PoScope Plasma SensOut Torch Height Controller User Manual

Plasma SensOut Torch Height Controller
User Manual

Please read the following notes

1. All information included in this document is current as of the date this document is issued. Such information, however, is subject to change without any prior notice.
2. PoLabs does not assume any liability for infringement of patents, copyrights, or other intellectual property rights of third parties by or arising from the use of PoLabs products or technical information described in this document. No license, express, implied or otherwise, is granted hereby under any patents, copyrights or other intellectual property rights of PoLabs or others. PoLabs claims the copyright of, and retains the rights to, all material (software, documents, etc.) contained in this release. You may copy and distribute the entire release in its original state but must not copy individual items within the release other than for backup purposes.
3. Descriptions of circuits, software, and other related information in this document are provided only to illustrate the operation of the products and application examples. You are fully responsible for the incorporation of these circuits, software, and information in the design of your equipment. PoLabs assumes no responsibility for any losses incurred by you or third parties arising from the use of these circuits, software, or information.
4. PoLabs has used reasonable care in preparing the information included in this document, but PoLabs does not warrant that such information is error free. PoLabs assumes no liability whatsoever for any damages incurred by you resulting from errors in or omissions from the information included herein.
5. PoLabs devices may be used in equipment that does not impose a threat to human life in case of the malfunctioning, such as: computer interfaces, office equipment, communications equipment, test, and measurement equipment, audio and visual equipment, home electronic appliances, machine tools, personal electronic equipment, and industrial robots.
6. Measures such as fail-safe function and redundant design should be taken to ensure reliability and safety when PoLabs devices are used for or in connection with equipment that requires higher reliability, for example, traffic control systems, anti-disaster systems, anticrime systems, safety equipment, medical equipment not specifically designed for life support, and other similar applications.
7. PoLabs devices shall not be used for or in connection with equipment that requires an extremely high level of reliability and safety, as for example aircraft systems, aerospace equipment, nuclear reactor control systems, medical equipment or systems for life support (e.g. artificial life support devices or systems), and any other applications or purposes that pose a direct threat to human life.
8. You should use the PoLabs products described in this document within the range specified by PoLabs, especially with respect to the maximum rating, operating supply voltage range, and other product characteristics. PoLabs shall have no liability for malfunctions or damages arising out of the use of PoLabs products beyond such specified ranges.
9. Although PoLabs endeavors to improve the quality and reliability of its products, semiconductor products have specific characteristics such as the occurrence of failure at a certain rate and malfunctions under certain use conditions. Further, PoLabs products are not subject to radiation resistance design. Please be sure to implement safety measures to guard them against the possibility of physical injury, and injury or damage caused by a fire in the event of the failure of a PoLabs product, such as safety design for hardware and software including but not limited to redundancy, fire control, and malfunction prevention, appropriate treatment for aging degradation or any other appropriate measures.
10. Usage: the software in this release is for use only with PoLabs products or with data collected using PoLabs products.
11. Fitness for purpose: no two applications are the same, so PoLabs cannot guarantee that its equipment or software is suitable for a given application. It is therefore the user’s responsibility to ensure that the product is suitable for the user’s application.
12. Viruses: this software was continuously monitored for viruses during production, however, the user is responsible for virus checking the software once it is installed.
13. Upgrades: we provide upgrades, free of charge, from our website at www.poscope.com. We reserve the right to charge for updates or replacements sent out on physical media.
14. Please contact a PoLabs support for details as to environmental matters such as the environmental compatibility of each PoLabs product. Please use PoLabs products in compliance with all applicable laws and regulations that regulate the inclusion or use of controlled substances, including without limitation, the EU RoHS Directive. PoLabs assumes no liability for damages or losses occurring as a result of your non-compliance with applicable laws and regulations.
15. Please contact PoLabs support at support.poscope.com if you have any questions regarding the information contained in this document or PoLabs products, or if you have any other inquiries.
16. The licensee agrees to allow access to this software only to persons who have been informed of and agree to abide by these conditions.
17. Trademarks: Windows is a registered trademark of Microsoft Corporation. PoKeys, PoKeys55, PoKeys56U, PoKeys56E, PoKeys57U, PoKeys57E, PoKeys57CNC, PoScope, PoLabs, PlasmaSens, and others are internationally registered trademark

Description

PlasmaSensOut is a universal torch height controller (THC) for use with the PlasmaSens torch height sensor device. Thanks to an optical connection, it is fully electrically (galvanically) isolated from high voltage plasma cutter’s equipment and so it is safe to use.
The device supports a wide range of plasma arc voltage (from 45V up to 265 V).
PlasmaSensOut provides standard programmable ARC OK, UP, and DOWN signals and it’s compatible with most CNC controller boards on the market. A simple user- friendly interface allows quick and efficient moving through the menu using three menu buttons. Led display in default state shows current arc voltage and led diodes to signalize the state of the output. Users can set the following THC parameters: reference voltage, hysteresis (non-active range around the reference height), the delay time for outputs, and anti-dive limit voltage. All parameters can be modified during operation and the last setup is saved. An additional feature “test mode” allows easy torch height setup without plasma arc being in operation.

Features

• Output signals: Arc Ok, Up, and Down (normally-open solid-state relay outputs)
• Programmable reference and hysteresis voltage, delay time, and anti-dive limit voltage
• Current plasma voltage presentation on the LED display
• LED signalization of arc present, up and down signals
• Full optical input isolation; transmitter and receiver connected over an optical cable
• Test mode operation
• Wide power supply voltage range (6 – 36 V)
• Compatible with most CNC controller boards
• DIN-rail mountable housing

Connectors and pinout

Connection to PlasmaSens and CNC controller board

PlasmaSensOut requires a DC power supply. The voltage applied can be from 6 V to 36 V. Use the provided optical cable for optical connection with PlasmaSens. Make sure that the connector on the optical cable is fully inserted.
Read the PlasmaSens user’s manual for detailed information on how to connect PlasmaSens to plasma cutter equipment!
All outputs signals are isolated. Solid-state relays are used.

Please refer to your CNC controller board’s manual for detailed information about input ports.

Users interface

Parameters can be modified during operation and will immediately affect the output signals! PlasmaSens will automatically save the last settings.
During the plasma cutter’s operation, the current arc voltage is shown on the display.
If there is no arc voltage present, the display shows – – -.
The reference voltage (Ref) can be set by pushing V (left) or ꓥ (right) button. (During operation the green (OK) led flashes when a reference voltage is setting). Users can set Ref from 45 V to 265 V. Factory setting 180 V.

Setup menu

To enter a setup menu press and hold the • (middle) button for one sec. The LED display will start flashing then the setup menu will appear.
Select the parameter by pressing the • button. Press V / ꓥ button to modify the parameter’s value.
Set – Set delay time from 0.1 to 9.9 sec. The time between Arc OK signal appears and generation of signals up and down is enabled. Factory setting 0.5 s.
HYS – Hysteresis from 2V to 32 V (2 V step). Voltage frame around the reference. If arc voltage is higher than Ref + HYS/2 then a down signal is generated. If voltage is lower than Ref – HYS/2, an up signal is generated (see the output signal example below). Factory setting 6 V.
ADL – Ant-dive limit from 50 V to 300 V. Arc voltage that disables THC. If the voltage goes higher than the Anti-dive limit all output signals go low. The parameter’s value must be set higher than the reference voltage. Factory setting 220 V.
tSt – Test mode. Only available when no arc voltage is present! Pressing V or ꓥ button generates output signals. The display indicates direction.
To leave a setup menu, do not press any button for around 2 seconds.
In case of communication failure E – I is shown on the display. Please check the optical cable is properly inserted on both sides and that the PlasmaSens sensor device is turned on.

Mach3 – PlasmaSensOut configuration using PoKeys57CNC

Download and install the latest PoKeys Mach3 plugin from www.poscope.com. Look for the PoKeys setup package, which also includes the Mach3 plugin.
In Mach3 software under Plugin, Control-> Configure PoKeys57CNC->Device settings you will find the PoKeys mapping tab. Map connected pins as shown below. In our example, we select PoKeys pins 8, 12, and 13 as input. In the Pulse engine settings tab at THC, settings-axis Z selects Up/Down signals.

Note: PlasmaSenseOut should not be configured with a separate ‘PlasmaSens’ option in the PoKeys plugin configuration dialog. PlasmaSens option is used with direct connection of the optical cable to PoKeys57CNC via PlasmaSens interface.

Mach4 – PlasmaSensOut configuration using PoKeys57CNC

Download and install the latest PoKeys Mach4 plugin from www.poscope.com. Unzip and copy files:
Mach4PoKeysPlugin.m4pw and Mach4PoKeysPlugin.sig to “Mach4\Plugins” folder.
Run Mach4 (Plasma profile)

• Go to Configure –> Control… -> Axis Mapping tab enable axis X (0), Y (1), Z (2) and OB1 (6)
  

• Under the Motors tab enable Motors for X (0), Y (1), Z (2), and OB1 (6). The motor tuning settings for Motor5 (OB1 (6)) must match those of Motor 2 (Z)!

Please read also Mach4 user’s documentation located in the Mach4 folder under Docs\Plasma_Configuration.pdf

• Configure –> PlasmaScreenConfiguration Set Default THC mode: Digital; THC Axis: 6
  

• Configure –> Control… -> Input Signals tab. Select PoKeys input pins for THC On, Up and Down signals

• Use Mach4 THC Cut Start Settings and THC tab to set up cutting parameters. If “Touchoff” is included the Probe input must be mapped! (Configure –> Control… -> Input signals tab)

Grant of license

The material contained in this release is licensed, not sold. PoLabs grants a license to the person who is using any compatible PoLabs product, subject to the conditions listed below.

1. Access
   The licensee agrees to allow access to this manual only to persons who have been informed of and agree to abide by these conditions.

2. Usage
   The information in this release is for use only with PoLabs products.

3. Copyright
   PoLabs claims the copyright of and retains the rights to, all material (software, documents, etc) contained in this release. You may copy and distribute the entire release in its original state, but must not copy individual items within the release other than for backup purposes.

4. Liability
   PoLabs and its agents shall not be liable for any loss or damage, howsoever caused, related to the use of PoLabs equipment or software unless excluded by statute.

5. Fitness for purpose
   No two applications are the same, so PoLabs cannot guarantee that its equipment or software is suitable for a given application. It is therefore the user’s responsibility to ensure that the product is suitable for the user’s application.

6. Mission Critical applications
   Because the software runs on a computer that may be running other software products and may be subject to interference from these other products, this license specifically excludes usage in ‘mission-critical applications, for example, life support systems.

7. Errors
   This manual was continuously monitored for errors during production, however, the user is responsible for error checking the manual once it is used.

8. Support
   There could be errors in these manual, but if you found some, please contact our technical support staff, who will try to fix the problem within a reasonable time.

9. Upgrades
   We provide upgrades, free of charge, from our website at www.poscope.com. We reserve the right to charge for updates or replacements sent out on physical media.

10. Trademarks
    Windows is a registered trademark of Microsoft Corporation. PoKeys, PoKeys55, PoKeys56U, PoKeys56E, PoKeys57U, PoKeys57E, PoKeys57CNC, PoScope, PoLabs, PoExtBus, PoExtBus Smart, PoRelay8, PlasmaSens, and others are internationally registered trademarks.

support: www.poscope.com

References

• PoLabs Support
• PoLabs web store - Polabs
• PoLabs web store - Polabs

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