R953A

[R953A.doc rev: 0807]

Plasma torch height control system

for profile cutting machines
- control PCB.

Features:

- DC 24V output for standard brushed permanent magnet motor

- constant torch height control done by means of sampling the
arc voltage
- initial height sensing prior to cut
- adjustable gain and up/down speed
- single DC 24V supply
- PCB size 100 x 80 x 30 mm

General description:

The R953A control system is an interface between CNC controller or tracing head and Plasma unit. R953A
provides all necessary signals for controlling the up/down movement of the cutting torch.

Detailed description:

A switch mode servo driver drives the motor. For simplicity of interfacing the speed feedback (tacho,
encoder, etc.) has been omitted and the back EMF voltage from the winding of the motor is integrated and
used as a speed feedback for the driver. The driver can deliver close to 2 amperes peak current at nearly
100 % duty cycle. When the up (or down) input is activated, this connects the positive (or negative) supply to
input of the driver.

The arc voltage must be externally divided into less than 5 volts. This signal is applied to ARC_VOLTAGE_1
and _2. The difference between arc voltage and reference voltage is amplified and fed to the servo driver.
The speed of the movement is proportional to the difference of these voltages. The reference voltage is a
preset value of the arc voltage, 0 to +5V, delivered from panel mount potentiometer or analogue output from
the CNC.

The auto sequence logics are used for the initial height sensing. When enabled (+AUTO) and +PLASMA
signal is toggled on (from manual START switch or CNC controller), the torch is lowered down, the
+24V_AIR and +24V_PROXY outputs are activated. The +24V_AIR is used for solenoid controlling a spring
returned air cylinder, which lowers the proximity switches to the height of tip of the torch. When the torch is
lowered to the cutting height, the proximity switch is activated (the NPN_PROXY input switched to 0V), the
down movement and +24V_AIR output are deactivated, what retract the proxy switches to the safe position
and plasma on relay is activated, this starts the plasma cut. When +PLASMA is off the up movement is
activated.

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
1
 R953A
[R953A.doc rev: 0807]

ERROR AMPLIFIER
REF THC
+ THC ENABLE
- DOWN
ARC_VOLTAGE1 +
0 UP
ARC_VOLTAGE2 -
GAIN +V
SERVO DRIVER
-V ERROR AMPLIFIER
DIFFERENTIAL AMPLIFIER + OUT1 MOTOR1
0
+THC IN
SPEED - OUT2 MOTOR2
+DN

+UP
0 PWM DRIVER

BACK EMF INTEGRATOR

+PLASMA +PLASMA +DN

PLASMA_ON1
+UP

+AUTO +AUTO PLASMA_ON

PLASMA_ON
+24_AIR
PLASMA_ON2
NPN_PROXY +24_PROXY

AUTO SEQUENCE LOGICS +24_AIR

+24_PROXY

NPN_PROXY

Fig. 1.

Interfacing:

Fig 2. and 3. shows the typical connection of R953A (953-000) control system. Both examples use same
interface to the plasma unit, CNC controller and cutting torch. The differences are only in the connection of
mode selection switches. The whole control system must be supplied from DC 24V power supply; capable
delivering enough current for all outputs (motor, solenoid, etc.) plus few hundreds of milli-amperes for R953A
PCB. Usually, the 4 amperes power supply is enough.
24V/~3A
CNC CONTROL +24
+24
PLASMA_START1
PLASMA_START2 +24

ARC_ON-SENCE1 0V
ARC_ON-SENCE2
0V 0V
THC_EN1
THC_EN2

CUTTING TORCH ASSEMBLY

PLASMA UNIT
+24
ARC_ON_RLY1
ARC_ON_RLY2

PLASMA_ON1
PLASMA_ON2

ARC_VOLTAGE1
SCREEN
ARC_VOLTAGE2
14

13

12

11

10

LIMIT_2
100V/3A
+24V
0V

0V

MOT2

MOT1
+PROXY
THC_EN

+24_AIR
NPN_PRXY
+PLASMA
PLASMA_ON2

PLASMA_ON1
ARC_VOLTAGE2

ARC_VOLTAGE1

J1
AIR_VALVE

J2
LIMIT_1
UP/DOWN DC MOTOR 100V/3A

14
+24V
13
+24V
12
0V
11
0V
10
THC_EN
9
THC_EN
8
+PLASMA
7
+PLASMA
6
GND

GND
+Vin

+Vin

+AUTO
OUT

OUT

5
+AUTO
4 +
REF
3
+THC
2
PLASMA_ON 3K3 1
+DN CONNECTED TO INTERNAL CIRCUIT A
+UP
RELAY OUTPUT 5A CONTACT
-
AUTO_INIT UP/DOWN
10K 953-000
TCH_ON ARC_VOLTAGE PROXY_NPN PROXY_NPN
LM336-5 MULTITURN POT WITH DIAL

Fig. 2.

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
2
 R953A
24V/~3A
[R953A.doc rev: 0807]
CNC CONTROL +24
+24
PLASMA_START1
PLASMA_START2 +24

ARC_ON-SENCE1 0V
ARC_ON-SENCE2
0V 0V
THC_EN1
THC_EN2

CUTTING TORCH ASSEMBLY

PLASMA UNIT
+24
ARC_ON_RLY1
ARC_ON_RLY2

PLASMA_ON1
PLASMA_ON2

ARC_VOLTAGE1
SCREEN
ARC_VOLTAGE2

14

13

12

11

10

LIMIT_2
100V/3A
+24V
0V

0V

MOT2

MOT1
THC_EN

+24_AIR
PLASMA_ON2

PLASMA_ON1

NPN_PRXY
+PLASMA

+PROXY
ARC_VOLTAGE2

ARC_VOLTAGE1
J1

AIR_VALVE
952-000
J3 J2

LIMIT_1
100V/3A
14 14
+24V +24V
START STOP 13 13
IDC RIBBON CABLE

+24V +24V
12 12
0V 0V
11 11
0V 0V
10 10
THC_EN THC_EN
9 9
THC_EN THC_EN
8 8

UP/DOWN DC MOTOR
+PLASMA +PLASMA
THC AUTO +PLASMA
7
6
7
6
+PLASMA

GND

GND
+AUTO +AUTO

+Vin

+Vin
OUT

OUT
5 5
+AUTO +AUTO
4 4 +
J5 J4 REF REF
3 3
+THC +THC
2 2
POT_LOW
POT_ADJ

+DN +DN CONNECTED TO INTERNAL CIRCUIT

1 1 A
POT_HI

+UP +UP
RELAY OUTPUT 5A CONTACT
+DN
+UP
+24

953-000
PROXY_NPN PROXY_NPN
3
2
1

3
2
1

2K - 10K
UP/DOWN ARC_VOLTAGE
MULTITURN POT WITH DIAL

Fig. 3.

CNC controller:

A dry relay contact should be activated between PLASMA_START1 and PLASMA_START2 to start the
plasma unit. A 24 V output from CNC controller connected to PLASMA_START2 can be used instead of
relay output. The controller to signalize to the CNC that manual start of the plasma has been activated can
also sense this line. A DC 24 V can be sensed between ARC_ON-SENSE1 and ARC_ON-SENSE2. This is
usually used to start the motion of machine. If the CNC controller requires a dry contact or different level of
signal, insert a coil of additional 24V relay between ARC_ON-SENSE1 and ARC_ON-SENSE2 and with
contact of the relay simulate the level, which is required. The CNC controller should provide a normally
closed contact, which disables the THC while the machine, does not cut at full cutting speed (e.g.. when is
slowing down on the sharp corners or during lead-in or lead-out). This contact should be connected between
THC_EN1 and THC_EN2.

PLASMA UNIT:

The plasma unit must be able to be started from external contact. This contact is between PLASMA_ON1
and PLASMA_ON2. As well the plasma unit must have an output, which signalize that the arc is on. This is
usually done by a current relay inside the plasma unit, which close the contact between ARC_ON_RLY1 and
ARC_ON_RLY2. If this signal is not a dry contact or DC +24V, connect a coil of additional relay to this signal
(coil rated same as value of this signal e.g.. AC 110V) and use contact of this relay to close ARC_ON_RLY1
and ARC_ON_RLY2 lines. Many of plasma units have already build in a voltage divider of the arc voltage.
This is usually 25:1, 50:1 or 100:1. The voltage from this divider should be applied to ARC_VOLTAGE1
andARC_VOLTAGE2. A twisted pare screened cable should be used and screen should be terminated only
on one end. If the plasma unit does not have suitable voltage divider installed, please see section Selection
of voltage divider for arc voltage. This divider should be fitted inside, or very close to, the plasma unit to
decrease the possibility of radiation of noise from arc current.

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
3
 R953A
[R953A.doc rev: 0807]
CUTTING TORCH MOVEMENT ASSEMBLY:

The up and down movement of the torch must be motorized and driven by standard permanent magnet DC
24V motor. The limit switches for upper and lower limit should be normally closed and the contact should be
bridged with diode that allows driving only to the opposite direction of the position of the limit. If initial height
sensing is used, one or more normally open NPN type proximity switches should be used together with
solenoid valve for air, which activates the spring, returned air cylinder for lowering the proxy switches to the
height of the tip. The proximity switches can be substituted with mechanical switches with extended
actuators and air cylinder together with solenoid valve can be substituted with electromechanical solenoid.
The electromechanical solenoid should lower the actuators of the switches below the tip of torch, and when
the actuator tough the plate solenoid should retract the switches above the tip of torch.

Mode selection switches:

In the second example (Fig.3.), connection to switches is simplified by using the R952 PCB. This PCB is also
available from Rutex. See appendix B for description of this PCB. When installing this PCB, four switches
(PLASMA START, PLASMA STOP, AUTO and THC) are fitted on the front panel and R952 PCB is directly
soldered onto these switches. The up/down switch and the potentiometer for arc voltage are connected via
screw-in terminals. The R952 and R953A PCB are connected with 16 ways ribbon cable. The first example
(Fig. 2.) is hardwired version of R953A PCB.

Test circuit:

The Fig. 4. shows a bench test circuit of R953A board. This setup should be used before the first installation
or when testing a different type of motor etc.
PLASMA_ON

PROXY_SW

PROXY_ON

+24
AIR_ON

2K2
0

10K 10K -

A
5V1/0.4W
+
0 +24 +24
14

13

12

11

10

UP/DOWN DC MOTOR
+24V
0V

0V
THC_EN

+24_AIR

+PROXY
NPN_PRXY

MOT2

MOT1
PLASMA_ON2

PLASMA_ON1

+PLASMA
ARC_VOLTAGE2

ARC_VOLTAGE1

J1

J2
14
+24V
13
+24V
12
0V
11
0V
+24 10
PLASMA THC_EN
9
THC_EN
8
+PLASMA
7
AUTO +PLASMA
6
+AUTO
5
+AUTO
4
THC REF
3
+THC
2
+DN CONNECTED TO INTERNAL CIRCUIT
1
+UP
RELAY OUTPUT 5A CONTACT

UP/DOWN 953-000

Fig. 4.

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
4
 R953A
[R953A.doc rev: 0807]
Selection of voltage divider for plasma arc.

The function of voltage divider is to divide the arc voltage in ratio that the output voltage from the divider
does not exceed 5V. When THC operates correctly and certain voltage (REF J2 pin 4) is preset, the height of
the torch is adjusted so that reference voltage (J2 pin 4) is equal to divided voltage from arc.

For example a 50:1 divider is used and required arc voltage is 125 volts. The reference voltage must be
preset to 125 / 50 = 2.050 volts.

When using R953A PCB, which has 5V reference diode on board, with standard 10-turn multi turn
potentiometer with 15 turns dial a voltage can be directly read from dial of this pot. The low side of this pot
must be adjusted to 1 volt, high side to 3 volts and dial set from 50 to 150. With 50:1 divider, the preset
voltage 2.050 will be read on dial as 125 +/- tolerances.

When selecting values of resistors for voltage divider an input impedance of 20-kilo ohms on ARC
VOLTAGE inputs (across pin 12 and 14 of J1) should be taken in account in case of use high value resistors.
The output of the divider should be bypassed by the capacitor (in ten or hundreds of nanofarads) to
attenuate high frequency from arc and protected by a high-speed low voltage transient suppresser (such
General Instrument SA5.0, SGS-Thomson BZW03P5V8, AVX-Kyocera VA100005A150).

A standard 50 : 1 divider is also available from Rutex (p/n R983).

Installation and adjustment.

During the initial installation the arc voltage should be supplemented with a low current variable DC supply 0-
300V (or range of expected arc voltage). Plus of this supply should be connected to ground, negative to input
of voltage divider (not directly to R953A board!!!). Correct polarity of connection of voltage divider should be
verified by an error LED located on the R953A. If the LED lit up, when the power is on and the arc voltage is
applied, swap wires between pin 12 and 14 of J1.

They are only 2 pots for adjustment. The SPEED pot should be set while toggling the UP/DOWN switch and
adjusting up & down speed of torch lifter for required speed. For most of the application this can be set to
about 20 V DC measured across the motor. The GAIN pot should be adjusted by simulating normal cut by
changing the voltage from DC supply connected to the voltage divider. The GAIN pot should be adjusted to
maximum available gain just before the point when the correction starts overshooting.

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
5
 R953A
[R953A.doc rev: 0807]
APPENDIX A

Connector J1 (14 pin KLIPPON connector)

pin Name Description Notes

#

1 MOT1 output for DC motor 24V PWM output 20-30kHz

2 MOT2 output for DC motor 24V PWM output 20-30kHz
3 +24V Supply DC+24V maximum 36V

4 0V Supply return 0V
5 +PROXY +24V output for supplying Output is activated when plasma input (J1 pin 8) or
proxy switches plasma switch (J2 pin 7&8) is activated and AUTO (J2
pin 5&6) is selected

6 +24V_AIR +24V output for supplying Output is activated after plasma input (J1 pin 8) or
mechanisms for lowering plasma switch (J2 pin 7&8) is activated and AUTO is
switches for initial height selected, until NPN_PROXY (J1 pin 7) is activated.
sensing

7 NPN_PROXY input - active, when Output from NPN proxy switches or mechanical
switched to 0V switches activated when torch is lowered to initial
height.

8 +PLASMA Input - +24V active Control from CNC to start the plasma. Same as J2 pin
7&8.

9 PLASMA_ON1 Relay output Connected to Plasma unit; plasma start

10 PLASMA_ON2 Relay output Connected to Plasma unit; plasma start

11 THC_EN Input - +24V active Enables function of height sensing. This input must be
interlock with the ARC ON RELAY from plasma unit
and CORNER SLOW DOWN output from CNC
controller. Directly linked to J2 pin 9&10

12 ARC_VOLTAGE1 Analog input from voltage Differential input in range -5 to +5 V

divider (+V)
13 0V Screen of arc voltage Screen of the cable should be grounded only on this
cable end

14 ARC_VOLTAGE2 Analog input from voltage Differential input in range -5 to +5 V

divider (-V)

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
6
 R953A
[R953A.doc rev: 0807]
Connector J2 (14 pin IDC connector*)

pin # Name Description Notes

1 +UP input 24V activates movement UP of the motor

2 +DN input 24V activates movement down of the motor

3 +THC input 24V activates function of THC

4 REF analogue input preset of the arc voltage DC 0-5V
5&6 +AUTO input 24V enables automatic initial height sensing
7&8 +PLASMA input 24V when AUTO (J2 pin 5&6) not selected directly
activates the plasma relay output (J1 pin 9 and 10);
when AUTO (J2 pin 5&6) is selected activates the
initial height sensing before activating the plasma
relay output(J1 pin 9 and 10).

9&10 THC_EN supply for THC switch Directly linked to J1 pin 11.

11& 0V return of supply same as J1 pin 4 & 13

12
13& +24V supply 24V same as J1 pin 3

14

* - for a upward compatibly a 16-pin header is used with pin # 15 & 16 removed

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
7
 R953A
[R953A.doc rev: 0807]
APPENDIX B

K1

0V
G5V
S1 START S2 STOP 24

V15

1N4004
J3
R40
1 470R
SW-MOM SW-MOM
2
3
4
S3 THC S4 AUTO 24
5
0V
6
7
8
9 R42
10
11 470R
0V
12
0V 24 SW-LATCH SW-LATCH
13
24 J5
14
3PIN
IDC14
1 UP SWITCH
2 COMMON
3 DN SWITCH
R41
470R 1 ARC POT 3V
0V
2 ARC POT ADJ
3 ARC POT 1V
24
R39 R37 J4
3K3 R38 5K 3PIN
V11
5K
LM336-5

0V

952-000 PCB

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
8
 R953A
[R953A.doc rev: 0807]

+27 +27
?

AC110V OXY CUL VALVE

DC24V MANUAL CUT SW

0
?
BURNY 2.5 RS +27
+27
PLASMA_START1
PLASMA_START2
DIODE
CONNCETED TO SUPPLY CAPACITOR
ARC_ON-SENCE1
ARC_ON-SENCE2
0V 0V
THC_EN1
THC_EN2
HL82 OXY ONLY ( NO PLASMA PROVISION)
MAX 100
+27
ARC_ON_RLY1
ARC_ON_RLY2

PLASMA_ON1
PLASMA_ON2

ARC_VOLTAGE1
SCREEN
ARC_VOLTAGE2
14

13

12

11

10

1
MOT2

MOT1
+PROXY
0V

0V

+24V
THC_EN

NPN_PRXY
+PLASMA
PLASMA_ON2

PLASMA_ON1

+24_AIR
ARC_VOLTAGE2

ARC_VOLTAGE1

J1
LIMIT_2
100V/3A

J2
14
+24V
3K3 13
+24V
12 LIMIT_1
0V
11 100V/3A
0V
10
THC_EN
9
THC_EN
8
+PLASMA
1K 7
+PLASMA
6
+AUTO
5
+AUTO
1K 4 +
REF
3
+THC
2
+DN CONNECTED TO INTERNAL CIRCUIT
1 A
+UP
UP/DOWN RELAY OUTPUT 5A CONTACT
-

LM336-5 953-000
TCH_ON UP/DOWN DC MOTOR
1K ARC_VOLTAGE
1K 2- 4 V ( eq. to 100 - 200 V arc)

CUTTING TORCH ASSEMBLY

R953A (953-000) interfaced to the MAX100 plasma, Burny 2.5 controller and old type HL82 tracing head.

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
9
 R953A
[R953A.doc rev: 0807]
CNC CONTROL +24 PLASMA 1 PLASMA 2
PLASMA_START1
PLASMA_START2

ARC_ON-SENCE1
ARC_ON-SENCE2
0V +24
THC_EN1
THC_EN2
+24 PLASMA UNIT 2
ARC_ON_RLY1
ARC_ON_RLY2
PLASMA UNIT 1 PLASMA_ON1
ARC_ON_RLY1 PLASMA_ON2
ARC_ON_RLY2
ARC_VOLTAGE1
PLASMA_ON1 SCREEN
PLASMA_ON2 ARC_VOLTAGE2

ARC_VOLTAGE1
SCREEN
0V 0V
ARC_VOLTAGE2
14

13

12

11

10

14

13

12

11

10
9

1
NPN_PRXY

NPN_PRXY
+PROXY

+24V

+PROXY

+24V
THC_EN

THC_EN
+24_AIR

+24_AIR
MOT2

MOT1

MOT2

MOT1
PLASMA_ON2

PLASMA_ON1

PLASMA_ON2

PLASMA_ON1
ARC_VOLTAGE2

ARC_VOLTAGE1

ARC_VOLTAGE2

ARC_VOLTAGE1
0V

0V

0V

0V
+PLASMA

+PLASMA
J1 J1

J2 J2
14 14
+24V +24V
13 13
+24V +24V
12 12
0V 0V
11 11
0V 0V
10 10
THC_EN THC_EN
9 9
THC_EN THC_EN
8 8
+PLASMA +PLASMA
7 7
+PLASMA +PLASMA
6 6
+AUTO +AUTO
5 5
+AUTO +AUTO
4 4
REF REF
3 3
+THC +THC
2 2
+DN CONNECTED TO INTERNAL CIRCUIT +DN CONNECTED TO INTERNAL CIRCUIT
1 1
+UP +UP
RELAY OUTPUT 5A CONTACT RELAY OUTPUT 5A CONTACT

Two R953A (953-000) interfaced to one CNC and two plasma units

© 2001-2008 RUTEX, 8 Jean Ave, Berkeley Vale 2261, Australia, ph +61-2-43884798 (http://rutex.com)
10