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IHT 3000

1. COSA Rede Eor abe pF ae E eee IN TS KS Cy Co EY a hoy Ke 310 OO AA O N oO O lt g oO O ur x g 76 A ON Ca Aa EN EF A A N NP NP New Na LS a Co Cy EY Cy CO HE Oe SEI ZI TZV EP ZEE ZEP IE ED PEN amp gt gt A Machine rear mounting plate 5 9 IHT 3000 Clearance Control System e h User s Manual i System Components Top View LINEAR DRIVE IHT 2346 Heavy Load Version Electrical connectors Dimensions in millimeters 140 Linear Drive Control Cable Linear Drive Power Cable O PE on Grounding Terminal ye EN connected to machine ground Coax Cable connector for capacitive mode Important Notes for usage AN WARNING Don t touch the Linear Drive at the bellow The bellow could be damaged A damaged bellow must be exchanged because infiltrating dust can damage the mechanics Check the bellow to make sure that the folding is not buckled inwards Rev 2 9 IHT 3000 Clearance Control System e h User s Manual i System Components 5 3 Capacitive Sensor Components for Oxyfuel Cutting Option C
2. IHT 6531 Oxyfuel Torch mounted at Linear Drive Rotate to centre ring electrode RING ELECTRODE Type IHT 6534 6560 6575 Optional Outer 34 60 75 mm N lt lt INN es e g Ring Electrode 14 mm for T R I GIG Wo rk plece LLL a a A AAAA A L N approx 3 4 mm to lower edge of the nozzle tip Ring Electrode types and appropriate clearance Note Ring Electrode 6534 is primarily used for oxyfuel torches Rev 2 9 6 23 IHT 3000 Clearance Control System M a t User s Manual Installation 6 26 Interface Inputs for Capacitive Mode Bold printed functions No 8 13 14 and 15 are for oxyfuel operation Input Voltage Description to Activate Function Piercing Height Oxyfuel Pierce height for oxyfuel cutting BET DEE EEE a Start Clearance Control Clearance control for oxyfuel cutting active 24V a on oe O e who i omen O SS er e a Rev 2 9 6 24 IHT 3000 Clearance Control System M a t User s Manual Installation 6 27 Interface Output for Capacitive Mode Bold printed functions No 1 2 11 12 and 13 are for oxyfuel operation Output Output Voltage Contact Description to Nr Activate Function Interface Power 24V Operating voltage connection for 24 V stabilized Interface Ground Power Ground 0 V reference potential for input output signals to CNC 3 Collision Collision Attention Negated output No Collision 20V Enable Ignition Ign
3. Connecting cables can be found in table chapter Devices and spare parts Rev 2 9 5 21 IHT 3000 Clearance Control System h t User s Manual i System Components 5 8 OPERATOR TERMINAL IHT 7261 Handheld Version Technical Data Dimensions of housing 200x160x61 mm VISION essen ca 1 35 kg IF pari NO euere enden 100406 with 5 m connecting cable IHT part no uusn24eenennenenee nennen 100407 with 10 m connecting cable Rev 2 9 5 22 System Components 5 9 OPERATORT Parameter Cutheight Dependent on choice o control mode Cutting Height Pierce Delay Pierce Height lt lt gt B Elevation Height Control Delay Retract Position Upper Threshold Dynamic Gas Pre Flow End of Cut Mode Select ARC Voltage Cutting Height Capacitive Height Select mm inch System Properties English System Parameters Startup Time K Device Info Serial No Hardware Version Software Version Rev 2 9 IHT 3000 Clearance Control System User s Manual ERMINAL Menu Overview Operator Terminal 7260 Display Cutting Height Ideal Voltage Real Voltage Parameter Favorite A V lt gt N A V Commands S Reset Regulator Off Threshold Off for kerf and edge detection Scrap Cut Status Info Status Corner Ref Position Upper Treshold Cap Active Control Active Cycle active Real Voltage 122 5
4. INTERFACE OPERATOR TERMINAL A ooo Yi ARC voltage from plasma source LINEAR DRIVE with initial position finding Rev 2 9 4 1 IHT 3000 Clearance Control System e h User s Manual i 5 System components and technical specifications 5 1 General Technical Data POWEFSUDDN aussen CUNEN ee ee Revers voltage protection u04444Re nennen Initial Position Findings Clearance control in plasma mode ACCU ACY as ale ea ee ee ee Clearance control in oxyfuel mode 0 Nominal clearance measured between bottom line RING ELECTRODE and work piece RING ELECTRODE 6534 u ee RING ELECTRODE 6560 Na RING ELECTRODE 575 su anne anenee ACCU ACY en ae E E E 24 VDC 10 EP 6 5 A max built in tactile or touch less by nozzle sensor for dry cutting with plasma torch capacitive clearance control for dry cutting with oxyfuel torch ee by plasma arc voltage BEN appr 0 3 mm hed bos by capacitive measurement with RING ELECTRODE 8mm 14 mm 16 18 mm approx 0 3 mm with Ring Electrode Depends on the diameter of the Ring Electrode and the mounting conditions of the environment These parameters data are guaranteed with IHT components This sensor system conforms to CE Rev 2 9 5 2 Rev 2 9 LINEAR DRIVE IHT 3000 Clearance Control System h t User s Manual i Features e fa
5. 0 f0to 300V________ Oto 300V____ Linear Drive X203 Interface IHT 7250 Terminal X201 JO OOO OOOO OQOOOOQO OO ht 5 18 System Components IHT 3000 Clearance Control System User s Manual 5 6 3 Output Connector X305 17 pole connector with srew on clamps COOOOOOOG00000900 Linear Drive X203 Interface IHT 7250 Terminal X201 JOOGCOOOQDOO0O0000 Interface IHT 7250 X305 Power N gt Q gt O c D u Note Interface Power 24V Interface Ground Plasma Start relay contact input Plasma Start relay contact output 6 Ok to Move Upper Limit 8 Delay Time 9 Plasma Start Control Active Error Collision Enable Ignition Oxyfuel Reference Retract Position Separate Ignition Plasma Reference Position 0 AddressO i Address 1 2 Address2 3 Address3 IE EEE The detailed description can be found in chapter Installation Rev 2 9 EE Ee a8 17 RUN Fault Cutbus X202 N ol 9600 apao 2 1920_ 3 28800 4738400 O ht 9 19 IHT 3000 Clearance Control System e h User s Manual i System Components INTERFACE IHT 7250 5 6 4 Connector X202 Cutbus Interface RS 485 Connects to CUTBUS CABLE IHT 7250 1 904 5 Using SUB D 9 pole Male with other side open ended to connect CUTBUS with machine control CNC SUB D 9 polig female Contact Function Not used 5 6 5 Connector X201 Operator Terminal e e Interf
6. down with the keys MANUAL UP and MANUAL DOWN Rev 2 9 1 4 IHT 3000 Clearance Control System User s Manual 7 6 Check of Collision at LINEAR DRIVE Manually drive the LINEAR DRIVE into middle position A N A N JN JN N IN V Y V V Y JS N AN N AN IN Push the torch until the collision indication appears at the Operator Terminal ur 7 A NY J N A N O O Rev 2 9 7 5 IHT 3000 Clearance Control System User s Manual 8 Operation and Setup 8 1 Settings at the Operator Terminal 8 1 1 Setting of Language Operator Terminal 7260 Display Cutting Height Ideal Voltage Real Voltage Parameter Cutheight A V System Properties English S lt gt System Parameter Device Info Rev 2 9 8 1 IHT 3000 Clearance Control System User s Manual Operation and Setup 8 1 2 Setting of Operation Modes 3 Operation Modes 1 ARC Voltage Cutting height will be set via arc voltage setting This mode can be used for test cuts Example 130 0 V 2 Cutting Height Cutting height will be directly set in mm This is the standard operation mode Example 2 5 mm 3 Capacitive Oxyfuel This mode will be used for oxyfuel flame cutting with ring electrodes Example 50 relative value no a
7. htautomation Clearance Control Systems for IHT 3000 thermal cutting machines Abstandsregelungssysteme f r thermische Schneidmaschinen User Manual IHT 3000 Torch Clearance Control System for Plasma and Oxyfuel Cutting Machines 20g AR Rev 2 9 July 1 2009 IHT Automation GmbH amp Co KG Bahnhofstra e 63 Phone 49 7221 39419 0 Internet www iht automation com 76532 Baden Baden GERMANY Telefax 49 7221 39419 70 E Mail info iht automation com Handelsregister Mannheim HRA 201231 Pers nlich haftende Gesellschafterin IHT Innovationsgesellschaft f r HF Technik in der Industrie Verwaltungsgesellschaft mbH Mannheim HRB 201211 Gesch ftsf hrer Kurt Nachbargauer IHT 3000 Clearance Control System e h User s Manual i Content 1 Pr O E E E ee ee ee eee 1 1 COM CCE USIJE ane E E E Ei 1 1 2 Safety instructions anne a aaa ea a a aG 2 1 3 IHT 3000 Application and System Description u 22020220000 n000nnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnn 3 1 A System OVeIVIEW in a 4 1 5 System components and technical specifications uurus0 n000nn nn0nnnnnnnnnnnnnnnnnnnnnnnn nun 5 1 5 1 General Technical Data 02 20002400022000000nn0nnnnnonnnnn nenne nenne nnnnne nenne nnnnne nenne nnennennnnnnenenn 5 1 5 2 LINEAR ORIVE ee ee ee ne eines neh sehe 5 2 5 3 Capacitive Sensor Components for Oxyfuel Cutting Option cceecceeseeeeeeaeeeeeeseeeeeeeaees 5 7 5 3 1 RING ELECTR
8. ie inde deus shaawendoweneonweds 8 1 8 1 1 SENGO Lal AC Gs sn EE EE EEE EE E EEA EE 8 1 91 2 OSUING OF OPESlavlOn MOdES scssi nn iek eu 8 2 8 1 3 AEG eNOS sariaren E EEE E reine 8 3 8 14 Commands and Sal sense nee einem 8 4 8 1 9 TAC TINS MON ek oases ah E eure 8 5 8 1 6 Additional Functions of Push ButtONs cc ccceccceceeeeeeeeeeeeeseeeeesseeeeeeseeeeesaeeeeessaeeessaaes 8 6 8 2 Signal Flow during Plasma Cutting us aa 8 7 8 3 End oF CUMING Relract Poslli na n uss nenne aaa 8 8 8 4 Plasma Arc BIEAKOOWI ee ee een 8 8 8 4 1 Detection of Kerfs and Edges during Cutting uus22240000n0nnne nenne nennen nnennnn nennen enennnnn nenn 8 9 ee IN a een een 8 10 8 4 3 Procedure with Gas Pre Flow ccccccescecseeeceeeeecesceceaeeeceaeeeseucesseecessaeeessaeeesaeeesansessaees 8 11 8 5 Operational Workflow and Control during Oxyfuel Cutting ccc ecceceeeeeeeeeeeeeeeeeeeesaeeeeeens 8 13 8 6 Operating of NOZZLE SENSOR unseren inne 8 15 8 7 Activating and Deactivating of the touch less Initial Position Finding by NOZZLE SENSOR 8 15 8 8 Reierenee MOVEmehl ern ee ee 8 16 8 9 Troubleshooting at NOZZLE SENSOR ana 8 1 9 IARI IN een ee 9 1 10 Devices and Spare Panls escorts sense ende iccoentoeicuncoveseccsaneceect eceesuanseoneatacduaeceuececceia 10 1 11 Troubleshooting nie 11 1 11 1 Fault Indication and Reset at the OPERATOR TERMINAL 222200022200nnnnnee nennen een 11 1 12 REVISION EIISIOFV ssori
9. A Suitable for operating a LINEAR DRIVE e Operates with supply voltage 110 230 VAC 50 60 Hz selectable Technical specifications DimensionsS uuusnesneeneneenennennenne nennen 199x110x50 mm Length x Width x Height Input AC Voltage 2222ennneeneeenennnnnnen 88 132VAC 3 2A or 176 264VAC 1 6A selectable FIELEN Gy ee meets 50 60 Hz Output DC Voltage 22uu0224sennenneeen 24VDC stabilized 6 5A max Protection class u 44404n nenn IP 20 acc EN60529 IEC529 Environment conditions 0 40 C 20 90 relative humidity Weight unseren ee 0 8kg IAT pa Osis cesses res 100229 Input Voltage switch 230 VAC 115 VAC Attention Pre selected to 230 VAC Supply Voltage Phase L 230VAC protect externally with 1 6AM medium slow Supply Voltage Phase N 230VAC D PE Protective Earth Connector V Output OV Output 24VDC 6 5A Ground GND Protect externally with 10AT slow Rev 2 9 5 14 IHT 3000 Clearance Control System e h User s Manual i System Components 5 6 INTERFACE IHT 7250 The Interface IHT 7250 is the central signal distribution point fort the IHT 3000 System gt Hs m F Features Rev 2 9 Power supply 24 VDC 0 5A Connector to LINEAR DRIVE Connector to OPERATOR TERMINAL Interface for CUTBUS used for serial communication to CNC Discrete Input Output terminals 24 VDC to connect IHT 300
10. Environment Temperature 25 to 75 C Relative Humidity 2000442 no non condensing 5 to 95 HOUSING ee E plastic housing 111x72x25 mm Length x Width x Height Mounting of Housing u on symmetric mounting rail according to EN 60715 or mounting provided parts on a mounting plate Connection Cable for USB 1 8 m included in delivery USB connector type A to type B Driver Supported u02222022220022nn0 02 Windows98 ME 2000 XP Linux IHT DAVE NO ae 100400 Note ATTENTION The use of this converter is recommended to get a data transfer without any problems If another type of converter will be used it must be free of switch over time Additional technical data and information for installation are enclosed as a separate user manual for each device Rev 2 9 5 25 IHT 3000 Clearance Control System User s Manual System Components 5 12 Connecting Cable INTERFACE ges Operator Terminal Cable IHT 7260 1 901 eae lt lt OPERATOR TERMINAL Linear Drive Control A er Cable IHT 7250 1 901 Cutbus Cable IHT 7250 1 904 Cable IHT 2300 1 901 __ i f m a SUPPLY i te Linear Drive Power EAI ip POWER LINEAR DRIVE Coax Cable IHT IHT 1991 1 100 6 Operator Terminal Gabe length 10m ir rzeo roorno 100365 a cubus Cate lenghsm __ _ fmrrzeomsam ae o Cubus Cate nam 10m fmrrzsonsoane je Rev 2 9 5 2
11. Plasma Start relay contat No function O6 Ok To Move Dem Tm 9 Plasma Start Control Active active Enable Ignition Oxyfuel Reference Retract Position Power Ignition Separate Ignition Plasma g Rev 2 9 6 20 IHT 3000 Clearance Control System i h t User s Manual Installation 6 21 Mounting of the OPERATOR TERMINAL IHT 7260 6 22 Drawing for Installation 16 6 23 OPERATOR TERMINAL Electrical Connection The Operator Terminal Cable IHT 7260 1 901 connects the Operator Terminal with the connector X201 at the Interface The power supply is provided by this cable as well OPERATOR TERMINAL CABLE IHT 7260 1 901 See oOo Se Oe Slee oe N Rev 2 9 6 21 IHT 3000 Clearance Control System i h t User s Manual Installation Attention when mounting the operator panel Connect PE Terminal to PE potential of machine grounding Faston connector 6 3 mm Wire gauge 0 75 qmm on PPr not used fe f j 7 7 N ar oz T 3 not used PR h he Connection for OPERATOR TERMINAL CABLE 6 24 Default Setting of DIP Switch Do not change this setting on E I E E OFF Eg Rev 2 9 6 22 IHT 3000 Clearance Control System User s Manual Installation 6 25 Mounting of the Sensor Components for Capacitive Mode Option Connection to LINEAR DRIVE COAX CABLE IHT 1991 Hose Clamp SENSOR CONNECTOR UNIT
12. The prime initial position finding is a reference movement where the nozzle of the plasma torch touches the metal sheet softly All following movements of finding initial position will be done touch less by high speed Especially the position of thin metal sheets can be detected This is useful for a metal sheet which has a thickness of 2 mm or less So there is no risk of deformation of the metal sheet during finding the surface The NOZZLE SENSOR accelerates the initial position finding because the cycle time from cut to cut will be minimized by high speed movement Reduced Cycle Time from Cut to Cut by the NOZZLE SENSOR Tactile Initial Position Finding NOZZLE SENSOR Position of Torch Pierce Height Pierce Height FI AE eee ae eee lt lt educed time Rev 2 9 5 11 IHT 3000 Clearance Control System e h User s Manual i System Components Requirements for the NOZZLE SENSOR Rev 2 9 The NOZZLE SENSOR is suitable for plasma cutting without the influence of water It must be checked if the used type of plasma torch is suitable to operate with the NOZZLE SENSOR IHT provides a listing of suitable plasma torches For each type of plasma torch respectively manufacturer a different clip may be necessary The clip is part of the NOZZLE SENSOR Please contact IHT to get useful information The clip must be isolated from the cap Therefore the clip is coated with an isolating layer If the isolation is damage
13. a RESET Pushbutton il Select COMMANDS Mark RESET and enter by pushbutton OK IHT 3000 Clearance Control System M fa t User s Manual j 9 Maintenance All components are free of maintenance except the SENSOR TORCH CLAMP and RING ELECTRODES The RING ELECTRODES may be influenced by hot and molten metallic splashes during the cutting process and should be exchanged if necessary ATTENTION The SENSOR CONNECTOR UNIT 6531 torch clamp should be kept clean Dust deposition may influence its function Cleaning housings e Switch power off e Dirt and grease may be removed using a cloth dampened with a mild detergent and water solution e To prevent damage avoid using chemicals that contain benzine toluene xylene acetone or similar volatile solvents Also avoid abrasive cleaners e Dry the surfaces carefully Rev 2 9 9 1 IHT 3000 Clearance Control System e h n User s Manual 10 Devices and Spare Parts 1 Linear Drive IHT 2343 1 100 V01 100354 Tactile initial position finding Load capacity 12 kg 2 Linear Drive IHT 2343 1 100 VO3 100725 Additionally provided for operation with Ring Electrode and Nozzle Sensor touch less initial position finding Linear Drive IHT 2346 1 100 100354 Tactile initial position finding Load capacitiy 30 kg 5 Linear Drive Coni Gabe ong 10m iT 725010170 nase 6 e conoi cae nonzom ___ Immrsersnm mm Linear Drive Power Cable length 10 m IHT 2300 1 901 10 100361 ner
14. appropriate electrical safety regulations e In particular the accident prevention regulations DIN VDE 0100 Directions for the erection of power plants with nominal voltages up to 1000 volts and the European standard EN 60204 1 Machine safety electrical equipment of machines regulations must be followed WARNING AN Never put your hand under the ring electrode or the torch e ATTENTION Parts mounted close to the ring electrode can influence the height control e ATTENTION The capacitive mode with ring electrodes may not be used with water Water influences the sensor system and causes malfunction Protect the capacitive sensor system from water and dampness Rev 2 9 7 1 IHT 3000 Clearance Control System i h p User s Manual Start up 7 2 Requirements and Hints for first Start up Are all cables and wires connected and locked properly 2 Can the torch move in all directions Is the linear drive in vertical direction and mounted correctly 3 Are the torch and the cable hose mounted correctly weight compensation and collision protection set properly Are all settings and signals from and to IHT 3000 correct 5 Are all grounding connections from the IHT 3000 system to the cutting machine and all cable shields connected to machine ground as described in the instructions Is the power supply 24V stabilized 6A of the IHT 3000 System installed properly Is the resistance between ground and earth of
15. is called initial position finding 1 when cutting with plasma e tactile by softly touching the work piece or e touch less with the nozzle sensor 2 when cutting with oxyfuel e capacitive with a ring electrode Touch less height control The height control takes place during the cutting process 1 when cutting with plasma e measuring of electrical voltage of the plasma arc 2 when cutting with oxyfuel e clearance control of the ring electrode based on the capacitive measuring principle Rev 2 9 3 1 IHT 3000 Clearance Control System User s Manual IHT 3000 Application and System Description Movement of torch Initial lgnition Cutting gt Position Torch Pierce Height N Cutting Height Clearance Control Active Plate Time P Note IN Under water cutting or cutting with water table can only be done in tactile mode Rev 2 9 3 2 IHT 3000 Clearance Control System User s Manual 4 System Overview The vertical torch movement for initial position finding and clearance control is handled using the IHT LINEAR DRIVE The built in electronics in this LINEAR DRIVE processes all control signals from the CNC and the plasma arc voltage for height control The INTERFACE connects to the CNC machine control to the plasma sources for receiving the plasma arc voltage and connects to the OPERATOR TERMINAL System overview CNC Machine Control
16. makes a reference movement calibrating the sensor system The speed downwards is lower as in normal operation until the torch touches the metal sheet softly If the reference movement fails the cutting cycle starts by a tactile initial position finding Starting the following cutting cycle the system tries a reference movement again If this fails a tactile initial position finding will be done again This sequence is repeated at each cut until a successful reference movement of the NOZZLE SENSOR was found It is possible to cause a reference movement by a manual RESET command at the OPERATOR TERMINAL This is recommended if parts of the nozzle or of the sensor system are exchanged RESET at OPERATOR TERMINAL Pushbutton il Select COMMANDS Mark RESET and enter by pushbutton OK If the IHT 3000 LINEAR DRIVE is not in the upper reference position it moves automatically to this position and is ready for the prime initial position finding Rev 2 9 8 16 IHT 3000 Clearance Control System M by t User s Manual Operating and Setup 8 9 Fault Rev 2 9 Troubleshooting at NOZZLE SENSOR CAP is not indicated at the display of the Operator Terminal while the LINEAR DRIVE is at reference position Check the shielding and grounding of XY motor cables of the cutting machine Check of wiring Check of grounding at SENSOR TORCH CLAMP Check of insulation of the clip at the nozzle Remove the cap at the torch and clean inside Make
17. menu Device Info Former versions have a fixed threshold of 30V The variable value has been introduced to minimize the delay time until the arc voltage has dropped down at the end of cut Therefore the time is short between cuts 8 4 Plasma Arc Breakdown It is possible that the plasma arc breaks down during cutting process The Linear Drive moves back up to the reference position as arc voltage is missing and the clearance control cannot operate anymore Rev 2 9 IHT 3000 Clearance Control System e h n User s Manual Operation and Setup 8 4 1 Detection of Kerfs and Edges during Cutting This feature avoids that the plasma torch moves down into the kerf which has already been cut whilst moving across If the adjustable Upper Threshold exceeds the limit during cutting the clearance control will be switched off when crossing kerfs Crossing Kerf Work piece A Ose ele nn aa es e g 125V BE ARC Voltage gt e g 120V gt Time Track Gearan Conte on ie Va Clearance Control off e A Display at Operator Terminal u in the Status Menu pr aa Rev 2 9 8 9 IHT 3000 Clearance Control System M fa t User s Manual Operation and Setup 8 4 2 Scrap Cutting The automatic finding of initial position is disabled when scrap cutting is activated The IHT 3000 system sets the following parameter automatically Pierce Height 0 mm Retract Position 0 mm P
18. nan EEEE A AE ENEE EEA 12 1 13 APPEND iaai recusutiasecutconsiconctswecaveansecunmassicsixtancdenxemcineeontiuesnens 13 1 13 1 Grounding a Cutting Machine 0004444000B0ennnn nennen nennen nennen nnennnnnnnnnnn nennen nennen 13 1 13 2 Grounding a Cutting Machine u004444000B0ennnennennnn nennen nnennnnnnennnnnnnnnnnnnennnnnnennnnnnnnn 13 1 13 3 Notes to the Plasma Current Return Path 2u0s04024000B0nnn nennen nennen nennen ennennne nenne 13 3 13 4 Notes about a Proper Electrical Contact u2 20022020022n0ennnnnnnennnennnnnnnnnnennnnnenennnnen 13 3 Rev 29 008 IHT 3000 Clearance Control System e h User s Manual i 1 Preface Correct Usage This manual explains the correct usage of the IHT 3000 which will be integrated in a machinery Risks caused through other than the described use underlie the responsibility of the user WARNING AN To avoid fatal errors and for work safety this manual must always be used in combination with the manuals of the machinery Any other than the described use is not intended Only the use of spare and wear parts recommended by IHT guarantee the correct usage of this system within the machinery Only authorized well informed and qualified personnel who is aware of the dangers is allowed to work with maintain or repair the machine and the system All relevant accident prevention regulations as well as all other genera
19. pin 3 March 17 2009 6 Table at page 6 12 exchanged due to revised arc voltage input Detailed explanation of output signal Reference Retract Position July 3 2009 wu Nozzle Sensor added Rev 2 9 12 1 IHT 3000 Clearance Control System i fa f User s Manual j 13 Appendix 13 1 Grounding a Cutting Machine This information and recommendations which are described here should help to understand the importance of correct machine grounding Furthermore all manufacturer installation instructions for cutting machines and plasma sources must be complied with The accurate grounding of plasma cutting machines is one of the most important parts to ensure proper functioning This prevents electromagnetic interference EMI problems which can disturb electrical devices and causes a malfunction The aim is to achieve low electrical impedance from machine ground to earth ground This is described below Attention AN It implicates an improper use if no sufficient grounding is provided 13 2 Grounding a Cutting Machine All components of the machine which need grounding must be connected to a single star point Preferably this star point is affixed at the cutting table and is connected to a ground rod by a suitable cable The distance to the star point should be less than 3 meters The resistance to ground should be less than 1 Ohms All metallic parts of the machine servos control console and height control components mu
20. the plasma source less than 3 Ohm All shields of cables going to the plasma source should not be connected at the plasma source They must be connected in the control cabinet with the shortest possible connection to the machine ground 7 3 Checking of Grounding These components e POWER SUPPLY 7504 IN e LINEAR DRIVE 2343 e SENSOR TORCH CLAMP 6530 must be connected to machine ground PE as described in the installation instructions to obtain a safe and reliable operating system Rev 2 9 1 2 IHT 3000 Clearance Control System i h t User s Manual Start up 7 4 Power On 1 The LINEAR DRIVE moves the torch up to the upper reference position 2 Operation check at the Interface Both green LED s should be on 3 Checking of operation at the Operator Terminal After the power is switched on an initialization process runs for approx 5s The green LED at the Operator Terminal is on Firmware Version and Date Status of Initialisati Active Keys gt nitialisation Rev 2 9 1 3 IHT 3000 Clearance Control System i h t User s Manual Start up After initialization the main menu appears If the terminal displays Communication Error the serial communication has failed At the same time the yellow LED will flash Correction Check the power to LINEAR DRIVE Check the connection to OPERATOR TERMINAL CABLE 7 5 Checking of LINEAR DRIVE functions Move LINEAR DRIVE up
21. 0 to CNC machine control system 2x17 removable screw terminal strips Special coding avoid mix up Integrated isolation amplifier for ARC voltage 0 10 VDC und 0 300 VDC from the plasma source 3 rotating knobs to set Device address of Cutbus Baud rate for Cutbus optional range for ARC voltage LED s for Ready Communication and Fault Assembly on top hat rail for installation in a control cabinet 5 15 IHT 3000 Clearance Control System e h User s Manual i System Components INTERFACE IHT 7250 Technical Specifications IADPUT VOIAgE u sia 24 VDC 10 with integrated reverse voltage protection Switch Input Voltage Represents ARC Input resistance setting range Voltage oe 0 to 300 VDC 0 300 VDC ca 3 MOhm Input Plasma ARC Voltage 0 to 10 VDC 0 300 VDC ca 100 KOhm 0 to 6 VDC 0 300 VDC ca 100 KOhm 0 to 10V 0 250VDC ca 100 KOhm Digital input of control signals 24 VDC 10 Resistor Ri 7 kOhm Digital output of control signals 20 VDC Resistor Ri 150 Ohm short circuit proof Relay contact for Enable Ignition Load 0 5A at 125VAC 1A at 24 VDC BUG Tale soa sinsicsnstiunsvinsavesicivunsiseuneeweusescnseews switch setting 0 4 9600 14400 19200 28800 38400 Address Setting ccccccecseeeeceeeeseeeenees 0 3 Screw on terminals 0 for wires max 2 5 qmm DIMENSIONS 0ccccseeeeseeeeceeeeeeeeeeeaeees 90
22. 1 for Capacitive sensors with nozzle sensor or ring electrode Connect as short as possible to machine ground less than 0 5 m Rev 2 9 6 5 IHT 3000 Clearance Control System i h t User s Manual Installation 6 5 LINEAR DRIVE Grounding of Torch Clamp The notes of grounding described in chapter 13 must be observed for N This cable is required for safe operation or a proper usage Note This grounding cable is not included in delivery Cable length 0 6 m Cable 6 qmm AWG 8 yellow green lengthwise striped 2 connectors Faston 6 3mm 0 8 mm i s Grounding Cable connect as short as possible to machine ground wire gauge min 6 qmm AWG8 lt Grounding Cable Torch Clamp gt R AN ATTENTION The length of the cable may not be too short The movement of the lifter may not be hindered by the grounding cable up to the lower limit switch Rev 2 9 6 6 IHT 3000 Clearance Control System i h User s Manual Installation 6 6 LINEAR DRIVE Grounding for Capacitive Sensor Mode Using RING ELECTRODE SENSOR CONNECTOR UNIT SENSOR TORCH CLAMP j PE Cable connect to terminal on top of Linera Drive ATTENTION length 0 6m This part must not touch any other parts wire gauge min 6qmm Cable included in delivery of Sensor Torch Clamp 6530 Length 0 15 m Cable 6 qmm AWG 8 2 Connectors Faston 6 3 0 8 mm ATTENTION The terminal on top of Linear Drive
23. 6 IHT 3000 Clearance Control System i h t User s Manual 6 Installation 6 1 LINEAR DRIVE IHT 2343 Installation Important handling note for the LINEAR DRIVE AN ATTENTION Don t touch the bellows of LINEAR DRIVE The bellow could be damaged A damaged bellow must be exchanged as infiltrating dust can damage the mechanics Check the bellow and make sure that the folding is not buckled inwards Pull out inwardly buckled foldings Rev 2 9 6 1 IHT 3000 Clearance Control System User s Manual Installation For vertical mounting at the cutting machine Optionally 4 screws M6 DIN 912 drill hole dimensions 70x270 mm or 4 screws M8 DIN 912 drill hole dimensions 100x270 mm can be used to fix the Linear Drive from the front 120 Front ERY ZZZZ 7 e alternative 4 x M6 for rear za mounting ee eee eee ker de Rev 2 9 IHT 3000 Clearance Control System i h p User s Manual Installation 6 2 LINEAR DRIVE Adjustment of Weight Compensation This feature enables the adjustment of minimum vertical downward force when the nozzle touches the work piece while getting the initial position The plasma torch must be mounted the cable and the hose package must be clamped The cable and hoses outside must be held flexible so the sliding part of the LINEAR DRIVE is not hindered Note Otherwise do not fix the cables and hoses in the clamp If necessar
24. C Central ground Terminal 7260 Control Cabinet ATTENTION IN If two different power supplies are used for LINEAR DRIVE and INTERFACE Both units must be supplied at the same time after power on Otherwise the function of the complete system is blocked if one power supplies follows the other Rev 2 9 6 11 IHT 3000 Clearance Control System i h t User s Manual Installation 6 11 Installation of the INTERFACE IHT 7250 The Interface is build for mounting on a 35 mm DIN rail in the control cabinet or the operation panel 6 12 Electrical Connection of the INTERFACE IHT 7250 Both 17 pole screwing terminals for input and exit are pluggable Due to a certain code they cannot be mixed up To remove the screwing terminals put a screw driver in the slot of the housing and push it upwards a Driver Rev 2 9 6 12 IHT 3000 Clearance Control System User s Manual Installation 6 13 Interface Input ht Bold printed functions No 2 3 6 7 9 14 and 15 are the minimum configuration for plasma operation Note If the plasma source is not equipped with a low voltage output of arc voltage e g 0 to 10 VDC than connect the high arc voltage e g 0 to 300VDC to terminal No 1 If a low arc voltage output is available the use of this voltage is recommendable to achieve higher noise immunity Use the terminal No 2 as described below Input Input Voltage X301 Description to No Activate Function 1 H
25. ER SINE IE NEAR 60g IH Par None 100279 Rev 2 9 5 9 System Components IHT 3000 Clearance Control System e h User s Manual i 5 3 4 SENSOR CONNECTOR UNIT IHT 6531 Rev 2 9 Features e Adaptor for Ring Electrodes Types 6534 6560 and 6575 e easy assembling of ring electrode by plug in and fixing by screw e simple to centre the Ring Electrode to the nozzle tip e integrated high voltage protection e thermal radiation and spatter protection plate Technical Data CORO seeen a E EE 139 mm DiAMetel ccccccscccceseecsseeecesereneneeeneees max 38 mm High voltage protection u max 14 kV Stock Operating Temperature 0 85 C Relative Humidity ceeceeeeeeeeeeeeeees no condensation between 20 to 90 WEIgNl essen 305 g IHT part No 22uusss22ssseeennenneeeennennn 100212 5 10 IHT 3000 Clearance Control System User s Manual System Components 5 4 Nozzle Sensor Touch Less Initial Position Finding for Plasma Cutting Option The NOZZLE SENSOR is an optional component of the IHT 3000 clearance control system for plasma cutting Features e Touch less initial position finding e high repeatability e no rebound at initial position finding cutting thin sheets e no damage of the surface of the sheet e suitable also for coated or rusty sheets NOZZLE SENSOR It provides a touch less finding of the surface of a metal sheet
26. ODE IHT 6534 6560 6575 uuueenssuneennennnnnennnnnnnennnnnennnnnnennnnnnnennnn nennen 5 8 5 3 2 SENSOR TORCH CLAMP IHT 6530 uuuuuesnesenenennnnennennnnnennnnnnnennnn nennen nnennnnnnnennnn nennen 5 9 599 COAXCABLE TAT II ea ee ae aaa aS 5 9 5 3 4 SENSOR CONNECTOR UNIT IHT 6531 uss224000020snnennennnennennnnnnennnn nennen nnennn nenne 5 10 5 4 Nozzle Sensor Touch Less Initial Position Finding for Plasma Cutting Option 5 11 5 5 POWER SUPPLY IHF 7 90 een een nn 5 14 5 6 INTERFACE IAT 72 SO en ee near een 5 15 5 6 1 Connections and settings INTERFACE IHT 7250 4uussnesnnennennnennennnnenennnnennennn nenne 5 17 5 6 2 INPUl Connector X30 are een seen nennenswerten a a Hrn 5 18 5 6 3 Output Connector X30 Isser anana a aiia na a aaa a neuen en kenne 5 19 5 6 4 Connector X202 Cutbus 2u0222200220000nnnnonnnnnonnnnnnnnnnennnnnennnnnennnnnennnnnnnnnnnnnnnnnnnnnennnnnennnnnenn 5 20 5 6 5 Connector X201 Operator Terminal u0220002400240020n0 nenn nnnn nenne nenne nenn nenn nnne nennen 5 20 5 7 Operator Terminal IHT 7260 u 22200022400020nnonnnnnennnnennnnnennnnnennnnn nenne nnnnnennnne nenne nnnnne nennen 5 21 5 8 OPERATOR TERMINAL IHT 7261 Handheld Version us4424400424000 Rennen nnnnnn nennen 5 22 5 9 Operator Terminal Menu Overview eneuuessssessssnesnnnnennnnnennnnnnnennnnnnnnenennnnnnnnnnnnnne nennen nenne nennen 5 23 5 10 Co
27. Ove Poner Gat engh 20m harao ioe o operarea INT z60 100 Hm aa covenensas o y 25 cowerrossrses OO y oo Rev 2 9 10 1 IHT 3000 Clearance Control System M fa t User s Manual 11 Troubleshooting 11 1 Fault Indication and Reset at the OPERATOR TERMINAL Operator Terminal 7260 Display Cutting Height Ideal Voltage Real Voltage Error Display Automatic in the Display Weight Compensation Fault ARC Voltage Collision Overload Motor Polarity Encoder Error Press Button MAN UP Fault Indication Effect Cause Correction Weight compensation No initial position 1 The hose of the torch 1 Loosen the attachment of the finding pulls upwards hose 2 Setting of weight 2 Turn knob at Linear Drive compensation too strong counter clockwise Check of the weight compensation 3 Switch of initial described in chapter 4 position finding Get in contact with IHT Service ARC Voltage No finding of initial Arc voltage is missed at Check the connection between position Interface plasma source and Interface Rev 2 9 11 1 IHT 3000 Clearance Control System User s Manual Troubleshooting Faultindication Effect Gauss Correction Collision Linear Drive moves Collision protection was Eliminate the barrier to upper reference active Increase retract position if position Torch moved against a Necessary barrier Overload No Movement 1 Load too much Check the load 2 Mo
28. V inear Drive UP DOWN Help Text Error Register Automatic in the Display Fault Weight Compensation Fault ARC Voltage Collision Overload Motor Polarity Encoder Error Press Button MAN UP 5 23 IHT 3000 Clearance Control System e h User s Manual mi System Components 5 10 Converter for Serial Interface RS232 RS485 Option Interface converter for connection from the Interface 7250 to a notebook or personal computer This converter is only necessary when information is read from or written into the IHT 3000 system e g for service purposes The converter can also be used for the Cutbus RS232 Technical Data Power Supply cccceeececeeceseeeeeeeeeeeeees 10 30 VDC Power COnSumption cccccccceeeeeeeeee 0 05 A at 24 VDC Reverse Voltage Protection built in Communication RS485 2 wire differential input asynchronous half duplex screwing terminal block with connection for power supply Communication RS232 automatic adaptation to baud rate of 300 to 115200 PN Soret tee eee P EURE AEE E E Connector 9 pole D SUB Galvanic Isolation Isolation voltage 3000 VDC Environment Temperature 25 to 75 C Relative Humidity u00244004e nennen no condensation between 5 to 95 HOUSING anna Plastic housing 111x72x25 mm Length x Width x Height Mounting of Housing u
29. ace RS 485 SUB D 9 pole female Contact Function IF GND Da Data o tv Note For test and service purposes the Cutbus Interface X202 can be connected to a personal computer to collect data of the operation For this purpose the RS 485 interface with the converter must be converted to the RS 232 interface of the personal computer In this case the Terminal connector of the X201 has to be connected to the Cutbus of the machine Rev 2 9 5 20 IHT 3000 Clearance Control System User s Manual System Components 9 7 Operator Terminal IHT 7260 Error Communication Ready Display Information menu Manual UP Manual DOWN Fast settings Menu upwards ESCAPE Help Menu Back to menu Menu downwards OK ENTER Technical Information PONDI sun ee 24 VDC 10 with integrated reverse voltage protection CONSUMPTION ueneeeeeneseennennennnneenennenen 60 mA Over Voltage protection 30 V Graphic Display cccccsecceseeseeeeeees 128x64 pixel blue white with LED backlight Serial Interface ccccecccssseesseeeeseeees RS485 Environment temperature 0 to 50 C Relative Humidity cccccecseeeeeeeeeeeees 98 non condensing Protection class cccceeccceeceeeeeeeeeeeeees IP10 EN60529 IEC529 for assembly into operator console DIMENSIONS a se5 seinen 160x120x35 mm VISION wur een ern en approx 0 4 kg HAT DALE DO nern 100363
30. al No 9 Ok To Move Release signal to start XY movement by machine 20V control CNC required when CNC is not generating this signal by itself The selected upper threshold value in of ARC 20V voltage is crossed by the measured ARC voltage e g crossing kerfs edges etc Clearance control is blocked as long as upper threshold is exceeded Delay Time Pierce delay time starts with Start XY and ends 20V after the Pierce Delay Time After end of the delay time clearance control begins Plasma Start Output signal to start ignition Signal to plasma 20V source This function is active at the same time as the relay contact on terminal No 3 and 4 Control Active Clearance control is active 12 Collision Collision in cutting process the torch immediately moves up to the upper position ATTENTION Inverted output active low Enable ignition Oxyfuel Enable ignition Enable ignition for oxyfuel torch 00 Enable ignition for oxyfuel torch 00 torch Reference Retract This output signal is active if 20V Position 1 after power on the reference position is reached or a fault was released 2 the Retract Position is reached This signal announces to be ready for a new cut If a fault appears this signal remains at OV until the fault is released and the reference position is reached Separate Ignition Plasma Separate ignition for gas pre flow Reference Position Upper start up position E S dino function Note Referen
31. asmal IHT Ready CNC IHT Start XY IHT CNC Ok To Move IHT Delay Time IHT Control Active IHT CNC Corne Procedure 1 Finding initial position and move to pierce height for ignition 2 Pierce height ready Plasma Start feedback signal Ready from plasma source main arc active Start XY movement descent to cutting height Delay Time starts or at the same time movement to Elevation Height if value greater than 0 and Pierce Delay greater than 0 seconds after Pierce Delay the Delay Time starts gt lt Cutting Off Descent to Cutting Height after Delay Time is finished the clearance control will be active Clearance control active command corner interrupts clearance control 6 End of cutting torch moves to Retract Position Rev 2 9 8 7 Operation and Setup IHT 3000 Clearance Control System M fa t User s Manual 8 3 End of Cutting Retract Position The Linear Drive moves up to the retract position if following 3 requirements are fulfilled signal nitial Position Start off signal Start XY off arc voltage less than 85 This threshold value can be changed at the Operator Terminal in the parameter menu by the function End of Cut and is adjustable between 0 to 100 referring to the ideal arc voltage Note This adjustable function is possible from firmware release No 1 09 at Operator Terminal 1 07 at Linear Drive The firmware release No is visible under the main
32. bsolute height value Operator Terminal 7260 Display Cutting Height Ideal Voltage Real Voltage Parameter Cutheight A V Mode Select ARC Voltage Cutting Height J Standard Setting vats System Properties Device Info Rev 2 9 8 2 IHT 3000 Clearance Control System User s Manual Operation and Setup 8 1 3 Cutting Settings Operator Terminal 7260 Display Cutting Height Ideal Voltage Real Voltage Parameter Cutheight ESC Dependent on choice of control mode lt I gt B lt gt 9 Cutting Height Pierce Delay Pierce Height Elevation Height Control Delay Retract Position Upper Threshold Dynamic Gas Pre Flow End of Cut Mode Select Select mm inch System Properties Device Info Rev 2 9 Height during cutting Time during piercing Distance during igntion Additional lifting during ignition Starts with signal START XY Height after end of cutting Blocking of clearance control when crossing kerfs Reaction rate of clearance control Gas Pre Flow starts with START INITIAL POSITION FINDING Setting in percent of ideal arc voltage to detect end of cut standard setting 85 ht 8 3 IHT 3000 Clearance Control System M fa t User s Manual Operation and Setup 8 1 4 Commands and Status Operator Terminal 7260 Display Cutting Height Ideal Voltage Real Voltage Commands and Status Commands S Linear Drive moves to upper re
33. ce ground potential of output signals No 5 to 15 is terminal No 2 INTERFACE GROUND Upper Threshold Rev 2 9 6 18 IHT 3000 Clearance Control System User s Manual Installation 6 19 Wiring Example of Control Signals for Plasma Mode Minimal Configuration INTERFACE 7250 High Arc Voltage Minus 300 V Reference Low Arc Voltage 0 VDC Reference High Arc Voltage 0 V or Low Arc Voltage 10 V No function No function Initial Position Start 8 Plereing Height oue o Comer 3 aa mana ooo 45 Manual Dom Output X305 Function No 3 Interface Powers _ 2 Interface Ground ov 3 Plasma Start retay contact 4 Plasma Start retay contact 6 orms o e bamme o Pemas Rev 2 9 Plasma Source ht Power Machine Control 6 19 IHT 3000 Clearance Control System User s Manual Installation INTERFACE 7250 Input X301 No High Arc Voltage Minus 300 V 6 20 Wiring Example for Plasma Mode with Gas Pre flow Arc Voltage Plasma Source Z Reference Low Arc Voltage 0 VDC Reference High Arc Voltage 0 V or Low Arc Voltage 10 V 4 No function 6 Initial Position Start Ready Start XY 8 Piercing Height Oxyfuel o Comer Machine Control 15 Manual Down INTERFACE 7250 Output X305 Function No 3 interface Power 24V 2 interfaco Ground 3 Plasma Start relay contact a
34. cy for oxy fuel cutting e easy installation to SENSOR CONNECTOR UNIT 6531 e useful for precise clearance control up to 0 3 mm e suitable for cutting without influence of water Technical Data IHT Ring Outer Inner Nominal Clearance Part No Electrode Diameter Diameter between bottom line of IHT Type Ring Electrode and work piece mm 100271 6575 1 100 ATTENTION The capacitive height control system with Ring Electrode is only suitable for oxyfuel cutting with no influence of water Water influences the sensor system and leads to malfunction Rev 2 9 5 8 IHT 3000 Clearance Control System User s Manual System Components 9 3 2 SENSOR TORCH CLAMP IHT 6530 Features e clamp for SENSOR CONNECTOR UNIT 6531 e fits to all torches of diameter range from 32 to 59 mm e hex wrench for hex screws M4 is attached for ease of ring electrodes adjustments e Protective earth connector Faston 6 3 mm IHT Part No 100268 5 3 3 COAX CABLE IHT 1991 Features e connects SENSOR CONNECTOR UNIT with LINEAR DRIVE e coax cable with additional temperature protection e length 1 2 m Technical Data Length nee 1 2m CONIA CCION sciseceascocistncuicnesdeucnceivaces an BNC male Temperature splash protection silicone hose Stock Operating Temperature 0 85 C Relative Humidity cceccceeeeeeeeeeeeeees no condensation between 20 to 90 MW SGI eere eara IE N EI
35. d the clip must be exchanged The clamp of the SENSOR CONNECTOR UNIT must be grounded by an additional cable with a wire gauge of 6 qmm AWG 8 or more This cable must be connected with the PE terminal of the IHT 3000 LINEAR DRIVE The motor cables of the XY drives must be shielded and grounded to PE potential at the motor amplifier After power on the prime initial position finding must be done starting at the upper reference position For finding initial position the plasma torch must be 25 mm or more above the metal surface Note the different part number 100725 of the IHT 3000 LINEAR DRIVE IHT type number 2343 1 100 V03 which provides the software functions for the capacitive measurement system 5 12 IHT 3000 Clearance Control System User s Manual System Components The SENSOR KIT 4 part number 100377 provides all the needed parts to use the NOZZLE SENSOR Pos Device IHT Type No IHT Article Nr SENSOR CONNECTOR UNIT IHT 6531 1 100 100212 SENSOR TORCH CLAMP IHT 6530 1 100 100268 COAX CABLE IHT 1991 1 100 100279 NOZZLE SENSOR IHT 6590 1 100 100366 COAX CABLE IHT 1991 1 100 SENSOR CONNECTOR UNIT IHT 6531 1 100 SENSOR TORCH CLAMP _ T IHT 6530 1 100 Cable NOZZLE SENSOR IHT 6590 1 100 Clip on nozzle cap Rev 2 9 9 13 IHT 3000 Clearance Control System User s Manual System Components 5 5 POWER SUPPLY IHT 7504 Features e Stabilized power supply 24 VDC 6 5
36. e ae J ae SEES ar a ae CF ESF C 75 S Rear mounting plate Torch max 360 min 140 76 Rev 2 9 5 3 IHT 3000 Clearance Control System e h User s Manual System Components Top View LINEAR DRIVE IHT 2343 Electrical connectors Dimensions in millimeters w 120 Connector for Linear Drive Connector for Linear Control Cable u Drive Power Cable L i PE ee Grounding connector to be a connected to machine ground Coax Cable connector for capacitive mode Important Notes for Usage IN WARNING Don t touch the Linear Drive at the bellow The bellow could be damaged A damaged bellow must be exchanged because infiltrating dust can damage the mechanics Check the bellow to make sure that the folding is not buckled inwards Rev 2 9 5 4 IHT 3000 Clearance Control System User s Manual System Components Side View of LINEAR DRIVE 2346 Heavy Load Version View with plasma torch Dimensions in millimeters Rev 2 9 Hose Clamp min 100 max 300 245 Torch
37. e must not be connected at AN the plasma source ground but has to be connected in the control cabinet or the metal housing PE Potential with the machine ground in the shortest possible way Plasma Source Interface built in control cabinet Control Cabinet Big SS IN Se Sy Se ie ee i SIII u N Shielding not Shielding only connected here connected Short connection to central machine ground Rev 2 9 6 16 IHT 3000 Clearance Control System i h t User s Manual Installation 6 17 Setting of Arc Voltage Range SO0O009002000009 Linear Orive X203 Interface IHT 7250 gh RUN Faut Te rminal x201 Cutbus X202 IDOOSGOOGSDIOOTIIOFIHG Setting Output Voltage of Plasma Source According an Arc Voltage Arc Voltage Range Po cave T T Rev 2 9 6 17 IHT 3000 Clearance Control System M a t User s Manual Installation 6 18 Interface Output Bold printed functions No 1 2 3 and 4 are the minimum configurations for plasma operation Output BR Output Voltage Description X305 No Function Active Interface Power 24V Power for Interface and Operator Terminal 24 V stabilized Interface Ground Power Ground 0 V reference potential for input output signals to CNC Plasma Start Input to internal relay contact This function is active at the same time as the terminal No 9 Plasma Start Output from internal relay contact This function is active at the same time as the termin
38. e setting of Operator Terminal or by Cutbus If both inputs are not active the setting may be done by the Operator Terminal by Cutbus Rev 2 9 6 14 IHT 3000 Clearance Control System M ia t User s Manual Installation 6 15 Connection of Arc Voltage at the Interface The INTERFACE offers a high voltage input 0 to 300VDC and a low voltage input 0 to 10VDC for the arc voltage connection It is recommended to use a low voltage input 0 to 10V DC if the plasma source AN offers corresponding outputs for the arc voltage This reduces the interference between ignition voltage and arc voltage Example 1 Wiring of a plasma source with a high voltage output of 0 to 300 VDC Example 1 Wiring of a plasma source with a high voltage output of 0 to 300 VDC High Voltage Output INTERFACE 7250 Minus 0 to 300 VDC High Arc Voltage Minus 300 V Reference Low Arc Voltage 0 V Reference High Arc Voltage 0 VDC Reference 0 VDC JSG KERLE ELLE KANNE Example 2 Wiring of a plasma source with a low voltage output of 0 to 10 VDC Low Voltage Output INTERFACE 7250 Input X301 No 0 VDC Ref High Arc Voltage Minus 300 V in 2 Reference Low Arc Voltage 0 V 0 to 10 VDC SE PEENI AT AS HAS Rev 2 9 6 15 IHT 3000 Clearance Control System User s Manual Installation 6 16 Arc Voltage Cable Connection of Shielding ATTENTION The shielding of the arc voltage cable to the plasma sourc
39. ference position Regulator Off Clearance control is stopped Threshold Off Kerf and edge detection off Scrap Cut Initial position finding is stopped Status Info af Status Corner Ref Position Kerf Cap active Control active Cycle active Real Voltage 122 5 V The Status shows the functions which are active during cutting Rev 2 9 8 4 IHT 3000 Clearance Control System User s Manual Operation and Setup 8 1 5 Favorite Menu Using this menu the main cutting parameters can be set quickly Operator Terminal 7260 Display Cutting Height Ideal Voltage Real Voltage Parameter Favorite Cut Height Pierce Delay lt gt N Pierce Height Control Delay Rev 2 9 IHT 3000 Clearance Control System M fa t User s Manual Operation and Setup 8 1 6 Additional Functions of Push Buttons Operator Terminal 7260 Display Cutting Height Ideal Voltage Real Voltage Ideal Voltage Help Text UP DOWN va lt I gt Rev 2 9 8 6 IHT 3000 Clearance Control System Operation and Setup User s Manual A Time Track es gt gt 1 2 3 4 5 6 e Cutting On 8 2 Signal Flow during Plasma Cutting Clearance Reference Position Retract Position Elevation Height Pierce Height Cutting Height Surface of work piece State From To Signal CNC IHT Initial Pos Start IHT Plasma Plasma Sta Pl
40. heck the protected earth connector PE The notes of grounding described in chapter 13 must be observed for or a proper usage Protect the exit 24 VDC with a 10AT fuse Connect exit 0V V of the POWER SUPPLY with electronic GROUND at the power supply of the machine control Width of cable 2 5 qmm AWG3 or more ATTENTION Before switching on the power supply make sure that the wiring is completed correctly Input Voltage switch 230 VAC 115VAC Attention Pre selected to 230VAC m O a A gt Be _ u O m mmm rn a m ee en ee M un m _ am u an Tr u a u D Z gt ms u N p EEE ee oe u an En ne eg nn am A am X m m o oo lt m oo al gt ae mm ue am e protect with 230 VAC Trimmer to adjust output voltage PE Ground max 28 VDC V V Output OV Output 24VDC 6 5A Ground GND Protect with external fuse 10AT slow 6 10 IHT 3000 Clearance Control System User s Manual i h t Installation 6 10 Power Wiring and Fusing Linear Drive 2343 Linear Drive Power Cable IHT 2300 1 901 Fuse 10AT slow acting Fuse 1AM O O 24 VDC a ne Interface Line Fuse Power 7250 m Supply 230VAC 1 6AM 1 GO S ae 120VAC 3 2AM Operator Terminal Cable medium acting IHT 7260 1 901 0 VD
41. height Delay Time starts or at the same time torch moves up to Elevation Height 8 12 IHT 3000 Clearance Control System User s Manual Operation and Setup 8 5 Operational Workflow and Control during Oxyfuel Cutting w Work piece u 4 1 2 3 5 Clearance Cutting height Ignition Piercing Height ON Piercing Height OFF Control reached protects nozzle START XY ON Enable Ignition Clearance control Clearance control Clearance control Clearance control OFF OFF ON ON A Start Clearance Control OFF at input No 13 of INTERFACE Piercing Height Oxyfuel input 8 at INTERFACE ATTENTION 1 The Ring Electrode must not touch the torch or other parts 2 During cutting the flame may not touch the Ring Electrode A direct influence of the flame modifies the electrical field around the ring electrode This the height distance Explanation During ignition and piercing the work piece reflects the flame which impacts on the RING ELECTRODE No correct clearance control is possible and must be switched off during this time Rev 2 9 8 13 IHT 3000 Clearance Control System User s Manual Operation and Setup 3 If the RING ELECTRODE approaches to an edge or corner of the work piece the clearance control must be off until the whole RING ELECTRODE moves back to the work piece The distance will decrease relative to the adjusted distance when only a part of the ring electrode diameter is above
42. ierce Elevation 0 mm e Cutting Height O mm Procedure Select SCRAP CUTTING at Operator Terminal in the command menu Move the torch to the start position manually Move the torch to suitable cutting height manually e activate Initial Position Start and Start XY Reference Position Manual Down Cutting Height Work piece gt Time Track To Signal Plasma Plasma Sta Ignition rH A EI Clearance Con Tf Cutting ON a Cutting OFF gt Rev 2 9 8 10 IHT 3000 Clearance Control System User s Manual Operation and Setup 8 4 3 Procedure with Gas Pre Flow Advantage The time of gas pre flow after reaching the piercing position is eliminated and the cutting cycle is shortened significantly Requirement You need to be able to ignite the plasma source with a separate signal The gas pre flow already starts with the command Initial Position Start Therefore the torch can be ignited immediately after reaching the piercing position Settings e Select the menu parameter Cut Height at the Operator Terminal by using the ESC key and select Gas Pre flow Set the time for gas pre flow Max 6 seconds Note If the set time is greater than 0 seconds the gas pre flow function is active Procedure e Initial Position Start ON Y e atthe same time the output No 9 Plasma Start at the Interface will be active This will trigger the plasma source t
43. igh Arc Voltage High arc voltage input minus 300 VDC minus 300 VDC Low Arc Voltage Low arc voltage input 0 V Reference Ground High Arc Voltage 1 high arc voltage 0 V Reference 0 V or or Low Arc Voltage plus 10 VDC a FE 7777 DE BEE e OSS 6 Initial Position Start Start finding initial position for plasma mode Tan Piercing Height Piercing Height when cutting with oxyfuel 24V Oxyfuel o Comer Comer switch off of clearance control v 13 Start Clearance Clearance Control for oxyfuel cutting is active 24V Control Oxyfuel aa Manual up movestorn w 45 Manual Down Moves toren dom w S BEE ar Pnotimaten 2 Low arc voltage input max 10 VDC The input voltage to activate the function of terminal No 6 to 15 is 24 V referring to the INTERFACE GROUND at output terminal No 2 as described on page 6 17 Rev 2 9 6 13 IHT 3000 Clearance Control System i a t User s Manual Installation 6 14 Setting of Retract Position by Wiring at Interface 4 selectable retract positions at Interface Input Input Voltage to X301 Description Activate No Function Retract 1 Retract position 20 mm above cutting height Retract 2 Retract position 50 mm above cutting height Retract 1 Retract 2 Retract Position Fixed selection by wiring has priority ow oo Upper Reference Position ATTENTION The fixed wired and activated 24V retract position at the inputs 10 and 11 has priority against th
44. ition enable for oxyfuel 20V Oxyfuel 14 Reference Retract This signal is active if Position 1 after power on the Reference Position is reached or an error has been released 2 the Retract Position is reached This signal informs about the readiness to start a next cut If an error appears this signal remains at OV until the error is released and the Reference Position is reached i o o o o Reference Position Reference Position is reached SC rSC s S S Rev 2 9 6 25 IHT 3000 Clearance Control System i h t User s Manual Installation 6 28 Installation of the NOZZLE SENSOR OPTION Requirements e It must be checked if the used type of plasma torch is suitable to operate with the NOZZLE SENSOR IHT provides a listing of suitable plasma torches e For each type of plasma torch respectively manufacturer a different clip may be necessary The clip is part of the NOZZLE SENSOR Please contact IHT to get useful information e The clip must be isolated from the cap Therefore the clip is coated with an isolating layer If the isolation is damaged the clip must be exchanged a E fixing screw for Nozzle Sensor Cable use an Allen key 3mm 4 Nozzle Sensor _ Cable NOZZLE SENSOR Clip on nozzle cap Rev 2 9 6 26 IHT 3000 Clearance Control System i h t User s Manual Installation of NOZZLE SENSOR Turning Knob for Weight Compensation Removed Protection Cap ok Connec
45. lly known safety related and job safety regulations must be complied with Arbitrary changes on the system exclude the liability of resulting damages The user operator of the machines has to make sure that all safety systems are constantly in good working condition Regular checks are necessary to verify that the equipment is in proper working condition This instruction manual does not substitute instructions by service personnel and required training Only authorized well informed and qualified personnel are allowed to work with the machine Everyone who works with the equipment has to read and understand the safety regulations and all parts of the manual relating to the specific functions in use Rev 2 9 1 1 IHT 3000 Clearance Control System e h User s Manual i 2 Safety instructions Please read the users manual carefully This user s manual must always be used in combination with all other manuals of the whole machine Installation getting started and maintenance work may only be executed by trained experts observing the recognised rules of safety and technology The electrical safety regulations must be followed when connecting In particular the accident prevention regulations the regulations of DIN VDE 0100 Directions for the erection of power plants with nominal voltages up to 1000 volts and the European standard EN 60204 1 Machine safety electrical equipment of machines must be followed The protecti
46. must be connected The SENSOR CONNECTOR UNIT must be connected with the machine ground via the SENSOR TORCH CLAMP Discharge of excess voltage will not be possible This will cause damage The notes of grounding described in chapter 13 must be observed for or a proper usage Rev 2 9 6 7 IHT 3000 Clearance Control System i h t User s Manual Installation 6 7 LINEAR DRIVE Grounding for Capacitive NOZZLE SENSOR Assemble all components and connect the grounding cables as described below The grounding cables should be as short as possible ATTENTION If the grounding is not correct installed there will occur a malfunction Grounding cable strand 6 sqm AWG 8 Length approx 300 mm 2x Cable Lug 4 6 sqm 4 3 mm Connect PE terminal to ground at machine body PE Terminal i N wa R iA x Grounding cable strand 6 sqm AWG 8 Length approx 900 mm 2x Faston 6 3x0 8 mm Connect torch clamp to PE terminal Grounding cable strand 6 sqm AWG 8 Length approx 900 mm 2x Faston 6 3x0 8 mm Connect SENSOR TORCH CLAMP to PE terminal PE Protective Earth ground earth potential Note The short grounding cable with a length of 150 mm is not needed The delivery of the SENSOR TORCH CLAMP 6530 includes this cable Rev 2 9 6 8 IHT 3000 Clearance Control System User s Manual Installation 6 8 Installation of the POWER SUPPLY 7504 The Powe
47. nennnnnnennnnnnnennne nenne nnennnennnn 6 12 6 12 Electrical Connection of the INTERFACE IHT 7250 0 0 cece ccccceeeeeseeeeeeeeeeseeeeeseeeeseeees 6 12 8 9 WATS IAC NPU yeeros asics etss ase emecsteeces nee ee ehren 6 13 6 14 Setting of Retract Position by Wiring at Interface ceeccccsseeeeeseeeeeeaeeeeeeeeeeeeeeeeeeeeeaeeeees 6 14 6 15 Connection of Arc Voltage at the Interface us 240000004n0nnennnn nennen nnennnnnennnn nennen 6 15 6 16 Arc Voltage Cable Connection Of Shielding cc ceeccccceeeeeeeeeeeeeeeeeeeeeseeeeeseeeeeeeeeeeeesaeeeeeas 6 16 8 17 Selling Of Arc Voltage R nge un animal 6 17 8 18 WTS TAS OU re ee ee er EEE 6 18 6 19 Wiring Example of Control Signals for Plasma Mode Minimal Configuration 6 19 6 20 Wiring Example for Plasma Mode with Gas Pre flow 2u00004400B00nnnnnnnnnnnnenne nenne 6 20 Rev 29 00D IHT 3000 Clearance Control System e h User s Manual i Content 6 21 Mounting of the Operator Terminal IHT 7260 cccccccccseecceeeeeeeeseeeeeesaeeeeeeeeeeeseeeeeeesaeeeeas 6 21 0 22 Drawing Tof WS FAA OM sesoses ne ee ee rede TERES 6 21 6 23 Operator Terminal Electrical Connection 2220022220022000nnnnnnnnnnnennn nenne nenne nnnnnnnnnnenn 6 21 6 24 Default Setting of DIP Switch wscactusaccassindiazensanicieseacandetsquannae sajiteuddsnkd tudencsianed seuenweeudumindaaaanewedeaens 6 22 6 25 Mounting of the Sensor Comp
48. nverter for Serial Interface RS232 RS485 Option 002220002220020n00snnnnnnnnnnennnnnenennenn 5 24 5 11 Converter for Serial Interface USB RS485 Option 02220002200022200020nno nenn enenne nennen 5 25 512 Connecting Cable na nennen nee el a a aia 5 26 ENS 0 1 1 11 ea saicete rigs racoe cn E a E E 6 1 6 1 LINEAR DRIVE IHT 2343 1H8 llalen nee ee ade 6 1 6 2 LINEAR DRIVE Adjustment of Weight Compensation us00424s0ennenne nennen nnennne nenne 6 3 6 3 LINEAR DRIVE Check of Collision Protection 2 2002222002200002nnn nenne nenne nnnnneennnnen 6 4 6 4 LINEAR DRIVE Electrical Connections 0002220002000000n0ennnnnnnennnnnnnnn nenne nenne nnnnnnennnenn 6 5 6 5 LINEAR DRIVE Grounding of Torch Clamp 4u0s020400ennnnnnennennnn nenne nnnnnnnennennne nennen 6 6 6 6 LINEAR DRIVE Grounding for Capacitive Sensor Mode Using Ring Electrode 6 6 7 LINEAR DRIVE Grounding for Capacitive Nozzle S NSOFP ccccecceeseeeeeeeaeeeeeaeeeeeeeaeeeeeens 6 8 6 8 Installation of the POWER SUPPLY 7504 2uusssssuensnsennennennnnennnnnnnnnnnnnennnnnnnnennnnnennnnnnnennnn 6 9 6 9 Electrical connection POWER SUPPLY 7504 2uus22uussnsnusnsnnennnnnonennnonennnnnennennnnn nennen 6 10 8 10 POWER VUN and FUSING Eee ehesten 6 11 6 11 Installation of the INTERFACE IHT 7250 usnsuuuessnenneenennnnnnnnnnnn
49. o turn on the gas pre flow e Torch moves down e Torch moves to ignition height e Ifthe selected time of gas pre flow is completed and the torch has reached the ignition height the output No 15 Separate Ignition Plasma will be active at the Interface This is the signal for the plasma source to ignite The further process is the same as the standard procedure Rev 2 9 8 11 IHT 3000 Clearance Control System Procedure with Gas Pre flow Reference Position Elevation Height User s Manual Pierce Height for Ignition Cutting Height Work piece From To Signal CNC Initial Pos Start IHT Plasma CNC IHT Plasma CNC IHT CNC Clear Contr ON Procedure T Ignitio Cutting ON Time Track Initial position finding and moving to ignition height at the same time output No 9 Gas Pre flow is active until the set time is finished 2 After the Gas Pre flow is completed and the torch has reached the ignition height Ignition signal for Plasma through output 15 at Interface main arc ON feedback signal of plasma source Ready If the value is greater 0 and Pierce Delay greater than 0 seconds Delay Time starts after Pierce Delay Lower to pierce height after Delay Time the height control is activated End of cut torch moves to Retract Position Rev 2 9 3 Start XY movement torch descents to cutting
50. on symmetric mounting rail according to EN 60715 Connection Cable for RS232 1 8 m included in delivery MY FIN NO nenne 100395 Note ATTENTION The use of this converter is recommended to get a data transfer without any problems If another type of converter will be used it must be free of switch over time Additional technical data and information for installation are enclosed as a separate user manual for each device Rev 2 9 5 24 IHT 3000 Clearance Control System e h User s Manual Ini System Components 5 11 Converter for Serial Interface USB RS485 Option Interface converter for connection from the Interface 7250 to a notebook or personal computer equipped with a USB port This converter is only necessary when information is read out or written into the IHT 3000 system e g for service purpose The converter can also be used for the Cutbus Bs USB e i wy CS amp gt C en w N Y nY W L ay Technical Data Power Supply ccccceececeeeeseeeeeeeeeeeeees supplied by USB port of the Host PC Communication RS485 u 00 2 wire differential input asynchronous half duplex screwing terminal block with connection for power supply Communication USB automatic adaptation to baud rate of 300 to 115200 Compatibility cccecceessseeeeeeeeeeeeeees USB 1 1 and 2 0 standard Galvanic Isolation Isolation voltage 3000 VDC
51. onents for Capacitive Mode Option 022220022220000 6 23 6 26 Interface Inputs for Capacitive MOdEe cccccceccccceecceeececeeececeeeceseueeeseeeessesesseeesseeeesaeeesaaes 6 24 6 27 Interface Output for Capacitive MOdE ccccccceccccseececeececeeececeeceeseeceesuecesseeeeseeeseeeeseneensnes 6 25 6 28 Installation of the Nozzle Sensor Option ccccccccsseseeceeeeeeeseeeeeeseeeeeeeeeeeeeeseeeeesaeeeeesaeeees 6 26 6 29 Wiring of Control Signals for Oxyfuel Mode ccccccecceecseeeeeeeeeeeeeeeeeeeeaeeeeeseeeseeesaeeeesaeeeeens 6 28 Va C6 0 AT ene E ee B ne ee ee A ee er ee ae ee eee ee ee eee 7 1 7 1 Safety Regulations cccccsescccccesececceseeccseneeecsegeeecsaeeeeeeaseeessugeeecsagececseeeeesageeessageeessscseeessaass 7 1 1 2 Requirements and Hints for first Start Up 200022200s2snnennnnnnnnnnnnnnnnennnnnnnennennnnnn nennen nnnnenn 7 2 1 3 Checking of Grounding u 440004ennne nennen nennen nnennnn nennen nnnnnnnnnnnnnnnnennnnnnennnnnnsnnnnnnnernnnnnnn 7 2 7 4 PONE ee nee ee ee ee eee ee ee ee ee 7 3 7 9 Checking of LINEAR DRIVE functions cc ceccccceeeeeeeeeeeeeeceeeeeeeeeeeeeeaeeeeesaaeeeesaeeeeessaeeesaaess 7 4 7 6 Check of Collision at LINEAR DRIVE cccccccccccseececseeeeseeeeceeeeeeeeceeseeeesseeeeseeeeeseeeesaeeessnees 7 5 CS UO and SEUD eein nE EE E AE EAE EEE EREA 8 1 8 1 Settings at the Operator Terminal un
52. onnection to LINEAR DRIVE COAX CABLE SENSOR TORCH CLAMP jo SENSOR CONNECTOR UNIT _ j Oxyfuel Torch Turn to center f Mounted at LINEAR DRIVE Ring Electrode o RING ELECTRODE 6534 6560 6575 Optional outer 34 60 75 mm These components are available in 3 different kits depending of the diameter of the RING ELECTRODE which defines the nominal clearance between the RING ELECTRODE and the metal workpiece Device No Contains RING ELECTRODE IHT Part No with diameter mm Ring Electrodes measure touch less the distance to the metal work piece Content of a SENSOR KIT Pos Device IHT Type No IHT Part No SENSOR CONNECTOR UNIT IHT 6531 1 100 100212 SENSOR TORCH CLAMP IHT 6530 1 100 100268 COAX CABLE IHT 1991 1 100 100279 RING ELECTRODE IHT 65xx 1 100 Rev 2 9 5 IHT 3000 Clearance Control System e h User s Manual i System Components 5 3 1 RING ELECTRODE IHT 6534 6560 6575 e Ring Electrodes measure touch less the distance to the metal work piece e Ring Electrodes are available for different torches with diameters 34 60 and 75 mm e The nominal clearance between Ring Electrode and es C work piece is between 8 to 16mm depending on the type of Ring Electrode Features e special spatter protected surface for high reliability e 3 standard types matching different torch diameters e special small ring electrode Type 6534 offers high workpiece efficien
53. r Supply must be installed enclosed in the machine control cabinet Outer dimensions of the power supply 199x1 10x50 mm Length x Width x Height The power supply can be mounted on the base or the side face N Attention Maximum length of engagement into the housing 4 mm Hole pattern with outer dimensions for mounting the power supply at the base terminal strip left 4 mounting screws M3 199 Position of the terminal strip Hole pattern for mounting the power supply at the side face terminal strip right Mounting holes for M3 screws Lf 29 iamas 33 a ym Rev 2 9 Installation IHT 3000 Clearance Control System User s Manual 6 9 Electrical connection POWER SUPPLY 7504 A A Power Phase L 230 VAC external fuse 1 6 AMP medium u Power Phase N Rev 2 9 Observe the safety regulations when connecting the power supply Check the supply voltage selector switch factory setting 230 VAC At a supply voltage of 120 VAC switch the sliding switch The power supply must be mounted in an enclosure so that contact with other devices or humans is avoided Insert correct fuse in AC line Phase L Fuse Phase L at 230 VAC with 1 6A medium slow Note instructions at the POWER SUPPLY 7504 ATTENTION Connect and c
54. st be connected to the star point The four corners of the cutting table must be connected to the rail Rev 2 9 13 1 IHT 3000 Clearance Control System i by t User s Manual Grounding a Cutting Machine Example of a Cutting machine with a cutting current up to 150 A The same cables used for welding can be used as grounding cables Figure1 View from above top view Rail width of cable 2 0 AWG Rail equivalent 70 qmm on all 4 corners Plasma source Ground Rod width of cable 2 0 AWG equivalent 70 qmm Cutting Table Star Point Chassis of Machine Control Positive Plasma Voltage Output width of cable 1 0 AWG equivalent 50 qmm stranded wire 2 0 AW equivalent 70 qmm orch Lifter Note For a higher cutting current more than 150 A the width of cables should be increased to 4 0 AWG equivalent 95 qmm Rev 2 9 13 2 IHT 3000 Clearance Control System i by t User s Manual Grounding a Cutting Machine 13 3 Notes to the Plasma Current Return Path The plasma cutting current is generated by the plasma source The current flows from the negative terminal to the torch flows through the arc and the work piece to the cutting table From the star point the current flows back to the positive terminal of the plasma source To achieve a trouble free operation the impedance of the return path must be as small as possible For this purpose the proper elec
55. st vertical drive for precise clearance control of plasma and oxyfuel torches to metal sheets e integrated control e dust proof chamber protects rail and gear e built in vertical collision protection e 3 dimensional collision protection at the torch clamp e clamp for hoses and cables e high temperature proof bellows made of silicone rubber e US Patent No US 6 239 573 B1 Euro Patent No 0997801 General technical data MOTOT serene EEE ER ARRERER 24 VDC max 6 5A POWER nee een 100 W OOKO oaia RE 210 mm Torch Clamp for Torch Diameter 35 53 mm standard or 30 35 mm option Protective Earth Connector Screw M4 Weight cccseceeeeeeeeeeeeeeeeeeees 12 kg Dimension of Housing approx 115x226x160 WxHxD Dimensions overall approx 120x730x250 mm WxHxD Features of versions LINEAR DRIVE IHT 2343 1 100 IHT 2346 1 100 IHT part no 100354 100356 stoke zom zom AN Note The LINEAR DRIVE can only be used for vertical operation IHT 3000 Clearance Control System e h User s Manual Ini System Components Side View of LINEAR DRIVE 2343 View with plasma torch Dimensions in millimeters Hose clamp min 90 max 310 u O_O Linear Drive IHT 2343 226 7 FA Y t 2 I u Fy J NA KS Cutting Machine oe oi e
56. the deflection loading force Turn adjusting screw clockwise with a hex wrench 5mm H PU lt _ Hose Clamp lt Push here Collision Protection Unit Ensure that deflection is not Da blocked when adjusting screw has i been driven to hard Put in hex wrench 5mm Hex wrench 5 mm ATTENTION Turn clockwise only as far as necessary to maintain sufficient deflection Note Otherwise the built in collision switch doesn t function and the unit may be damaged in case of collision The adjustment range of the vertical deflection force is from 30 to 120 N Rev 2 9 6 4 IHT 3000 Clearance Control System i h t User s Manual Installation 6 4 LINEAR DRIVE Electrical Connections INTERFACE POWER SUPPLY ee HHHH ee u a RE ANOOOODOOO90N0900 rer SS mE mE ee mie ee Aa a ee a Be Sas if Fel tt yooo o ET ei L g n A Da a ur u Gee Fr Fe LIE FL ICH ole See oe dr LINEAR DRIVE CONTROL CABLE IHT 7250 1 901 LINEAR DRIVE POWER CABLE IHT 2300 1 901 LINEAR DRIVE PE Grounding Terminal D Connector 6 3 mm Faston or terminal for M4 screw Wire minimum 6 qmm AWG8 Connector for __ Ly COAX CABLE IHT 199
57. the work piece ATTENTION Risk of collision Torch RING ELECTRODE I Work piece O WH 1 ed Risk A collision Edge of Work piece Rev 2 9 8 14 IHT 3000 Clearance Control System i h t User s Manual Operation and Setup 8 6 Operating of NOZZLE SENSOR The complete NOZZLE SENSOR must be installed 1 Power on The display of the OPERATOR TERMINAL shows CAP if the NOZZLE SENSOR is ready If the former mode was Cutting Height the OPERATOR TERMINAL shows this mode 2 Only if CAP is displayed the touch less initial position finding will be done Otherwise the tactile initial position finding operates 3 The prime initial position finding is a reference movement where the nozzle of the plasma torch touches the metal sheet softly 87 Activating and Deactivating of the touch less Initial Position Finding by NOZZLE SENSOR The IHT 3000 LINEAR DRIVE activates the touch less initial position finding automatically if the sensor system is properly assembled In that case you can find the message CAP at the display of the OPERATOR TERMINAL To deactivate the NOZZLE SENSOR the COAX CABLE must be removed Attach the protection cap to the connector at the top of IHT 3000 LINEAR DRIVE Rev 2 9 8 15 IHT 3000 Clearance Control System i a t User s Manual Operating and Setup 8 8 Reference Movement After power on and during the prime initial position finding the IHT 3000 LINEAR DRIVE
58. tor Amplifier faulty Get in contact with IHT Service 3 Motor faulty Motor cables interchanged After power on the Motor cables Interchange motor connectors at torch lifter moves interchanged pcb board downwards instead of upwards Encoder Torch lifter moves Encoder or cable Check the cables and connectors to limit switch connection faulty Rev 2 9 11 2 IHT 3000 Clearance Control System e h 3 User s Manual 12 Revision History Rev Page No 2 4 May 07 Interface 7250 equipped with additional arc voltage input range 0 to 6VDC 2007 according an arc voltage of 0 to 250 VDC Setting No 4 at Interface 7250 Added notes at page 13 1 Attention It implicates an improper use if no sufficient grounding is provided According notes in chapter 6 5 6 6 and 6 8 added Resistance to ground less than 1 Ohm reduced from 3 Ohms May 31 5 21 recommended use of converter 2007 5 22 December 12 New function Reference Position at output 16 of Interface 2007 New setting menus for End of Cut and selection mm inch new in menu commands and status cycle active new in menu Error Display Error In table output 16 updated Same Menu Parameter CutHeight updated Menu Status updated by Cycle active New function Detection of end of cut by adjustable threshold of arc voltage December For internal use only 2008 January 12 In table connector X201 Operator Terminal 2009 pin 6 DATA added Jumpered inside the Interface 7250 with
59. tor for COAX CABLE 1 Check the weight compensation refer to IHT 3000 Instruction Manual 2 Turn knob of weight compensation 1 turn counterclockwise Note This avoids that the tactile initial position finding appears before the NOZZLE SENSOR detects the surface of the metal sheet Because the tactile initial position finding is active at the same time an initial position finding will be done also if the NOZZLE SENSOR fails This secures the function of initial position finding Rev 2 9 6 27 IHT 3000 Clearance Control System M fa t User s Manual Installation 6 29 Wiring of Control Signals for Oxyfuel Mode INTERFACE 7250 High Arc Voltage Minus 300 V Reference Low Arc Voltage 0 VDC 3 Reference High Arc Voltage 0 V or Low Arc Voltage 10 V No function Initial Position Start Ready Start XY 8 Piercing Height Oxyfuel Co feom a ManwalUp as manuo 7 INTERFACE 7250 Machine Control Output pias mars Bomann 2 Tinterface Ground a Plasma Stat relay contact 6 oxtowowe ooo e DelayTime o Plasma Stan gt Rev 2 9 6 28 IHT 3000 Clearance Control System i h p User s Manual 7 Start up 7 4 Safety Regulations Please read the user s manual carefully e Installation getting started and maintenance work may only be performed by trained experts in compliance with the generally accepted rules of safety and technology e When wiring follow the
60. trical connection to the star point and to the plasma source have a great influence These electrical connections should be well maintained Figure 2 Plasma Source Torch Work sie Bu BEZ plus 1 az Return Path Star Point Cutting Table 13 4 Notes about a Proper Electrical Contact A proper electrical contact needs connections which are made with bare metal to metal contact The connections have to be very tight and should be protected against rust and corrosion Grounding connexion has to be connected to the machine ground in the shortest possible way Cable width should not be smaller than 2 5qmm Copyright 2007 2009 IHT Automation GmbH amp Co KG Subject to change without prior notice Rev 2 9 13 3
61. ve earth PE terminal of LINEAR DRIVE 2343 SENSOR TORCH CLAMP 6530 POWER SUPPLY 7504 must be connected to protective earth potential machine ground potential Carefully observe all plasma source producer s interconnections wiring instructions e Thorough care must be taken to ensure proper grounding of the plasma source in order to prevent EMF disturbance paths to the IHT 3000 system e The main ground earth resistance must be kept below 3 Q for adequate grounding precautions The shielding of the Arc Voltage Cable to the plasma source must not be connected at IN the plasma source ground but has to be connected in the control cabinet or the metal housing PE Potential with the machine ground in the shortest possible way Rev 2 9 2 1 IHT 3000 Clearance Control System e h User s Manual i 3 IHT 3000 Application and System Description The height control system IHT 3000 enables a touch less and precise clearance control of plasma and oxyfuel torches on cutting machines Using this height control system leads to high quality results when cutting with or without the influence of water The IHT 3000 system automatically controls the distance between the plasma or oxyfuel torch and the metal sheet Initial position finding of the work piece Before the system starts cutting IHT 3000 precisely detects the position of the work piece and finds the pre selected PIERCE HEIGHT ignition height This process
62. x75x112 mm Length x Width x Height Mounting of HOUSING u on symmetric mounting rail according to EN 60715 Protection class 002220022220 nennen Housing IP40 Clamps IP 20 according to EN60529 IEC529 Environment conditions no condensation at 0 50 C 20 90 relative humidity Weight una ia 0 33kg IAT pat INO een 100358 Digital input of control signals 7AHCT14 Input GND Digital output of control signals Output GND Rev 2 9 5 16 IHT 3000 Clearance Control System e h User s Manual i System Components 5 6 1 Connections and settings INTERFACE IHT 7250 Standard setting 0 to nna ao Linear Drive 2343 Address Baud rate ARC Voltage range Discrete signal inputs X301 Fault Interface IHT 7250 Communication Terminal X201 Cutbus X202 Discrete signal DIDADODSDIDOSOOITIIOIG outputs X305 Ready to Cutbus Operator Terminal RS 485 7260 Rev 2 9 5 17 System Components 5 6 2 Rev 2 9 IHT 3000 Clearance Control System User s Manual Input Connector X301 17 pole connector with screw on clamps Interface IHT 7250 X301 Signal Inputs High ARC Voltage Input Minus 300 V Reference for Low Arc Voltage Input Ground OV Reference for High ARC Voltage Input 0 V Low ARC Voltage Input max 10V 6 Initial Position Start Ready Start XY Piercing Height Oxyfuel 9 Corner Retract 1 Retract 2 12 1617 O
63. y use an extended bracket 1 Rotate the knob Weight Compensation clockwise until a slight lift up of the torch occurs 2 Rotate the knob counter clockwise until the the lifter slide on the lower chock safely 3 Check the weight compensation Adjusting Knob for Weight Compensation N on J Hoses Cables Check the sliding part of LINEAR DRIVE Plasma Torch Lift up here and release it again um fal It The lower chock must be touched tightly Adjustment with the weight compensation knob ATTENTION Rotate knob Weight Compensation counter clockwise only as far as necessary to rest on the lower chock safely The touching force will be unnecessarily high when the nozzle touches the work piece otherwise Rev 2 9 6 3 IHT 3000 Clearance Control System User s Manual Installation 6 3 LINEAR DRIVE Check of Collision Protection Push the torch clamp out of it s normal position until the recess is left and release it again Check The torch must return into correct vertical direction If the torch doesn t safely return into the vertical direction then check that the hose does not hindered the deflection If necessary correct the position of the hose However the torch do not move exactly to the vertical direction then increase

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