DTHCiV-Setup-Config_..

DTHCiV-Setup-Config_..

USING THE RAV-01 TO FIRE THE TORCH

(for plasam units with no external connector to fire the torch or with a hand torch

The next internal signal you need to locate is the TORCH SWITCH. If you are connecting to a unit with a Hand Torch you will need to find and tap into the two wires coming from the torch switch in the hand piece. How will you know? First the wires will be smaller and different colors than the ELECTRODE or PILOT ARC (more about that later) wires. In most cases there will be four smaller wires. Two will be the torch switch and two will be the PIP or CIP

(Consummables-In-Place) wires. Once again the manufacturers documents can be of service here identifying colors and even connection points. If you do not have the manufacturers service information with schematics and cannot find them on-line you will need to do a little detective work to identify the torch switch wired.

The first thing your should do is get an Ohmmeter, and with it set to low ohms. Short the leads together and make sure the meter shows the change and displays low (close to zero) ohms. If your meter has a “squaker” continuity tester position then use that as a tone indication. Clip across two of the four smaller wires. If you get no reading or tone (or an OV or OL indication) the circuit is open. Activate the torch switch on the hand piece and if the reading goes to a low value of ohms (<100) or the tone sounds, it is the switch contacts.

Confirm the reading by pushing the torch switch several times. Keep testing wires until you find the pair that changes the meter. Note the colors. Use your meter to test the other wires. You may well find a pair that causes the meter to go to low ohms as soon as you touch them, but working the torch switch WILL NOT change the meter. Those are NOT the torch switch pair. Once you have identified the Torch Switch pair study the diagram on page

____ and using the two ScotchLOC connectors slide one over each of

That concludes the internal connections you will have to make for your unit.

Make sure all leads are insulated and away from possible physical damage.

Double check to make sure there are no loose connections and that you have attached/ re-attached any wires mentioned in the above guidelines.

Replace all covers and safety devices on the plasma unit and plug the plasma unit into power with the unit switched off. Turn the unit on, and make sure the unit works correctly in manual mode. (i.e. cut a piece of metal by hand). If you have a machine torch manually fire the torch from the Torch On button in MACH3

CandCNC

Page: 70

USING the RAV-01 to fire the Torch (unit has no external connector to fire the torch)

NOTE : Some models of plasma cutters that have a CNC connector (CPC connector) have a safety lockout to prevent firing the hand torch remotely. The listed connection will fire the torch the same as pulling the trigger. Both the trigger and the software can fire the torch. There may be a way to bypass the lock-out and use the CPC connector to fire the torch. Contact us via e-mail for other possible solutions on plasma cutters that have a CPC connector.

Use ScotchLoc IDC Splices (RED) to tie Torch Switch output on THC Sensor

(J10) Screw Terminals. Locate Orange and Violet wires at J10 in the

PowerMAX box and tap each wire as shown. To test short two screw terminals on J10 THC Sensor and torch should fire (Plasma Unit on)

CONNECTING HAND TORCH TO THC SENSOR CARD

Wire colors will vary by brand

Connect to Screw terminals J10 1 & 2 on the THC Sensor Card

IMPORTANT:

the PowerMAX

When making any connection inside

disconnect the unit from the AC

Line (unplug it).

on the AC line.

Do not open the case with power

THERE ARE DANGEROUS

VOLTAGES present in the unit anytime it is connected to an AC source EVEN IF IT IS TURNED OFF.

FROM HAND TORCH CABLE

Page: 71

Using the RAV-01 to fire the torch

J15

RAV-01 Raw Arc Volts CARD

CAUTION: High Voltages Present

When TORCH is ON.

Tip Volts

Workclamp

+ [POS]

- [NEG]

Tip Volts

REV 18

L2

+

Volts

SW1

1 1

Out

VOUT

MANUAL

SW3

TORCH

Divided

TP1

-

+

TP2

-

+

FIRE

-

Volts

J5

1

SW2

1

Local Connections

R1

CAUTION: High Voltages Present

When TORCH is ON.

4

ARC OK

3

ARC

OK

2 1

TORCH

SWITCH

Torch Fire wires see previous page for connecting to Hand torch models without CPC connectors

PART # CCAB-31

Connection to THC SENSOR PWM

Module

1

CandCNC

Page: 72

CandCNC RAW ARC VOLTS (RAV-01) Voltage divider card

J15

CAUTION: High Voltages Present

When TORCH is ON.

Tip

+ [POS]

Volts

Workclamp

- [NEG]

Tip Volts

Electrode

R1

CAUTION: High Voltages Present

When TORCH is ON.

REV 18

L2

+

Volts

SW1

1 1

Out

VOUT

MANUAL TORCH

Divided

TP1

-

+

TP2

-

+

FIRE

-

Volts

J5

SW3

SW2

1

Local Connections

4

ARC OK

3

ARC

OK

2 1

TORCH SWITCH

TORCH

SWITCH

CONNECTING TO HAND TORCH SWTICH

WIRES FROM RAV-01 sWTICH WIRES FROM

PLASMA HAND PIECE

RJ45 (Cat5) cable to

DTHCII Module

ALTERNATE METHOD TO FIRE HAND TORCH IF NOT

USING RAV-01 CARD

1

TORCH

ARC

ON OK

TEST +5V +12V

TORCH

SWITCH on Plasma

ARC OK

CANDCNC

Model

THC SENSOR PWM

Plasma Pickup Module for DTHC II

From

Plasma

TO DTHC II

Module

USE CAT5 UTP

CABLE

ARC VOLTS remove back cover for access to test buttons

DIVIDED ARC

VOLTS IN

MAX VOLTS

36VDC

Advanced

P WM

Technology

Divided volts from

CandCNC Raw Arc

Volts card

Use the same two wires on the 4 pin connector for the PWM Module REV 21

CandCNC

Page: 73

CandCNC RAW ARC VOLTS (RAV-01) Voltage divider card

100 VDC or more

to WORKCLAMP connection (+)

RAW ARC

VOLTS IN

350 VDC (Max)

To Electrode connection

(-)

CAUTION: HIGH VOLTAGE PRESENT

ON CARD WHEN TORCH IS FIRED

J15

Tip

Volts

+ [POS]

REV 18

L2

+

Volts

1

SW1

Out

VOUT

Divided

TP1

-

+

TP2

+

-

-

Volts

MANUAL TORCH FIRE

J5

SW3

Local Connections

SW2

1

- [NEG]

Tip Volts

Electrode

R1

1

ARC OK

Raw Volts Present

Raw volts TEST

BUTTON

NOTE: PRINTING ON REV 18 PCB for Torch Switch and Arc OK are WRONG! Use this diagram

PUSH BOTH BOTTONS TO

MANUALLY FIRE TORCH

TESTING /TROUBLESHOOTING RAW ARC VOLTS CARD

o Make sure all of the connections to the ARC OK (if units has that signal) and the TORCH

Switch (START circuit) are connected according to the manual.

o

To Test the Torch Firing circuit

1. Turn on the plasma unit.

2. Clear all persons away from torch.

3. USE BOTH TORCH FIRE BUTTONS at the same time. Use an insulated pair of probes to activate the switches

4. If torch fires it indicates the Torch Switch wires are connected correctly.

5. If the plasma unit fails to fire and start the arc, then the connection is not correct, or the unit has a safety lockout to prevent remote firing a hand torch. NOTE IF YOU ARE NOT

FIRING THE TORCH THROUGH THE RAV-01 Card THAN THIS TEST WILLNOT FIRE THE

TORCH! If you are using the RAV-01 JUST for divided volts SKIP THIS TEST.

o

To test the voltage divider circuit

above.

you MUST have passed the TORCH FIRING TEST

1, To test to see if the voltage divider circuit is working use the two TORCH FIRE

BUTTONS to fire the torch (or do it from MACH if you have that capability and depress the RAW

VOLTS TEST BUTTON at the same time.

2. The RAW VOLTS PRESENT LED should light. It indicates that Divided volts is reaching the divided volts cable.

3. If it fails to light then check the RAW ARC VOLTS connections and their polarity. If the leads are reversed you will NOT get any divided volts and the LED will not light. Clip Meter across TIP VOLTS terminals set on 200VDC and fire torch with TORCH FIRE BUTTONS

(Caution high voltage). Reading should be between 130 to 180 VDC on plasma units (open circuit voltage)

NOTE: With the RAW VOLTS TEST Button active the TORCH VOLTS reading in MACH will not be correct. The test loads the circuit. This is normal and it is used only to determine if the unit is getting and dividing the RAW ARC VOLTS.

CandCNC

Page: 74

HYPERTHERM 1000/1250/1650

Connecting THC SENSOR PWM CARD

J15

+

J16

-

TIP VOLTS CONNECTION

J15 and J16 are Slide-on connectors located on the PCB

Use 18 or 20ga insulated Hookup wire

Insulation rating to 400V Min

DAMGER

HIGH VOLTAGE

WHEN TORCH is ON

To TORCH -

(ELECTRODE WIRES)

CONNECTION (-) CONNECTION (+)

J19 Located inside Cabinet on PC Board

J14

TO ELECTRODE

CAUTION!

WHEN TORCH is ON

+ [POS] W

AMP ORKCL TO W internal connections

ARC XFR

START SIGNAL

D13

CAUTION!

HIGH VOLTAGE

CandCNC

PICKUP

R6

C1

CAUTION

FIRES

TORCH

TORCH SWITCH

ARC OK

SAC-01 Shieilded Cable to Torch Sensor PWM

Module

Connect to THC SENSOR PWM VIA

CCAB-31 Cable

CandCNC

Page: 75

HYPERTHERM 1000/1250/1650 andThermal Dynamics units with rear CPC connector and no Arc Voltage Divider

Raw arc volts connection points vary from one model to another

Refer to manufacturers manuals for locations

+

-

Use 18 or 20ga insulated Hookup wire

Insulation rating to 400V Min

TO CPC CONNECTOR ON REAR

OF PLASMA

OPTIONAL RAV-01

MOUNTED INSIDE PLASMA

J15

CAUTION: High Voltages Present

When TORCH is ON.

Tip

+ [POS]

Volts

- [NEG]

Tip Volts

Electrode

R1

CAUTION: High Voltages Present

When TORCH is ON.

REV 18

L2

+

Volts

SW1

1 1

Out

VOUT

MANUAL TORCH

Divided

TP1

-

+

TP2

+

-

FIRE

-

Volts

J5

SW3

SW2

1

Local Connections

4

ARC OK

3

ARC

OK

2

1

TORCH

SWITCH

Route shielded cable through rear bulkhead

METHOD TO CONNECT TO UNIT

WITH MACHINE TORCH USING

REAR CPC CONNECTOR FOR

TORCH FIRING AND ARC OK

MIC-02

For units with CPC but NO

Internal Voltage Divider

RJ45 (Cat5) cable to

DTHCII Module

1

TORCH

ARC

ON

OK

TEST

+5V +12V

TORCH

SWITCH on Plasma

ARC OK

From

Plasma

CANDCNC

Model

THC SENSOR PWM

Plasma Pickup Module for DTHC II

TO DTHC II

Module

USE CAT5 UTP

CABLE

ARC VOLTS remove back cover for access to test buttons

DIVIDED ARC

VOLTS IN

MAX VOLTS

36VDC

Advanced

P WM

Technology

THC SENSOR PWM MODULE

Divided volts from

CandCNC Raw Arc

Volts card

CandCNC

Page: 76

HYPERTHERM PowerMAX 45

Connecting THC SENSOR CARD

NOTE: THE Hypertherm 45 comes stock with a rear CPC connector and a 50:1 internal voltage divder. The preferred connection method is to use the MIC-01 cable kit fom CandCNC

RAV-01

1 & 2

Screw

Term 3 & 4

Drawign not to scale

LOCATION OF J19 and J21

Inside PowerMAX 45

FRONT

J19 or J18

(white wire)

CAUTION: Make sure wires and terminals do not touch anything but the screws for

J19 and J21. HIGH

VOLTAGE IS PRESENT

WHEN TORCH IS ON.

CandCNC

J2

1

(w ork lea d)

TP 19

W

192 VDC

+ -

TP 18

R

192 VDC

+ -

TP 17

B

To RAV-01 Card J15

POS input terminal

To RAV-01 J14

NEG input terminal

Page: 77

THIS SECTION RESERVED FOR POWERMAX 65.85 HOOKUP DATA

CandCNC

Page: 78

THERMAL DYNAMICS

Automated Cutmaster® 151

CONTROL CABLE PIN - OUT DIAGRAM

2 / White

Alignment

Spline

1 / Black

3 / Red / Torch Switch

5 / Orange (Negative) Divided Arc Volts

4 / Green / Torch Switch

7 / Yellow / Arc Volts (Negative)

Alignment

Splines

Alignment

Splines

14 / White - Red / OK to Move

8 / Logic Common

12 / White - Black / OK to Move

Use CandCNC part # MIC-01

APPENDIX 7: INTERFACE PCB SWITCH SETTINGS

(MOST COMMON SETTINGS)

1

1

0

0

1

SW 4

2

0 0

1

1

0

1

0

1

0

0

3

Automation Interface Switch Setting Chart -

Common Voltage Divider Output Settings

SW3

4

SW2 SW1

Volts Out for

5 6 7 8 100vdc In

0 = DOWN = OFF, 1 = UP = ON

Volts Out for

200vdc In

Factory Default Settings

Suitable for Thermal Dynamics SC-11 Standoff Control:

0 0 12.00

1

1

0

1

0 0 0 0 6.00

Other Common Settings:

0

1

0

0

1

1

0

0

1

1

0

0

1

0

1

0

5.00

3.3

2.5

2.0

0 = DOWN = OFF, 1 = UP = ON

10.00

6.6

5.0

4.0

Division

Factor

16.3:1

20:1

30:1

40:1

50:1

CandCNC

Preferred Setting

Match THC Sensor PWM setting to this

Page: 79

THERMAL DYNAMICS

Thermal Dynamics

AUTOMATION INTERFACE PC BOARD

SWITCH LOCATIONS

Automation Interface PC Board

Arc Volts Divider

Set Swtiches

CandCNC

Page: 80

1TORCH

E64

E35

ATC CONNECTOR

7

8

5

6

3

4

1

2

7

8

5

6

3

4

1

2

-

+

AUTOMATION

TORCH SOLENOID

/PIP

/START

24VAC RETURN

24VAC SUPPLY

5

6

7

3

4

1

2

78

79

80

81

82

83

OK-TO-MOVE

+12VDC

Automation

Interface PCB

(Arc Voltage divider) is an OPTION

4

5

6

7

8

1

2

3 3

4

5

6

1

2

7

8

CNC INTERFACE STANDARD ON A40 & A60 UNITS

CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS

8

7

6

5

4

3

2

1

14

13

12

11

10

9

}

OK TO MOVE

(5A @250VAC / 30VDC )

}

/START / STOP

(Sink 50mA @12VDC)

7

8

5

6

3

4

1

2

To -V OUT 1 on PCB1

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

* *

To configure DIVIDED ARC VOLTS signal output

No jumper installed for ARC VOLTS /16.67

Jumper pins 1 & 2 for ARC VOLTS / 50

Jumper pins 2 & 3 for ARC VOLTS / 16

7

8

5

6

3

4

1

2

+12VDC

K1

11

12

13

14

7

8

9

10

5

6

3

4

1

2

}

/START / STOP

}

(-)

(+)

*

DIVIDED ARC VOLTS

(-)

}

(+)

ARC VOLTS

(W/ 100K IN SERIES (2))

}

OK-TO-MOVE

PCB4

AUTOMATION

INTERFACE PCB

COMPATABLE

CABLES:

For units with CPC rear connector (only) order

AMIC-02 cable

For units with CPC rear connector AND

Automation Interface

PCB installed order

AMIC-01 cable

J2 PINOUT

7

3

11

14

1

4

8

12

Automation Interface

Cable Port

Input Power Selection

Filter Assembly

Gas Inlet Port

THERMAL DYNAMICS

Use the drawing to determine if your

Thermal Dynamics

Plasma cutter has the rear panel CPC connector and/or the complete Automation

Interface (provides Arc

Voltage divider) Some

52/82/102 units may have the rear connector and the

Automation interface.

All “A” series units have the rear panel connector with the two signals. Your A series

MAY have the

Automation Interface

Option as well.

Once you have determined the options you have installed then contact CandCNC to determine what options you may need to purchase.

CandCNC

Input Power Cord

Page: 81

HYPERTHERM

TORCH SETUP

6

5

3

4

1\

14

13

Refer to the follwwing table when connecting the Powermax65 or Powermax85 to a DTHC II torch height controller with a Custom CandCNC Machine Interface Cable

Signal

Start

(start plasma)

Type

Input

Arc

Transfer

(ARC OK)

Output

(start machine motion)

Notes Connector sockets

Normally open.

18 VDC open circuit voltage at

START terminals. Requires dry contact closure to activate.

Normally open. Dry contact closure when the arc transfers.

3, 4

12, 14

CandCNC

Cable wires

Green, White

Red, Black

Ground

Voltage divider

Ground

Output

Option. Not on all units

13

5 (-), 6 (+)

Shield

Red (-), White (+)

Note: Wire colors for CandCNC Hypertherm CPC Interface cables are different from the wire colors for a Hypertherm CPC interface cable

Hypertherm and Powermax are registered trademarks for the Hypertherm INC.

CandCNC

Page: 82

HYPERTHERM

HYPERTHERM 45/65/85 Machine Interface

Connection points



Connection

Points for

Hand Torch

Torch Switch

BLU

ORG

VIO

YEL

WHT

J27

WORKCLAMP

J20

1

2

BLU

ORG

VIO

3

4

5

RED

6

7

8

9

10

CAP

START

(on hand torch)

Small headers

(pins) on Main

Control PCB

J21

1

2

3

4

J33

1

2

TORCH

RED

BLK

GRN

WHT

BLK

RED

BLK

141157

VOLTAGE DIVIDER

BOARD

RED

3

6

5

4

4

3

14

12

14

13

START

START

ARC OK

ARC OK

1\

5

Divided Arc Volts (neg)

6

Divided Arc Volts (pos)

CPC

REAR

CONNECTOR

CandCNC

Page: 83

Connection Points

For Machine Interface

Pin functions are listed previous page

1

4

J21

Small cable

J33

1

3

CandCNC

Physical Location of J21

Page: 84

As long as your PWM module is mounted within about 48 inces or less to the

CPC connector the factory default of 50:1 divider ratio is recommended.

Only change the setting if you are having problems with torch noise causing erratic votlage readings.

TORCH SETUP

SETTING THE 5 POSITION DIP SWITCH FOR USE WITH CandCNC DTHC II TORCH SENSOR PWM

To change the factory preset voltage divider from 50:1 to the 20:1 setting

1.

Turn OFF the power supply and disconnect the power cord

2.

Remove the power supply cover.

3.

Locate the voltage divider DIP switches on the left side of the power supply

Note: The figure below shows the default setting (50:1) with the number 4 switch up

4.

Set the DIP switc

2 0 : 1

5 0 : 1

Note: The Hypertherm document has additional swtich settings for other divider ratios but ONLY the 20:1 or 50:1 ratios work with the DTHC IV and the THC SENSOR PWM module. The divider setting inside the THC SENSOR PWM case (bottom removed) is changed to work with a 20:1, a 50:1 and a 7:1 (CandCNC Raw ARC Volts divider card) input.

Hypertherm and Powermax are registered trademarks for the Hypertherm INC.

CandCNC

Page: 85

Interfacing using Circular Plastic Connector on Plasma Units with Automation features.

NOTE: The presence of a CPC connector on a Plasma Cutter does not necessarily indicate that it has all (or any) of the signals for direct connection to the DTHC II system.

The diagrams and examples listed in the following pages are for specific units that have

CPC connectors and a pinout that is consistant with the cables we supply. Several import Plasma units have added

CPC (CNC interface) connectors but they do not have the same pinouts and require custom cables. We have not been supplied with any sample units and the manuals are confusing so interface support from Candcnc will be minimal.

As of this published date the following units have CPC connectors with the correct pinout:

Hypertherm 1000/1250/1650 (no divided arc volts)

Hypertherm 45 (stock with rear CPC connector and voltage divider)

Hypertherm 65/85/105/125 (CPC option with divided arc volts)

Thermal Dynamics 52/82/102 series (option for connector and Automation

Interface)

Thermal Dynamics A60/A80/A120 (CPC connector standard; Arc Volts divider is an

OPTION)

Thermal Dynamics Automation 151 with optional TD Automation Interface Card

There may be other models and brands with CPC connectors using the same pinouts.

Check with you plasma authorized reseller or service representative for technical information about any automated connectors and pinouts.

On units that have the CPC connector but DO NOT have the Arc Volts Divider, you will need to purchase an arc volts divider. The RAV-01 is an ARC VOLTS divider card that is available from CandCNC.

On units with a machine torch you can elect to make all of the connections via the RAV-

01 card of use it only for divided Arc Volts and the MIC-02 cable to connect to the rear

CPC for the TORCH FIRE and ARC OK.

CandCNC was a whole series of Connection Kits designed to connect to the units listed above or by using our

Universal Connection Kit

virtually any other plasma cutter.

Visit http://www.CandCNC.com/PlasmaHT-Connect-Kits.html for Hypertherm Kits or http://www.CandCNC.com/PlasmaOther-Connect-Kits.html for other brands of plasma cutters.

For hand torch models you

may not be able to fire the hand torch via the remote

START signal

. In that case you will need find and tap into the Torch Switch wires coming from the hand torch. It is suggested that for Hand Torch installs even if the unit

CandCNC

Page: 86

MIC-01

Shown with THC Sensor PWM Module

Connects THC Sensor PWM Module directly and picks up:

START (remote start)

TRANSFER (Arc OK)

Divided Arc Volts cable comes prewired to plug into the

CandCNC THC Sensor PWM Module and the standard CPC plug on the back of 45, 65 and

85 units that have that option. See the previous pages for recommended settings.

CandCNC

1

MIC-02

For units with CPC but NO

Internal Voltage Divider

Page: 87

MIC-01 is for use with Hypertherm models 45, 65,

105, and 125 that have the CPC option installed.

The CPC is a round plastic connector on the rear of the units

CPC comes with

Machine Torch option or can be ordered separately. See the previous pages for the location of the receptacle .

setting up and plasma cutting with the dthc IV system

The following pages will take you through the initial setup and testing for CNC Plasma Cutting. There are several critical setups that if skipped WILL create bad results. Please take the time to go though the sections and perform the tests. If at any point your setup fails a test STOP! It is indication that something is wrong and you cannot just ignore it and force it to cut properly.

CandCNC

Page: 88

SETTING UP YOUR Z AXIS FOR

AUTOMATIC TOUCH-OFF.

µ

Make sure your Z is calibrated. So when you move it 1” by the DRO it actually moves exactly 1”.

If it does not, find the axis setup section in the manual for your control (BladeRunner AIO User

Manual “Motor Tuing Section” for the Bladerunner products) and run the axis setup and calibration. All axis MUST have the correct Steps per Unit setting in MACH.

µ

Check to make sure your Z HOME is working.

Make sure MACH is out of RESET

. Open

MACH to the DIAGNOSTIC Tab and watch the upper right quadrant while you manually trip the Z

µRaise your Z above a piece of material. Run a Ref Z move on Z by clicking on the Ref Z button next to the Z DRO (readout). The Z should start to move down towards the material. If it moves in the wrong direction STOP the move and use the CONFIG

HOMING/LIMITS in MACH to change the polarity of the

Home Neg value

. To change it click on the symbol (green check or red X) and it will change to the other value. Save it by clicking OK.

µ When the Torch Tip hits the metal the Z will continue to move down until it trips the switch. The Z should stop and reverse slightly.

µ

Use the Z Zero Button (next to the Z DRO) and reset the Z DRO to 0.000.

µ You may want to lower your Jog % in the Diagnostics Tab to 10% or less to slow down the manual jog rate. Carefully jog the Z up using the keyboard hotkey (default is Page

Up Key) until you can slip a piece of paper under the torch tip.

µ

Perform the move again and confirm the value. Once you have several readings within

.005 then write down the Z DRO reading

µ

The value you have is the Net Switch Offset and will be used in either MACH OR in

SHEETCAM (post)

but NOT BOTH

.

CandCNC

Page: 89

SETTING switchOffset in SHEETCAM TNG

Note to SHEETCAM (and SheetCAM TNG) users.

We have provided special Posts for MACH3 and the DTHCIV to be used when generating output from SheetCAM. It has an automatic “touch-n-go” feature that reads the traveled distance and once it exceeds 500mm (about 20 inches) a Z reference is performed

just prior to the next pierce

.

This post is intended for use with the DTHCII and DTHCIV and a floating head setup.

There are MP3000 named posts and DTHC IV named POST. You should use the DTHC

IV named posts

The SheetCAM-CandCNC_Install.exe (Support Install) off the CD is located in the MasterInstaller[root]/SheetCAM-CandCNC-Support folder or as a download off the Candcnc website. It adds in new POST processors and a full toolset for most Hypertherm Plasma Cutters. Please read the addendum on

SheetCAM TNG for an overview of new features these new POST take advantage of.

If you are using SheetCAM TNG you need to open the specific post (or posts) you use with a text editor (Notepad, etc) and find the line in the post that sets the value of the

SwitchOffset. It will look something like this: dist = 9999999 refDistance = 10* scale

--Put your switch offset value here switchOffset =.052

lastz = 0

The

switchoffset

value needs to be set to the number you wrote down when you did the tests on the previous page (

SETTING UP YOUR Z AXIS FOR AUTOMATIC TOUCH-OFF).

Make sure you save the file with the .post or the .scpost file extension it had to start with.

refdistance

is the distance you let XY travel before you do the next touch-off sequence.

You can change how close (and how often) that sequence happens by raising or lowering the value. Scale in this context is 25.4. Refdistance in in mm so in the example above the actual distance is 254 mm (about 10 inches). That is the combined distance of both X & Y movement. On thin material that may need a touch off before every pierce that the number to 0. Save the POST with another name and select it when doing your final CAM post to

G-code.

NOTE: Latest DTHC-HYT-TAP_SoftPierce+Marker-rev#.scpost coupled with SheetCAM

TNG

Development

5.1.22 (released 1/7/14) has the switchOffset and refDistance options as POST parameters. At some point SheetCAM TNG (stable) willbe upgraded and have the features in the development version. You can use the edit the POST method or if you have the following screen in the Options/Machine/Post Processor window set the parameters there.

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POST SETTINGS OPTION IN SHEETCAM

This new option no longer requires you manually edit the POSTs you use to add in the variables but you must do it for EVERY post you use b.

For non-SHEETCAM users.

You will not have auto - touch off and will ahve to manually insert the G-code if you have the floating torch holder (or the FT-01 Ohmic Sensor)

G00 Z.75

G28.1 Z.5

G92 Z0

G00 Z[your switch travel here in decimal]

G92 Z0

G00 Z.5

This should be inserted just prior to the Torch ON (M03) event at any given pierce point where you wish to re-reference the Z

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6. Cut quality in plasma is a function of several factors:

· Clean DRY air.

· Sufficient and consistent air pressure (typically 65 to 80

PSI)

· Good consumables.

· Accurate Pierce Height (Initial Height Sense aka “touch-off”)

· Proper Cut Height (Proper adjustment of THC voltage)

· Correct Pierce Delay

· Proper Feedrate (cutting speed)

· Proper settings of the DTHC Parameters

· Correct Cut Profile Settings for Span and Tip Saver

If your cut edges are flared in or out, check all but the last factor. If your MP3100-DTHCIV (BladeRunner DTHCIV models) does not respond fast enough you may need to open the DTHC Settings tab and either select the next higher preset or to use the custom tuning. WARNING: The

Acceleration in the Z DTHC motor tuning (different than the Z motor tuning in MACH3) is critical to good performance from your DTHCIV. You need to set that tuning via the HUB

UTILITY and the DTHC Settings in that location.

HUB UTILITY SCREEN

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DTHC MACH3 Screen Section

FUNCTIONS

NOTE: The DTHC IV is compatible with all of our Plug-n-Run products including the MP3000, MP3100, BladeRunner Dragon-

Cut, and the PlazPak series. If the text refers to one of the specific products then take that to mean the same as “any DTHC based product” in this section

UP ARROW Button:

The UP arrow increases the

PRESET VOLTS by one full volt per click in essence raising the torch and increasing the gap. It increments the PRESET VOLTS DRO and

automatically sends the value to the DTHC

. This can be useful since you can change the PRESET VOLTS while cutting which will adjust the CUT GAP at the TORCH. Sometimes a volt ot two of “tweek” can improve the cut. At the end of the cut the Current Settings will remain (for the next cut) and they become the new “Current Settings” in the memory of the DTHC

DOWN ARROW Button:

Performs the same function as the UP ARROW but decrements the PRESET VOLTS

DRO (value). It has the same effect as lowering the torch and decreasing the Tip Volts.

TORCH VOLTS DRO (readout)

Displays the actual ARC VOLTS at the plasma as reported by the DTHC IV and sent back to MACH via RS485 (C3BUSS HUb) You MUST have RS485 communization before the value will display. If there is no voltage showing and the torch is fired you need to check that the DTHC ONLINE is ON. This voltage should be close to what the cut chart calls for when DTHC is OFF and should be close to the RESET VOLTS with the plasma cutting metal a the proper feedrates and correct AMP setting on the plasma

PRESET VOLTS

. Preset volts

is probably the most important function

since it sets the “target” ARC VOLTS voltage you want to run at. It sets the voltage point that the

DTHC IV uses to decide if the Torch needs to move UP (to increase volts) or DOWN (to decrease volts). If the TORCH VOLTS from the torch is correctly calibrated than the

PRESET VOLTS should hold a correct ARC GAP (height from the torch tip to the material). It is important to understand that the DTHC does not have “radar” and does not know how far it is above the material without the TORCH VOLTS feedback. It depends in that beng accurate to properly adjust the volts.

DTHC ON/OFF BUTTON:

Unlike the older DTHC and DTHCII the Torch Height is no longer part of the MACH program and the THC logic in MACH is NOT used. The DTHC

ON/OFF turns off the signals from the DTHC IV (stops moving the Z anddoes not send the UP DOWN indicators via RS485 to MACH3. The DTHC IV when coupled with the

DTHC IV POSTs for SheetCAM use DYNAMIC DTHC control so the DTHC IV is controlled from the G-CODE and by conditions set by the CAM operator. Several things are automatic. See the addendum on SheetCAM TNG for more information. The operator may override the DTHC from the code but the code may turn it back on depending on the conditions. If you want to run out no DTHC IV you need to make sure you use a TOOL (plasma tool) in MACH with the DTHC disabled.

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DTHC MACH3 Screen Section

FUNCTIONS

TORCH HEIGHT CONTROL section (continued)

The TORCH ON/OFF button controls turning the Torch on/off. Under normal cutting condiitons (e.g. running from code) the Torch ON/OFF is controlled from the software. You have the option of turning the torch on or off manually using the button. The Torch button will fire the torch anytime MACH is out of

RESET. The TORCH LED above the button shows the status of the Torch output. When it is illuminated the signal is being sent to the MP3000 to turn on the torch. Anytime the Torch is on (or should be on) through manual OR software activation that LED should will be on.

UP & DOWN LED indicators

. These two screen LEDS in MACH show the actual UP and DOWN commands MACH is receiving from the DTHC Module. As the torch cuts and with the DTHC active, you will see the UP and DOWN LEDs change. It will tell you at a glance that MACH is getting the proper signals and coupled with the TIP

VOLTS DRO show you the activity of the DTHC. In the DTHCIV the the UP and DOWN signals come into MACH via the C3BUS (rs485) since the DTHC IV does not use “hard” inputs into MACH3 (port pins) and are NOT on the high speed parallel port.

ARC OK Indicator

. The ARC OK is a integral part of our cutting system. It is a signal that tells MACH (and the DTHC module) you have a fired the torch and it has a valid arc and you are ready to cut. It also detects the loss of arc and MACH will stop movement BUT not turn off the torch output signal. The DTHC can be set to do that function independent of MACH (see the section on General THC

Settings). If you do not get Arc OK the DTHC IV will not release motion (HOLD will Stay active) and the DTHC will not start processing data to send UP and DOWN commands. Some Plasma units have a signal (normally “dry contacts...which are basically relay contacts with no connection to the internal circuit or voltage. On other machines you may have to order the optional DCP-01 IT’s a REQUIRED SIGNAL.

DTHC ONLINE Indicator. This screen LED show if thare is valid communication between MACH3 and the DTHC IV. ALl communicatin is via the C3BUS hub . It MUST be on to get DTHC functions

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TAB Fly-out on DTHC IV Screens

NOTE: The DTHC IV is compatible with all of our Plug-n-Run products including the MP3000, MP3100,

MP3500 BladeRunner Dragon-

Cut, Ether-Cut and the PlazPak series. If the text refers to one of the specific products then take that to mean the same as “any DTHC based product” in this section

TORCH HEIGHT CONTROL section

CUT CURRENT AMPS is an actual readout of the plasma current AT

THE CUT in AMPS. You MUST HAVE the DCP-01 installed and working to get a value in this DRO.

Current Fault Indicator

shows if there is an existing Current faul;t as defined by the readout of the Cut Current AMPS being withint he CUt

Current Tolerance (see DTHC IV Setup via the CUT PROFILE

PRESET AMPS

This DRO is an INPUT (will take a value) andis used

ONLY if you have a full TAP™ complianet Plasma cutter (example

Hypertherm 65/85/105/125 modelWITH RS485 Serialport.) This funcion

REQUIRES you have our HyT-Connect RS485 SIMKit connected through the C3BUS to the Hyopertherm RS485 serial port which allwos remote setting of the CUT CURRENT . This value can be set from this

DRO or from G-CODE using the updated DTHC IV POSTS for

SheetCAM TNG

% of Preset Amps;

This is an informational DRO (dispaly only) and shows what the current PERCENTAGE of the PRESET AMPS the torch has been commanded (typically from a value sent from the G-Code )

This ONLY WORKS with the fullTAP™ setup where cut current canbe controlled from software dynamically.

come on and stay on. Check your settings if this occurs.

CandCNC

DTHC DELAY:

The amount of time the DTHC waits to take over after the torch fires. The number will vary depending on the POST used.

Newer posts (like the

DTHC-HYT- has Auto DTHC Delay

TAP_SoftPierce+Marker-rev#.scpost has auto DTHC delay so the

DTHC does not take over unitl AFTER the pierce and plunge to cut height. The normal setting for the DTHC delay is in the 1 to 3 sec range. The Auto DTHC delay values should be from .2 to .5

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TAB Fly-out on DTHC IV Screens

The TIP SAVER LED

is a indicator to let the operator know that the

DTHC TIP SAVER circuit has activated and has locked the Z down movement. The parameters used for the Tip Saver are set in the

DTHC Cut Profiles Popup window. The settings and operation of the

DTHC is covered the DTHC Operation and Setup and the CUT

PROFILES part of the manual. NOTE:

It is normal for the TIP SAVER to go active at the end of a cut where you would normally get a head dive or as it’s cutting if it cuts across or very close to an existing cut. If the torch preset value is wrong for the type material and tip you are using then the TIP SAVER may false trip.

UPDATE for DTHC IV users: The DTHC IV when put in medium or fast modes is fast enough that it won’t will drive the torch at the end of a cut

You can try loweringthe TIP Saver percentage to 2% ior even lower . It that results in it locking on when it should not or not stopping the diving you should use the Cut Rules IN SHeetCAM to set a GLOBAL cut rule to turn off the DTHC :”Before end of Cut” and set it to about .3 to .5

inches (depending on how fast you are cutting) . If you have problems on corner diving you can set an OPERATION Cut Rule to turn off the

DTHC before a corner and back on after a corner. See the SheetCAM

Advanced Settings Addendum in this manual.

TIP SAVER ON/OFF button/led. Turns the Tip saver off or on and the

LED shows (GREEN right side )

HT ONLINE indicator

(Hypertherm Online). Indicates if the

Hypertherm RS485 serial port is talking through the c3BUS Hub and to

MACH3

This LED is only used with the full TAP (Total Automation Plasma) setup . If you have the Hypertherm RS485 Option on your

65/85/105/125 and the CandCNC HyT-Connect RS485 SIM kit

(Advanced Connection Kits) than this LED should be ON.

Using Smart-Kut for Plasma.

UPDATE for DTHC IV. It is suggested you leave this turned off and use the PRESET VOLTS and the DCC features to control your cuts. Smart -Cut needs several inches of straight (constant speed) cuts to measure from and that is not always the case . Working from a Cut Profile for the material and consumables you are using is a much better way to control the quality of your cuts

Smart-Kut® has been disabled in the DTHC interface

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TAB Fly-out on DTHC IV Screens

You must have the DCP-01 hooked up and working to use the

CUT CURRENT list below

USING CUT CURRENT FOR TROUBLESHOOTING A BAD CUT.

The CUT CURRENT can be a valuable tool to help diagnose and fix poor cutting or loss of arc and other annoying problems. Not all cut issues are from improper current but a good plasma cut cannot occur if the cut current is too far out of the specified value. The whole process of Torch Height Control depends on the current being constant and the value set on the plasma unit.

If you are experiencing problems cutting with the DTHC and it has passed all of the self tests, then setup and make a manual cut at a constant height (the recommended Cut gap) and watch the CUT CURRENT DRO. While cutting it should be close to the value you have set on the plasma machine front panel (dial value) If it is not here is a list of things to check:

CUT CURRENT TOO LOW

CUT CURRENT VARIES DURING CUT

Bad Workclamp Connection (either end)

Workclamp not on material

Current Setting on Plasma Unit wrong

Plasma Current not calibrated to knob

Bad Workclamp Connection (either end)

Bad material (rusty/dirty)

Worn defective consumables

CUT CURRENTTOO HIGH

Current Setting on Plasma Unit wrong

Constant Current circuit in Plasma Unit not working

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THIS PAGE LEFT BLANK

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CUT PROFILE SETTINGS MACH SCREEN

CURRENT SETTINGS BUTTON:

Shows the current profile and settings being used by the DTHC. The DTHC uses a real time processor to process the torch volts and send the proper signals to MACH. The processor stores the settings in NVRAM (nonvolatile ram) Changing any setting in the Settings Group or the General THC Settings and using

OK

(closes the window) saves the profile (writes it to the DTHC processor

RAM. You must close the window to be able to access the MACH screen and to move the machine (JOG) or RUN g-code.

Cancel

cancels any changes you have made before you exit

The DTHC module “remembers” the settings you used last even if you power everything off. The Cut Profile values are sent to the DTHC module (via a serial connection from the PC to the UBOB and up to the DTHC module) The “Current

Values are what is in the DTHC memory. Values are transferred when you hit OK

NOT when they are just displayed. ONLY the CURRENT SETTINGS values are what the DTHC uses during cutting. If you pull up a profile and do not transfer it to the

DTHC module

PROFILE LIST BOX :

parameters will be transferred to the Current Settings screen. You can Add new Profiles using the

Add button

Shows a list of all saved profiles. Any profile can be selected and those

.

Delete

Button

. If for any reason the DTHC module has lost communication with MACH the settings on the screen ARE NOT SAVED to the NVRAM and opening the screen again to display CURRENT

SETTINGS will show the old settings. Check to make sure the THC ONLINE LED is on.

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CUT PROFILE SETTINGS MACH SCREEN

Adding Profiles

. As you do cutting on your table using the DTHC Digital Torch

Height Control you will be able to choose optimized settings for each type of cutting you do. You can edit and save an existing Cut Profile or ADD a new one of you own. Since there are variables that change from one machine to another the sample values may or may not be usable in your environment. It’s best to start out with the default Settings and use the Tip Volt Preset recommended by your plasma manufacturer.

If your plasma machine has no documentation or recommended cut charts then go to the Plasma Setup section in this manual and use the Initial setup and calibration methods to establish a base line for building your own charts.

The two most critical components are the feedrate (set in the G-Code and CAM program) and the Tip

Volt Preset. Since both values vary between machines it’s best to run a series of tests. Even the cut gap (distance from the tip to the material) and the gap volts (actual tip volts) varies from one plasma manufacturer to another.

Example: A Hypertherm G series calls for .063 (1/16 ) cut gap and a tip volts reading of 140VDC on 10Ga material with a 40A tip. A Thermal Dynamics unit uses a wider cut gap (about .1 to .12) and lower tip volts (about 110VDC) for the same material.

Other machines will vary. It’s best to develop your own values for your machine over time and store them in the Cut Profiles. NOTE:

The Cut Profiles are stored in a flat file named THC_Profiles.txt located in the main MACH3 folder.

It’s a good idea to back up your MACH settings (XML files), Screens (SET Files) and the Cut Profile listed. Restoring values from a backup copy can save hours or frustration.

IMPORTANT INFORMATION: If you use the DCC features available with the DTHCII and

DTHCIV when you use SheetCAM TNG and our custom POSTS that expand the Tool table settings you can store your Cut Profile directly in that JOB file and the settings will be changed

automatically

when you run the code. It eliminates the need to have the operator remember to change to another Cut Profile of to enter new settings at the console. You DO NOT have to be running a specail brand ot type of plasma to use DCC. It is totally between the Cut Profiel settings and the DTHC IV

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IMPORTANT INFORMATION

The following section on the setup and testing of the DTHC IV Is CRITICAL to the success of having a working table.

We understand that most users do not like reading manuals and would rather just pull the system out of the box, plug it in and load some code and make a cut. Perhaps if you invest in a complete

CNC plasma table and pay for their expertise and time to do the setup and testing than you can expect it all to just be setup calibrated and tested and be able to start out with cutting material. The DTHC IV in your system has been tested and calibrated at several points along the production process including a final system test of all the products together that you ordered. It is not setup for your specific CNC table/hardware or plasma cutter.

We provide an abundance of information and detail with the assumption our customers may be doing this for the first time and may have little or no hands-on experience with either CNC or plasma cutting. You can skip some steps and get lucky and it will work fine. The problem occurs when it does NOT work fine and trying to figure out WHICH step was not done or done properly. If you call our Tech Support, we will ask you the results of some of these tests and if it becomes apparent you have not done the tests we will direct you back to the manuals.

Without baseline readings it becomes much more difficult to analyze problems and affect cures.

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FINAL TESTING

Doing a startup test using a manual cut ....DO NOT SKIP THIS TEST!

1. To establish that the DTHC is working and to find the best Torch Volts (Preset Volts) setting and initial cut height parameters, you should make a cut with the DTHC Button in

MACH turned

off , (and using a g-code file that does not dynamically turn the DTHC

ON/OFF see next page)

with the tip at the right cut gap for your plasma and watch the

TORCH VOLTS DRO on the MACH screen.

a. Generate a cut file consisting of long straight cuts. You need enough time to watch the screen indications (DRO readouts and LED’s) Unlike the older DTHCII that ran though

MACH3 and used the MACH3 THC Logic,The DTHCIV runs outside MACH3 so the old THC button on old screens DOES NOTHING. The THC function in MACH MUST be OFF.

The DTHC IV is DYNAMIC in the fact that it is turned ON and OFF via G-code commands which can override the Manual DTHC button on the fly out. Since the specific commands to turn the DTHC ON/OFF are generated by the custom DTHC IV posts older POSTs will not have that function. You should do one of the of the below listed methods to do the test cuts with the DTHC IV off.

1. TURNING the DTHC IV off using a non-DCC Post (like the simple MP3000-

DTHC .scpost or the older MP1000-THC.scpost)

2. Edit an existing post and replace any S20 command with an S10 b.

At this point you should have your touch-off moves and distance setup and calibrated.

IF YOU DO NOT or do not have a floating torch holder you will not be able to do automated cutting of thinner material.

c. With the cut gap set to the recommended distance (varies from .063 to .130 depending on the specific plasma unit) Make a series of long straight cuts WITH THE DTHC BUTTON

IN MACH TURNED OFF (Manual cut mode). NOTE: The THC is set to automatically turn on when the torch fires in most CUT PROFILES. Simply turn if OFF with the DTHC

BUTTON to do the test. The G-code can turn on the DTHCIV (and does automatically in most POSTS. See next page to use a POST that does not turn it on. The Z should remain steady (no movement) d. As the cut is made watch the indicators on the DTHC screen in MACH. The TORCH

VOLTS will display the actual volts at the cut. It should be close to the recommended volts the torch manufacturer calls for. If you don’t have those numbers then watch the voltage and pick an average and make note of it. If the voltage is way off from recommended, check the current setting on the Plasma unit. Check the tip size and for excessive wear. Replace consumables if necessary. Make sure you have a GOOD Workclamp connection to the

Material (not just the table or cut grid).

e. The TIP saver should not react if the DTHC is not active. If it does either turn it off via the button on the fly-out or check to make sure the DTHC LED is off an the DTHC has been switched on.

f. As the cut progresses and you have the TORCH VOLTS number THEN watch the other

DTHC indicators. The UP and DOWN should be active if the Target Volts setting is close to what you are seeing on the TORCH VOLTS. Make sure you have a constant ARC OK indication while the torch is on.

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TURNING OFF THE DTHC

IMPORTANT CONCEPT:

Torch Volts reflects the Arc Gap (distance between the tip and the material with the torch cutting.

It is what the DTHC uses to measure height. Because the ARC Gap is small it takes very little voltage change to indicate a relative major gap change. Changes of .020 in a gap of .063 are significant! The Preset Volts(Target Volts) tells the DTHC what you want that gap voltage to be. It is not a magic radar that senses the height. The manual test is to establish that the ARC Volts are indeed close to being correct with no adjustment of the torch that would change them. It also establishes a valid setting for the DTHC

Target Volts. If you get a number from TORCH VOLTS that is more than 5% out or the recommend volts (on average) or you do not have a chart to work from then

USE THE TORCH VOLTS setting you get from the manual test AS A BEGINNING

POINT FOR THE TEST WITH THE THC BUTTON ON!

g. After the first cut and you have a TORCH VOLT Reading, Use the UP or

DOWN (or type the value and hit ENTER to load the value you have derived in the first test into the PRESET VOLTS DRO.

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h.

Run the manual cut test again with the new PRESET VOLTS value.

Watch the UP and the DOWN LED indicators. You should see them turn on and change as the cut progresses. The ARC OK MUST be active (ON) for the UP and DOWN from the DTHC to work. The UP should come on any time the TORCH VOLTS is less than 1 volt LOWER than the PRESET VOLTS. The DOWN should come on any time the TORCH VOLTS is 1 volt higher than the PRESET VOLTS. All this happens pretty fast so you may need to make several manual test cuts. On each test it’s important that the actual ARC GAP (Tip to material distance) is constant and the material is flat so you get consistent readings.

IMPORTANT!

If you have skipped the manual cut test or did not get consistent results from it, your

DTHC IV is NOT GOING TO FIX THE PROBLEM AUTOMATICALLY. Just setting a random value (shooting in the dark) or just using the values in the cut chart and expecting it to just work is a formula for failure.

DO NOT CALL FOR SUPPORT IF YOU

CANNOT GIVE US THE RESULTS OF THE MANUAL TEST.

TESTING THE DTHC IV WITH an AUTOMATED CUT FILE.

If you have the Floating Torch Holder setup (Auto touch off) then you should have it already setup with the correct values so that it will touch off, raise the Z up to the top of the material and reset the Z to zero (from the g-code). The automated test cut file needs to be generated from a POST that is for MACH3. If you have SHEETCAM, select

any post that is for an

MP3000 or DTHC in the name.

setup.

Those posts

ONLY WORK

WITH THE FLOATING HEAD

1. Generate a series of basic shapes in your CAD/DRAWING. Process them in CAM to define the cut parameters. In SHEETCAM you define certain parameters for plasma cutting in the TOOL you use to generate the G-Code.

2. Use the DTHC IV settings you derived from your manual tests. Make any adjustments to the PRESET VOLTS one volt at a time using the UP arrow or DOWN arrow buttons on the

DTHC screen in MACH.

3. Remember that each tip (nozzle) size and material type/thickness needs different settings to cut properly. The PRESET VOLTS does not set an absolute height, it just defines a height

under specific conditions.

The CUT PROFILES is a Stored Settings feature that lets you enter and store various parameters for different types of cutting.

4. One of the most frequent mistakes made is either having the current setting on the plasma unit wrong for the nozzle you are using OR forgetting to clip on the Workclamp. The DCP-01 will detect those type of conditions and warn the operator.

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NOTE: Not all the parameters you see will appear on your screen. It depends on which POST you are using because the

POST defines added tool parameters and other features (like

Cut Rules) . IF you do not have the added (highlighted yellow) parameters you should make sure you have the latest

POST processors from CandCNC and then use the

OPTIONS/MACHINE/

Post Processor and import post processor to load and use the

POST

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Screen Shot from Tooltable in SHEETCAM

Kerf width:

Sets the width offset used for inside or outside cuts. If you don’t know the value go back to your manual cut you made and measure the width. Note wide will vary based on: Nozzle size used an age of consummables, Arc gap (height) , feedrate of the cut.

You can expect an AVERAGE width that will reamin fairly close if you hold the listed variables to a narrow range.

Feed Rate:

The recommended feedrate for this material and settings . This is a default value and can be changed when you build the OPERATION to match the material you are cutting.

Preheat:

Not used for plasma.

Pierce Delay:

Zero for material thinner than .187. The Pierce Delay is a total of this setting

PLUS the time it takes the ARC OK to light PLUS the time it takes the torch to PLUNGE (at the Set rate) from Pierce Height to Cut Height. Excessive pierce delay can result in voltage spikes that will “confuse” the DTHC and cause the TIP saver to lock on or the torch to plunge. Whatever the recommended pierce delay is on your chart make sure you subtract the cycle time of the numbers above.

Pierce Height:

The recommended piece height for your plasma. Usually 2 times the recommended cut height on material thicker than .125 (3mm). This define how far the torch will lift above the material after a touch off.

Plunge rate:

How fast the Z moves down from Pierce height to Cut height. This value should be close to the normal Z VELOCITY (motor tuning value in MACH3 for Z) not the Z velocity set in the DTHC IV tuning described earlier.

Cut Height

: The beginning cut height before the DTHC takes over after its programmed delay (default 1 sec). This is the normal “stand off” distance the plasma torch manufacturer recommends for automated cutting. Not all plasma manaufacturers publish or know what the optimum stand off distance is since they

Pause at end of cut:

A pause after the torch is turned off from MACH to let the arc die out and voltage to go to zero. Recommended ½ sec to 1 sec.

ADDED PARAMETERS (based on POST Processor used in SheetCAM TNG)

Preset Current.

The Cut current the plasma will be set to begin the cut. You MUST HAVE

A PLASMA that has the ability to be remotely controlled from the tooltable settings via Gcode. That requires the RS485 serial communications option on the plasma cutter AND the

CandCNC “TAP” setup (HyT-Connect RS485 SIM Kit). Just because these parameters may appear in your tooltable they will do nothing unless you have the full TAP (Total Automation

Plasma) options fully implemented.

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Preset Air Pressure. The air pressure (as recommended by the manufacturer ) for this type material and consumables. You MUST HAVE A

PLASMA that has the ability to be remotely controlled from the tool table settings via G-code. That requires the RS485 serial communications option on the plasma cutter AND the CandCNC “TAP” setup (HyT-Connect RS485

SIM Kit). Just because these parameters may appear in your tooltable they will do nothing unless you have the full TAP (Total Automation Plasma) options fully implemented.

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ADDENDUM

1. DCP-01 Digital Current Probe Install & setup

2. Grounding Practices for plasma noise suppression

3. Troubleshooting Charts

4. FT-01 Feather Touch (revised)

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Block diagram of DCP-01

Connections

RAW ARC VOLTAGE

PLASMA UNIT

TORCH SWITCH

DCP Interconnect cable

RJ45 (CAT5) to DTHC II Moduler

Input connector

DCP

CandCNC

Workpiece Clamp

Good connection to the workpiece with clamp is essential for proper operation of the THC

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Digital Current Probe

Model DCP-01

Physical install and hookup

DCP-01 Digital Current Probel uses the existing THC SENSOR (rev14 or above) and slips over the Plasma System

Workclamp lead wire to provide DC amp feedback to the DTHC and to the MACH screen. The following series of photos shows the DCP being hooked up to a plasma cutter.

Start by removing the ground clamp from your plasma workclamp. If it has a large ring terminal on the end where it attaches to the clamp you will need remove the ring terminal and replace it with a new one after you push it through the DCP unit.

Loosen the cable strain relief/clamps on each end of the box by twisting the retainer nut counterclockwise viewed from the end. The

Strain relief has an internal collar that clamps down on the wire the more it is tightened.

Straighten the wire as much as possible and start feeding it from the right hand side.

Clamp End

Left hand Strain Relief

Plasma Unit End

Cable passes through center of DCP-01

CandCNC

Plasma Unit End

Clamp End

Right hand Strain Relief

Push the wire through gently. If it hangs try rotating the wire and pushing but do not force it. There is a round hole in the Hall probe inside the box that the wire has to pass through. It is located close to the right side of the unit. If you have problems getting the wire to go though pull the wire out and remove the 4 screws holding the top and remove the top and the PCB with the Hall

Probe (see next page). Thead the wire though the right side strain relief and pull enough through so you can thread the Hall

Probe on the card and then over and out of the left side strain relief.

Page: 110

Digital Current Probe

Model DCP-01

Workclamp Lead Wire goes through Hall Probe center as shown. Top shown flipped 180 degs

NOTE: Your DCP-01 unit will ship with a

8 ft interconnect cable to connect it to the THC SENSOR card. That connection is covered in the Setup and Test section for the DCP and comes in the side of the unit. If you remove the top cover pull carefully to prevent breaking or disconnecting the interconnect cable. If it comes loose the DCP setup section has the wire colors and hookup for the cable

When you have the Workclamp lead wire threaded through the box, hand tighten the outside nuts on each strain relief until it is tight around the cable. It is important that each end is sealed to keep out plasma dust and smoke. Position the DCP-01 along the cable close to the plasma unit and in a place it will not get stepped on, crushed or can will dragged across the floor if you decide ot move your plasma unit or use it manually in the shop. The enclosure is sealed and rugged but it can be damaged by excessive abuse.

CandCNC

Page: 111

Digital Current Probe

Model DCP-01

SETUP, TESTING and CALIBRATION of the DCP-01 DIGITAL CURRENT PROBE

Do the following steps in order:

1. Connect the DCP-01 interface cable (RJ11 flat silver to the THC SENSOR PWM front panel jack labeled DCP. You should get a postive “click” as the cable is seated. Removing the cable should require releasing the locking pin

2. If your THC SENSOR is mounted in a box or inside the plasma unit then you will need to make provisions to route the wire to the THC SENSOR. Keep the DCP interface cable away from the high voltage TIP Volts end of the THC SENSOR card.

3. If you are connecting up your DTHC II and THC SENSOR PWM for the first time, make the connections to the THC SENSOR PWM Module and the CAT5 cable back to the DTHC

II module (front Panel connector on the MP3000-DTHC or the BladeRunner Dragon Cut.

Do this BEFORE you make the Tip Volts (Arc volts) connection or the TORCH SWITCH.

You can run some tests on the THC SENSOR Card and the DCP without having the plasma unit turned on or the Tip Volts present.

CandCNC

Page: 112

Digital Current Probe

Model DCP-01

4. Start MACH3 on the controller PC and load the profile and screen set for the DTHC. If this is the first time you have used the DTHC and MACH you should have had MACH loaded and setup. If you do not, STOP! Go back to the MP3000-DTHC or the BladeRunner AIO manual and first setup MACH and get your table moving and the proper MACH profile loaded for your system.

This dialog box or one similar to it should appear the Fly=out (TAB) part of your MACH main screen if you are running the right profile. The important readouts (DRO’s) are the

TORCH AMPS. We will be using the

TORCH AMPS readout to calibrate the DCP and then use the Stored

Settings Button to preset some values for the DCP. It’s important that you have gone through the

DTHCIV setup in this manual FIRST and that you have confirmed that it is working properly. The DTHC

ONLINE Led at the main screen bottom should be ON (Green). If it is

NOT you cannot go further in the

DCP setup until the issue is resolved!

5. Power up the MP3000-DTHC or the BladeRunner (or your UBOB Builders Kit + DTHC) so the DTHC module has power. The first thing you should see is that the +15

LED and - 15 LED on the font of the DCP light up. The

ACT (activity) LED will NOT be on.

6.. Bring MACH out of reset. On any unit with our ESP smart power controller (including Bladerunners) you

MUST have the DC power to the motors on to come out of reset. At this stage you should have MACH setup, running and know how to come out of reset.

7. Make sure that the DTHC II module is communicating with MACH. The DTHC ONLINE Led should be ON

(green)

When you activate the DTHC II Self-test the

TORCH VOLTS should change from 100 to 150 and the THC UP and THC DOWN leds (and ARC OK) will alternate off and on.

The TORCH VOLTS comes from the DTHC

across the PC serial port connection to

MACH. Without the serial communications you will not get Torch Volts and you will not be able to see

TORCH AMPS

CandCNC

Page: 113

Digital Current Probe

Model DCP-01

8.. Once you have determined the DTHC passes self-test then locate the small hole in the front of the

DCP unit (marked CAL and TEST). You will need a small screwdriver or probe tip (paperclip?). You will feel the button click. Push it once to turn on the

TEST/CAL function. When it is active the ACT LED

(yellow) will flash.

TO TURN OFF TEST/CAL MODE on the DCP-

01 push the recessed CAL/Test button once and the ACT LED should stop flashing and the

TORCH AMPS readout should return to 0

Calibration/Test Button

(recessed)

9.. While you are in TEST/CALmode (LED blinking) the TORCH AMPS should display a value. If you are installing a DCP on an existing product with a DTHC the calibration will be off so the number you see could be anything from ___ to ____. I your unit displays 100 volts as shown then you continue on to final testing and CUT PROFILE Setup. IF YOUR

VOLTAGE IS NOT 100 You will need to proceed to the CALIBARATION SECTION

CALIBRATION of the DCP-01

Use this section any time you put the unit into TEST/CAL and the displayed value in the TORCH APMS readout is NOT 100 as shown.

1. To calibrate the DTHC module to the DCP-01 you must have access to the top of the DTHC Expansion Module. Refer to your product manual to identify and access the

DTHC module. It is the small PCB card behind the panel on all CandCNC units where the DB9 cable from the THC Sensor plugs in. In most cases all you have to do to gain access is remove the top cover (MP3000-DTHC) or the Front panel (BladeRunner

AIO). Use the photos below to find and identify the DTHC card and the correct adjustment point for the DCP. CAUTION there are two identical pots (variable resistors) in the card. One is the DCP calibration pot.

The other is the TORCH

VOLTS calibration pot and is set at the factory DO NOT ADJUST THE WRONG

POT. IF YOU ACCIDENTLY CHANGE THE TORCH VOLTS (wrong pot) you will throw your DTHC unit out of calibration and you will need to run the TEST/CAL sequence on the THC SENSOR PWM module and reset the displayed volts.

NOTE: SOME later rev’s of the DTHC II module may not have the arc volts calibration pot. If it does not exist then ignore the above procedure.

Check the photos. Study the board orientation and MAKE SURE you are adjusting the pot. This calibration should only have to be done once so take the time to do it right.

DCP Calibration (Cont)

CandCNC

Page: 114

Digital Current Probe

Calibration

DCP calibration is set at the factory

Only do this if the test shows it to be off by more than 2 amps

1. DTHCIV EXPANION MODULE. Located above the UBOB III card in most CandCNC products.. Ribbon cable connecting DTHC IV down to

UBOB card may cover adjustment pots. If so, gently move it out out the way. Do not unplug the ribbon cable or the card will be disabled.

2. Using the diagram below and with the DCP in the TEST/CAL mode

(LED flashing) adjust the DCP calibration pot while watching the

TORCH AMPS DRO in the MACH screen. Adjust the pot until the value displayed is 100 AMPs.

Your calibration procedure is complete!

16 pin header (plug) for DTHC to UBOB

Cable

DCP Calibration

POT Factory set for 100A test

Four wide cable is for UBOB cards prior to REV 15

Set JP4 and JP5 ON

(jumpered) for REV15

UBOB . OFF for earlier versions

TORCH VOLTS Calibration

DO NOT CHQANGE THIS

SETTING!

NO

!

FRONT PANEL

RS485 JACK

CandCNC

RESET

Page: 115

Digital Current Probe

Model DCP-01

OPERATION of the DTHCII with the DCP-01.

The primary purpose of the DCP-01 is to give the operator real time feedback of the actual Cut Current. Using the settings in the Cut Profile you can set fault points (based on a percentage of the variance from the current preset value to warn the operator if cut current is too high or too low. The ACT LED on the front of the DCP-01 (when not in Text/Cal mode) will light up anytime the detected current is above 20A It’s just a visual indicator that the DCP-01 is reading current. If the LED lights when you fire the torch and have a valid arc and you do not see the Current displayed on the TORCH AMPS DRO on the

MACH screen then go back through the test and calibration section. If you see cut current out of range or get a Current Fault then check the workclamp connection, the current setting on the plasma unit, the consumables, the Cut

Current setting in the Cut Profile (stored settings) and determine why the current is not what it should be.

It’s important to understand that the CUT PROFILE does NOT the cutting current UNLESS you have the full TAP options with a

set

Hypertherm models 65 thru 125 and the Hyt-Connect RS485 SIM Kit

Option.. Only the manual adjustment on the plasma unit sets that value.

The DCP-01 just tells you what the cut current REALLY is at the cut and

This LED comes on any time detected current is 20A or greater

CandCNC

Page: 116

Grounding practices to reduce noise and increase safety

PC w/MACH3

MP3000-DTHC/Bladeruner/Plazpak

Interface-Control Box

Note THC Sensor Card shielded cable is not connected to any ground in the Control box

Do

NOT

Ground PC or Controllers to

Earth Ground Rod. Controllers will reference themselves to power ground through their AC lines

“clean ground”

Digital

Signal

Total isolation from

Plasma Side Ground

PWM MODULE

Controller Cabinet

X

NO

LOCAL

COMMON

GROUNDs

Divided Volts

Analog

MP3000 and UBOB have built in isolation on all inputs from the table to prevent noise transfer and ground loops

THC Sensor Card

CNC PLASMA TABLE

Use ground strap to gantry from table

Gantry

CandCNC

Tabel I/O

Card

(limits, home

Aux relay)

PLASMA

UNIT

Attached to metal

Chassis

#10 to #4 Ga heavy wire

Ground Rod or Metal pole in earth ground

“Dirty”

Ground

Ground runs should be less than 10’

Grounding plate

#10 to #4 Ga heavy STRANDED wire

Page: 117

PAGE 76

Troubleshooting DTHC Problems.

1. DTHC does strange things after a pierce (TIP SAVER locks on or tip plunges to the metal.)

2. UP and DOWN (LED’s) not coming on (no Z movement)

?

DTHC settings are wrong (wrong PRESET

VOLTS).

?

Pierce delay too long

?

DTHC Delay in CUT PROFILE too SHORT.

?

Arc OK not working. DTHC not working (run selftest). MACH inputs not working.

3. UP & DOWN LEDs work but no Z movement

4. Z moves but erratically or loses steps.

5.

UP or DOWN LED is on but Z stops moving (won’t go further down or up)

Torch won’t cut low enough or high enough even though the UP or DOWN is on and THC Button is ON

6. Z DRO does not agree with actual height at the end of a cut.

7. Torch pierces at wrong height

8. Torch cuts too Low/High. UP and

Down and Z is working.

9. TIP SAVER comes on and stays on

(it is normal for the TIP SAVER to flash on/off especially at the end of a cut or if the feedrate has slowed down. Only make changes if the cut quality is poor.

?

DTHCIV Z motor tuning wrong

?

?

Z motor tuning wrong.

MACH too high.

THC RATE setting in

?

THC Corrections (Max and Min) are set too low/high. (settings tab in MACH). NOTE: MAX and

MIN settings are in “units”. If you are running in MM units you need to change both settings by a factor of

25.4

?

Wrong set of macros for the DTHCIV and M5 macro is wrong

?

Pierce height in G-code (from CAM) is set wrong.

Touch-off values (switchOffset) are wrong. Z is losing steps during a cut (see #6)

?

PRESET VOLTS is wrong for the material, tip and feedrate you are using. Preset needs to be adjusted in 1 volt increments and in the same direction as the error. Raise PRESET value to raise the torch. Lower PRESET VOLTS value to lower the torch. DO NOT GUESS AT A VALUE! Run the manual cut test to establish the proper PRESET

VOLTS value OR run the SMART-KUT option (one time) if all of the pierce heights and beginning cut height are correct.

?

TORCH VOLTS is above the PRESET. Turn off the TIP SAVER or increase the percentage in the

CUT PROFILE and try the cut. If it holds the correct height then either increase the THC Delay in the cut profile (NOT MACH) or increase the Tip Saver percentage in the CUT PROFILE.

CandCNC

Page: 118

Troubleshooting DTHC Problems.

10. Torch oscillates wildly UP and

DOWN while cutting

11. Torch slowly rises UP while cutting

12. DTHC works fine sometimes and then does not other times using the same parameters.

?

Torch is overshooting. Use the DTHC Settings tab in the MACH Cut Profiles section )page 49 and lower the DTHC Tracking and DTHC Sensitivity until the oscillations stop

?

Check Torch Volts reading. IF it is above the

PRESET VOLTS then the DOWN LED should be on. See also the TIP SAVER locking on issue.

?

Possible noise problem. Make sure you have your table and plasma well grounded with a local ground rod. Try not to run your PC and Controller out of the same subpanel as the plasma. keep the gorunds for each side separated locally.

13 Torch runes for a while then shuts off while cutting or does not stay lit after the pierce.

?

Check the Indicator LED on the THC SENSOR card for the TORCH ON (relay) It should remain

ON steady. If the torch still turns off (with it on) then the problem is with a connection (torch switch terminals or a problem at the torch.

DO

DO

Do’s and Don’ts

run the manual cut test and record the conditions you see including the LED indications make sure you understand that the setups for Touch-off, pierce height and cut height are working correctly

DO

DO

have the results of any testing ready for the support person.

take the time to understand the basic concepts of how an ARC VOLTAGE THC (like the

DTHC) works.

DO

DO

realize there are external conditions and torch problems that can effect the DTHC.

follow all of the grounding rules for the plasma. HF start units need extra attention to proper grounding for reliable operation.

DO

understand the relationships of Torch Volts, Torch AMPS, feedrate and air pressure/quality in plasma cutting.

DO NOT

assume there is an electronics problem until you have eliminated ALL possible problems of incorrect settings and things like consumables and air

DO NOT

attempt to run plasma without the proper MACH Profile (XML) loaded. Must be a

CandCNC profile or a copy from our profiles.

DO NOT

DO NOT

call for support with vague descriptions or having not tested to a point make changes in the MACH config to the base profile. Use a Clone copy and then only make one change at a time. The pin settings (mappings) are complex for our systems

CandCNC

Page: 119

FT-01 FEATHER TOUCH

Ohmic Sensor (Option)

FT-01 FeatherTouch Ohmic Sensor for use with

CandCNC BladerRunner Dragon-Cut , BladeRunner

Ether-Cut, MP3000-DTHCII, MP3100-DTHCIV

MP3500 and Plazpak.

REV 5 Manual

1/15/14

CandCNC

FeatherTouch

Ohmic Sensor

Power

WARNING

Use with

Floating

SENSE

Torch Only

OUT

IN

1

4

3 2

1

To Torch Tip

(Ohmic tab)

To PLATE

(Machine Frame)

Old Touch Switch COM

Old Touch Switch NC

6 5

OUT

4 3 2 1 2 1

4 3 2 1

Limit

String

IN

Z

Switch

Plate

(WC)

Tip

This manual contains new connection suggestions for the FT-01 based on previous manuals. If you already have an FT-01 installed and working you should review this section and determine if you should make changes to the installation

CandCNC

Page: 120

IMPORTANT INFORMATION:

It has been brought to our attention that with the old touch-off swtich wired to the table I/O limits input as per the previous manuals, the swtich does NOT stop motion if the Z is a

homing move

and the FT-01 fails to sense. In this manual we have changed where the Z safety switch is connected so it now functions as an E-stop rather than a limit. The previous labeled LIMITS wire

(Green) in the UTP cable is now no longer connected to the 5 wide connector but is connected as shown.

Connecting up the old TOUCH=OFF switch (Z Safety Switch)

1. You should check your Z safety switch and make sure it can be wired as Normally

Closed. That means there is conduction between the COM and the NC terminal when the switch is not activated and it OPENS (no conduction) when the switch is activated

(Tripped). Use an ohmeter or continuity tester to chack the switch. THE E-STOP

INPUT SIGNAL IN MACH CANNOT BE CHANGED to make it work with a Normally open. There are other switches in the EPO circuit (in series ).

2. When you strip jacket off the UTP cable to expose the individual wires take off enough so you can make the green LIMIT wire about 3 to 4 inches longer than the others.

3. Strip back about 1/4” of onsulation off the green wire and apply a .250 Crimp-on terminal to the exposed wires.

4. Remove the factory supplied jumper wire across the EPO (E-Stop) tabs on the Table

I/O card.

5. Temporally plug the LIMITS wire to the EPO terminal as shown in the illustration.

Measure so the remainng wires in the UTP will reach the header fo the 5 pin connector and cut them off.

6. Unplug the Limits wire and strip each wire in the UTP cable so about 3/16” is exposed and insert them in the screw terminal openings in the 5 pin connector as shown. It is important that the insulation is off back far enough that the exposed wires are making good contact with the metal contacts in the screw terminal but that the bare wires do not stick out far enough that they can touch each other. Poor wiring on this plug is the leading cause of problems with the FT-01 not working.

7. Once you have the 5 wide plug wired insert it into the header on the board as shown and reconnect the Green Limits wire over to the OUTSIDE EPO TAB (closest to the edge with the other TABS) tab as shown.

To test the EPO part of the install power everything up and take MACH out of RESET.

IF you cannot get MACH to come out of reset and you have an “External E-STOP

Event “ error flash in the diagnostics screen than the Z safety is either not wired as

Normally Closed . or there is a wiring problem with the 5 wide connector.

CandCNC

Page: 121

Connecting up the Z Safety Switch (CONT)

8. To test if the EPO is still working temporarily short across the two EPO pins and make sure you can come out of RESET . In systems with an ESP or ESPII power supply from CandCNC (BladeRunners, Plazpaks,) the Motor DC poser MUST be ON before you can come out of RESET.

9. You MUST have the jumper in place on the FT-01 module of LIMIT STRING or you must have a sring on Noramlly Closed switches into these inputs

3. The previous “LIMIT” switches on your system will be come E-STOP switches when wired in through the FT-01. If want to keep them as LIMITS you will need to wire the two ends of the string with one end tied to any of the Table I/O common TABS (inside row) and the other end into the old LIMITS input (center terminal)on the 5 pin connector

You will need to setup you LIMITS as before using the X++ (X limits) input.

4. It is highly recommended that you get your system moving and cutting BEFORE you add the FT-01 into the mix and start changing the E-Stop conections

CandCNC

Page: 122

OPTION: FT-01

FeatherTouch Ohmic Sensor

FeatherTouch™ Ohmic Sensor for

CandCNC BladeRunner. Plazpak

CandCNC

FeatherTouch

Ohmic Sensor

Power

WARNING

Use with

Floating

SENSE

FRONT SIDE VIEW

OUT

Torch Only

IN

For REV1 & REV2 Units

MANUAL RELEASE 5

2.502"

If your lable shows TIP as

2 and Plate as 1, it is

WRONG. Use this

6 5

OUT

4 3 2 1 2 1

4 3 2 1

Limit

String

IN

Z

Switch

The CandCNC FeatherTouch Ohmic Sensor Module is designed to work with all existing CandCNC plasma controls including all MP1000-THC, MP3000-DTHC/DTHCII, BladeRunner Dragon-Cut, and Plazpak systems. It uses an active circuit to sense the tip of the torch touching the plate (material to be cut). It is totally isolated from the normal inputs to the Table I/O. The inputs on all CandCNC interface and BoB products have always been isolated from the PC ground to both prevent spikes and surges from harming sensitive port inputs on the PC and to reject noise that might come through sharing a dirty ground. The Table I/O inputs all use the same input common and it is designed to “float” and not be attached to a circuit that has a ground connection to the table (i.e. switches and devices not connected to the table electrically). If you allow one side of the Table I/O circuit to be connected to the table side ground than the isolation is partially or completely defeated. Noise from plasma cutting is exponentionally higher than from routing or milling setups and needs to be considered in any input or sensor feed to the controls

The Ohmic Touch circuit is operated from it’s own stand-alone power source ( 9 to 14VDC wallplug) and it’s output is opto isolated so it can maintain the integrity of the noise canceling and isolated inputs of the Table I/O. It’s sensor input is surge and voltage protected so normal plasma start and run voltages do not effect it. It offers a fairly low sense impedance and filtering to prevent false triggering.

Here is a list of rules to follow to get good results:

1. Always use the Ohmic Touch with a backup sensing system that will stop down motion if the sensor fails to work. This can happen on dirty, oily, rusty or painted metal. The Floating Torch Holder (mechanical Touch-off) acts as both a mechanical shock absorber and a limit switch to protect the torch from damage. DO NOT RUN

WITHOUT A BACKUP MOTION LIMIT.

2. Keep the tip of the nozzle on your torch clean and free from trash and slag. If you start to have contact problems on material that is rusty or dirty, keep a spray bottle of water handy and wet down the surface for better conduction..

3. Be careful to observe polarity when hooking up the Inputs to the Torch Tip and Plate (ground) terminals. A reversed connection can result in a false signal and possible damage if left connected wrong.

4. The DC power terminals are marked for polarity. Do NOT reverse connect a source of DC or you will damage the module. If in doubt, meter it out! The + must go in the side marked + on the label.

5. Make sure to go though the hookup and calibration to test the proper functions of the Ohmic touch and the backup limit to stop the motion.

6. Do not attempt to use ohmic touch with unshielded consumables. it won’t work. Some consumables may need special shields (like the Hypertherm Fine Cut with a special Ohmic shield)

7. The ohmic touch is designed for use with automated plasma cutting using controls from CandCNC. We cannot support other uses or interface to outer users systems..

CandCNC

Page: 123

ADDENDUM

OHMIC SENSOR (FT-01)

212 732

226 763

212 733 219 676 212 724 212 734

Note. Your ohmic sensor for your torch may be different that those shown here. The objective is to have a connection to the shield at the tip of the torch and it is not connected to the body of the torch or touching the frame of the torch holder.

Shield sense tab provides feedback to a compatible torch height controller before starting the cutting process. Place the shield sense tab between the cup and shield.

Newer 45/65/85/105 consumables for Machine Torch

FineCut Consumables

Ohmic Shield

Hypertherm Part # 220948

Ohmic Retaining Cap

Hypertherm Part # 220953

220930

Fine Cut

Nozzle

Normal Fine Cut uses unshielded ring. Will not work with Ohmic Touch

CandCNC

Page: 124

CandCNC

FeatherTouch

Ohmic Sensor

Power

WARNING

Use with

SENSE

Floating

Torch Only

OUT

IN

1

4

3

2

1

4 Wide Pluggable

Screw terminal

Touch Switch COM

Touch Switch NC

TERM2

(PLATE)

Torch Holder (part of table structure)

Stranded Insulated

Wire size 24 -to 16ga

TERM 1

Ohmic Tab

Insulated Barrel

(Retaining Cup)

Ohmic Connection Tab

(Shield Sense Tab)

Mechanized Shield

(TIP)

Requires special Ohmic Consumable

See your torch vendor for ordering

CandCNC

1. Attach the Ohmic Sensor module close to the torch mount on the Z carriage. Use a Velcro strip

2. BE CAREFUL of POLARITY when making the connections. If the PLATE and TIP leads are connected backwards and the torch is fired possible damage to the Ohmic Sensor Module is possible. Units are not repairable.

NOTE: SOME REV1 UNITS HAD THE

TERMINALS MARKED WRONG ON THE LABEL

SEE THE DIAGRAM ON PAGE 1

3.

The PLATE lead must be connected to metal that is part of the cutting grid (where the metal to be cut is placed)

Most tables are electrically connected between the gantry and fable parts and the cutting grid. If your table has a separate table for cutting make sure it is attached to the gantry superstructure and torch holder via a strap or you will have to extend the PLATE wire (Term 2) down to the actual plate you are cutting.

Page: 125

K

D11

K4

J5

K4Panel

COM

Table I/O REV 6 - 8 versions

Earlier versions will work as well

1

J2

6

J18

NO

10

D3

K3

K4

OK

D15

K

OK

ARC

K3

DOWN

D18

K

K

LIMITS

D5

K

YHome

D4

K

Xhome

D6

D7

K

AHome

C4

K

ZHome

UP

K

D17

K

CandCNC

OPTION: FT-01

FeatherTouch Ohmic Sensor

4

6 5

OUT

4 3 2 1

2

1

#2 pin b

Limit

String

IN

Z

Switch loc

3

2 1

Plate

(WC)

Tip

Shipped

Jumpered

See text to use as part of string of limits

Jumper MUST be in place on installs that do not have a string of

LIMITS already setup. See the instructions for more details

These Wires are not part of the cable bundle and

U

TP

C

A

B

LE

NO

COM

NC

Existing Touch-off

Switch on Floating

Torch Holder wire as

NORMALLY CLOSED

Table I/O Card

Located inside

BladeRunner and newer Plazpaks

+ DC

- DC

NOTE: The indicators on the Table I/O card will light when the signal is active (ON) between the input terminal and the

Common terminal across from it (inner row). It will give you visual indication that the signal is getting to the inputs and that the

Table I/O is connected to the UBOB card in the controller.

Page: 126

ADDENDUM

TABLE I/O REV 8 w/ Ohmic Sensor Interface Card

Table I/O REV 6 - 8 versions

Earlier versions will work as well

NO Com2

REV8

TABLEI/O

C&CNC

R2

K3

J4 K4

R4

DANGER!

R3

K3Panel

T11

T10

T13 T15

Xhome

YHome

T12 T14

DANGER!

+

C1

D2

K4

T21

EPO

T20

Com

T3

DOWN

T7

T4

T8

Power

LED

T5

T9

UP

To UBOB III

Card

This connection changed from previous manual to use old touch=off swtich in NC mode to E-Stop the system

A Home (if used)

End view

X

To 9 - 14VDC power source

Strip wires and attach plug as

Shown

1

ZHome

Common LIMITS

+DC

-DC

35 ft UTP

Cable

TO FT-01 Ohmic Sensor module

The 35 ft UTP cable is shipped with the 6 wide IDC connector attached and the other end of the cable unterminated. The 5 pin Mini

Eurostyle plug is shipped un-attached to the cable so the cable is easier to thread down exiting cable routes. Cut the cable to length then Strip the wires on the unterminated end and carefully wire the wire colors as shown. It is important that you get the wires oriented as shown. the 5 pin and jack are keyed so it only fits one way. Plug it in the jack first to determine the orientation. NOTE in the

cable there are 8 wires but only 5 are used.

The White/Green wire and the Brown and

White/Brown are NOT used. Cut them off

CandCNC

Page: 127

TABLE I/O REV 10 w/ Ohmic Sensor Interface Card

REV 10 Table I/O was released to production 2/15/13

NO Com2

20A240VMAX

DANGER!

9 - 14VDC

Floating

(wallplug)

K3

K3

R2

D11

J4

K4

D12

PWRIN

FT-01

J1

+++

T11

D15

+

- - -

Xhome

5

InsideRow COMMON

Strip wires and attach plug as

Shown

N

EG- DC

+

D

C

D4

T12

POS

T13

Xhome

Input CO

M

Z

H om e

D5

T14

Yhome

YHome

T15

X

FT-01

D6

T16

1

ZHome

ZHome

T17

AHome

T18

T10

D7

T19

AHome

35 ft UTP

Cable

Lim its

D8

T6

D2

T2

LIMITS

LIMITS

K4

T7

T3

DOWN

D18

T20

T21

EPO

DOWN

NC

T9

UP

D16

UP

T5

Remove factory jumper.

This connection changed from previous manual to use old touch=off swtich in NC mode to E-Stop the system

1

Shown Above: New Table I/O REV 10 table I/O card. This card is a redesign. The PORT 2 inputs are removed (not used). Jack for Ohmic Sensor is added along with the floating power input for the Ohmic Sensor Module. It uses the same cable as the previous REV 8 model with the Ohmic Sensor Interface Card. The normal Port 1 inputs and outputs are the same as the previous Table I/O cards although the exact position on the cards has changed. The card is smaller and easier to get into tight spaces.

The 35 ft UTP cable is shipped with the 6 wide

IDC connector attached and the other end of the cable unterminated. The 5 pin Mini

Pluggable Termial is shipped un-attached to the cable so the cable is easier to thread down exiting cable routes. Cut the cable to length then Strip the wires on the unterminated end and carefully wire the wire colors as shown. It is important that you get the wires oriented as shown. the 5 pin and jack are keyed so it only fits one way. Plug it in the jack first to determine the orientation. NOTE: in the cable there are 8 wires but only 5 are used. The

White/Green wire and the Brown and White/Brown are NOT used. Cut them off If you have enough length you can use them for the wires to connect your TIp and Material (plate) wires and/or your old touch-off switch.

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Page: 128

BY-PASS OPTION SWITCH FOR E-STOP

( not included in FT-01 kit)

9 - 14VDC

Floating

(wallplug)

20A240VMAX

K3

R2

D11

K3

DANGER!

J4

K4

Com2 NO

+++

- - -

Strip wires and attach plug as

Shown

N

EG- DC

InsideRow COMMON

D4

T12

FT-01

D12

PWRIN

Xhome

Xhome

T13

YHome

5

J1

Yhome

D5

T14

T15

X

FT-01

D6

T16

1

ZHome

ZHome

T17

T11

D15

T10

T18

D7

T19

AHome

AHome

+

D8

T6

D2

LIMITS

LIMITS

T2

T21

K4

EPO

T20

D18

T7

T3

DOWN

DOWN

Z

H om e

Lim its

UP

T9

D16

UP

T5

You can setup a bypass switch and locate it close to the operator so you can bring MACH out of RESET and manually jog the axis off the switch to clear the condition. The switch needs to be a MOMENTARY type so it won’t be left on and defeat the E-STOP from the

Z Safety and any LIMITS connected through the FT-

01.

Normally Open

Momentary

Switch

Press to Bypass

E-STOP

FROM Z Safety

You will need to crimp two wires into the EPO Tab that has the green wire. Cut off the crimp terminal on the Green wire and strip back the insulation on both wires and carefully warp the wire from one side of the Bypass Switch around the green wire and then crimp the pair into the fresh crimp-on terminal. The type of switch used for the Bypass is not critical as long as it is Normally Open and closed when you push it. When you release it should return to Normally Open.

Most pushbutton switches are configured this way. Because the circuti is NC most of the time noise on the Bypass Switch or wires has no effect .

NOTE: This can be used on any Table I/O version shown if the EPO is used for other E-STOP inputs.

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ADDENDUM

FeatherTouch Ohmic Sensor

SETUP AND TESTING:

1. Make the connections between the Ohmic Sensor and the Table I/O card as shown on page # . .

Provide DC power to the module. Modules ship with a DC wallplug power supply that should be used unless you have access to a source of FLOATING (ground neg side is not tired to any other circuit). See the section power hookups and options.

2. Make sure the wire jumper is in place at the location indicated. The jumper is applied at the factory and only should be removed if you are going to integrate the LIMIT for the touch off in with existing limits on your table (see section on hooking to existing limit string.

3. Use the section on hooking up the touch-off switch (not part of the Ohmic Touch kit) on your Floating

Torch Holder.

4. Plug in the power to the Ohmic Sensor. Confirm that the power LED (Green) is on. If it is not unplug it immediately and locate the cause of the lack of power to the module using a DVM

5. Check the settings on your Limits input. The limit input is port 8 pin 11 in all most UBOB based systems.

(new Ether-Cut system is an exception) At least one of the ++ or – signal (usually X--) needs to be Enable

(green check) if you are using it for just the touch off. It has to be set different than if you are using other limits in a normally closed string

THIS SECTION HAS BEEN SUPERCEDED BY USING THE Z SAFETY SWITCH AS AN E-STOP

THIS IS INCLUDED ONLY IF YOU WANT TO CONTINUE TO USE AN EXISTING STRING OF LIMITS

WIRED DIRECTLY TO THE TABLE I/O

This needs to be turned on

(enabled) for

LIMIT INPUT to work. Active Low setting detemines if it trips on NO or

NC switch action.

Use this setup if you have no limits setup and are connecting the LIMITS up directly to the table i/o and NOT through the FT-01. IF they are connected through the LIMITS STRING input terminals on the FT-01 they are Np longer

Limits and become part of the E-STOP chain

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Page: 130

What to do if you already have a string of LIMITS

OPTION ONE (add the Z Safety touch switch into the existing limits string of NC switches)

1. Using the screw access on top, Remove the jumper from the LIMIT STRING INPUT

2 Remove the ends of the limit string from the limit terminals on the Table I/O card and re-route them to the.LIMIT.String Input.

3 Wire your Touch off switch on the Floating Holder

as Normally Closed (NC)

by using the COM and NC terminals on the switch.

4. The Touch Off switch is now in the limit string and ANY switch that is activated including the Touch off should cause MACH to go into reset.

You no longer need to define any LIMITS (++ or - - inputs) since the old limit string is now part of the E-STOP (EPO) string

OPTION TWO (Use the limit string wire directly to the LIMIT input on the Table I/O ) You can setup your LIMITS as shown in the Ports & PIns.

Ports & Pins setup screen from Ether-Cut systems that have a PORT2 set of inputs to allow the LIMITS input tab on the table I/O board to be used. This is ONLY if you want separate LIMITS and E_STOP

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Page: 131

BLANK PAGE

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Page: 132

FOR SETUPS THAT HAVE EXISTING SEPARATE LIMITS ON

OTHER AXIS USING a NC STRING OF SWITCHES:

(if you do not have this setup then (disregard this page)

Note Your switch pinout may be different

SEPARATE LIMIT SWITCHS (Normally Closed)

THIS SETUP PUTS THE LIMITS in the STRING INTO the E-STOP circuit and they operate as part of the

ESTOP and no longer just limits. They will NOT be ignored durign a Homing Move

Beginning of Limit

String

End of Limit

String

6 5

OUT

4 3 2 1

2 1

4 3

2 1

Limit

String

IN

Z

Switch

Tip

Plate

(WC)

CandCNC

1. Take Limit string loose from Table I/O card

2. Remove jumper on limit string

3. Put two ends of limit string into the LIMIT STRING terminals

4. Connect the LIMITS OUT wire (white in this manual) as shown to LIMITS input terminal.

Page: 133

The End

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Page: 134

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