USER’S MANUAL

Controls

During operation, press the SP.

During operation, press the UP button to VOLTS+ button to increase set point
move the drive upwards. For use during voltage. For use during setup, see the
setup, see the following chapter
125.5 following chapter

During operation, press the DOWN button During operation, press the SP. VOLTS-
to move the drive downwards. For use button to decrease set point voltage.
during setup, see the following chapter For use during setup, see the following
chapter

During operation, indicates the position

within the control sequence. Press the THC Mode button to change the control mode from AVC OFF
During setup, indicates the selected to AVC ON – the LED “MODE” indicates the selection. For use during
parameter. setup, see the following chapter

 Press and hold the “THC MODE” button for entering to the setup menu.

Pr. 1

 When profile select menu will be appear release “THC MODE” button. “ESC MENU” LED will
flash.

SET.U

 Press Torch UP/Down buttons to navigate to a parameter.

 Press the THC MODE button to enable a change in parameter.

125.5

 Press SP.VOLTS +/- buttons for change the parameter.

 Press again THC MODE button to return from submenu.
 Press and hold THC MODE button to exit from setup menu and store the parameter in the
operator interface.
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Set-Up of Cutting Sequence

Parameters

NOTE: Default unit is mm. To change to inches, first change the units. Controller has two
independent profiles and general settings data bases for mm and inches systems. If you change
units, please check all parameters.

The cutting profile setup menu allows you to set up the following parameters:

Parameter Range Steps

Cutting profile select menu Allow to select cutting profile from database
Set Point Voltage 25 volts to 250 volts 0.5 volts
2 mm to 20 mm 0.1 mm
Pierce Height
0.08 in to 0.8 in 0.01 in
Pierce Time 0 s to 10 s 0.1 s
0.5 mm to 25 mm 0.1 mm
Cut Height
0.01 in to 1.0 in 0.01 in
AVC Delay 0 s – 10 s 0.1 s
THC Dynamic 1.0-30.0 0.1
Lock Head Down Level 4-20% of Arc Voltage 1%
10 mm to 60 mm 1 mm
Retract Height
0.4 in to 2.5 in 0.01 in
Transfer Height 50 - 450% of cut height 1%
SHOT mode select On/Off
Testing mode Select to start test of the cutting sequence
Re Reference Select to start homing procedure
Configuration menu Select to enter to the configuration menu of the controller

Set Point Voltage

The Neuron.THC system maintains the Set Point Voltage during a cut in the Auto
SET.U mode. Raising the Set Point Voltage will increase the torch height during a cut,
while lowering it will decrease the cutting height of the torch. The Set Point
Voltage can be adjusted from 50 to 250 volts in 0.5 volt increments.

Pierce Height
This value determines the height at which the torch pierces the workpiece.
PrS.H
Pierce time
This is the value for the Pierce Time. During this time, the X/Y cutting motion is
PrS.t delayed to allow the plasma to fully pierce the workpiece.

Cut Height
This value for the height at which the torch cuts the workpiece, but before then
CUT.H AVC closed loop control will be started (if AVC ON).

AVC Delay
This value sets the number of seconds that are required for the cutting machine

AUC.d and plasma torch to achieve steady-state operation at the cut height. After this
delay, the AVC is enabled for the remainder of the cut.
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THC Dynamic
This gain is used when the THC is operating closed-loop arc voltage control.
dYn How to use: If this value is set too high, the lifter positioning during closed-loop
arc voltage control will become unstable and prone to oscillation. If this value is
set too low, the arc voltage control can become slow and inaccurate. The value
of 7 is appropriate.

The THC Response can be tested by change value during cutting under closed-loop arc voltage
control and checking that the THC quickly and accurately reaches the set arc voltage.

Very high speeds on very thin or highly warped metal may require increasing the Response
setting to respond faster. Be careful to not go so high the torch overshoots and oscillates up and
down. Remember you will generally want to go back to 7 normal cutting. To optimize this
response, raise this value until a very slight oscillation is detected during a cut and then reduce
the setting by 1 or 2.

Lock Head Down Level

This feature avoids that the plasma torch moves down which arc voltage is up

LHd.L (for example on the end of cut, when crossing a kerf or hole or going off the
edge of the plate). If the adjustable Lock Head Down Level exceeds the limit
during cutting, the clearance control will be disabled.
Note: For disabling this future set the Lock Head Down Level to lower then 4 value.

Retract Height
This parameter specifies height above the workpiece to which the torch retracts

rtr.H at the end of a cut.

Note: for set full retract mode set the Retract Height value more than 60 mm
(2.5 in).

Transfer Height
This value determines the height above the workpiece where the torch is initially

trF.H
fired. It is the torch height after an IHS and is entered as a percentage of the
Cut Height.
This setting can be used to improve the ability of the torch to transfer to the
workpiece for processes that use a very high Pierce Height or have difficulty in transferring.

SHOT mode
This mode can be used to marking (for example make small corner on the

SHOT
centers of the holes). When the CNC issues Cycle Start signal, the controller
turns on the cutter. After receiving the ArcOK (transfer) signal from the plasma
supply starts “Torch ON” delay timer. When the delay timer will end, controller
turns off the cutter. If SHOT mode enabled, controller will make request for “Torch ON” time (0 –
10 sec).

Testing Mode
This mode allows starting test of the cutting sequence procedure.

tESt
THC Control Mode (Voltage control/Sample voltage)
This menu allow to select THC mode – Voltage control mode (SET.U) or Sample

SETP voltage mode (SET.H).

When Sample Voltage is ON (SET.H), the THC measures the voltage at the end
of the AVC Delay and uses it as a set point for the remainder of the cut. When
Sample Voltage is OFF (SET.U), the "Set Point Voltage” is used as the set point for torch height
control.
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Display in IDLE mode:

Set Point Voltage mode. Operator can change set point arc voltage value by
125.5 “SP.Voltage+/-“ buttons.

h. 1.5
Sample Voltage mode. Operator can change “Cut Height” value by
“SP.Voltage+/-“ buttons.

Configuration Menu
Push on the THC MODE button to enter to configuration menu. See Setup main
COnF controller settings.

Start Homing (reference) menu

This menu allow to start homing procedure. Select “YES” and exit from menu.
rEF.P Controller will start Homing procedure.

Setup main controller settings

Parameters

The basic configuration menu allows you to set up the following parameters:

Parameter Range Steps

5 mm to 40 mm 1 mm
IHS Start Height
0.2 in to 1.6 in 0.01 in
Transfer Time 0 s to 20 s 1 sec
Retract Delay 0 s to 10 s 0.1 sec
Dead Band 0.25 volts to 3 volts 0.25 volts
3000 mm/s – 10000 mm/s 10 mm/s
Automatic velocity
120 in/s – 400 in/s 1 in/s
1000 mm/s – 10000 mm/s 10 mm/s
Jog velocity
40 in/s – 400 in/s 1 in/s
100 mm/s – 500 mm/s 10 mm/s
IHS Velocity
4 in/s – 20 in/s 1 in/s
2 2
50 mm/s to 500 mm/s 10 mm/s2
Acceleration
4 in/s2 to 20 in/s2 1 in/s2
Automatic Collision Detect Stop (stop cutting) – run (ignore) - ACA
Float Head offset setup Select to start float head offset setup
Slide length setup Select to start slide length setup
Pulse In Unit Integer Part 0. – 20000. pulses (integer part) 1
Pulse In Unit Decimal Part .0 – .999 pulses (decimal part) 1
Inches/Millimeters Setup Select to enter to select Metric or Imperial system

IHS Start Height

This is the height above the last known workpiece position that the THC switches
IHS.H from Automatic speed to the slower IHS speed. This height should be set high
enough to avoid contacting the workpiece.

Transfer time
This is the number of seconds that the controller will wait for transfer before
trF.t attempting a retry.
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Retract delay
The Retract Delay time is the time between the removal of a start signal and the
rtr.d retraction of the positioner. In this case the plasma power supply turn off
immediatly, then delay timer will start. After finishing of the delay Motion signal
will off and retraction of the torch will start. This future for example can use for disabling plasma
power supply before end of cut (few tens of milliseconds) for reducing divots.

Dead Band
This value is an interval of an arc voltage where no AVC occurs.
dB.U
Automatic Speed
This speed is used for all automatic rapid moves such as the End-of-Cut-Retract

UEL.A
or the Initial Approach to the workpiece. This value depends on the lifter motor
speed, the screw pitch, the weight of the lifter load and the desired speed of
operation.
Jog Speed
Jog speed is the speed at which the positioner moves when operator push on the
UEL.J Torch UP/DOWN buttons. Note, the positioner moves at an IHS speed when the
up/down buttons are initially pressed. The speed is increased to the jog speed if
the buttons are held down.

IHS Speed
This parameter sets the slow speed for the final approach to the workpiece
VEL.I during an IHS operation. It is also used as the slow speed for jog moves.

Acceleration
This acceleration is used for all automatic, manual, IHS moves end arc voltage

ACC closed loop control. This value depends on the motor parameters, the weight of
the lifter load and the desired speed of operation.

Automatic Collision Avoidance

This safety feature allows the control to automatically adjust the torch height

COLL during a cut to help prevent torch crashes. If automatic collision avoidance is
enabled, the arc voltage is automatically increased any time when contact is
sensed between the torch and the plate, provided that the Use Ohmic function is
enabled. If the torch contacts the plate while a Hold signal is applied, the torch retracts to the
programmed Cut Height, provided that the Use Ohmic function is enabled.
Allowed modes on collision – Stop cutting – Ignore collision – ACA.

Float head offset setup

This function allows to setup offset for float head switch.
FLHD
Slide Length setup
This value is the length of the lifter’s usable travel (Soft Limit function).
SLd.L
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Preflow In IHS (enable/disable)

This menu allows enable/disable preflow in IHS if using ohmic sensor on the
PrFL water table.
If you keep the water low enough so it does not splash mass quantities on the
torch, then ohmic will work fine with a water table. If water gets on the surface
of the material, expect the ohmic sensor to sense the surface of the water, not the metal. If
water gets back inside the torch, often it will cause a false sense as well as it shorts from the
shield to the nozzle internally. The water in a water table becomes full of suspended solids of the
metal you are cutting which raises the conductivity of the water. Enable the “Preflow in IHS”
mode to activate the torch postflow before sensing the material and to make the ohmic function
work better with high water levels. This blows water out of the torch and keeps water away from
the sensing area. If Preflow in IHS will enabled, controller make request for “Torch ON” time
(0.1-10 sec). Usually 0.2 second value is OK.

Pulses in unit integer part

The value is based on the counts of pulses for motor driver. It is equal to the
PUL.I number of pulses in the one unit (millimeters or inches). For example slide has
5.08 mm pitch screw and on the motor driver set 1000 pulses per one motor
shaft revolution value. Pulses in unit will be 1000/5.08 = 196.850
You have to set pulses in unit integer part value to 196.

Pulses in unit decimal part

The value is based on the counts of pulses for motor driver. It is equal to the
PUL.d number of pulses in the one unit (millimeters or inches). For example slide has
5.08 mm pitch screw and on the motor driver set 1000 pulses per one motor
shaft revolution value. Pulses in unit will be 1000/5.08 = 196.850
You have to set pulses in unit decimal part value to 850.
NOTE: after changes pulses in unit value Slide Length and Float head offset setup required.

Reverse direction
This menu allows changing the polarity for Direction signal (for reverse motor
rUrS direction). Please note that motion direction is also related to motor-driver wiring
match. Exchanging the connection of two wires for a coil to the driver will
reverse motion direction.

Inches/Millimeters setup
This menu allow to change of units (mm/inches)
SYST NOTE: controller has two independent profiles and settings databases for mm
and inches. If you change the units, check all settings and make initial setup of
the controller motion engine.

Cutting sequence LEDs

During operation, indicates the position within the control sequence.

During set up, indicates the selected parameter.
- AVCOFF led indicates that the Automatic Voltage Control (AVC) is OFF.

In IDLE mode indicates:

 IHS led: show state of the IHS input (float head or ohmic sensor).
 TRNSF LED: show state of the ArcOK (Transfer) input.
 AVCOFF LED: show state of the THC OFF input.
 IDLE LED: show the state of the Home input.
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Requirements and Check List for first Start-up

Step Instructions OK

1. Are all cables and wires connected and locked properly?

2. Can the torch move in all directions without hitting anything? Is the slide in
vertical direction and mounted correctly?
3. Are all settings and signals from and to Neuron THC correct?

4. Is the power supply (+ 12V/0.5A) of the Neuron THC System installed

properly?
All shields of cables going to the plasma source should not be connected at
5.
the plasma source. They must be connected in the control cabinet with the
shortest possible connection to the machine ground.

Power Up
1. Power off plasma cutter.
2. Push on the “TORCH UP/DOWN” buttons and hold, then switch on controller power supply.
3. Controller will switch to the initial setup and diagnostic mode. Display will show state of the
inputs. Also controller will activate/deactivate outputs signals for checking (1.5 sec On/Off
period). Push on the “Torch DOWN” or “SP.VOLTS -” for select input (lower segment), then
push on the “SP.VOLTS +” for change “ActiveLow/ActiveHigh” properties for selected input
(upper segments).
In the IDLE mode all sensors is triggered off. Change “ActiveLow/ActiveHigh”
properties for set “triggered off” state on the display (upper segments).
For example, in this picture shows the state of the controller inputs. Homing input
has active state (triggered on) and has selection for change ActiveLow/ActiveHigh.
Also ArcOK input has active state too.

4. Push on the “THC MODE” button to exit from this mode.

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5. Controller will start homing procedure. Check, that the torch move UP to homing switch. If
direction is wrong, push on the TORCH UP or DOWN button to terminate homing procedure.
Error (Er.01 - Fail go to home) will issue. Push on the “THC MODE” button to clear Error.
6. Enter to the configuration menu.
7. If torch move direction during homing procedure was incorrect, set reverse motor direction in
the “Reverse direction” menu.
8. Select mm or inches system. After exit from mm/inches menu controller will reboot.
9. After the reboot an initialization process runs for approx. 2 s. – The LED screen at the main
control module show “BOOT” message. If the LED screen shows error, check the error table in
Chapter Trouble-Shooting.
10. If all is correct controller show “PUSH” message for start homing procedure. Push on the
“THC MODE” button for starting. The torch slide automatically moves to the upper reference
position.
11. Enter to the configuration menu.
12. Setup integer part and decimal part of the “StepInUnit” value.
13. Setup the maximum values of the acceleration and Automatic, Jog, IHS velocities values of
the torch moving as your system allowed (avoid lost steps for steppers motors).
14. Push and hold “THC MODE” button to exit from configuration menu and save configuration.
15. Power OFF controller.
16. Power ON controller.
17. Enter to the configuration menu.
18. Setup Slide Length value.

SLd.L YES 175.7 SLd.L

Push on the Select YES Push on the Move torch down by Push on the
THC MODE by THC MODE TORCH UP/DOWN THC MODE
button SP.Voltage button to Buttons for set slide Button to
+/- buttons start length Store Slide Length value
start

19. Setup Float Head offset value. Put on the table plate, thickness not less 3 mm.

FLHd YES 148.1 FLHd

Push on the Select YES Push on the Push on the Push on the
THC MODE by THC MODE TORCH UP/DOWN THC MODE
button SP.Voltage Button to Buttons for correct Button to
+/- buttons confirm start the distance 4 mm Store offset value
start

19.1 Push on the THC Mode button for entering to the Float Head offset setup menu.
19.2 Select YES by “SP.Voltage+/-“ buttons and push on the “THC MODE” button to start
procedure.
19.3 Controller will start Initial Height Sensing procedure. When the IHS will be
completed the torch will be moved up on the 4mm for metric system or 0.2 in for
inches system under surface of the plate. Check the distance between the surface
of the plate and torch nozzle. If it’s not 4mm (0.2 in.) (check it for example by
standard drill) correct it by TORCH UP/DOWN buttons.
19.4 Push on the THC MODE button to exit from submenu.
20. Setup IHS Start Height, Transfer Time, Retract Delay, Dead Band to desired values.
21. Push and hold “THC MODE” button to exit from menu and store values in the operator
interface.
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Cutting sequence test

You can make cutting sequence test procedure for control all settings.
1. Push and hold THC MODE button to go in the cutting setup menu. Navigate to “TEST”
submenu.
2. Push “THC MODE” button to enter to Cutting sequence Test submenu.
3. On the display will appear current torch position. For starting push “SP.VOLTS +” button.
4. Controller will start Initial Height Sensing procedure.
5. Push on the “SP.VOLTS +” button to go to next cutting state.
6. After then Retract state will complete, controller finished testing and exit from submenu.