220 Installation & Setup Guide

Control & Cable Pinout for Sensor™ THC

I/O Configuration Type “P”

Note: A 9C Amp connector is provided on the back of the control ( I/O Type “P” ) for interfacing.

Control 9C Divider J2
Analog Pin # Description Pin #
1 24V Common 1
2 Nozzle Contact Sense + 2
3 Nozzle Contact Sense – 3
4 Nozzle Contact Enable + 4
5 Nozzle Contact Enable – 5
6 Analog + 6
7 Analog – 7
8 Hold Ignition + N/A ( direct to power supply )*
9 Hold Ignition – N/A ( direct to power supply )*
Ground Stud Shield No Connection

Analog Mating Connector

Connector AMP # 206708-1
Backshell AMP #206966-1
Sockets #66105-3 ( 20-24 ga )

VDC Mating Connector

8C Phoenix Connector – Phoenix Part # 1803633

Cable
Belden #9505 or equivalent

* Note: It is recommended that the Hold Ignition input be wired to the Power Supply through an
external relay for noise immunity. Please refer to Instructions from the supply manufacturer for
details on connection to the Hold Ignition Input.
218 Installation & Setup Guide

Control & Cable Pinout for Sensor™ THC

I/O Configuration Type “P”

Note: A 9C Amp connector is provided on the back of the control ( I/O Type “P” ) for interfacing.

Control 9C Divider
Analog Pin # Description Pin #
1 24V Common J2-2
2 Nozzle Contact Sense + J1-1
3 Nozzle Contact Sense – J2-1
4 Nozzle Contact Enable + J2-3
5 Nozzle Contact Enable – J2-2
6 Analog + J2-4
7 Analog – J2-5
8 Hold Ignition + N/A ( direct to power supply )*
9 Hold Ignition – N/A ( direct to power supply )*
Ground Stud Shield No Connection

Analog Mating Connector

Connector AMP # 206708-1
Backshell AMP #206966-1
Sockets #66105-3 ( 20-24 ga )

VDC Mating Connector

8C Phoenix Connector – Phoenix Part # 1803633

Cable
Belden #9505 or equivalent

Note: It is recommended that the Hold Ignition input be wired to the Power Supply through an
external relay for noise immunity. Please refer to instructions from supply manufacturer for details on
connection to the Hold Ignition Input.
 Tech Memo #032

Technical Memorandum

Product: 12” Sensor™ THC Date: 10/2002

Subject: Baseline setups for 12” Sensor™ THC with 100W Yaskawa Servo Motor

Action: N/A

Instructions: See Below

Instructions:

WARNING! : Operation and maintenance of automated equipment involves potential hazards.

Only authorized service personnel should perform this service.

-------------------------------

The following is a basic outline of the core set up parameters for the
Sensor THC Sensor Torch Height Control. This outline applies only to the 12” slide
with 100W Yaskawa AC Servo Motor supplied by Hypertherm
with 100W Automation.
AC Servo
This outline will focus on the THC Axis and Speeds setups for this
configuration of THC. Additional THC tuning that is unique to the
Plasma process will not be included here as this is specific to the
selected plasma system and process being used.

The information will be displayed for the selected control setup and
will be followed by a definition of the relevant parameters. Suggested
parameter values will be offered with the definition. Screens displayed
here may vary slightly depending on the version of software being
used.

Sensor THC must first be enabled at the Machine Setups Screen.

Note: Assembly and wiring must be completed as outlined in the schematics provided with the slide and
motor. The Amplifier has been pre-tuned prior to shipment. The Amplifier should not require additional
adjustment for most applications. Final tuning of the system will be performed as outlined in this Tech
Memo. However, if Amplifier tuning is required, it may be performed with a software package and cable
available form Hypertherm Automation. Cable Part # CABL-0069 Software Part # SOFT-0011
THC Axes Setup

Proportional Gain
Proportional Gain correlates to Elastic Stiffness in the control loop. Increasing the proportional gain
increases the static stiffness, but decreases response of the servo loop.

Under proportional loop control, the drive system will apply a restoring torque to the motor in proportion the
position error of the axis.

With a Proportional Gain too high, the system will be unstable which will result in overshoot, and a
generally “nervous” and shaky axis. This is also referred to as a “hot” control loop. With a proportional gain
too low, the system will respond in a loose or sloppy manner. This can be seen in the test pattern when
the outside corners become rounded and the circle segments do not all meet in the center.

Generally, it is recommended that this value be set to a value of 65

Integral Gain
Integral Gain improves the positioning accuracy of the control loop. Integral Gain can be used to
compensate for static friction or gravity. Excessive Integral Gain can result in system instability.

For almost all applications, this parameter should be set to Zero (0).

Derivative Gain
Derivative Gain helps to dampen sudden changes in velocity. The higher the derivative gain, the slower the
response time to the control loop.
Generally, it is recommended that this value be set to a value of 0 – 20.
Feedforward Gain
Feedforward Gain can be used to drive the following error to zero during machine motion. In all digital
control loops there is a finite amount of error that is introduced by the velocity command. Increasing
Feedforward Gain can reduce this introduced error. This Gain Value is outside the position loop.

Generally, it is recommended that this value be set to a value of 0 – 30. This value may change depending
on the weight of the torch assembly.

Voltage Gain
The Voltage Gain parameter is used as a scaling factor to adjust the sensitivity or responsiveness of the
Sensor THC. A value of 1 being the least responsive and a value of 10 being the most responsive. Note:
This scaling factor is tied directly to the Proportional Gain. Changes to the Proportional Gain may require
changes to the Voltage Gain.

Generally, it is recommended that this value be set to a value of 5. It can then be adjusted higher or lower
depending on the responsiveness required for the specific plasma supply and process.

Servo Error Tolerance

Allows the user to program the amount of servo loop Following Error to be allowed prior to display an error
message. The parameter is limited to a maximum value of five inches.

Generally it is recommended that this value be set to a value of .2 inches / 5mm.

Stall Force
The Stall Force Parameter allows the user to select the amount of Following Error (inches / mm) to be
used as the motion limit when performing manual IHS / plate sensing. Example: If the value is set to .1
inches, the THC Axis will continue to move the axis until .1 inches of following error has been reached.
The will indicate the Plate location during IHS.

NOTE: With AC Servos such as the Yaskawa 100W provided with the 12” slide, it is very important that
the Nozzle Contact Enable Output from the control be connected to the Current Limit (P-CL) Input of the
amplifier. The torque produced with the combination of motor and slide may not be sufficient to create
enough Following Error to detect Stall Force without being switched to lower current mode. This may result
in damage to the system if not correctly configured.

Encoder Counts per inch

The Encoder Counts per Inch parameter is the number of encoder edges per inch of machine travel. It is
possible to enter fractional encoder units and the control will keep track of these fractions automatically.
Encoder Counts per inch are equal to the resolution of the encoder, multiplied by the encoder revolutions
per inch or mm (based on the slide gearing).

For example: The resolution of a 4X - 1000 line encoder counts both edges ( lines ) of channel A and
channel B to equal 4 counts per line multiplied by the 1000 lines per revolution would equal 4000 counts per
revolution. If the encoder revolutions per inch to travel are 1:1, we would have 4000 encoder counts per inch
of travel.

Encoder Counts/ Inch = 4 Counts/ Line x 1000 Lines/ Rev x 1 Rev/ Inch = 4000

The Encoder Counts parameter for this slide is 20,807.68 /inch or 819.2 /mm.

Drive Type
This parameter is used to tell the control what type of control loop to run. If you are running an external
velocity loop drive (indicated by having an integrated tachometer in the motor), select Velocity. If you are
running in torque mode (no tachometer), select Current.

Selection for this application is Velocity only.

DAC Polarity
This parameter allows changing of the analog output polarity to establish proper control loop feedback
(direction of motion) without any wiring changes.

Selection for this application is Negative.

Encoder Polarity
This parameter allows changing of the encoder input polarity (direction of motion sense/feedback) for
correct machine motion without any wiring changes.

Selection for this application is positive.

Encoder Decode Mode

Encoder Feedback varies slightly from different encoder manufactures. The 4X encoder decode mode is
recommended as this allows increased positional accuracy.

Selection for this application is 4X mode.

Slide Length
This parameter is used to specify the overall motion length of the Slide mechanism being used for the THC.
This information is used to set the travel limits of the slide after homing.

The value for this slide is 12.65 inches or 321.31 mm.

Home
The Home parameter is used to activate use of the Home feature for the THC Axis. Depending on the Slide
mechanism used, the THC may be Homed to Hard Stop, Hard Stop w/ Current Limit or Home Switch.

The Homing option for this Slide should be Hard Stop Current Limited. This will activate the Nozzle
Contact Enable Output during homing to allow the amplifier to switch to low current mode. The Nozzle
Contact Enable Output from the control must be connected to the Current Limit (P-CL) Input of the
amplifier.
THC Speed Setup

Note: Only those parameters relating to the operation of the Sensor THC are shown.

Plasma Hi/Lo Speed Percentage

The Hi/Lo Speed specifies the percentage of the entered Cut Speed below which the control will activate
the Torch Height Disable feature.

Plasma Distance To Corner

The Plasma Distance to Corner parameter specifies the distance to the corner at which the plasma system
should switch from High current to low current and disable the Automated Height Sensor. Distance to
Corner is active whenever the speed drops below the Plasma Hi/Lo Percentage, or segments intersect at
an angle greater than the tangent angle.

Generally, this parameter has a value of 0. This may be increased depending on the process selected to
disable or “freeze” the Torch Height control before the corner.

Plasma Distance From Corner

The Plasma Distance from Corner parameter specifies the distance from the corner when exiting, at which
the plasma system should enable the Automated Height Sensor. Distance from Corner is active whenever
the speed drops below the Plasma Hi/Lo Percentage, or segments intersect at an angle greater than the
tangent angle.
Generally, this parameter has a value of .5 inches or 12.7mm. This value is dependent upon the process
selected to and may be increased or decreased to disable or “freeze” the Torch Height control after the
corner. This tends to stabilize the Torch Height while the machine motion accelerates.

For additional details on how the Torch Height Disable feature of this control operates, please refer to the
Cutting Section of the Operators manual.

THC Acceleration Rate

This parameter allows the operator to set the acceleration rate for smooth and stable movement of the
Sensor™ Torch Height Control. The higher the acceleration rate, the quicker the THC will get up to speed.
The lower the acceleration rate, the smoother the machine will position the cutting device. Values are
entered in Milligees.

Generally, a good starting value for this parameter is a value of 100 mG.

Maximum THC Speed

Enter the maximum speed for the Sensor™ THC movement in inches/millimeters per minute.

The value for this slide configuration is 900 ipm or 22860 mmpm

THC Jog Speed

Enter a value for the desired THC jog speed for manual motion.

A recommended value for this parameter is 5 ipm / 127mmpm to 200 ipm / 5080 mmpm depending on
desired response.

THC Home/Fast IHS Speed

The THC Home/Fast IHS Speed entered here is used to home the torch at the top of the slide and to
quickly maneuver the torch from the selected IHS height to the plate.

A recommended value for this parameter is 50 ipm / 1270 mmpm.

THC Slow IHS Speed

The THC IHS Speed is used to retract the torch after the plate has been sensed. The torch will retract at
this speed until the contact sense is lost. This determines the exact distance to the plate, regardless of
any flexing of the plate. A very small speed is recommended for optimal accuracy.

A recommended value for this parameter is 5 ipm / 127mmpm.

Appendix B: Sensor™ THC 179

Appendix B: Sensor™ THC

Sensor™ Torch Height Control Overview
Sensor™ THC is a proprietary Automated Torch Height Control system that is designed
specifically for use with your shape cutting control. Sensor™ THC utilizes the most current
technology available to provide superior plasma cut performance with unmatched ease of use.

During the plasma cut process, variations in the distance between the torch tip and the cut
material will affect the cutting arc voltage and ultimately, the quality of the cut. Through use of an
automated torch height control to maintain the appropriate cut height for the set arc voltage, we
are able to obtain the optimum cut quality regardless of variations in plate positioning.

Sensor™ THC is operated as a separate closed loop servo axis on the control and has several
setup parameters available to customize the system for optimal performance and individual
requirements. The THC system is made up of four parts: the control, the analog input card
mounted in the control, the voltage divider card and the mechanical slide with a motor to operate
the slide. The voltage divider card, which would be mounted in the plasma power supply,
monitors the arc voltage of the cutting process at the torch then transmits 1/40th of this voltage to
the analog input card in the control where it is multiplied up to the original value. This value is
then compared to the selected Set Arc Voltage. If the values are different, the control will raise or
lower the torch on the slide to correct the cut voltage. This Appendix will highlight the features
which are unique to the Sensor™ THC.

For operation, this feature must first be enabled in the password machine setups. Setup
parameters specific to the cut process and the THC axis will then be available for configuration.
Note: This feature is not available on control systems with the Type “B” or “M” interface
configuration.

Warning! Installation, Setup and Calibration should only be performed by trained service
personnel. Extreme care should be used when installing this product.
180 Operator’s Manual

Cut Setups

THC Voltage Offset

The THC Voltage Offset Parameter is used to offset the individual Sensor THC™ Arc Voltages
from the master set Arc Voltage. This allows the individual THCs to be adjusted to compensate
for consumable wear and obtain optimum cut quality.

Note: The THC Voltage Offset parameter may be automatically adjusted using the Volts per
Minute parameter of the Change Consumable feature. Please refer to the Change Consumable
information in this guide for additional details.
Appendix B: Sensor™ THC 181

Plasma Setups
I/O Configuration Type “P” and “V”

The Purple arrow at the left edge of the softkeys indicates additional softkeys are available.
Pressing the shift key allows the test lifter function to be available.

Test Lifter
Pressing the Test Lifter softkey will command the torch lifter to lower to the plate, sense the plate
and retract to the pierce height
182 Operator’s Manual

I/O Configuration Type “P” and “V” (Timing Diagram)

Press the Space Key to view the timing diagram from setups.

Retract Delay
The Retract Delay Parameter is used to specify the amount of time delay that the used between
the cut off and the torch retract.

Auto Voltage Set

When enabled, the Auto Voltage Set feature is used to sample the Arc Voltage being generated
when cutting at a specific cut height. Then the Arc Voltage value relative to the manual cut height
sample will be used when cutting the part instead of a predetermined Arc Voltage.

Set Arc Voltage

The operator may input the desired Arc Voltage for the material being cut.

Cut Height
The Cut Height setup parameter is used to select the desired cut distance from the plate. This
will set the initial cut height before arc voltage control is activated when operating in automatic
mode.

Pierce Height
The Pierce Height setup parameter is used to select the desired Pierce Height. This may be
entered as a multiplication factor that is calculated times the Cut Height or an actual Pierce
Height distance.

Voltage Control
This setup parameter allows the operator to select the Sensor THC to operate in Manual or
Automatic mode. Manual mode will disable the torch height control, allowing the torch to cut at
the specified cut height and voltage. Automatic mode allows the THC to command the torch up
and down to maintain the voltage at the specified arc voltage setpoint.

Ignition Output
Enables use of the Ignition Output for use in igniting the plasma torch. If your plasma system
requires a separate ignition signal, toggle Ignition to ON. If not, leave Ignition OFF.
Appendix B: Sensor™ THC 183

Voltage Tracking Range

The Voltage Tracking Range parameter specifies the allowable variation in arc voltage from the
setpoint. If the arc voltage should go above or fall below this allowable range, the system will
fault and pause cutting.

IHS in Manual
The IHS in Manual setup parameter allows the operator to select whether or not to use the Initial
Height Sense feature when operating the Sensor THC in manual mode.

Retract Full/Partial
Selects the retract distance to be set at Full or Partial. In the Full retract mode, the torch will
retract to the Home position. In Partial retract mode, the torch will retract to the set retract
distance.

Partial Retract Distance

This setup parameter is used to select the THC Retract Distance when configured for partial
retract mode.

Start IHS Distance

The Start IHS Distance specifies the distance of travel for the THC to move the torch at high
speed before switching to low speed and beginning Initial Height Sense. Caution should be taken
when selecting this distance so that the torch does not crash into the plate.

Skip IHS Within

The Skip IHS Within feature is used to disable Initial Height Sense at pierce points if it falls within
the selected distance to increase cutting productivity. The distance is measured from the end
point of the cut segment to the next pierce point. If this distance falls within the selected Skip IHS
Within distance, no IHS will take place.

Preflow During IHS

Selecting ON will activate Preflow during the IHS cycle.

Early Preflow if Skip IHS

Selecting ON will activate Preflow during the traverse prior to the pierce while the skip IHS feature
is used.

Nozzle Contact IHS

This parameter would be set to ON to select the Sensor THC to use Contact Sense to detect the
plate during the IHS cycle. It is recommended that Nozzle Contact Initial Height Sense be used
when cutting light gauge material to prevent plate deflection.

Nozzle Contact During Cut

This parameter would be set to ON to select the Sensor THC to use the Contact Sense input to
detect the plate contact during cutting and pause operation.

Offset IHS
The Offset IHS feature is used to activate a remote probe for plate detection and Initial Height
Sense. With this feature enabled, the control system will execute the Tool / Marker Offset
number nine. This will move the Plasma cutting torch the distance of the offset, perform the IHS
and then return the Plasma torch to the pierce location at each commanded pierce / cut on. The
Z axis parameter is used to adjust for height differences between the torch and the probe.
184 Operator’s Manual

Auto Kerf Detect

The Auto Kerf Detect feature reduces the possibility of the torch diving into the plate. When
enabled, the THC will detect sudden changes in arc voltage when crossing a Kerf path and will
freeze motion of the THC.

Auto Kerf Voltage Change

The Auto Kerf feature of the Sensor THC will detect a voltage change when the torch passes over
a previous cut and will disable the THC to prevent the torch from diving. This setup parameter is
used to specify the allowable variation from the voltage setpoint at which the THC will detect the
voltage change and disable the THC.

Kerf Detect Reacquire Time

The Kerf Detect Reacquire Time determines the time limit at which the control will force the THC
to adjust the THC height to meet the voltage setpoint if the Automatic Voltage Lock On has not
been established after a Kerf crossing.

Note: Depending on the performance of the plasma system being used, a creep time may be
required to allow for ramp up of the cut voltage after the pierce.

Marker Setups
I/O Configuration Type “P” and “V”

The Purple arrow at the left edge of the softkeys indicates additional softkeys are available.
Pressing the shift key allows the test lifter function to be available.
Appendix B: Sensor™ THC 185

Purge Time
Specifies the time delay from torch ignition until motion is enabled.

Start Time
Specifies the time delay from when torch completes lowering until motion is initiated at Creep
Speed. Used to allow the Marker to completely transfer to the material before moving.

Sample Voltage
When enabled, the Sample Voltage feature is used to sample the Arc Voltage being recorded
when cutting at a specific cut height, then that Arc Voltage value will be used when cutting the
part instead of a predetermined Arc Voltage.

Set Arc Voltage

The operator may input the desired Arc Voltage for the material being cut.

Mark Height
The Mark Height setup parameter is used to select the desired cut distance from the plate. This
will set the initial cut height before arc voltage control is activated when operating in automatic
mode.

Start Height
The Start Height setup parameter is used to select the desired Start Height. This may be
entered as a multiplication factor that is calculated times the Start Height or an actual Start Height
distance.

Voltage Control
This setup parameter allows the operator to select the Sensor THC to operate in Manual or
Automatic mode. Manual mode will disable the torch height control, allowing the torch to cut at
the specified cut height and voltage. Automatic mode allows the THC to command the torch up
and down to maintain the voltage at the specified arc voltage setpoint.

Voltage Tracking Range

The Voltage Tracking Range parameter specifies the allowable variation in arc voltage from the
setpoint. If the arc voltage should go above or fall below this allowable range, the system will
fault and pause cutting.

IHS in Manual
The IHS in Manual setup parameter allows the operator to select whether or not to use the Initial
Height Sense feature when operating the Sensor THC in manual mode.

Retract Full/Partial
Selects the retract distance to be set at Full or Partial. In the Full retract mode, the torch will
retract to the Home position. In Partial retract mode, the torch will retract to the set retract
distance.

Partial Retract Distance

This setup parameter is used to select the THC Retract Distance when configured for partial
retract mode.
186 Operator’s Manual

Start IHS Distance

The Start IHS Distance specifies the distance of travel for the THC to move the torch at high
speed before switching to low speed and beginning Initial Height Sense. Caution should be taken
when selecting this distance so that the torch does not crash into the plate.

Skip IHS Within

To increase cutting productivity , the Skip IHS Within feature is used to disable Initial Height
Sense at pierce points if it falls within the selected distance. The distance is measured from the
end point of the cut segment to the next pierce point. If this distance falls within the selected Skip
IHS Within distance, no IHS will take place.

Preflow During IHS

Selecting ON will activate Preflow during the IHS cycle.

Nozzle Contact IHS

This parameter would be set to ON to select the Sensor THC to use Contact Sense to detect the
plate during the IHS cycle. It is recommended that Nozzle Contact Initial Height Sense be used
when cutting light gauge material to prevent plate deflection.
 A B C D E

R E VISIONS
R EV ECO D ATE D R A WN BY D ATE A PPROVED

4 4

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P C B ONLY S P ACER S PACER S PACER

041669 008897 008897 008897

1 1

H Y P E R THERM AUTOMATION
Ti tle
V O L T A GE DIVIDER 3 W/24V POWER

S i ze D o cument Number R ev
D S C-057 -

D ate: Monday, March 12, 2001 Sheet 1 of 1

A B C D E