DTHC-SETUP/INSTALL MANUAL CandCNC

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10. Torch oscillates wildly UP andDOWN while cutting11. Torch slowly rises UP while cutting12. DTHC works fine sometimes andthen does not other times using thesame parameters.13 Torch runes for a while then shutsoff while cutting or does not stay litafter the pierce. Torch is overshooting. Increase SPAN value inCUT PROFILE. Torch is losing steps. DecreaseTHC RATE by 5% in MACH. Check couplings andZ for binding or looseness.Check Torch Volts reading. IF it is above thePRESET VOLTS then the DOWN LED should beon. If the TORCH is not going down then MACH isignoring the down command (THC Corrections iswrong) If the UP LED is on then the PRESETVOLTS maybe set wrong. If neither LED is on butthe torch moves up then Z is gaining steps fromoutside noise. Contact us. See also the TIP SAVERlocking on issue. Possible noise problem. Make sure you haveyour table and plasma well grounded with a localground rod. Try not to run your PC and Controllerout of the same subpanel as the plasma. keep thegorunds for each side separated locally. Check the Indicator LED on the THC SENSORcard for the TORCH ON (relay) It should remain ONsteady. If the torch still turns off (with it on) then theproblem is with a connection (torch switch terminalsor a problem at the torch.Do’s and Don’tsDO run the manual cut test and record the conditions you see including the LED indicationsDO make sure you understand that the setups for Touch-off, pierce height and cut height areworking correctlyDO have the results of any testing ready for the support person.DO take the time to understand the basic concepts of how an ARC VOLTAGE THC (like theDTHC) works.DO realize there are external conditions and torch problems that can effect the DTHC.DO follow all of the grounding rules for the plasma. HF start units need extra attention toproper grounding for reliable operation.DO understand the relationships of Torch Volts, Torch AMPS, feedrate and air pressure/qualityin plasma cutting.DO NOT assume there is an electronics problem until you have eliminated ALL possibleproblems of incorrect settings and things like consumables and airDO NOT attempt to run plasma without the proper MACH Profile (XML) loaded. Must be aCandCNC profile or a copy from our profiles.DO NOT call for support with vague descriptions or having not tested to a pointDO NOT makes changes in the MACH config to the base profile. Use a Clone copy and thenonly make one change at a time. The pin settings (mappings) are complex for our systemsand some settings are critical to the overall operation.PAGE 50
Some torches will have more than one set of small wiresfor other sensors in the head. Confirm switch pair with an ohmmeterwhile operating the switch (Plasma Unit power OFF)Air and/or tip voltageHi VoltsWorkpiece ClampGood connection to the workpiece with clamp is essentialfor proper operation of the THCTorch Switch WiresHOW DTHC (THC/AVC/DTHC) WORKSAutomatic Torch Height Control (often called just THC) works by reading the Arc Gap Voltage whilecutting. Plasma uses constant current cutting. If the Current stays constant and you vary the gap (eitherby moving the torch or moving the material UP or DOWN) then the voltage will change in proportion tothe change in arc gap. Much like the altimeter on a plane (that measures barometric pressure todetermine altitude) the Arc voltage indicates the RELATIVE distance from the end (tip) of the nozzle tothe top of the material. The change in voltage for a change in height is a small percentage of the overallcutting voltage. A 1% change in voltage (100 to 101 volts) is equal to several thousands (typically .025 ormore) of arc gap change so the THC must be able to see and act on a small change in a large number.The THC control must take the actual cut voltage and compare it to a preset “target” and move the TorchUp or Down to try and correct the height based on it’s arc voltage. The process forms a “servo loop”where an “error” voltage from a preset is used to physically move the torch Up or Down to “correct” theerror. Under normal cutting conditions the voltage stays constant but certain conditions that effect the arcgap voltage can skew the gap volts and case the THC circuit to overreact. The feedrate (how fast the tipis moving across the material) determines the current density and the Gap Volts. A slower feedrate willcause an increase in Torch Volts (if no THC servo is there to correct). With THC engaged the circuit willsense the higher voltage and based on the error created lower the torch to try and correct. This conditionappears when a CNC machine has to slow it’s feedrate to make a sharp turn or to cut small detail. TheDTHC has added features that sense a non-standard change in arc volts and locks downward movementto prevent “head bounce” Arc Gap = Arc volts=Torch Volts 1volt (change) = approx .025”(change) >Arc volts = > Arc Gap. (greater the Arc Gap the greaterthe Arc Volts) Z moves opposite Arc Volts based on Preset Volts. TorchVolts Above Preset: LOWERS torch; Torch Volts below Preset:RAISES torch. Control has “window” (Span Volts) where no UP or DOWNoccurs. (prefect cut height) Anything inside the Span (+ or -)from the Preset generates NO change. SPAN VOLTS is set in1/4V increments in the Cut Profile and stored in the DTHCmemory.Arc Gap-Gap Volts+PAGE 51
Page 1 and 2: DTHC-SETUP/INSTALLMANUALREV5JAN 201
Page 4 and 5: PRELIMINARY TESTING THE DTHC MODULE
Page 6: J15TipVoltsWorkclamp+ [POS]L4R7- [N
Page 12 and 13: HYPERTHERM PowerMAX 45Connecting TH
Page 14 and 15: THC SENSOR CARD TESTINGBefore you m
Page 16 and 17: 1. Most plasma units have connectio
Page 18 and 19: INSTALLATION OF CURRENT TRANSFORMER
Page 20 and 21: Workclamp Lead Wire goesthrough Hal
Page 22 and 23: 2. Start MACH3 on the controller PC
Page 24 and 25: DTHC EXPANION MODULE. Locatedabove
Page 26 and 27: PC w/MACH3Grounding practices to re
Page 28 and 29: SETTING UP YOUR Z AXIS FOR AUTOMATI
Page 30 and 31: PAGE 30
Page 32 and 33: MP3000-DTHC Screen SectionThe follo
Page 34 and 35: ALTERNATE SCREEN SET FOR SMART-KUTU
Page 36 and 37: To Adjust PRESET Volts (andheight)
Page 38 and 39: CURRENT SETTINGS BUTTON: Shows the
Page 40 and 41: INFORMATION GROUP:The Information s
Page 42 and 43: TIP SAVER %: This value determines
Page 44 and 45: GENERAL THC SETTINGSThe General THC
Page 46 and 47: FINAL TESTINGDoing a startup test u
Page 48 and 49: Kerf width: Sets the width offset u
Page 52: RAW ARC VOLTAGEPLASMA UNITTORCH SWI

DTHC-SETUP/INSTALL MANUAL CandCNC

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