follow shows,



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Figure 4-2 Torch retaing cap IHS wiring.

Torch retaining cap IHS

THC receives arc start signal from CNC, lift torch down, when torch retaining cap touches steel, THC lift

torch up to set IHS height. After IHS, THC control plasma to start arc.

Note：：：：

A、、、、 The cable from SHIELD（（（（marked as Shield on THC））））to torch retaining cap.

B、、、、 The GND must be well grounded WORK must connected with ground，，，，and the

grounding cable must be >4mm².

C、、、、 The cable connected to retaining cap must be High Voltage cable.



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Sh

ield

Work

GND

Figure 4-3

4.2.2 Proximity switch IHS

XPTHC-Portable300 supports torch retaining cap IHS and proximity switch IHS

both. We recommend proximity switch IHS, which can do IHS and anti-collision

function job both, especially cutting rusty/painted steel.

Work

table/material



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Proximit Switch IHS uses 3-pin connector, named on THC“Switch IHS”, Pin definition as follow,

3-pin socket

Figure 4-4

XPTHC-Portable300 uses 2 Proximity switches connected as above drawing，any one of them

effective, THC can receive this signal, as figure 4-5 shows.

Work Process：：：：Once THC received Arc Start signal from CNC, torch moves down, when it reaches

workpiece, Proximity Switch leaves proximity position, THC receives this signal, lifts torch to the set

height, (Proximity Switch recovers during lifting). After IHS, THC drives plasma Start Arc.

Proximity Switch IHS is suitable for all plasma IHS.

Figure4-5

1

2

3

Blue：power com

Black：signal

Brown：power，+15V

Proximity switch



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4.3 Plasma connection

XPTHC-Portable300 connect to plasma via 4-pin port，as right picture shows,

Pin definition as follow,

Pin No：1------------------START1

2-----------------START2 3-----------------VOLT+ 4-----------------VOLT-

Pin(s) Signal Description & Ratings

1 ，，，，2 START1，，，，START2 Plasma arc start signal output

（Relay out）

3 VOLT + Plasma arc after voltage divide input+

4 VOLT - Plasma arc after voltage divide input -

Figure 4-6

Note：：：：

The pin VOLT+与与与与 VOLT- input should be Arc Voltage after 100:1 voltage divide, DO NOT

connect directly with Actual Plasma Arc, or it will make damage. And the cable used for this

Pin must be shield cable.

4.4 TO CNC control system

XPTHC-Portable300 connect to CNC system via 8-pin port, as follow picture shows,

Pin：1-------------------AUTO

2-------------------UP

3-------------------DOWN

4-------------------IHS_ARCON

5-------------------DIR_ARCON

6-------------------TRANSFER1

7-------------------TRANSFER2

8-------------------COM

Definition as follow,



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1 AUTO

Auto signal，low-level effective，

Controlled by CNC’s corner signal or THC enable signal,

pin8 is control Com

2 UP Up signal，low-level effective

pin8 is control Com

3 DOWN Down signal，low-level effective

pin8 is control Com

4 ARC ON with HIS

Arc start with IHS，low-level effective

pin8 is control Com

5 EX ARC ON

Arc start without IHS，low-level effective

pin8 is control Com

6 , 7

Arc ok signal

RELAY OUT (dry

Contact)

Connect to CNC’s arc feedback signal input

Relay output (dry contact)

8 Control COM Isolation control COM

Figure 4-7

The interface circuit uses optical isolation, design as follow; user may take it as reference for wiring.

Figure 4-8



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4.6 Lifter Motor Connection

XPTHC-Portable300 connects to Lifter via 5 pin，

Pin：1---------------------MOTOR1

2---------------------MOTOR2

3---------------------DOWN_LIMIT

4---------------------UP_LIMIT

5---------------------COM

Pin definition as follow,


1 , 2 DC Motor Drive

（（（（Output））））

DC motor drive output

Drive DC24Vmotor directly

Max 40W

PWM

3 Down LIMIT

（（（（Input））））

Down limit input

Limit switch normally closed

Short connect pin3 and 5

（optical ISOLATED）

4 Up LIMIT

（（（（Input））））

Up limit imput

Limit switch normally closed

Short connect pin4 and 5

（optical ISOLATED）

5 LIMIT COM COM

Figure 4-9



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5 XPTHC-Portable300 Wiring Diagram

Figure 5-1


6. Some advice

1. When Torch Retaining Cap IHS adopted, we suggest customers use Anti-Collision Fixture (Figure

6-1) to fix cutting torch and lifter and connected it with Torch Retaining Cap. In practice, when the

contact between Retaining Cap and workpiece is weak (especially the workpiece is Rusty or Dirty steel

plate,) Proximity Switch IHS takes effect; it is more effective to protect cutting torch. If Torch Retaining

Cap IHS and Proximity Switch IHS both installed, both will be active during cutting.

2. When it is using proximity switch function, we suggest try some more proximity switches, and all

switched by external circuit, install as Figure 5-2.

3. When the CNC can not receive the Arc Start Enable signal, it should use Time-Delay to run the CNC.

In other word, after CNC sent Arc Start signal, delay the CNC Running.

4. THC cable connected with motor must be shield cable, and must be away from plasma cable, to

avoid lead in high voltage of Pilot Arc into THC control circuit.

Figure 6-1：Anti-collision fixture

Documents

XPTHC-Portable300 Arc Voltage Torch Height Controller · XPTHC-Portable300 Arc Voltage Torch Height Controller ... Arc voltage torch height controller XPTHC-Portable 300 ... controllers