Instruction manual

Plasma Torch Height Control.

DANI THC09SDP
DANI THC011DP

Safety notes
When the device is in operation, there is a voltage of terminal
connections, which is dangerous to health and human life.
The device should only be connected by a qualified and authorized person.
Improper connection can cause serious injury or death. Before installation and operation, carefully read the
entire installation and maintenance manual and be absolutely sure you fully understand and are able to
make the decision and determine whether you are capable of safe and correct installation.
Remember that, inside the device and on the connection terminals, the voltage is dangerous.
The following actions, must be strictly observed:
Installation of this product by an unqualified person should not be performed.
No physical contact with any electrical connections, while under power.
Do not work with this product with wet hands, wet gloves or wet clothes.
Before switching on the device, ensure the safety of others and read and understand all instructions.
If you have questions or concerns, do not proceed.
Provide adequate protection for all risks associated with plasma cutting.For more detailed i
nformation on the risks associated with plasma cutting, see the owner's manual of your plasma cutter .
Touching uninsulated and unearthed elements can be fatal. Provide a safe place for your device.
After installation, protect the contact terminals from touching the operator.
It is strictly forbidden to make any repairs or modifications to this product!
Performing one of these actions can cause serious injury to yourself and / or others.

Terms of Use:
By continuing to install and use this product, you completely understand and agree
with the Manufacturer and neither He nor their distributors are responsible for
any incident or event leading to direct loss, indirect loss, injury to oneself or others, damage to property or
loss or damage of any kind.
The end user assumes all risks.
If you do not agree to these terms in their entirety, do not proceed and return this product for full recovery.

If you have questions or are unsure about something in this

contact your dealer or manufacturer immediately.

DaniFix LTD
Website : danifix.company.site/ pdf instruction files : https://files.fm/danifixdb
https://files.fm/unifixdb
Email : danifixdb@gmail.com / videos: https://youtu.be/cmACnYxtp04
Goce Delchev 2900 Bulgaria
PhoneN : +359898616634 Whatsapp or Viber
 Device information
The device is a modern analog – digital microprocessor controller that controls the height of the
plasma torch , working by analyzing changes in voltage from the plasma source
to variations in height between the tip of the torch and the material being cut.
The microprocessor decides whether to raise or lower the burner
based on the strength of the reported voltage signal.
It is equipped with an easy-to-read LED display and two user-friendly keys, which makes the operation easy and
does not require additional meters.
The device is built with the highest quality components to ensure safe, durable
and reliable long-term operation. The main parameters of the device:
Supply voltage (7- 28 VDC)
Maximum input current 220mA
Maximum direct input voltage HV 1000V DC *
Maximum read input voltage HV 350V DC *
Maximum direct input voltage LV 35V DC *
Maximum read input voltage LV 10VDC *
Possibility to eliminate HV / HF ionizing voltage 0.3kVAC - 3kVAC-
Ability to remove HV / HF ionizing frequency> 100kHz 75kHz
HV / LV elimination duty cycle (%) 100% -
Output capacity 300mA .DIR – (Direction) , PUL (Pulse) signals ,logic level 5v.Active low.
Input DIR – (Direction) , PUL (Pulse) signals ,logic level 5v.Active low.
Start-up and operation: Parameters:
Set - Set Voltage
Hys - Hysteresis / Tolerance
Dlt - Delay Time
Div - Divider /Calibration
Hvc - High Voltage Cut
Lvc - Low Voltage Cut
dSr - Distance – Speed Reaction
Spd - Set Speed
Test - Test/Smoothness
 If there is no Arc voltage , pressing buttons “up“ or “down” the controller
moves the motor up or down!
The device is pre-configured at the factory, and after making the correct connections, it immediately functions properly
with most plasma devices. After switching on the power, the THC controller's display shows the input voltage.
By simultaneously pressing both the up/down keys, the THC controller starts the Set-up Parameters.

First, to set is the "Set Voltage" parameter.

By pressing the up/down keys, you can modify the voltage setpoint. This setting
determines the distance between the torch and the metal plate. Higher voltages
correspond to greater distances.
Set Voltage The "Set Voltage" parameter can be adjusted while the machine is running without
Target distance entering the menu mode. Simply press the "up" or "down" button to change this
parameter.

To determine other parameters, simultaneously hold both keys until you see the desired
parameter on the display. When you release the keys, its value will be displayed. Use the
up/down keys to set the desired value for the parameter.
The lag between making a change, such as increasing or decreasing voltages, and the
response or effect of that change is typically referred to as the turn-on and turn-off points
in electrical systems. In this case, the response of the output signal when it goes "down"
will be the torch voltage plus the hysteresis value, while the response when it goes "up"
“HYS" (Hysteresis) will be the torch voltage minus the hysteresis value.
Voltage Tolerance For example, if the "Hys" value is set to 3V and the Set Voltage is 100V, the "down"
output will respond if the torch voltage goes over 103V, and the "up" output will respond
after the torch voltage goes under 97V. In the voltage range of 97V to 103V, the outputs
will remain off. The torch voltage changes depending on the distance between the torch
tip and the metal plate. The "Z" axis motor moves the torch up and down to bring the
torch voltage to the value of the Set Voltage, thereby maintaining a constant
distance.The hysteresis value helps prevent frequent movement of the torch for slight
and insignificant changes in distance. The setting range for the hysteresis value
is from 1 to 10. The default value for the hysteresis is 3V.

Drilling time or piercing time refers to the necessary time for the plasma torch to pierce
through the metal plate before it begins to cut. The delay time is activated when the arc is
turned off and then on again. During the delay time, the Torch Height Control (THC)
outputs are not active.
Delay Time The delay time set on the THC must correspond to the piercing time set in the G-code
( Drilling time) loaded on Mach3.
It can be set within the range of 0.1 to 10.0 seconds.
The default value for the delay time is 1.7 seconds.
 The controller has a built-in voltage divider (1/50). but the operating voltages are
different for different plasma manufacturers. Some models have built-in voltage dividers.
This setting allows a wide range of input signals to be used. For standard plasma arc
Divider . outputs, 50–150 v settings must be 50 (default). Due to material deviations, the recorded
Voltage divider plasma voltage may need adjustment. According to an external reference, such as a
calibration voltmeter, you can modify the plasma voltage reading by adjusting these settings. If you
increase the value, the readings on the THC display will decrease, and vice versa. By
default, the THC readings show actual arc voltages (on the HV input). On LV input (if
using an internal plasma divider), the readings will correspond to the actual arc voltages
if the outputs are 0 – 5 volts. The adjustment range is (20-90)default 50.
( if outputs are 0 –10 volts, these settings must be adjusted.)

The working voltage range can be adjusted with an upper limit. This adjustment is
necessary for the following reasons:
High Voltage Cut:
High voltage limit (1) When the pilot voltage is close to the "Set Voltage," the torch may rise before
starting the cutting process (activated by the pilot arc). This limit allows the Torch
Height Control (THC) to recognize working voltages based on the pilot arc voltage.
(2) During the cutting of circles or a complete detail, at the end of the cycle, the torch
may fall into an area that has already been cut. In this situation, the output voltage of the
torch rises, but it is not necessary for the "Z" axis to move downward. To address this, a
high voltage limit is introduced. The limit is set to determine when the controller should
stop lowering the torch ("Z" axis).
The upper limit is determined by the value of the "Maximum Cutting Voltage" setting
plus the "Set Voltage." For example, if the "Set Voltage" is 100 and the "Maximum
Cutting Voltage" is 50, then the shutdown limit for the "Z" axis motion will be 150.
The range is 20 to 70, with a default setting of 5

The range (50 – 150 ) can be adjusted in the lower limit. When the arc voltage drops below
this value( from 10 to 70) ,the "Z" axis will stop rising
The range is (10 - 70) default 50.
Low Voltage Cut
Low voltage limit
 Distance - Speed Reaction. The controller has two different speed reactions. The
controller moves the "Z" axis up or down, depending on the distance between the
torch and the metal plate. The movement speed can be constant or variable,
determined by this setting.
Distance -Speed Variable speed - The speed of the "Z" axis motor is slower when the
Reaction torch is close to the set point and faster when it is far.

Constant speed - The speed of the "Z" axis motor is constant, set by a
specific parameter (Spd).

Change the speed of the motor (1 to 10) default 5.

The Dani THC can generate pulse frequency from 100 Hz up to 2000 Hz( Pulses
per a second), to ensure motor rotation.The speed of the “Z” axis motor changes
while cutting proses .In “dSr” settings if set to “Var”(Variable)-
Speed The torch head ("Z"axis) moves faster when is far from the desired distance and
slower when is close , to ensure fast and smooth adjustment for a very curved
metal surfaces .
The speed can be adjusted .Calibration is required.
If using dip switches settings 800 pulses / 4 steps THC speed (Spd) set 1-5.
If using dip switches settings 1600 pulses / 8 steps THC speed (Spd) set 6-10.
Set the dip switches on Stepper driver coresponding to the output frequency.
If using Mach3 software Calibration is required.Set the motor tunning parameters
of the Z axis motor coresponding to the THC speed and dip switches settings
of the Z axis motor driver.See pictures below.

This setting allows the control of the "Z" axis to be tested.

The test is an automatically generated signal from the Controller that raises and
lowers the plasma torch by controlling the"Z" axis.
"Test and Smoothing" The setting values determine the lifting and lowering distances of the plasma torch.
(Cycle starts with lifting)
In addition to the test, these values also determine the depth of filtering and
smoothing the signal from the plasma torch , which is used for automatic control
of the "Z" axis.
At a lower value, the automatic control response is faster.
At a higher value, the automatic control response is slower.
"At" value 1 "the microprocessor collects 10 values from the plasma toch and calculates
the average - the control response is 100 cycles per second.
At value of "10", the microprocessor collects 100 values from the plasma torch and
calculates the average - the response to control is 10 cycles per second. )
Lower setting values make the controller more sensitive to signal interference from the
plasma torch.

When the plasma cutter is turned on, the display shows the measured voltage value of the plasma output, and LED
diodes indicate the current status of the outputs.
The "Arc on" LED indicates the detection of the pilot arc.
To connect the THC to the power supply, follow these steps:
First, connect the GND wire to Pin "-" on the THC.
Connect the outputs on the THC to the inputs on the driver.Use active low inputs ("-").
Connect the outputs (Dir/Step) from the Breakout board to the inputs on the THC.
Ensure that the GND of the Breakout board, GND of the driver, and "-" on the THC are connected.
Connect the 5V supply pin from the Breakout board to the positive inputs on the driver PUL(+) and DIR(+).
Make sure that the +5V supply is present. Last ,connect the +24v wire to the (+) pin on the THC.

Using Breakout Boards Mach3 interface and DaniTHC

The Breakout board must be connected to the computer to supply 5v for the driver input
(Pulse and Direction) operation .If not using Breakout board 5v power supply is needed
Select “Step Low Active” to use (-) negative (PUL)(Step) input on the stepper driver as active.
If necessary to change the direction of the motor rotation ,select “Dir Low Active

Z Axis Settings:
 • Set "Step per" to a value between 65- 80 if the THC Speed (Spd ) is set 1-5.
• Set "Velocity" to a value between 650-800 if the THC Speed (Spd ) is set 1-5.
• Set "Step per" to a value between 100 -200 if the THC Speed (Spd ) is set 6-10.
• Set "Velocity" to a value between 1000-2000 if the THC Speed (Spd ) is set 6-10.
• Configure "Dir / Pulse" to be within the range of 5-15 microseconds.
• Set "Step / Pulse" to 15 microseconds. See table below.

Make sure to consult the documentation for your specific stepper driver to confirm the functionality of each dip switch
and its impact on the motor control. Additionally, test the system in a controlled environment to ensure that the Z axis
operates as expected with the THC "Spd" setting within the specified range.
Always follow safety guidelines and take precautions when making adjustments to stepper motor settings,
especially in industrial or critical applications. If possible, consult with the manufacturer's technical support
or documentation for precise guidance on configuring your specific stepper driver.
When "dSr" (Distance-Speed-Reaction) is set to "Var" (Variable), it depends on the distance between the torch and the
metal plate regarding how far it is from the desired distance. If it is close to the desired distance, the z-axis movement is
slow, and it speeds up when the distance between the torch and metal plate is farther from the desired one. Below is
the table indicating the minimum and maximum speed values in pulses generated by the THC controller.

Pulses THC Generates on Frequency in Hz Motor Tuning settings on

Selected Speed set Mach3 Z Axis requirements

Speed Set THC Minimum Maximum Minimum Maximum Steps per: Velocity:
Spd puls per second puls per second

1 150 600 150 600 65 650

2 150 800 150 800 70 700
3 150 1000 150 1000 70 700
4 200 1000 200 1000 75 750
5 200 1200 200 1200 80 800
6 300 2500 300 2500 100 1000
7 300 3000 300 3000 150 1500
8 300 3500 300 3500 180 1800
9 300 4000 300 4000 200 2000
10 300 5000 300 5000 200 2000

Speed (Spd) set from 1 to 5

Speed (Spd) sset from 6 to 10

 To prevent the Z motor from moving too slowly or too quickly (beyond the maximum motor speed
capability), you can use the dip switches on the stepper driver to set appropriate
configurations. Here are some suggestions:
1. Microstepping Settings:
• Set the microstepping mode to an appropriate value for your application. Higher
microstepping settings can provide smoother motion but may reduce torque.
2. Current Limit:
• Adjust the current limit setting on the stepper driver to match the specifications of your
stepper motor. Ensure that the current is set within the motor's operating range to avoid
overheating.
3. Velocity (Speed) Settings:
• Some stepper drivers have dip switches or other settings related to velocity or speed. Adjust
these settings to set the desired speed range for your Z motor.
4. Acceleration Settings:
• Configure acceleration settings to control how quickly the motor reaches its target speed. This
helps prevent sudden jumps in speed that could lead to issues.
5. Limit Switches:
• If available, configure limit switches to define the safe working range for the Z motor. This
can prevent the motor from attempting to move beyond its physical limits.
6. Overcurrent Protection:
• Enable any overcurrent protection features provided by the stepper driver. This can help
protect the motor from excessive current that could damage it.
7. Fault Detection:
• Some stepper drivers have fault detection features. Enable and configure these features to
detect issues such as stalled motors or excessive load.
8. Refer to the Stepper Driver Manual:
• Always refer to the stepper driver's manual or documentation for specific guidance on dip
switch settings. Different stepper drivers may have unique features and configurations.
Remember to thoroughly test the settings in a controlled environment to ensure the Z motor operates within
the desired speed range without risking damage due to excessive speed or inadequate current.
 SheetCam cutting rules

From the side bar select tool ,then G code.

Create a role named "AD ON - Code M9P3." Code M9 will modify the output signal on output #3
(code P3). Output #3, linked to the THC AD input, will either activate or deactivate the AD (Anti-
Dive) function based on Mach3 output #3 settings (Active low or active high).

Create another role named "AD OFF - Code M7P3." Code M7 will alter the output signal on output
#3 (code P3). Output #3, connected to the THC AD input, will activate or deactivate the AD (Anti-
Dive) function, depending on the Mach3 output #3 settings (Active low or active high).
 In the "Add rules" section, select where you prefer to incorporate the AD ON and AD OFF
commands within the cutting process to prevent unnecessary torch diving.
 Mach3 settings using Anti-dive

Using anti-dive function

Use output#3 for anti-dive control signal signal.
Comand code M7 will change the output state and comand code P3 will select the output pin
number #3 .Comand code M9P3 will reverce the the state of output #3.