CHS-6000A

Capacitive Height Sensing System

Operation and Installation Manual

Haas Laser Technologies, Inc.

37 Ironia Road
Flanders, New Jersey 07836 USA

Manual-6000A Rev. 4
In consideration of the receipt of this document, the recipient agrees not to reproduce, copy,
use, or transmit this document and/or the information therein contained, in whole or in part or
permit such action by others, for any purpose, except with written permission of Haas Laser
Technologies, Inc.

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Manual-6000A Rev. 4
TABLE OF CONTENTS

TABLE OF CONTENTS ..................................................................... 2

1. INTRODUCTION ............................................................................ 4

2. SAFETY.......................................................................................... 5
2.1 Introduction ...........................................................................................5
2.2 Electrical Shock ....................................................................................5
2.3 Other Hazards and Alarms ...................................................................5
3. COMPONENTS AND INSTALLATION .......................................... 6
3.1 Principal of Operation ...........................................................................6
3.2 System Connection Diagram................................................................6
3.3 Installation Notes ..................................................................................6
4. OPERATION OF CHS-6000 ........................................................... 7
4.1 Introduction ...........................................................................................7
4.2 Sensor Cable (CHS-6000A-SC15) .......................................................7
4.3 Junction Box (CHS-6000A-JB) .............................................................7
4.4 Electrode cable (CHS-6000A-EC300, CHS-6000A-EC510) ................7
4.5 Analog signal ........................................................................................7
4.6 Two channel-technology.......................................................................7
4.7 Cable brake ..........................................................................................7
4.8 Touch signal .........................................................................................8
4.9 Reduce Gain.........................................................................................8
4.10 Q/A function ........................................................................................8
4.11 Plasma detection ................................................................................8
5. CALIBRATION OF THE CHS-6000 ............................................... 9
5.1 Procedure .............................................................................................9
5.2 Verification ..........................................................................................10
5.3 Sample Calibration Curve...................................................................10
6. TECHNICAL DATA ...................................................................... 11

7. TROUBLESHOOTING CHS-6000................................................ 12

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Manual-6000A Rev. 4
8. MAINTENANCE CHS-6000.......................................................... 13
8.1 ELECTRONICS ..................................................................................13
8.2 INTERFACING ...................................................................................13
8.3 SENSOR CABLE AND LASER NOZZLE TIP ....................................13
9. WARRANTY CHS-6000 ............................................................... 14

10. REPLACEMENT PARTS AND SERVICE CHS-6000 ................ 16

11. INTERFACING AND DRAWINGS.............................................. 17

11.1 LED’s and DIP Switch on the PCB ...................................................17
11.2 CNC Interface ...................................................................................18
11.3 I/O Connections ................................................................................19
11.4 Enclosure Dimensions......................................................................20

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Manual-6000A Rev. 4
1. INTRODUCTION
To attain high quality cutting results, a precise control of the nozzle tip stand-off distance
between nozzle tip and the workpiece is required. The nozzle tip stand-off can be controlled
within 0.01mm by using the CHS-6000 Capacitive Height Sensing System.

The CHS-6000 measures the nozzle tip stand-off distance and converts the measurement into
an analog output signal. After calibrating the system to three known stand-off distances, the on-
board microprocessor digitally linearizes the analog output signal to tip stand-off. Automatic
calibration can be accomplished by a simple PMC-interface.

Two channel technology allows the user to store two different calibration curves for different
nozzle types or distance ranges.

The CHS-6000 Capacitive Height Sensing System is designed to operate independently with a
Haas Laser Technologies, Inc. motion system or existing drive system.

CHS-6000 Features:

• Microprocessor controlled
• Software controlled nozzle tip calibration
• Digital output linearization
• Linear range of ± 3.5 mm
• +/-10vdc Analog output signal
• Automatic nozzle tip calibration
• Nozzle tip touch alarm
• Cable disconnected and break alarm
• 2 channel technology
• Position hold function
• Plasma detection function
• High speed cutting under plasma function
• Quick / Rapid approach function

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Manual-6000A Rev. 4
2. SAFETY

2.1 Introduction
The Haas Laser Technologies, Inc. CHS-6000 Capacitive Height Sensing System is capable of
providing high-speed movement. It can be dangerous if used improperly. Operators should
therefore read this manual carefully and ensure that they understand all the points below. If
there are any problems or questions, please contact Haas Laser Technologies, Inc.

NOTE
TO PROTECT OPERATING PERSONNEL, THIS SAFETY SECTION
SHOULD BE THOROUGHLY REVIEWED AGAIN AFTER
INSTALLATION AND BEFORE OPERATION.

WARNING
FAILURE TO OBSERVE OPERATING PROCEDURES AND
WARNINGS CAN RESULT IN SERIOUS BODILY INJURY OR DEATH
DUE TO ELECTRICAL HAZARDS.

2.2 Electrical Shock

The main power supply to the CHS-6000 is 110/230VAC. This equipment is designed to prevent
accidental exposure to hazardous voltages. Voltages used in this system are high enough to
endanger life. The installation of CHS-6000 should be done in accordance with national and/or
international standards for electrical equipment and laser safety. Refer connection, installation,
maintenance, adjustments, servicing and operation to competent personnel.
WARNING
DANGEROUS VOLTAGES ARE PRESENT IN THIS EQUIPMENT.
CONTACT WITH LIVE PARTS COULD CAUSE SERIOUS INJURY OR
DEATH.

2.3 Other Hazards and Alarms

The maximum operating temperature of the CHS-6000 should not exceed 40°C. The capacitive
height sensor should only be used in a dry environment.

The CHS-6000 offers alarm functions such as: cable break, tip collision, etc. These signals are
available at the parallel interface and can be linked to the CNC.

The sensor nozzle should not be touched under operation. Potentiometer and jumpers settings
should only be modified according to the instructions in this manual.

Keep hands, limbs, and loose clothing clear of the associated motion system when the
system is turned on. Failure to do so could result in serious bodily injury.

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Manual-6000A Rev. 4
3. COMPONENTS AND INSTALLATION

3.1 Principal of Operation

CHS-6000 is based on a capacitive gap measurement (i.e. the gap between laser nozzle tip and
workpiece is converted into a DC voltage output signal). To operate a capacitive height sensor,
a conductive work surface is required. Non-conductive materials require a tactile adapter (TTA-
3029-M8-AMX) in place of the capacitive height sensing nozzle.

3.2 System Connection Diagram

DB2
COM
CNC
Analog Out
CHS-6000 AO (Optional)

GND
SN1
BNC

Sensor Cable Ground Cable

Junction
SMA Box Electrode Cable

Capacitive Height
Sensing Nozzle

Surface

3.3 Installation Notes

• Enclosure should be mounted securely with the four bolts and washers provided (or
equivalent).
• The Ground Cable and Sensor Cable should be routed away from strong inductive
sources.
• The Junction Box should be electrically isolated. (Nylon shoulder washers are provided)
• For CNC Interface, +24VDC must be supplied on PIN 19 of CN1 (see Section 11.2).

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Manual-6000A Rev. 4
4. OPERATION OF CHS-6000

4.1 Introduction
Control and operation of the CHS-6000 is performed through a simple I/O interface with a DB-
25 connector. The I/O interface is optically isolated from the measurement side of the unit and
its internal power supply; therefore a 24VDC input is needed (COM1 PIN 19 and 6).
Operational and warning indicators can be monitored either directly from the LED’s on the board
(Section 11.1) or through the COM1 interface (Section 11.2). Linear calibration of the unit can
only be completed with the COM1 interface. Some settings are on the DIP switch S1 (Section
11.1).

4.2 Sensor Cable (CHS-6000A-SC15)

The connecting cable between junction box and control unit is a low noise triaxial cable (50Ω)
and limited to a 15m cable length. The cable ground must be connected to the CHS-6000
ground post for proper operation. For best performance, the sensor cable should not be routed
with power cables.

4.3 Junction Box (CHS-6000A-JB)

A junction box mounted near the laser process head couples the sensor cable and the electrode
cable. The junction box housing must be electrically isolated from the mounting surface.

4.4 Electrode cable (CHS-6000A-EC300, CHS-6000A-EC510)

The connecting cable between the capacitive nozzle body and the junction box is a low noise
coaxial cable (50Ω). This cable is designed to easily detach if snagged and can be ordered in a
300mm (12”) or 510mm (20”) length.

4.5 Analog signal

To match the analog output signal with the PMC requirements, the signal range of +/-10V (eq.
+/-2mm) or 0 to +10V (eq. .2mm to 5mm) can be selected. Range selection is determined by
DIP switch S1 on the height sensor board (see Section 11.1). Factory setting is 0 to +10V.

4.6 Two channel-technology

The CHS-6000 can store two linearization curves within its memory. They can be used to
calibrate two different laser nozzles or two different working ranges. The channels can be
selected by digital input signal on PIN 15 of COM1. Switching from one memory to another
takes a few seconds calculation time for the linearization. LED 1 blinks at 1Hz for Memory 1
and 0.5Hz for Memory 2.

4.7 Cable brake

The cable break level is calibrated during the sensor calibration cycle. LED 14 on the control
unit is off when the cable is broken or connection is cut.

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Manual-6000A Rev. 4
4.8 Touch signal
Touch signal, LED 13, is on if the nozzle tip contacts the workpiece (Grounding of the
workpiece table must be done carefully).

4.9 Reduce Gain

Normally the output is refreshed every 0.5-1ms. The reduce gain function decreases the
refreshing rate to make the output response slower. This function can be useful while cutting
materials that create plasma (brass or aluminium). Set PIN 17 high on COM1 to activate
Reduce Gain. LED 10 lights when the reduce gain function in on.

4.10 Q/A function

This function can be used to approach the workpiece at high speed in tracing mode. At a
distance of approx. 25-30mm the EDGE signal (PIN 21 of COM1) becomes 1 when Q/A function
is active (PIN 5 =1 of COM 1) and the nozzle approaches the workpiece. The EDGE signal
should be used to reduce the tracing gain in the CNC to avoid collision with the workpiece. The
EDGE signal must turn off the Q/A function (IF EDGE = 1 then Q/A = 0). After turning off the
Q/A function the sensor works in the normal range of 0-5mm.

4.11 Plasma detection

The CHS-6000 has a plasma detection function. When plasma occurs during cutting, plasma
alarm (PIN 22 of COM1) is set to 1. Two different threshold levels can be selected by Plasma
detect bit (PIN 16 of COM1).

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Manual-6000A Rev. 4
5. CALIBRATION OF THE CHS-6000
Linearization of the CHS-6000 requires a simple 3-point calibration. Any nozzle shape or
working range can be taught to the CHS-6000. The calibration cycle is supported by software
and requires a simple handshake with the machines PMC. The following procedure is used to
calibrate the unit to any nozzle.

5.1 Procedure
1. After the CHS-6000 has stabilized from initial start-up (approx. 15min warm-up), select
the channel (memory) that should be calibrated. (PIN 15 of COM1).
a. Memory 1 is selected (PIN 15 = 0) when LED 1 flashes with 1 Hz.
b. Memory 2 is selected (PIN 15 = 1) when LED 1 flashes with 0.5 Hz.
c. There is an approximate 10 second delay after memory selection.
2. Select calibration mode (PIN 2 of COM1) LED 1 flashes every 400ms.
3. Move the sensor nozzle (by CNC-position command) to the most up Z-axis position and
send an in-position signal (PIN 3 of COM1) to LCIII (PIN 3 =1).
a. CHS-6000 confirms the position by sending a complete signal (PIN 8 of COM1)
to the CNC. LED 15 lit.
b. Upon receiving the complete signal turn the in-position signal off. (PIN 3 =0)
4. Move the sensor nozzle by CNC-position command to the Z-axis position where the
nozzle tip stand-off is 5.1mm (.200”)
a. Confirm nozzle tip stand-off with calibrated height gauge.
b. Send an in-position signal. (PIN 3 of COM1) to CHS-6000 (PIN3=1).
c. CHS-6000 confirms the position by sending a complete signal to the CNC (PIN 8
of COM1)
d. Upon receiving the complete signal turn the in-position signal off. (PIN 3 =0)
5. Repeat step 4 at 2.6mm (.104”) and 0.2mm (.008”) nozzle tip stand-off.
6. Move the nozzle by CNC-position command to the Z-axis position where the Quick
Approach signal should become active, (25mm).
a. Make Q/A select bit (PIN 5 of COM1) high and send an in-position signal (PIN 3
of COM1) to the CHS-6000.
b. CHS-6000 confirms the position with the complete signal. (PIN 8 of COM1)
c. Upon receiving the complete signal turn the in-position signal off. (PIN 3 =0)
7. Move the sensor nozzle by CNC-position command to the most up Z-axis position and
send an in-position signal (PIN 3 of COM1) to the CHS-6000.
a. The CHS-6000 calculates the linear output DCON signal.
b. PIN 17 of I/O CN1 turns off during calculation.
c. LED1 flashes every 200ms.
8. After DCON signal turns on again, the calibration is finished.
a. Turn the in-position signal off. (PIN 3 =0)
b. Turn the Q/A select bit off. (PIN 5 =0)
9. Set Mode Bit (PIN 2 of COM1) back to 0.

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Manual-6000A Rev. 4
5.2 Verification
If the calibration fails, status LED 11 or 12 turns off. In this case set Mode Bit (PIN 2 of COM1)
back to 0 and repeat calibration procedure.

NOTE:
For a calibration of .008” to .200” :
.001” = .052V or
.1V = .0019”

5.3 Sample Calibration Curve

Height Calibration

10.00
Output Volts

8.00

6.00

4.00

2.00

0.00
0 0.05 0.1 0.15 0.2

Distance (in.)
Memory 1 Memory 2 Ideal Line

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Manual-6000A Rev. 4
6. TECHNICAL DATA

Rated Voltage: 24VDC

Power consumption: ≥ 450mA

Workpiece: Electrically conductive. Connected with GND

Analog Output: DC ± 10V or 0-10V

Output limit: ≈ ± 12V

Response frequency: 500Hz

Operating temperature: 0 - 40°C

Stock temperature: -10 - +50°C

Output impedance: 100Ω

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Manual-6000A Rev. 4
7. TROUBLESHOOTING CHS-6000

Please check the following points if the CHS-6000 does not work properly:

Unstable analog output voltage:

• Check wiring.
• Check condition of sensor cables, especially loose or intermittent connections.
• Check the workpiece ground connection to the CHS-6000.
• Check selected output range. (DC ± 10V or 0-10V)
• Check calibration procedure.
• Check capacitive nozzle body for splatter or recast material, which can short the sensor
and guard electrode. Please clean this area.
• Check for electrical system noise.

Missing I/O Signals:

• Check Wiring.
• Check input voltage.

Missing TOUCH signal:

• Check calibration.
• Check capacitive nozzle body for splatter or recast material.
• Check workpiece ground.

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Manual-6000A Rev. 4
8. MAINTENANCE CHS-6000

8.1 ELECTRONICS
Periodic preventive maintenance is recommended to prevent industrial contaminants from
interfering with proper system operation. The cover of the enclosure should be kept closed to
prevent dust build-up on the internal electronic circuitry.

8.2 INTERFACING
Periodic preventive maintenance inspections are recommended on all interfacing cables and
connectors to make sure that they are in good condition and are not interfering with any moving
parts or in the laser beam path.

8.3 SENSOR CABLE AND LASER NOZZLE TIP

Periodic preventive maintenance inspections are recommended on the sensor cable, laser
nozzle tip and capacitive nozzle body. Inspect cables and connectors for laser burns and molten
recast deposits and make sure that they are not interfering with any moving parts or in the laser
beam path. Inspect the condition of the laser nozzle tip and capacitive nozzle body. Replace
parts as necessary.

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Manual-6000A Rev. 4
9. WARRANTY CHS-6000
Haas Laser Technologies, Inc. warrants to the original purchaser only and at original location
only that the product will be free from defects in material and workmanship for a period of six
months from delivery. Subsystems manufactured by other firms but integrated into Haas Laser
Technologies, Inc. systems are covered by the original manufacturers warranty.

Any internal adjustments or modifications without the express permission of Haas Laser
Technologies, Inc. will void the warranty. Customer-caused damages are non-warranted;
damages due to misuse, negligence or accident are non-warranted. ( Installation and
adjustments other than those stated in the "Installation" and "Operation" sections of this manual
void all warranties. Unauthorized repair also will void all warranties.) The liability of Haas Laser
Technologies, Inc. under valid warranty claims is limited to repair or replacement at Haas Laser
Technologies plant or purchaser's place of business, all at the option of Haas Laser
Technologies, Inc.

RETURNS AND ADJUSTMENTS

Warranty claim must be made promptly after occurrence of circumstances giving rise thereto
and must be received within the applicable warranty period by Haas Laser Technologies, Inc. In
no case should more than 30 days elapse after discovery of defect. Such claims should include
the data of shipment and a full written description of the circumstances giving rise to the claim.

Before any products are returned for repair and/or adjustment, authorization from Haas Laser
Technologies, Inc. for the return and instructions as how and where these products should be
shipped must be obtained. Any product or component returned for examination and/or warranty
repair shall be sent insured prepaid via the means of transportation specified by Haas Laser
Technologies, Inc. Haas Laser Technologies, Inc. reserves the right to reject any warranty claim
on any item that has been shipped by non-acceptable means of transportation. When any
product is returned for examination and inspection, or for any other reason, Buyer and its
shipping agency shall be responsible for all damage resulting from improper packing or
handling, and for loss in transit, notwithstanding any defect or non-conformity in the product. In
all cases, Haas Laser Technologies, Inc. has sole responsibility for determining the cause and
nature of failure, and Haas Laser Technologies, Inc. determination with regard thereto shall be
final.

If it has been found that Haas Laser Technologies, Inc. product has been returned without
cause and is still serviceable, Buyer will be notified and the product returned at Buyer's
expense; in addition, a charge for testing and examination may, at Haas Laser Technologies,
Inc. discretion, be made on products so returned. In all cases, Haas Laser Technologies, Inc.
has the sole responsibility for determining the cause and nature of failure, and Haas Laser
Technologies, Inc. determination with regard thereto shall be final.

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Manual-6000A Rev. 4
EXCLUDED PRODUCTS:

All optical components are specifically excluded from warranty.

WATER-COOLED PRODUCTS:

Haas laser Technologies, Inc. does not warrant any of its water-cooled products against
contingent or subsequent damage resulting from negligence in providing the required water-
cooling or from unexpected events which cause the required water-cooling to be interrupted
during operation of the equipment. Many Haas Laser Technologies, Inc. water-cooled products
include protective devices designed to deactivate the product in the event that water service has
not been provided or that water service has been interrupted. However, Haas Laser
Technologies, Inc. liability in the event of a protective device failure is limited to repair or
replacement of the protective device and does not extend to subsequent damages to the rest of
the Haas Laser Technologies, Inc. product.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES,

WHETHER WRITTEN, ORAL OR IMPLIED AND SHALL BE BUYERS SOLE REMEDY AND
HAAS LASER TECHNOLOGIES, INC. SOLE LIABILITY ON CONTRACT OR WARRANTY OR
OTHERWISE FOR THE PRODUCT. HAAS LASER TECHNOLOGIES, INC. DISCLAIMS ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE. IN NO EVENT
SHALL HAAS LASER TECHNOLOGIES, INC. BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE USE OF
OR THE PERFORMANCE OF THE GOODS DELIVERED HEREUNDER.

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Manual-6000A Rev. 4
10. REPLACEMENT PARTS AND SERVICE CHS-6000
REPLACEMENT PARTS AND SERVICE:

Replacement parts should be ordered directly from Haas Laser Technologies, Inc.
to ensure proper operation and implementation. Most standard replacement parts
are in stock and can be shipped over-night. Call for pricing and availability.

CORPORATE HEADQUARTERS:

Haas Laser Technologies, Inc.

37 Ironia Road
Flanders, New Jersey 07836
USA

Ph: 973-598-1150
FAX: 973-598-1151

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Manual-6000A Rev. 4
11. INTERFACING AND DRAWINGS

11.1 LED’s and DIP Switch on the PCB

12 10 8 6
13 15 17 19
11 9 7 5
14 16 18 20
1 I/O
2 Interface
3
4 CN1
5

8
7 Analog
DIP CN2
6
5
Switch
4 S1
3
2 (Factory Setting) Sensor
1 Input
1 0

LED 1 - Shows the operation mode Analog Output Range

(Mem. 1 = 1Hz, Mem. 2 = 0.5Hz) 00 = 0 to +10V
DIP 1
LED 2 01 = 0 to -10V
DIP 2
LED 3 Shows the progress of calibration 10 = -10V to +10V
LED 4 11 = +10V to -10V
LED 5 - Mode selection
LED 6 - Memory selection Baud Rate (CN1)
LED 7 - Position 00 = 9600 BPS
DIP 3
LED 8 - Plasma alarm select 01 = 19200 BPS
DIP 4
LED 9 - Average select 10 = 38400 BPS
LED 10 - Reduce Gain 11 = 57600 BPS
LED 11 - No function
LED 12 - Hold Function DIP 5 SPC : 0 = Effect, 1 = No Use
LED 13 - Touch alarm DIP 6 Average: 0 = Effect, 1 = No Use
Reduce
LED 14 - Cable break alarm DIP 7 0 = Effect, 1 = No Use
Gain:
LED 15 - Complete DIP 8 NvRam Initialize
LED 16 - In Range
LED 17 - DC on
LED 18 - Status 1
LED 19 - Status 2

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Manual-6000A Rev. 4
 11.2 CNC Interface

DB 25 CN1 I/O Description Comment

COM 1
1 1 I + 24 VDC System power supply
14 2 I + 24 VDC System power supply
2 3 I Mode Bit Calibration / Operation
15 4 I Memory Select Memory 1 or 2
3 5 I Position In-position signal from NC
16 6 I Plasma detect 0=Level 1 1=Level 2
4 7 I
17 8 I Reduce Gain Slow output response
5 9 I Q/A function Quick approach active
18 10 I Position Hold Inhibits change in voltage output
6 11 I N2 Com 0V for I/O
19 12 I P24 Com 24VDC for I/O
7 13 O Touch Tip touch alarm
20 14 O Cable Break Cable break alarm
8 15 O Complete Confirmation signal from LCIII
21 16 O In Range Is 1 if –10V position is reached
9 17 O DC On System Ready
22 18 O Plasma alarm Plasma detection alarm
10 19 O Status Bit1 Calibration fault 1)
23 20 O Status Bit2 Calibration fault
11 21 O Analog Output Analog output signal
24 22 Sensor GND Sensor GND (Workpiece GND)
12 23 Sensor GND Sensor GND (Workpiece GND)
25 24 Sensor GND Sensor GND (Workpiece GND)
13 25 0V System power supply
26 0V System power supply

1) Status Bit 1 Status Bit 2

0 1 Calibration fault
1 0 Wrong calibration step
0 0 other
1 1 normal

Connector CN2

Nr. I/O Description Comment

1 O Analog output Analog output (same as CN1-PIN21)
2 O GND Sensor GND

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Manual-6000A Rev. 4
11.3 I/O Connections

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Manual-6000A Rev. 4
11.4 Enclosure Dimensions

.470 DIA.
(4 PLACES)

10.50“

11.95“

9.00“

11.95“

6.82“

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Manual-6000A Rev. 4