ShenZhen H.Y.D CNC Technology Co.

,LTD
http://www.hydcnc.com

Instruction Manual

Arc Voltage Torch Height Controller XPTHC-100

Trademark: HYD

Please check this manual fully before use, and contact us for any further explanation
1、Brief Introduction

1.1 It can match almost all plasma cutters. Based on the Constant Current Characteristic of
Plasma power supply, THC monitors the torch height change during cutting process via
detecting the change of plasma Arc Voltage, to reach the aim of controlling the Height
of Cutting Torch.

1.2、Basic functions：

A、 Automatic Initial Height Sensing(IHS)：

Torch Retaining Cap and Proximity Switch (NPN and PNP), Proximity Switch IHS
needs the Anti-bump fixture designed by us.

B、 Torch Anti-bump function：

In any status, the touch-off circuit enables the torch head retract whenever it is
in risk of crashing during cutting.

C、 Automatic Torch Height Control.

D、 Display of the Set Arc Voltage and the Actual Arc Voltage:

The Set Arc Voltage and Actual Arc Voltage would be displayed on THC, helping
operator follow work of CNC. When the Actual Arc Voltage is higher than Set
Arc Voltage 30V (adjustable), Auto Height Control function stops to avoid torch
head’ s diving or crashing with workpiece.

E、 Support under-water cutting, on Auto IHS mode

It is our invention of underwater cutting on IHS of Retaining Cap. This function is

optional to customers.

F、 Lifting torch head on IHS Disabled status.

On IHS Disabled status, jogging torch head down until it reaches workpiece,
when Arc Starts, torch head would lift up automatically to the Set Height set via
the button SET-IHS.

G、 Lifting on TURN ON or Arc Off:

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 When CNC is TURN ON or Arc Off, THC would lift cutting torch for 2 seconds,
please notice this Function during commissioning, avoiding the possible damage of
limit switch or lift device.

H. Arc Voltage Enable output:

Setting the Button Set-PIERE, to delay the sending out of this signal (Arc Voltage
Enable), the signal is produced by detecting the existence of arc voltage, output
is Switch Signal.

I. Manual Operation:

Many functions can be operated on operation panel such as setting Auto/Manual

Up and Down, test of IHS and Arc Start….etc

J. Auto Operation:

After Arc Start signal was given by the CNC, THC completes IHS
automatically—--Plasma Start---Arc Transfer---Arc Voltage Enable signal.
Plasma cutter starts to cut when it receives Arc Voltage Enable signal.

K、Arc Voltage Detection:

Isolation Voltage Divide detection, the Voltage Divide ratio is 100:1.

2、 Specification
y Input Power：AC24V+5%，50Hz/60H z

y Down/Up Motor：DC24V DC MOTOR

y Motor Drive: PWM ;

y Output Current：1A-4A, Load capacity：100W,

y Working temperature：-10∽60℃

y Voltage Divide ratio :100:1

y Control accuracy ：±1V∽±3V

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

y The speed of lifting：1000mm/min∽2000mm/min(Contact the supplier if it exceeds the

range of speed）

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3、 THC Work Process
3.1、Mode 1 :
When the Arc Starting signal (IHS enabled) that connected with CNC is the 4th stitch of

the 10-pin aviation socket, THC starts with IHS, then drives plasma start arc, when

Transfer Arc produced, THC sends Arc Voltage Enable signal to CNC to start cut. When

THC sends Arc Start signal to plasma, it delays guiding arc voltage into THC, after that,

if THC is on Auto Mode and the CNC has already sent Auto Height Control signal, then

the THC is on Auto Height Control status.

3.2、Mode 2 :
When the Arc Start signal (IHS disabled) that connected with CNC is the 5th stitch of the

10-pin aviation socket, THC lifts torch to the height set by Set-IHS, without IHS, driving

plasma start arc directly. When Transfer Arc produced, THC sends Arc Voltage Enable

signal to CNC to start cut. Meanwhile, it delays guiding arc voltage into THC, after that,

if THC is on Auto Mode and the CNC has already sent Auto Height Control signal, then

the THC is on Auto Height Control status

4、 Function of Operation Panel

Display AV Set Arc Voltage IHS Setting Set pierce delay Arc test

IHS-Test Auto/Man Switch Manual UP/Down

Figure 1: Operation Panel

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 Arc Voltage

Before the 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 bigger the arc is, the higher the Torch

Height will be. On Auto mode, adjust the Set Voltage means adjusting the Torch Height.

Set IHS：

Set Initial Height, turn clockwise, the height increases; the IHS is reached by Time-Delay.

IHS Test

Every time we dial it up once, it would check IHS one time, which is used to check

whether it is a workable IHS or not.

Set-PIERE:

Set the Delay Time from Plasma Start to CNC starts cut (the arc voltage is delayed to

guide into THC), the Arc Voltage Enable signal would be sent to CNC only after arc

voltage is detected by THC.

Auto/Manual：

Set THC’ s auto or manual mode. Meanwhile enables the Auto Signal between connectors

of CNC and THC, (for EDGE system, the Auto Signal shall be connected as Normally

Closed.)

ARC Test：

Dial up and hold on to test the Plasma Arc Start. During test, Torch lifts up an IHS height.

Up/Down：

Manual operation button of Up and Down.

ARCON ：

It is ON means Arc Start is processing, note: the ARCON is off during IHS, if the Arc Start

with IHS Enable, it will turn on only after IHS is completed.

AUTO ：

On means it is on Auto mode, four conditions have to be satisfied: 1, the Auto signal has

been added on operation panel; 2, the Auto signal connected with CNC system enables; 3,

arc voltage has been guided in THC; 4, Actual Arc Voltage not exceeds Set Arc Voltage

30v. (Note: we usually set as 30v; it can be adjusted through adjustable resistance RP104

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 according to customer’ s situation.)

TRANS：

On means THC has detected arc voltage, and sent out Arc Voltage Enable signal.

5、 Voltage Divider
5.1、 None Isolation Voltage Dividing
The simplest way to divide the plasma arc voltage is None Isolation Voltage Divide by

Resister directly.

Figure2: None Isolation Voltage Divide circuit

Figure2: None Isolation Voltage Divide circuit

Note: The Arc Voltage that goes into THC is electronegative, if the electrode is mis-connected;

the Auto Height Control is inactive.

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 guiding Arc Voltage into THC, this interference can be

avoid effectively.

5.2、 Isolation Voltage Dividing

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

Isolation Voltage Divide mode, guided into THC after processed by Isolation circuit. This

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Voltage Divider can be connected as Isolation Voltage Divide or None Isolation Voltage Divide

mode.

AC220V Input - Actual Arc Voltage input +

100 ： 1
output
connector
Of None
Isolation
Voltage
Divide

— +
Output of Isolation Voltage Divide
Figure 3：Voltage Divider connection.

Note: On None Isolation Voltage Divide, AC220V power can be unconnected; but it must be

connected on Isolation Voltage Divide.

6. IHS (Torch Retaining Cap IHS and Proximity Switch IHS)

6.1、 Torch Retaining Cap IHS

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The Torch Retaining Cap should be metal, so the metal can be electric with steel plate.
XPTHC-100 has a piece of Isolated IHS plate that can be fixed in the THC directly, the
connection showed as Figure 4 below:

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 6.2、 Proximity Switch IHS (NPN and PNP).

Under Proximity Switch IHS, user needs to use our Anti-bump fixture, introduced on

Figure 12, (This fixture is not included in THC offer, optional to customer).

Proximity Switch IHS is backup for Torch Retaining Cap IHS, for cutting dirty or rusty

steel plate. It can work separately or simultaneously with Torch Retaining Cap. During

cutting dirty or rusty workpiece, if the sensitivity of Torch Retaining Cap is affected,

then Proximity Switch will secure cutting goes properly.

It is connected via Switch IHS on THC,

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.

Parallel connection can be used on Proximity Switch.

7. Interface Connection

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 TO-TORCH TO-CNC SWITCH-IHS GND POWER（AC24V）

TO-PLASMA WORK SHIELD

Figure 6：Interface of XPTHC-100

Connection details as follow,

7.1、 Power(AC 24V) (Connect JP1)
XPTHC-100 works under AC 24V, usually it can be directly connected to the AC 24V

Power Supply of plasma cutter, if not available, it needs Voltage Transformer (customer

supplied).

7.2、 TO TORCH (Connect JP7).

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TO-PLASMA (Connect JP5)

Figure 9：TO PLASMA connection (with plasma)

There are detailed wiring figure at the end of this manual ( Figure 12) shows the
connection of THC control module, Plasma, CNC, Lifter, Torch Retaining Cap IHS,
Proximity Switch IHS.

Attention: Please contact us if you are not sure about your connection, to avoid
damage of PCB of THC, or malfunction.

7.4 TO-CNC (connected with JP6.)

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 Figure 10. Connection between THC and CNC

The interface between THC and CNC adopts Optical Isolation.

TO CNC have 6 ports as below respectively,

A、 (EXAUTO) Auto/Manual： Low Level input is AUTO; High Level is Manual.

B、UP： Low Level---UP.

C、DOWN：Low Level---DOWN.

D、(Arc Start signal IHS Enabled)IHSARCON：Low Level active, IHS first, then Arc Start

automatically,

E、(Arc Start signal IHS Disabled)EXARCON：Low Level active, Arc Starts directly, torch

lifts to an initial height automatically. So in this mode, the torch should reach

workpiece first before Arc Start.

F、ARCTRANS1、ARCTRANS2：Switch Signal output.

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7.5、SWITCH IHS (Connect JP3 for Proximity Switch IHS)

JP3

Figure 11：Connection of Proximity Switch IHS(SWITCH IHS)

7.6、 Current Feedback Circuit Setting. The relationship between

adjusting the SP2 current and the ON/OFF of Switch.

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

4A OFF：PWM=9KHZ OFF OFF OFF
3A OFF OFF ON
2A ON：PWM=18KHZ OFF ON ON
1A ON ON ON

8. THC Assembly Wiring Figure (Figure 12 ---- go to end of the manual)

9、Maintenance
9.1、Please CONTACT US if you are not sure about solution for follow situation or your

supplier from whom you bought.

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Serial Malfunction Cause Solution
Number
1 No display, black No +5V voltage on the Check +5V voltage VCC3
screen voltage meter
2 No rotation of motor 1、 damage of drive 1、replace IR2110
or only one direction IR2110
rotates. 2、 drive voltage +15V， Check drive voltage VCC4
failure
3、 protection of D606 ∽ D609 （ IRF640 ） is
over-current damaged or mechanical
blocked
3 Once turn on, cutting 1.Proximity switch is not Install the Proximity switch
torch keeps lifting 。 installed well in the perfectly
（NPN） open-circuit condition

2 、 damage of Proximity Replace Proximity switch

switch （signal：2mm，NPN）
4 Can not Start Arc 1 、 damage of Proximity Replace Proximity switch
automatically after switch, no return signal
the IHS 2、IHS time is too short, Prolong the IHS switch
no return signal
5 Instability of 1、check the connection with earth
controlling arc 2、check the water-proof

voltage 3、over-sensitive

6 CNC starts to work Setting time of 1、increase SET-PIERE time

before the SET-PIERE is too short 2 、 adopt the arc feedback
signal of Plasma itself
accomplishment of
Arc Start
7 Plasma Arc Start using the EXARCON Prolong the delay time of CNC
before the IHS signal, the delay-time of IHS
CNC controlling is too
short

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8 Cutting torch can not 1、Confirm the working situation of Plasma power
start arc 2、Check the height of IHS
3、Check the cutting torch fittings
9 Arc of Torch can not 1、Check the connection of working lead
transfer to work 2、Check the cutting torch fittings
piece
10 Cutting torch move Prolong the time of piercing hole in the CNC system
before piercing hole
completed
11 CNC control starts, 1、Increase“ Set Arc Voltage”
cutting torch heads 2、Prolong the automatic time in the CNC system
down immediately 3、Decrease the Over Voltage Protection No.(30V)
4、Check the situation of Auto signal or Corner signal of
CNC system
12 Plasma arc out after 1、 Delay-time is too long
the arc transferring
and piercing hole
13 During IHS, the 1、 Time of HIS is too short
cutting torch touches 2、 Induced lead connect with protection badly
the steel plate but no
movement upwards.

14 Cutting torch keeps 1、 Weak contact between detecting cable and retaining
heading down after cap.
touching work piece, 2、 Proximity switch is damaged
and no Arc Start 3、 “ WORK” in THC is bad connection with earth
15 Cutting torch is 1、 THC is over sensitive，regulate RP501
unsteadily on auto 2、 THC damaged
mode
16 THC is too slow on 1、 THC is over sensitive，regulate RP501
tracking, on
auto-state
17 Arc off during the problem：THC can not stop immediately since it works
cutting, and Arc with arc voltage signal.
voltage Enable solution：adopt the arc feedback signal of Plasma itself
signal keeps sending
out, machine still
runs

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9.2、Cancel function of Cutting Torch Lift after Arc off,( Please contact us if you are no sure

about it)

The function of Auto Lift would choke the lifting device if the Limit switch not installed yet or

doesn’ t work properly. So if the CNC has Auto Control function for Up and Down, you can

cancel the Torch Auto Lift function on control PCB.

Cancel the R234 on the control PCB or Cancel the C218 on the control PCB.

We set 30v as Over Arc Voltage Protection (OAVP) according to our years practice; it should

NOT be changed before carefully checking. THC would cancel the function of Auto Height

Control if the Actual Arc Voltage is higher than Set Arc Voltage 30V. So if OAVP is too small,

the Auto Height Control function can not work.

OAVP can be adjusted via adjusting PR104 on control circuit panel. Turn one round clockwise,

4v decreased, anti-clockwise, 4v increased. It is mainly used protect torch head from diving,

avoiding crashing the torch head.

Some advice,
1. When Torch Retaining Cap adopted, we suggest customers use Anti-bump Fixer to fix

cutting torch and lifter and connected it with 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 takes effect, it is more effective to protect cutting torch. If

Torch Retaining Cap and Proximity Switch 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 outside circuit.

3. The wire connecting Voltage Divider and THC must be SHIELD cable, and shall be separated

away from Arc Start cable.

4. 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’ s Running.

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