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北京欣斯达特控制技术有限公司
Beijing Flourishing Start Control Technology Co., Ltd
Torch Height Controller for Plasma/Flame CNC Cutting Machine
SH-HC30
Manual
北京欣斯达特
控制技术
有限公司
Beijing Flourishing Start Digital Technology Co., Ltd
北京石景山区八大处高科技园区双园路 号 号楼.邮编: 100043
No. Shuangyuan Road, Shijingshan District, Beijing, 100043, China
Tel: 010)88909150
Fax: 010)88909271
Website: www.startsh.com
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Contents
1. Preface
2. Overview
3. Installation
4. Quick operation guide
5. Commissioning
6. Operating guide
7. Control panel
8. Troubleshooting
9. Initial positioning
10. Commands between CNC a nd height controller
11. Remote height controller
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3D View of Remote Controller Graphic model of remote
controller
All
rights
reserved
Forbidden to distribute or duplicate any file for the purpose of commercial,
communication or others without particular authorization. Compensation will be
incurred if any clause is violated. All rights belong to Microstep Control
Technology Co., Ltd.
D
is
c
l
a
i
m
e
r
We have made a consistency inspection to the contents of the printed file against the product described.
However, we can’t guarantee absolute accuracy due to the impossibility to eliminate inaccuracycompletely. Nevertheless, we will verify the information in the file regularly and make necessary
amendments in the revised version. Any suggestion for later improvement is greatly appreciated.
Microstep reserves all the rights to make necessary amendments on the basis of technical
improvement.
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Contents
1 Preface ................................................................................................. 1
1.1 Purpose ........................................................................................ 2
1.2 Important Statement.................................. ................................2
1.3 Warning ...................................................................................... 3
1.4 Terms Explanation......................................................................4
1.5 Company Information ............................................................... 5
2 Overview.............................................................................................. 5
2.1 Technical Features ..................................................................... 5
2.2 Main Technical Indicators........................ ………………………….7
3 Installation ...................................................................................... 8
3.1 Mechanical Installation............................. …………………………..8
3.2 Electrical Installation Connection ........................................... 14
3.3 Function Introduction of Volatge Divider Board ………………22
3.4 Dimensions Figure of Volatge Divider Board............................ 25
4 Quick Operation Guide for Capacitance and Arc Voltage Height
Controller .............................................................. …………………. . . . . 26
4.1 Control Operation of Electrical Operation Panel: (External
Switching Mode) ..............................................................................26
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4.2 SH-2002AH/SH-2200H Operation of CNC System Output
Interface (I / O Control Mode) .......................... ……………………….27
4.3 CNC system communication interface is used to complete the
operation (RS232 communication mode) ......... ………………………28
4.4 Operation Flow ........................................................................ 28
4.5 Daily Operation Flow................................ ………………………...29
5 Operating guide................................................................................. 30
5.1 Parameter Setting ..................................... ………………………. 30
5.2 Manual Operation..................................... ………………………...30
5.3 Automatic Operation ............................................................... 31
6 Debugging........................................................... ……………………31
6.1 Initial Debugging of Capacitive Detection……………………32
6.2 Debugging Steps of a Key Height Calibration………………32
7 Controller Panel ................................................................................ 32
7.1 Control Parameters................................... ……………………….33
7.2 Operation Panel ....................................................................... 34
7.3 Display Status Description........................ ………………………..36
8 Troubleshooting ................................................................................38
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9 Description of Initial Location Function....................................................39
9.1 Positioning Mode................................................................................39
9.2 Setting of Positioning Height .............................................................39
9.3 Process ................................................................................................39
9.4 Initial Arc Voltage Collection (Set Value A).....................................39
10 Instruction Functions Related to M of CNC System and Height
Controller……………………………………………………………………..40
10.1 Function M of Direct Control Output Port of CNC System .........41
10.2 Fixed Cycle of Function M .............................................................41
11 Remote height controller .........................................................................44
11.1 Function Introduction.....................................................................44
11.2 Operation Guide..............................................................................45
11.3 Wiring Instructions .........................................................................47
11.4 Installation Dimensions ...............................................................48
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1 Preface Whether in flame cutting mode or plasma cutting mode, it is vital to maintain the stability
of the distance (height) between cutting torch and work piece, for it will directly affect the
cutting speed and the cutting quality.
Fig. 1-1 Model SH-HC30 height controller for flame/plasma cutting torch
1.1 Purpose
Model SH-HC30 height controller for flame/plasma cutting torch is an automatic height
control module integrated with mechanical lifting and electric control features, which is
specially designed for portable flame and plasma cutting machine as another new product
developed by Beijing Microstep Control Technology Co.,Ltd. in the field of industrial automation
control
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Model SH-HC30 height controller for flame/plasma cutting torch is simple and easy to use,
convenient to commission and modest in price. In addition, it insists the sell points of all
Microstep products--good product performance at modest price. It is an ideal accessory to
match welding or cutting equipment.
1.2 Important statement:
In case of any discrepancy between Model SH-HC30 height controller
for flame/plasma cutting torch and the contents of this manual, the
actual product should be referred to. Any amendments of the product or its
accessories are subject to change without prior notice. For updated contents, please
visit our website at http://www.startsh.com/eng
or simply call Beijing Microstep Control Technology Co., Ltd.
Be sure to read the safety warnings and precautions carefully to avoid
any accidents due to incorrect operations.
Please strictly follow the detailed instructions in the manual before
installing and using this machine.
In case that Model SH-HC30 height controller for flame/plasma
cutting torch and/or this manual is illegally used, the user shall be
liable for all the aftermaths and Microstep will take no legal liability,
for it doesn’t represent Microstep’s position.
The safety warnings are used to prevent any damage to human body
or properties.
In case of any quality problem found in using this product, please call
the service center of the manufacturer or authorized agents or
distributors to get service and help.
It’s not allowed to duplicate, distribute or utilize any content of this
manual without a written permi
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who violates shall undertake all the liabilities for the loss.
1.3 Warnings
Please read and strictly comply with the following instructions before operating the product, thus to
assure the designed product control accuracy and prevent any damage and accident.
Installation must be carried out by certified technical personnel with relevant
experiences.
Please thoroughly read the instructions before starting installation.
Make sure the local power supply satisfies the required specifications.
Installation, plugging or unplugging power cord are prohibited when
the power switch is on.
The product should be positioned far away from any heat source if possible.
The controller shell must be grounded well to avoid electric shock or
affecting the controller.
The work piece must be well grounded too and maintain a good connection with
the controller shell for assured accuracy of height control.
Note: If the controller shell and the work piece are not properly grounded, the height controller will not
work normally.
Please handle the product with care and make sure no impact or
shock; otherwise, damage to the product might be incurred. .
Never try to disassemble the product or modify its internal construction;
otherwise, accident or fault might occur.
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easy.
1.4 Terminology Definitions
One-keystroke height calibration: In capacitance height measurement
mode, the specific inductive capacity between the capacitance
detection ring and work piece may affect the accuracy of height
measurement due to temperature, pressure, humidity, gas composition
and many other ambient factors. In addition, the serious non-linear
relationship exists between capacitance value and height value.
Microstep has developed the intelligent program of "one-keystroke
height calibration". Only one keystoke will automatically set the
product based on various ambient factors. And within the range of
3-30mm, high accuracy, high precision and high linearity is possible in
display and control.
High speed zone: When the difference between the actual height and the set
height is relatively big, the cutting head will advance towards the set value at the
highest speed in order to reach the set value the soonest; this travel zone is called
high speed zone.
Speed regulating zone: If the cutting head reaches the set value at a
high speed, severe oscillation may be caused and the height control is
unstable. In order to achieve a smooth transition, the speed regulating
zone is set. This zone is located between the high-speed zone and the
dead zone. In this zone, when it is far away from the set value, the
cutting head will move at a higher speed; otherwise, at a lower speed.
The range value of this zone is adjustable. If it is set too big, the
transition is smooth, but the tracking time is too long; if it is set too
small, the tracking is conducted
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Dead zone: Within a certain height range, the height of the cutting
head will not be adjustable any more. The range is called dead zone. If
the dead-zone range is set too wide, the control precision will be too
low; if it is set too narrow, the cutting head may oscillate up and down
easily. An appropriate value of dead zone will not only guarantee the
control precision but also generate no oscillation.
2. Overview
2.1 Technical Features
Stepper motor instead of conventional DC motor
Model SH-HC30 height controller for flame/plasma cutting torch uses
the proprietary stepper motor control technology of Microstep to
replace the conventional DC motor height control technology, which
makes it faster and smoother in addition to significantly intended
service life.
Directly displaying the height of cutting nozzle in capacitance height
control mode
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The advanced height linear calibration technology makes absolute
height display and control possible when the distance between the
cutting nozzle and work piece is within 3 ~ 30mm in the capacitance
mode under for automatic height control in unit of millimeter and
display accuracy of ± 0.1mm.
Integration of mechanical lifting device and height controller
Detector, controller and drive are highly integrated with adjustable
stroke up to 10cm.
All Digital Technology
Circuit uses SMD technology without any adjustable devices; all
digital control technology ensures high product reliability.
Simple and convenient linearization calibration
The feature of "one-keystroke height calibration" guarantees that in
any circumstances, the user only needs to press one key to calibrate
the absolute height measurement and achieve linear height
measurement.
Applicability in tough environment
The shell uses tamper-proof, waterproof and moisture-proof
aluminum box sealed design, particularly applicable to the severe
environment of high temperature or high electromagnetic interference
from flame cutting or plasma cutting operation.
Various interfaces easy to use.
The interface is simple and easy to control. It is suitable for any flame
cutting and plasma cutting CNC system or using alone.
RS232 communication interfac
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Asynchronous communication function enables connection with CNC
system and facilitates parameter setting, automatic/manual control,
taper angle transition control and data exchange.
2.2 Main Technical Parameters
Power Requirements: DC 24V ± 2 V 3 A
Applicable motor: 17/23 HS series of stepper motors
Manual adjustment range: 0-100 mm
Automatic height control range: 3 -30 mm
Adjusting speed of automatic height control: 3000 mm/min (30 ° slope)
Control precision: ±0.5 mm
Dimensions of box body: (155 × 87 × 71) mm
Operating temperature: -10 to 50
Weight:
Total weight of capacitance height control: 1.990kg
Total weight of arc voltage height control: 1.645kg
Detection system: capacitance height detector and arc voltage height
detector
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3. Installation
3.1 Mechanical Installation
The component names and positions of height controller are shown in Fig. 3-1.
Among them, the connecting components for capacitance detector are only
added in flame cutting operation
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Lift stepper motor
Standard high frequency cable
Detector ring anti-collision device
Operating display panel
Cutting torch holder
Detector ring holder
Flame cutting torch
Detector ring
Fig. 3-1 The positions, names and functions of controller components
6 M6 screw holes in the back of the height controller are used to fix the
box body to the support. Their position and size are shown in Fig. 3-2.
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Note:
1. Make sure the depth of bolts in
six mounting holes during
installation will not affect the
travel.
2. The length of each mounting
bolt beyond the shell of the height
controller internallymust be less
than 8mm, i.e., the bolt length
inserting into the interior of the
height controller shell must not
exceed 8mm.
Fig. 3-2 Mounting position of screw holes in the back of the controller
The right view of the height controller and related installation dimensions are
shown in Fig. 3-3.
The back view of the height controller and related installation dimensions are
shown in Fig. 3-4.
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Fig. 3-3 Right view of the controller
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图3-4 高度控 器背面视图
Fig. 3-4 Back view of height controller
The installation diagram of the height controller is shown in Fig. 3-5
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Fig. 3-5 Assembly diagram of height controller
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3.2 Electrical Connection
3.2.1 External Switch Control Mode
The external switch control mode is applicable to both
capacitance height control and arc voltage height control.
K1
Manual/automatic switching
K2
Manual ascendingK3
Manual descending
Ground
Electrical wiring diagram of external switch control
When K1 is off, the height controller is in manual mode;
When K1 is on, the height controller is in automatic mode.
When K1 is off, K2 and K3 are enabled.
When K1 is on, K2 and K3 are disabled.
3.2.2 CNC System Input/Output Control Mode (I/O control)
Electrical connection of capacitance-detection height controller
The electrical connection of capacitance-detection height controller is shown in Fig.
3-6.
The high-frequency cables and plugs are special parts. The high-frequency cables
can be provided up to1000mm according to different requirements.
The cable connection between height controller (15-pin connector) and CNC system
(25-pin connector) should be made by the user. The connection is shown in Fig. 3-7.
For the detailed pin definition of 15-pin and 25-pin, see Table 3-1 and Table 3-2.
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15
15-pin plug
BNC high-frequency cable
Back view of CNC system
Height
controller
25-pin connector
Fig.3-6 Electrical wiring diagram of capacitance height controller
Note: The diameters of 24 V power cord and ground wire should be larger than 0.75 mm2.
Manual/automatic switching
Manual ascending
Manual descending
Ground
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Table 3-1 Pin definitions of 25-pin connector of CNC system for the height control system
S/N AttributeDescription
5 Output Manual/automatic selective signal
6 Power
Supply
24V ground for power supply of height
controller
7 Output Manual lifting signal to drive cutting
torch up
12, 13 Power
Supply
24 V positive for power supply of height
controller
19 Output Manual descending signal to drive
cutting torch down
24, 25 Power
Supply
24 V positive for power supply of height
controller
Note: The pins whose serial numbers are not listed of the 25-pin plugs of CNC
system will not be used.
Table 3-2 Pin definition of 15-pin connector of height Controller
No.
Attribute
Description
Remarks
1 Serial port for common use
232-COM
2 Serial port for Receiving 232-RXD
3 Serial port for transmiting 232-TXD
4 Input
Signal
Arc voltage (height of cutting
torch) signal
5
Signal ground
Arc vol
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7、14 Power supply 24 V positive for power supply
of height controller
8、15 Power supply 24 V ground for power supply
of height controller
10
Input
manual/automatic selectivesignal
12 Input Manual ascending signal for
driving the cutting torch up
13 Input Manual descending signal for
driving the cutting torch down
Note: The pins whose serial numbers are not listed of the 15-pin plugs of the
CNC system will not be used.
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Electrical connection of arc voltage detection-type height controller
The electrical connection of arc voltage detection-type height controller is shown in Fig.
3-8.
The cable connections among height controller (15-pin connector), CNC system (25-pin
connector) and voltage divider board (9-pin connector) should be made by the user.
For the pin definitions of 15-pin, 25-pin connector and 9-pin connector, see Table 3-1,
Table 3-2 and Table 3-3
Height
Plasma Power Supply
Voltage divider
board
The back panel of CNC system
Fig. 3-8 Electrical wiring diagram of arc voltage height controller
Table 3-3 Pin definitions of 9-pin connector for volta
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S/N Attribute Description
2 Power
supply
24V ground for power supply of height controller
5 Power
supply 24V ground for power supply of height controller
6 Output Arc voltage signal serving as height signal of the plasma
cutting nozzle
9 Output 24V positive for power supply of height controller
Note: The pins whose serial numbers are not listed will not be used.
Connecting to voltage divider board
Connecting to torch height controller Connecting to CNC system
9-pin connector of voltage divider board
Arc voltage signal after voltage dividing
Automatic start
Arc voltage signal after voltage dividing
Manual ascending
Manual descending
24V Ground
15-pin connector of height controller 25-pin connector of CNC system
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Fig. 3-9 Wiring diagram of arc voltage height controller, voltage divider board and CNC system
Note: The wire diameters of 24V power cord and of ground wire should be larger than 0.5 square
millimeter.
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分压板 9芯接头
21
25-pin pl ug
print.com.cn
The electrical connection of height controller when both arc voltage detection
mode and capacitance detection mode are required to use.
Arc voltage
Arc voltage
15-pin pl ug
High-frequency cabl e
Heigh
Back view of CNC
Capacitance detecting ring
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24V Ground
Automatic start
Arc voltage signal Manual ascending
Manual descending
24V Ground
This figure should be kept on standby – it illustrates the automatic connection method
when both arc voltage mode and capacitance mode are required to use.
3.2.3 Communication interface control mode of CNC system (RS232 control)
The software debugging for the communication interface control mode of
CNC system is in process.
3.3 Functional description of voltage divider board
The voltage divider board is a functional module designed to reduce the voltage of
plasma cutting torch after arc starting in a certain proportion and separate and
convert it to the low-voltage signal reflecting the
piece. It is the indispensable accessory in the mo
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plasma cutting operation. The voltage dividing ratio of the voltage divider board in
standard configuration is 50: 1.
The various interfaces of the voltage divider board are illustrated in Fig. 3-10.
J3 AC power, connecting device
AC220V power supply
J2 arc voltage input, connecting to the
arc voltage terminal of plasma power
J1 arc voltage output of voltage dividerboar d,
connecting to height contr oller and CNC system
Fig. 3-10 Interface description of voltage divider board
The pin definitions of interfaces are shown in Table 3-4, Table 3-5 and Table 3-6.
Table 3-4 Pin definitions of J1 connector
S/N Attribute Description
2 Power
supply 24V ground for power supply of height controller
5 Power
supply 24V earth for power supply of height controller
6 Output Arc voltage signal serving as the height signal of
plasma cutting nozzle
9
Power
supply
24V positive for po
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Note: The pins without pin numbers will not be used.
Table 3-5 Pin definitions of J2 connector
No. Attribute Description
1 Power
supply Ground
2 Input Plasma arc voltage positive terminal
(connecting to the clip of steel plate)
3 Input Plasma arc voltage negative terminal (arc
voltage output)
Note: Push the orange button inwards and insert the stripped cable into the wiring hole
and then release.
Table 3-6 Pin definitions of J3 connector
No. Attribute Description
1 Power
supply AC220V±10%
2 Power
supply AC220V±10%
The voltage divider board may choose installation position as required,
but note should be taken J1 interface is for low-voltage signal and J2
is for high-voltage signal. In order to prevent low-voltage signal from
any interference of high-voltage and high-frequency signals and
improve the system stability, the wirings of J1 and J2 should becarried out separately.
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3.4 Dimensional drawing of voltage divider board
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Desce
Descen
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4. Quick Operation Guide of Height Controller in
Capacitance and Arc Voltage Modes
4.1 Control operation of electrical operation panel: (external switch mode)
For the wiring of height controller in capacitance mode, see Section 3.2 -- "Electrical
Connection"
For the wiring of height controller in arc voltage mode, see Section 3.3-- "Electrical
Connection"
The operation procedure is as follows: Set the automatic/manual control switch to manual mode
Set the
automatic/manual
control switch to
manual mode
Automatic
Manual
Cutting torch control
割枪控制
升 nd
2.Adjust the ascend/descend switch of the cutting to rch as needed.
Automatic
Cutting torch control
割枪控制 Ascend
Adjusts the
ascend/descend switch to
lift the cutting torch Manual
Adjusts the
ascend/descend switch to
lower the cutting torch.
Automatic
Manual
Cutting torch control 割 枪
Ascend d
3. Set the automatic/manual control switch to
automatic mode
Automatic
Cutting torch control
割枪控制
Ascend Set the automatic/manual
control switch to
automatic mode
Manual
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Fig. 4-1 Operation flow of initial use or when detection mode is intended to switch
4.5 Routine Operation Flow
Flow starts
Power on CNC system
and height controller
auto-detection of "manual
/auto" mode
Yes No Manual?
When the manualascending signal is atlow level, the cuttingtorch moves up.
The cutting torch adjusts itsheight automatically as per the set value of height.
When the manualdescending signal is at lowlevel, the cutting torchmoves down
Press the key “Up” on theoperation panel once to have theset value of height increased by 1
Press the key “Up” on theoperation panel once to havethe set value of height increasedby 1
Press the key “Down” on theoperation panel once to havethe set value of heightdecreased by 1
Press the key “Down” on the
operation panel once to havethe set value of height
decreased by 1
LCD indicates the actualheight
LCD indicates the set
value of height
Fig. 4-2 Routine Operation Flow
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5 Operating Guide
The height controller provides three modes after powered on: manual,
automatic and parameter editing modes.
5.1 Parameter Setting
In manual or automatic mode, press the key “Enter” and hold it for some time, the
height controller will enter parameter editing mode. Click the key “Enter” in the
editing mode, the height controller will return to manual or automatic mode, which
depends on the mode before entering parameter editing mode.
In editing mode, press the Function key to switch the parameters to be edited
circularly. The switching sequence is: H (upper limit value) → L (lower limit value)→
A (set value of height) → E (dead-zone value) → d (speed regulating zone value) → C
(detector mode selection) → b (non-board reduction parameters) → H (upper limit
value). (See 7.3)
If the up arrow is pressed once, the selected parameter value will increase by 1 (for theselective range of parameter values, see 7.1).
If the down arrow is pressed once, the selected parameter value will decrease by 1 (for
the selective range of parameter values, see 7.1).
5.2 Manual Operation
Manual/automatic signals: at high level, the controller is in manual mode.
Manual ascending signal: at high level, invalid; at low level, the cutting torch moves up.
Manual descending signal: at high level, invalid; at low level, the cutting torch moves
down.
If the key "↑" on the operation panel is pressed, the cutting head will move up.
If the key "↓" on the operation panel is pressed, the cutting torch will move down.
Modify the corresponding set value of height when the height controller is ascending or
descending in manual mode.
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5.3 Automatic Operation
Manual/automatic signal: at low level, the controller is in automatic mode.
In automatic mode, the height of the cutting torch is controlled automatically
according to the set height by the user.
If press the key "↑" on the operation panel once, the set value of height will increase by
1; if press and hold it down, the set value of height will increase continuously in step of
1.
If press the key“↓” on the operation panel once, the set value of height will decrease by
1; If press and hold it down, the set value of height will decrease continuously in step of
1.
6. Commissioning 6.1 Initial commissioning of height controller in capacitance detection mode
The height measurement in capacitance mode is to measure the distance between the
capacitance detection ring and work piece or the height through detecting the capacitance
between them thereby to achieve height control.
When the capacitance-mode height measurement is adopted, the specific inductive capacity
(SIC) between the capacitance detection ring and the work piece may affect the height
measurement accuracy due to such ambient factors as temperature, pressure, humidity,
gas composition and son on. In addition, there is serious non-linear relationship between
the capacitance value and the height value. Microstep has developed the intelligent
program of "one-keystroke height calibration ". Only one key needs to be pressed locally
to calibrate the height controller based on various ambient factors automatically; in the
meantime, the display and control in high accuracy, high precision and high linearity will
be achieved within 3-30mm.
In the following cases, height calibration is required.
1. The height controller is used for the first time;
2. The ambient environment of height controller cha
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3. The actual height of capacitance detection ring is not consistent with its display height
value.
Since "one-keystroke height calibration" is so simple and it only needs to press one key,
user may calibrate the height controller at any time.
6.2 Commissioning procedure of one-keystroke height calibration
Check and make sure the bottom of capacitance detection ring is parallel to the work
piece.
Power on the height controller of cutting torch.
Set the detector mode to capacitance detector mode (for the method, see 7.3).
In manual mode, adjust the cutting nozzle to approach work piece to an appropriate
position.
Press and hold the "down arrow" key on the height control panel for about two
seconds, the "one-keystroke height calibration” process will start automatically as
follows:
1. Move up to somewhere about 30mm high in five steps;
2. And then move down to about 10mm away from the work piece and stop;
3. All the calibration is completed.
By this step, the initial commissioning is finished.
For details about how to perform height control operation, see 5.2 and 5.3.
7 Controller Panel
There are LCD display and keypads on the height controller panel.
Through the panel operations, user
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monitor operation status.
7.1 Control Parameters
Set value (A: Accuracy Height): the expected value of the distance (height) between the
cutting nozzle and the work piece, which is set by user. For the set range and factory
default value, see Table 7-1.
Dead zone value (E: Error Area): When the actual height is A ± E, the height of cutting
torch will not be adjustable any more (see 1.4). For the set range and factory default
value, see Table 7-1
Speed regulating zone (d: Down Speed Area): the two speed regulating zones are
between A-E-d and A-E as well as between A + E and A + E + d (see 1.4). For the set
range and factory default value, see Table 7-1.
High limit point (H: High Limit): When the cutting torch position is higher than thisset value, an alarm will pop up and the cutting torch can not move up further. For the
set range and default value, see Table 7-1.
Low limit point (L: Low Limit): When the cutting torch is lower than this set value, an
alarm will pop up and the cutting torch can not move down further. For the set range
and factory default value, see Table 7-1.
Selection of detector (C: capacitance): 0 is for arc voltage detection and 1 is for
capacitive detection. For the set range and factory default value, see Table 7-1.
No board drop parameter (b):
In capacitive detection mode, when the detected height is higher than value b, the
cutting torch will descending stop descending; when the height becomes lower than
value b, automatic height control will be enabled again;
In arc voltage detection mode, when cutting torch is moving down manually and
encounters the zero-point signal, the cutting torch will move up to b mm. For the set
range and factory default value, see Table 7-1.
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Table 7-1 Setting range
H L A E d C b
Set range
(V) 100~300 10~40 20~200V 0~20 0~100
0~1 0~50
Arc voltage
Factory
default
value(V)
280 10 80 3 5 1 5
Set range
(mm)
20.0~30.0 3.0~10.0 6.0~25.0 0.0~4.0
0.0~4.0
0~1
2.0~
30.0
Capacitance Factory
default
value
25.0 4.0 10.0 0. 3 2. 0 1 25.0
7.2 Operation Panel
The operation panel is illustrated in Fig. 7-1.
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LCD
Up Arrow
Enter Key
Function
Key
Down Arrow
图7-1 Operate Panel
Enter key: To enter or exit the editing mode.
Function key: in manual mode, to perform the function of “one-keystroke
height calibration”; in editing mode, switch the active parameters to be
edited.
Up arrow: in manual/automatic mode, to have the set height value increased
by 1; in the editing mode, to have the active parameter decreased by 1.
Down arrow: in manual/automatic mode, to have the set height value decreased
by 1; in the editing mode, to have the active parameter decreased by 1.
LCD: the display functions are as follows:
1. Manual operation mode: to display detector mode, operation mode
and height set value.
2. Automatic operation m
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and the current height value.
3. Parameter editing mode: to display the parameter names being
edited and the corresponding parameter values.
7.3 Description of Display
Manual operation mode: The first digit indicates the detection mode;
the second one indicates the operation state and the last 3 digits
indicate the set value of height.
The first digit: C: capacitance detection mode, U: arc voltage detection
mode.
The second digit: no operation, flashing between and ; the formerstands for manual ascending and the latter stands for manual descending:
The last 3 digits: in capacitance mode, it is a decimal in mm; in arc voltage
mode, it is an integer in V.
Automatic operation mode: The first digit indicates the detection mode
(the same as shown above); the second one indicates the operation
state and the last 3 digits indicate the set value of height (the same as
shown above). The second digit is particularly described as follows:
When is fixed, it indicates the cutting torch is moving up
at high speed.
When is flashing, it indicates the cutting torch is moving
up at the a regulated speed.
When is fixed, it indicates the cutting torch is moving down
at high speed.
When is flashing, it indicates the cutting torch is moving
down at a regulated speed.
When is flashing, it indicates the cutting torch arrives the
expected place.
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When the last 3 digits are and the height value flashes,
it indicates anupper-limit alarm.
When the last 3 digits are and the height value flashes, it
indicates a lower-limit alarm.
When the last 4 digits are , it indicates the upper limit
position is reached.
When the last 4 digits are , it indicates the lower limit
position is reached.
Parameter editing mode: The first digit indicates the parameter name;
the second one indicates the equal sign ; the last 3 flashing digits
indicate the parameter value(In capacitance mode, it is a decimal
accurate to 0.1 mm; in arc voltage mode, it is a integer in V. The first
digit is particularly described as follows:
H: the upper limit value. When the height of cutting torch is
larger than this value, an upper-limit alarm will be triggered.
In this case, the cutting torch can only move down.
L: lower limit value. When the height is lower than this value,
it is a lower-limit alarm will be activated. In this case, the
cutting torch can only move up.
A: the set value of height; in automatic mode, this value is
used as the given value for automatic height adjustment.
E: Dead zone value (see 7.1).
D: Speed regulating zone value (see 7.1).
C: selection of detector mode (see 7.1).
b: No board descending parameter value (see 7.1)
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8 Troubleshooting
For the common faults, inspection methods and corrective measures see
Table 8-1.
Table 8-1
Fault Inspection items
Corrective measures
Powered on or not?
Power it on
the voltage of power supply
is normal or not
Check the power
supply
Motor does
not work
motor is overloaded or not Reduce load
No display Check the power supply Power on
Upper limit
alarm
The upper limit value is
exceeded
Check the upper limit
switch
Lower limit
alarm
The lower limit value is
exceeded
Check the lower limit
switch
Instable signal
the work piece is grounded
properly or not Ground it firmly
Inaccurate
height
Operating environment
changed
Run “one-keystoke
height calibration”
Vibrate wildly
Speed reduction zone value is
too small
Increase the speed
reduction zone value d
Too slow in
tracking
Speed reduction zone value is
too big
Reduce the speed
reduction zone value d
Slight
vibration Dead zone value is too small
Increase the dead zone
value E
Too low
accuracy Dead zone value is too big
Reduce the dead zone
value E
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initial use is because the arc column voltage may not the same for the
plasma power supply of different manufacturers even the cutting
operation is going on in the same environment. Collect the test results
for parameter A (see control parameters in 7.1). If the value of
parameter A has never been tested and the set value is smaller than
the actual voltage used in plasma cutting operation, then in automatic
cutting mode the plasma cutting torch will move down quickly until it
knocks the workpiece; otherwise, it will move up all the way until the
arc breaks.
For an unfamiliar new plasma power supply to be used with the height
controller for the first time, arc voltage test must be made for this
plasma power supply. As for standard plasma power supply, the
"cutting speed chart" in the instruction manual attached to the
plasma power supply should be referred to.
Simple test method:
Manually adjust the distance between the cutting torch and work
piece to an appropriate value according to the power specifications. In
the manual mode of plasma, manually control the height controller to
start arcing perforation. After perforation is completed, move the
cutting torch through the CNC system to perform actual cutting
operation; at this moment, the value indicated on the digital display of
the height controller is the actual arc voltage of the plasma power
supply in the current environment.
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10 M Commands between CNC System and
Height Controller
10.1 M Commands from CNC System for Direct Control of Output Port
M14/M15 On/off switch for ascending of cutting torch, M14 (on), M15 (off)
M16/M17 On/off switch for descending of cutting torch, M16 (on), M17 (off)
M38/M39 automatic/manual switch of height controller M38 (auto) M39 (manual)
10.2 M Commands for Routine Cycles
M07 fixed perforation cycle
The sequence of flame cutting operation is as follows:
M07
1. If the gas (acetylene) valve is not opened yet, then open it and start ignition;
2. The cutting torch descends (the descending time delay of cutting torch starts, see
M71);
3. Open the preheating oxygen valve to start the preheating delay. If the preheating
time is not enough, press the key【pause】, the preheating time will extend to 150
seconds automatically. If the preheating is completed before the time delay is up, press
the key【start】to end the preheating delay; in the mean time, the new preheating time
will be saved automatically in the preheating delay parameter;
4. The cutting torch ascends(the ascending time delay of cutting torch for perforation
starts, see M72);
5. Open the cutting oxygen valve (M12), perforation delay time starts. At the end of
the delay time, the cutting torch will descend (the descending time delay of cutting
torch for perforation starts, see M73);
6. Turn on the height controller (M38) and start the subsequent procedures..
The sequence of plasma cutting operation
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3. The cutting torch descends (M73)(no this action in
M07
1. The cutting torch descends (the descending time delay of the descend cutting torch
starts, see M71);
2. If the selected perforation position is valid, then the cutting torch will descend until it
hits the lower limit switch. Then the cutting torch will ascend until the perforation
positioning delay ends;
3.Turn on the starting arc switch;
4. Detect the signal of "arc voltage", if the arc voltage detection is set as 0 in parameter
settings (no detection), the arc voltage will not be detected. If arc starting succeeds, the
perforation delay will start (seconds)
5. Turn on the height controller (M38) to start the subsequent procedures.
M08 Fixed shut-off cycle of cutting operation
The shut-off sequence of flame cutting operation is as follows:
M08
1. Close the cutting oxygen valve (M13);
2. Turn off the height controller (M39);
3. The cutting torch ascends (M70);
The shut-off sequence of plasma cutting operation is as follows:
M08
1. Turn off the arc voltage switch;
2. Turn off the height controller (M39);
3. The cutting torch ascends (M70).
M50 perforation action:
1. The cutting torch ascends (M72)(no this action in plasma mode);
2. Open the cutting oxygen valve in flame mode (M12); or initiate starting arc in plasma
mode and detect the signal of "successful arc voltage
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To position the cutting torch in plasma mode, first le
4. Turn on the height controller (M38)
M70 Fixed ascending cycle of cutting torch:
It is used to lift the cutting torch when a cycle starts and after one cutting cycle is completed,
the so that the cutting torch can move to next cutting position quickly.
Operation sequence: turn on the ascending switch of the cutting torch (M14); start the
ascending delay of cutting torch; turn off the ascending switch of cutting torch (M15).
M71 Fixed descending cycle of cutting torch:
It is used before a perforation operation. Its role is contrary to M70, but the value is smaller
because descending is faster than ascending due to the action of gravity descend.
Operation sequence: turn on the descending switch of cutting torch (M16); start the
descending delay of cutting torch; turn off the descending switch of cutting torch (M17).
M72 Ascending cycle of cutting torch for perforation:
It is used at the end of preheating to lift the cutting torch a little bit so as to avoid anysprayed steel slag from blocking the nuzzle of the cutting torch when the cutting oxygen
valve is opened.
Operation sequence: turn on the ascending switch of cutting torch (M14); start the
ascending delay of cutting torch for perforation; turn off the ascending switch of cutting
torch(M15).
M73 Descending cycle of cutting torch for perforation:
It is used at the end of preheating. After M72 is executed and the cutting oxygen valve is
opened, the cutting torch is located in cutting position. It is the reverse action of M72, but
the value is smaller because descending is faster than ascending due to the action of gravity.
Operation sequence: turn on the switch of cutting torch (M16); start the descending delay
of cutting torch for perforation; turn off the descending switch of cutting torch (M17).
M75 Positioning time delay of cutting torch:
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it hits the lower limit switch (see the input port XXW 8), the cutting torch will stop
descending(M17). Then, the cutting torch will ascend (M14) until the positioning delay of
cutting torch is up (M15);
11 Remote Height Controller
In order to let user stay away from hazardous cutting site when controlling the cutting
operation, and make the use in an easier and, simpler way, a dedicated remote controller is
provided for user, as shown in Fig. X-1.
Fig. X-1 Exterior view of remote height controller
The remote height controller uses computer-based design and support communication the
master height controller via RS232 port. The adjustment of the height and the sensitivity
adopts simple knob design, which endues it the operation conveniences of analog circuit
and the accuracy and reliability of digital circuit.
11.1 Function Introduction
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3 indicator lights.
Power: when the light is on, it is in power-on state.
Manual: when the light is on, it is in manual operation mode; at the
same time, the automatic indicator light is off.
Automatic: when the light is on, it is in automatic operation mode, at
the same time, the manual indicator light is off.
3 buttons.
Manual/ automatic: switching between manual and automatic modes.
Ascend: the cutting torch ascends manually.
Descend: the cutting torch descends manually.
2 knobs, as shown in Fig. X-2.
Height: in automatic mode, the height of cutting torch is adjusted.
Sensitivity: in automatic mode, the control sensitivity of the cutting torch is
adjusted.
11.2 Operation Guide
When it is powered on, the controller will enter manual operation
mode and the indicator light "
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indicator light "Automatic” stays off. At this time, if the height of the
cutting torch needs to be adjusted, the buttons of "Ascend" or
"Descend" may be pressed as needed. When the button “Ascend” is
pressed and held, the cutting torch will keep ascending until the
button is released. In the similar way, when the button of "Descend" is
pressed and held, the cutting torch will keep descending until the
button is released.
When automatic height control is needed, press the button of "Manual
/Auto", the light of "Manual" will turn off when the light of "Auto" is
on, which indicates the height controller enters automatic control
mode. In this mode, the height of the cutting torch is adjusted
according to the set height value automatically.
Note: Two external control methods are adopted for the height
controller, namely, local switch control method and remote control
method. For this system, if two external control methods are used
simultaneously, only when both methods are in automatic control
mode, the height controller will enter automatic control mode;
otherwise, both are in manual control mode.
If the height does not meet the requirements, turn the knob of
"Height" to set. 0% is the lowest and100% is the highest.
If the adjustment accuracy is unsatisfactory, user can turn the knob of
"Sensitivity" to a lower position (towards 0%) to improve the
sensitivity, but it should not be set too low; otherwise, vibration may
occur to the cutting torch. When vibration occurs, turn the knob of
"sensitivity" to a higher position (towards 100%) until the vibration is
gone.
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4 5
4 8 4 8
mm
11.4 Installation Dimensions
96X48mm
12
68
96mm