User`s Guide - Proma
Contents
1. Operation Manual Plasma torch height controller Model Compact THC Controller 150 Notes on safety WHEN THE DEVICE IS IN OPERATION VOLTAGE HAZARDOUS TO HEALTH AND HUMAN LIFE IS PRESENT INSIDE THE HOUSING AND AT THE CONNECTION TERMINALS The device should be connected only by a qualified and authorized person Improper connection can cause serious injury or death Prior to installation and operating carefully read the entire installation and maintenance manual and be absolutely sure you full understand and are able to make the sole decision to determine if you are capable of a safe and proper installation Remember that inside the device and at the connection terminals voltage hazardous to health and life may be present The following actions although not all inclusive should be strictly adhered to Installation of this product by an unqualified individual should not be done No physical contact with any electrical connections while under power Do not operate this product with wet hands wet gloves or any wet clothing Before turning the unit on secure the safety of others and read and understand all instructions If you have any questions or concerns do not continue Warning Provide adequate protection for all risks associated with plasma cutting For more detailed information of the risk associated with plasma cutting refer to your plasma cutter s owner manual Touching non insulated and non grounded elements ca2. shield System rO 3 n Plasma grou Do not short circuit here ALGORITHM OF WORKING RA ESSURED SAO CT AGE HHF NN D d t Delay Time Start up and operation The device is pre configured at the factory and after the correct connections are made it immediately works properly with most plasma devices After switching power on the THC controller s display shows an animated thc message and then a flashing voltage value is presented for 1 second the device is undergoing automatic calibration at this moment gt gt HV When the device is ready for operation it displays which means that there IS no input voltage In this state by depressing both the up down keys simutaneously and holding for a few seconds the voltage setpoints can be modified and thus set the torch s height above the material Press shortly once to display the set value without modification To determine other parameters simultaneously hold both keys until you see the desired parameter on the display when you release the keys its value will be displayed using the up down keys to set the desired value HYS Hysteresis The hysteresis voltage a range in which the voltage is measured in which there are signals controlling UP DOWN 2 30V 1V 15V factory setting 8V 4V d t delay time delay time of output closed despite no supply voltage when the system detects the main cuttin
3. ce has patented solutions made with the highest quality components to ensure a safe durable and reliable long term operation Simplified block diagram LED Display Output Block Pilot Arc Interference Microprocessor Main Arc i E HV PLASMA voltage iE Filters Cuircuits Analyzer i Suppressor E THC Divider a T enn HE HV Matching Circuits Controller SMPS Keyboard Pilot Arc Voltage Neutraliser protection system which is responsible for removing spikes in the AC electrical flow which can be caused by a plasma source with contact less arc striking HV HF pilot arc generating a high voltage or from surges coming from plasma cutters equipped with contact arc striking system Main Arc Voltage Divider While in operation the cutter generates dangerous voltage levels unsafe for precision electronics A voltage divider system is incorporated to reduce this voltage to a safe level A quick acting filter system removes any interference that may pass through a voltage divider Filtered and scaled voltage values derived from the plasma cutter s raw arc voltage are then sent to the brain of the device The brain consists of a programmed microprocessor which in addition to the analysis of the cutting voltage parameters and proper output blocks controlling also supports the LED display and function keys A built in switching power supply ensures compatibility in a wide range of power supply voltages without the nee
4. d for heat sinking The power supply connection is optically isolated from the rest of the system which allows you to use to share power from existing systems providing they output the recommended voltage The last block is a relay output circuit to which the driver PC inputs are connected which is responsible for Z axis motor control of the CNC plasma cutter 3 The main parameters of the device Parameter name Supply voltage V Maximum input current i OMA Maximum direct input voltage Maximum input voltage of 1 50 divider Ability to eliminate HV HF ionizing voltage Ability to eliminate HV HF ionizing frequency Duty cycle 100 Duty Cycle of HV HF elimination 100 Capacity of relays 50mA 60V DC ooo O O Life of used relays declared minimum switching with a 500 000 000 capacity of 5V 10mA cycles O O ie Tested in the laboratory Power Connection Optional power supply 35 50V 7 35V DC 35 50V DC Zener Diode 18V I 3W sa C gt UOO v 220 GEL For lower limit switches of the device one can lead full output voltage of plasma source In this connection do not connect anything to the other input terminals of the controller i HANLONG CUTB TS rer tm on J NM Y f o Say s F fori oc A j DC INVERTER AIR PLASMA CUTTER don t connect Max JO0VDC material clamp gas linefelectrode When connecting directly use the shortes
5. g arc 0 1 9 9s factory setting 0 5s H U High Voltage value of the off load voltage detection in the plasma cutter used to detect the main cutting arc 50 300V by default 200V tSt Test Simulation of the controller s work the system simulates the appearance of floating voltage within the selected value causes the activation of inputs for easy system testing without switching the cutter on When the plasma cutter is switching on the display presents the measured voltage value and LED diodes present the current status of outputs Fast blinking of the measured value indicates the detection of pilot arc continuous display indicates the detection of the main cutting arc All parameters can be modified during operation these changes are reflected in real time in the control of output signals F
6. n be fatal Provide a safe place for your device After assembly secure protection of contact terminals from operator s touch It is strictly prohibited to perform any repairs or modifications to this product Performing either one of these actions could lead to serious injury or death to yourself and or others Terms of Use By proceeding with installation and use of this product you fully understand and agree Proma Elektronika nor their distributors are not liable for any incident or event resulting in direct loss indirect loss injury to self or others damage to property or loss or damage of any kind End user assumes all risks If you do not agree to these terms in it s entirety proceed no further and return this product for a full refund If you have any questions or are unsure about anything stated in this manual problem immediately contact a Proma Elektronika dealer or service centre for assistance 2 Device Information The unit is a modern analogue microprocessor plasma torch height controller that operates by analyzing voltage changes in the plasma source due to variations in height between the torch tip and the material being cut The microprocessor makes determinations to raise or lower the torch based off of the strength of the voltage signal being read It is equipped with an easy to read LED display and two user friendly keys making operation simple and does not require any additional measuring instruments The devi
7. t possible cables for connecting the plasma source with THC controller it is recommended the THC controller to be located directly at the plasma source 4 While being a universal THC accepting full raw arc voltage for most any plasma cutter on the market an exciting new standard feature of this unit is the addition of a 1 50 divider for an extremely fast simple installation on most major brands There will most likely be a direct connection for this on the outside of the plasma cuiter s unit Please refer to your plasma cutter owner s manual An example of how to connect the THC controller s measurement input with the output of the very popular Hypertherm Powermax45 The THC comes Standard equipped with a low voltage output of 1 50 divider This ratio is the most commonly used division in most major brands and there will most likely be a plug for this connection on the outside of the cutter s unit a EJ a s s on ch Be om ewer J por UGEN powermaxe Output Voltage Divider 1 50 i l g F ola SE Wa don t connect cite I don t connect MAX 10V DC ee ee The relay outputs Arc Up Down are controlling outputs via relays and should not be utilized for anything other then it s intended use COM terminal is a common input terminal connected to the ARC UP and DOWN relay contacts inside the device according to the diagram located on the cover above pict
8. ure Suggested route is to GND at driver oc end Do not jumper this connection to the 7 35V negative ARC output also known as Arc Okay is activated when plasma ignition is detected Route and configure for a software input Not required to operate UP output is activated when the measured voltage is lower than the voltage setpoints reduced by half the hysteresis voltage Route and configure for a software input DOWN output is activated when the measured voltage is higher than the voltage setpoints reduced by half the hysteresis voltage Route and configure for a software input Note No output relays are activated in case when only the pilot arc is detected and when the main arc is broken Relay outputs should be connected to the CNC system in accordance with the documentation of the CNC electronic system controlling the machine For this we use inputs of outermost connectors HOME or LIMIT THC relay contacts should be connected to the terminals the same way as limit switches connectors At the same time the common COM terminal relay should be connected to the CNC system to a common terminal for limit switches it is usually a GND terminal To reduce the possibility of the short circuit entering the CNC system the connection should be made with a shielded cable the shielding must be connected to grounding on the CNC system side Do not connect the shielding to the THC controller side your CNC Long line
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