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Summary of Contents for Hypertherm THC-2
- Page 1 THC-2 Torch Height Control Instruction Manual 800200 Rev. 6...
- Page 2 Torch Height Control Instruction Manual P/N 800200 Revision 6 September, 2002 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Hypertherm, Inc., 2002 All Rights Reserved HYPERTHERM is a trademark of Hypertherm, Inc. and is registered in the United States; International registration is pending.
- Page 3 63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 (Technical Service) Hypertherm Singapore Pte Ltd No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 841 2489 Tel...
- Page 4 The size of the surrounding area to be Earthing of Workpiece considered will depend on the structure of Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth the building and other activities that are tak- in compliance with standard EN50199. The for electrical safety, nor connected to earth ing place.
- Page 5 Hypertherm system. Any damage infringement, and Hypertherm’s obligation to indemnify shall be caused by the use of other than genuine Hypertherm parts may conditioned upon Hypertherm’s sole control of, and the not be covered by the Hypertherm warranty.
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Page 6: Table Of Contents
INSTALLATION - To Cutting Machine and Torch Lifter ....1-1 Install the THC-2 Control Module ................1-2 Mount the THC-2 Control Module ..............1-2 Connect the THC-2 Control Module to the Cutting Machine Computer Interface and Torch Lifter Motor ............1-3 SECTION 1a INSTALLATION - MAX100 or MAX100 ........ - Page 7 Figure 1-2 THC-2 Control Module Front and Rear Views ............1-3 Figure 1-3 Wiring Diagram - THC-2 to Cutting Machine Interface and Lifter Motor ........... 1-4 Figure 1-4 Typical DC Lifter Wiring ..................1-5 Figure 1a-1 Connections to MAX100 or MAX100 ..............
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Page 8: Description And Specifications
PAC-500/500L Plasma Control Console. The voltage divider reduces the arc voltage by a ratio of 25:1. Section 1 of this manual - Installation - describes mounting the THC-2 module and connecting it to the cutting machine computer and the torch lifter. Sub-sections 1a, 1b etc. describe hooking the THC-2 to Hypertherm products that utilize this type of torch-height control. -
Page 9: Installation - To Cutting Machine And Torch Lifter
Section 1 INSTALLATION - To Cutting Machine and Torch Lifter In this section: Install the THC-2 Control Module ............1-2 Mount the THC-2 Control Module ...........1-2 Connect the THC-2 Control Module to the Cutting Machine Computer Interface and Torch Lifter Motor ........1-3 Page 1-1 THC-2 Torch Height Control... -
Page 10: Install The Thc-2 Control Module
Interconnecting cable #023264 (Cable not available for PAC-500 systems) Mount the THC-2 Control Module 1. Mount the THC-2 Control Module in a convenient location for the operator. See Fig.1-1 for mounting dimensions. Note the length of the control cable (5 feet) that will connect... -
Page 11: Connect The Thc-2 Control Module To The Cutting Machine Computer Interface And Torch Lifter Motor
INSTALLATION - To Cutting Machine & Torch Lifter 2. To ensure proper grounding at the THC-2, run a #10 gauge copper cable from the ground stud on the rear of the THC-2 (Fig. 1-2) to a common earth ground. To correctly operate the THC-2 system, it must be grounded properly. -
Page 12: Figure 1-3 Wiring Diagram
INSTALLATION - To Cutting Machine & Torch Lifter 4. Feed the cable through one of the strain reliefs located on the THC-2 rear panel (Fig. 1-2). See Figure 1-3 for cable connections. Consult your cutting machine schematics, or call the cutting machine manufacturer for actual connections on the cutting machine interface. -
Page 13: Figure 1-4 Typical Dc Lifter Wiring
AUTO Double pole, single throw toggle switch - Mount in DOWN operator station Quantity (2), 2 pole, N/O relays, 115 VAC coils - Mount in the THC-2 115VAC 1TB-131 Jump to wire 106 on DC Power Supply 115VAC 1PS in THC-2... -
Page 14: Section 1A Installation - Max100 Or Max100
Section 1a INSTALLATION - MAX100 or MAX100 In this section: Mount the Voltage Divider to MAX100 or MAX100 ......1a-2 Install Interconnect Cable to MAX100 or MAX100 ......1a-2 Page 1a-1 THC-2 Torch Height Control... -
Page 15: Mount The Voltage Divider To Max100 Or Max100
MOUNT THE VOLTAGE DIVIDER TO MAX100 OR MAX100 Be sure to complete all steps in Section 1: Installation - To Cutting Machine & Torch Lifter - in addition to the following procedure for hooking the THC-2 to the MAX100 or MAX100 WARNING! -
Page 16: Figure 1A-1 Connections To Max100 Or Max100
INSTALLATION - MAX100 or MAX100 Voltage Divider MAX100 or MAX100 Harness 37 38 35 36 Interconnect Cable Figure 1a-1 Connections to MAX100 or MAX100 Page 1a-3 THC-2 Torch Height Control... -
Page 17: Section 1B Installation - Max200
Section 1b INSTALLATION - MAX200 In this section: Mount the Voltage Divider to MAX200 ..........1b-2 Install Interconnect Cable to MAX200 ..........1b-4 Page 1b-1 THC-2 Torch Height Control... -
Page 18: Mount The Voltage Divider To Max200
MOUNT THE VOLTAGE DIVIDER TO MAX200 Be sure to complete all steps in Section 1: Installation - To Cutting Machine & Torch Lifter - in addition to the following procedure for hooking the THC-2 to the MAX200. WARNING! The line disconnect switch for the MAX200 must be in the... -
Page 19: Figure 1B-1 Voltage Divider Template Location - Max200 Center Wall Right Rear
Figure 1b-1 Voltage Divider Template Location - MAX200 Center Wall Right Rear Lifting eye Top of MAX200 power supply Voltage divider mounting location Feed-thru White wire Figure 1b-2 Voltage Divider Mounting Location - MAX200 Center Wall Left Rear Page 1b-3 THC-2 Torch Height Control... -
Page 20: Install Interconnect Cable To Max200
4. Connect the white wire from the voltage divider to location #45 on R4 which is located on the left rear wall of the MAX200 power supply - Fig. 1b-4. This completes installation of the THC-2 to the MAX200. See Section 2 for operation instructions. -
Page 21: Figure 1B-4 Wiring Diagram - Thc-2 To Max200
INSTALLATION - MAX200 88 89 82 83 84 85 33 34 35 36 White Wire Voltage Divider Interconnect Cable SIGNAL RECP2 THC-2 Figure 1b-4 Wiring Diagram - THC-2 to MAX200 Page 1b-5 THC-2 Torch Height Control... -
Page 22: Section 1C Installation - Pac-500
Section 1c INSTALLATION - PAC-500 In this section: Mount the Voltage Divider to PAC-500 ..........1c-2 Install Interconnect Cable to PAC-500 ..........1c-3 Page 1c-1 THC-2 Torch Height Control... -
Page 23: Mount The Voltage Divider To Pac-500
MOUNT THE VOLTAGE DIVIDER TO PAC-500 Be sure to complete all steps in Section 1: Installation - To Cutting Machine & Torch Lifter - in addition to the following procedure for hooking the THC-2 to the PAC-500. WARNING! The line disconnect switch for the PAC-500 must be in the... -
Page 24: Install Interconnect Cable To Pac-500
1. The cable from the THC-2 to the PAC-500 console must be fabricated. Hypertherm recommends using 3-pair 22-gauge shielded cable. The cable will run between the plasma control console and the THC-2 module. Be certain to supply a cable that will reach between these two components. -
Page 25: Figure 1C-3 Pac-500/500L Plasma Control Consoles - 1Tb Location
Cable wire labeled 4 1TB terminal labeled 27 2 2 3 26 27 2 2 3 26 27 2 2 3 26 27 PAC-500 PAC-500L Figure 1c-3 PAC-500/500L Plasma Control Consoles - 1TB Location Page 1c-4 THC-2 Torch Height Control... -
Page 26: Figure 1C-4 Hf Compartment - Pac-500 Console
SIGNAL voltage divider terminal labeled GROUND Feed wires 5 and 6 through to other side Note: Internal components shown in HF Compartment may vary from your unit Figure 1c-4 HF Compartment - PAC-500 Console THC-2 Torch Height Control Page 1c-5... -
Page 27: Figure 1C-5 Top Rear View Of Thc-2
Figure 1c-5 Top Rear View of THC-2 9. Find the line filter (1F) on the inside of the THC-2 module - Fig. 1c-6. Solder interconnect cable wire labeled "2" to terminal that has THC-2 wire labeled 102 connected to it. -
Page 28: Figure 1C-6 Inside View Of Thc-2
#108 Solder wire labeled #2 to terminal labeled #102 Attach wire labeled #4 to terminal labeled #107 Attach wire labeled #6 to terminal labeled #119 (ground). Figure 1c-6 Inside View of THC-2 THC-2 Torch Height Control Page 1c-7... -
Page 29: Operation
Section 2 OPERATION In this section: Description of Controls and Indicators ..........2-2 Operating Instructions .................2-3 Notes on Operation ................2-3 Page 2-1 THC-2 Torch Height Control... -
Page 30: Description Of Controls And Indicators
Sets the delay time for the motion of the cutting machine after arc transfer. • UP/DOWN LEDs Indicates when the THC-2 gives the cutting machine a signal to move up or down. • POWER ON LED Indicates that the POWER switch to the THC-2 is on. -
Page 31: Operating Instructions
Operating Data or Cut / Gouging Chart section of your instruction manual. Adjust the torch height to the proper torch-to-work distance before starting cut. The THC-2 is now ready for operation and will be activated after the plasma START command is given. -
Page 32: Section 3 Parts List
Section 3 PARTS LIST In this section: THC-2 Torch Height Control Systems ..........3-2 Torch Height Control System for MAX100, MAX100 , MAX200 ..3-2 Torch Height Control System for PAC-500 ........3-2 THC-2 Interconnect Cable - #023264 ..........3-3 THC-2 Control Module - #053005 ............3-5... -
Page 33: Parts List
PARTS LIST THC-2 TORCH HEIGHT CONTROL SYSTEMS Torch Height Control System for MAX100, MAX100 , MAX200 Part Number Description Qty. 052002 THC-2 Torch Height Control MAX100/200 023264* Cable:MAX100/THC2 5' 041007** Volt Divider THC1/THC-2 053005*** Control Module, THC-2 800200 IM20:THC-2 Torch Height Control... -
Page 34: Thc-2 Interconnect Cable - #023264
Socket# 120VAC neutral Black 120VAC hot White Plasma Start White Plasma Start Brown Machine Motion Orange Machine Motion White Arc Voltage + White Arc Voltage - Figure 3-1 THC-2 Control Cable - MAX100/100 /200 Page 3-3 THC-2 Torch Height Control... -
Page 35: Figure 3-2 Thc-2 Front And Rear Panels
PARTS LIST 13 14 Figure 3-2 THC-2 Front and Rear Panels Page 3-4 THC-2 Torch Height Control... -
Page 36: Thc-2 Control Module - #053005
PARTS LIST THC-2 CONTROL MODULE - #053005 Part Item Number Description Designator Qty. 001037 Cov:THC-2 Rear Acs 029019 Card Cage SA:THC2 PC 001034 Pnl:THC-2 Fr 001035 Pnl:THC-2 Rear 001057 Pnl:THC-2 Top 001058 Pnl:THC-2 Bot 008068 Fuseholder:Pnl Mt 1P 1/4 X 1-1/4... -
Page 37: Figure 3-3 Thc-2 Interior
PARTS LIST Figure 3-3 THC-2 Interior Page 3-6 THC-2 Torch Height Control... - Page 38 PARTS LIST THC-2 CONTROL MODULE - #053005 (cont.) Part Item Number Description Designator Qty. 009040 Filter:3A 3WT AC Elek 014003 Xfmr:15VA 115V In/Out ISln 029019 Card Cage SA:THC2 PCB 041737 Relay PCB Assembly 003040 Rly:120VAC TD IceCube 003097 Rly:250VAC Sol State I/O Conv...
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Page 39: Figure 3-4 Voltage Divider -041007
PARTS LIST Figure 3-4 Voltage Divider -041007 Page 3-8 THC-2 Torch Height Control... - Page 41 2-5/16" (59mm) center to center 3-7/16" (87mm) center to center Voltage Divider Mounting Template for MAX200...
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