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DTHC IV -SETUP/INSTALL MANUAL

1. TORCH SWITCH TORCH SWITCH ARC OK TOROH ARC TEST 5V 12V e o e en A asma r ICKup Moauie for DTHC II oz x u RJ45 Cat5 cable to DTHCII Module Divided volts frgm CandCNC RawArc Volts card Advanced PVVM Technology remove back cover for Ca I access to test buttons THC SENSOR PWM MODULE Mounted outside plasma unit Connections for PWM MODULE REV21 are the SAME CandCNC Page 67 CONNECTING to YOUR PLASMA RAV 01 Raw Arc Voltage Divider Option For Plasma Units that have NO external Connector for the required signals OR do not have an internal voltage divider Mounting the RAV 01 Card inside your unit The mounting location for the card will vary from one type brand of plasma unit to another Pick a location and mount the RAV 01 using the Plexiglass shield using small self tapping screws not furnished or adhesive Velcro strips Mount the card at least 1 inch away on all sides from any internal cards terminals or bare wires The standoffs of the card are insulated and so the card can be mounted with the plexiglass shield against the chassis There is high voltage present when the torch fires at the end of the card where the RAW ARC VOLTS is connected Keep that end of the card away from ANY conductive object closer than 2 inches INSTALL Once you have the RAV 01 Card mounted in a safe location you will need to ma
2. INSTALL PWM MODULE DISCLAIMER AND LEGAL NOTICE The following section covers the installation of a Voltage Divider card inside the plasma unit There are dangerous and possibly lethal voltages present in a plasma power supply unit ALWAYS UNPLUG THE UNIT FROM THE AC POWER BEFORE REMOVING ANY COVERS ALWAYS REPLACE ALL COVERS AND SAFETY BARRIERS BEFORE TURNING THE POWER BACK ON You do any install of a card inside of your Plasma Power Unit AT YOUR OWN RISK If you do not wish to do the procedure either find a person qualified to do so OR contact us for options CandCNC Fourhills Designs hereafter referred to as CandCNC nor any of its resellers or agents will be responsible for any damage to any plasma unit or the loss of any income resulting from using any of our electronics or using our instructions written or verbal to connect to any electronics While we take care to provide accurate and concise information we will not be responsible for any damages to equipment personnel or surrounding equipment structures or land resulting from the direct or indirect use of our products The entire liability of CandCNC or any of its agents or employees is to replace or repair products provided by CandCNC Under no circumstances will we be liable for any damages or loss exceeding the value of the actual products provided by us regardless if the products are used as described and in the proper manner All CandCNC products carry a warranty
3. The PN200 has to be the last device in a group of devices The PN200 will worked plugged inot other jacks on the 4 PORT HUB except JACK 1 but you cannot use the E STOP option You can also use the PN200 jack on the hub for other RS 485 devices if you do not have a PN200 While the PN200 would work with other devices on the channel that have loop through pass through jacks the E STOP to EPO DOES NOT PASS THROUGH OTHER DEVICES 3 DTHC IV High Speed Digital Torch Height Control The DTHC IV uses the RS485 C3BUS for the following Transfer of screen information TO MACH 3 like Torch Volts Torch Amps and the status LED s for Torch UP Torch DOWN and ARC OKAY Unlike the DTHCII that uses defined parallel port inputs for the UP DOWN and ARC OK the DTHC IV sends the data across the RS485 The only hard input from the DTHCIV to MACH3 is the HOLD signal mapped to INPUT 1 on Ports amp Pins Communication to the plug in in MACH3 to update Z position when DTHC is active tells MACH3 where the DTHC has moved the Z while under THC mode Pass parameters and settings in MACH to the memory of the DTHC IV This includes all of the DIHC Cut Profile Settings either from the screen or from the G code when using DCC C3BUS MANAGING THE HUB During the install the CandCNC Hub Utility was added and an ICON was placed on your desktop Click on th icon to open the Hub Utility IMPORTANT The purpose of the HUB UTILITY is primarily to c
4. Device Manager File Action View Help w g Pm A i Bluetooth Radios 4 Computer See Disk drives B Display adapters 4 DYD JCO ROM drives its Human Interface Devices IDE ATA ATAPI controllers Keyboards lt Mach Pulseing Engine Mice and other pointing devices 2 Monitors BS Network adapters EF NVIDIA nForce Networking Controller J NVIDIA Network Bus Enumerator H Ports COM amp LPT Processors Sound video and game controllers Ta Chee ste x lh i NVIDIA nForce Networking Controll AE General Advanced Driver Details Power Management NVIDIA nForce Networking Controller Device type Network adapters Manufacturer MY TOL Location Location N YANETBUS Id OO00 0000 000 Device status This device is working properly Fou are having probleme with this device click Troubleshoot to start the traubleshooter Troubleshoot Device usage Use this device enable Ww THER CUT INSTALL Make sure the Network Adapter does not show disabled or not working warning symbol This does not mean the Device is actually working and will talk to a network or the Ether Cut It simply means Windows sees the device and it appears the right drivers are loaded If you have problems configuring or testing the port it can still be a bad Ethernet card or the w
5. crimp on two ring or fork terminals USE WIRES OF TWO DIFFERENT COLORS and long enough to reach the RAV 01 Card using an indirect route give yourself extra wire Run the first color wire red or the brightest color to where the WORKCLAMP attaches Normally that will be a heavy bus bar with other smaller wires attached If it is a single large stud you will need a ring terminal that will fit over the stud That will be your positive wire Use the other wire color and run a connection using a ring or fork terminal to where the ELECTRODE wires attach Carefully route both wires from their connection points over to where they will attach at spade inputs on the edge of the RAV 01 Card Keep the wires away from other high voltage wires or components on the circuit board Use nylon wire ties to secure the wires to other wire bundles or to the chassis DO NOT WIRE TIE THEM TO COMPONENTS ON THE PC BOARDS DO NOT USE LOW VOLTAGE WIRES LIKE THOSE USED FOR WIRING PHONES OF NETWORKS CandCNC Page 69
6. gey E ks i i oe ks F ok es gil pte The following section goes through the initial setup and checking of the DTHC IV The procedure is somewhat different than the previous DTHC and DTHC Il and if you are upgrading from those platforms please take the time to go through this section The end results will be more satisfactory tha just plugging everything in and trying to cut a file CandCNC Page 42 DTHCIV MODULE DTHC IV EXPANSION MODULE Located above the UBOB III card in most CandCNC products Ribbon cable connecting DTHC down to UBOB card may cover adjustment Eee P pots If so gently move it out out the way Do Cable not unplug the ribbon cable or the card will be disabled Four wide cable is for UBOB cards prior to REV 15 CE CE Set JP4 and JP5 ON 1 aar jumpered for REV15 UBOB OFF for Av ST O earlier versions P12 Q Lf TNOlldO JC LO MOTOR DRIVE 1 pe H gogn M N Q INSTALL DTHGC IV 4 l IIIIII IIIIIIIIIII r soe lIIIIIIIII SET FOR 126 128VDC INDICATED TORCH VOLTS Unit is calibrated at the factory DCP Calibration POT Factory set for 100A test 1O0 PUIUJJ O UU cC OO s CO O FRONT PANEL RS485 JACK in on li H ss LIOOOOOOO 3 00 Or OO gt d sss RS485Hdr rp o o o o Off Pt
7. gt Single Operator Console for all CNC settings and operations no knobs no manual settings gt Supports Dynamic Cut Control on all plasma cutters 2 gt Usable with virtually any plasma cutter with or without CNC connectors 4 gt Z motion speeds of 200 IPM with STEPPERS Setup and testing via RS485 and Windows Linux app HUB UTILITY 1 gt Z Response tuning has true PID settings to prevent overshoot and instability gt 6 Presets for response tuning cover most types of cutting and Z mechanical types gt Plug compatible with existing CandCNC MP3000 s and BladeRunner Plazpaks after Aug 2012 1 5 gt Works with all forms of pulse interface Parallel Port USB Ethernet 4 6 gt More than 5X faster than systems using MACH3 THC logic gt Engineered to do extreme cutting including corrugated and HVAC type materials gt Unique Patent Pending Hybrid Design shares single Z axis allowing G Code position control mixed 1 Requires optional USB to RS485 4 Port C3BUS Hub from CandCNC 2 Requires SheetCAM TNG and custom CandCNC POST Processor 3 MACHS only until 2014 Contact CandCNC for more information 4 May require other options connection kits 5 Upgrade kits available 6 USB not recommended for most installs CandCNC Page NOTE Machine Torches operate the same but do not have a switch in the torch to fire it Some torches will have more than one set of small wires for other sensor
8. m o 2 2 n 5 If you are using the CandCNC Digital Current Probe DCP you need not hook up any ARC OK signals to the RAV 01 card or the THC SENSOR PWM input The ARC OK signal is derived from the TORCH AMPS cut current feedback ARC OK trip point is set in the CUT PROFILES in MACHS See the section on installing and calibrating the DCP 01 02 on how to set the ARC OK trip point 6 If you have a plasma unit that DOES have an Arc Good signal or you have the DCP module DCP 01 unless you want the added features the DCP 01 can provide see DCP 01 documentation Just make the connection to the Arc OK terminals Some units provide only relay contacts dry Contacts For that type of signal the ARC OK inputs are J4 and J5 on the THC Sensor card Note The term Arc Good is interchangeable with Arc Ok Arc Xfer and OK to MOVE 7 NOTE IT is ESSENTIAL that the chassis of the plasma unit have a good earth ground Refer to the suggested grounding section of the diagrams HHHHH and provide for a good earth ground close to the table A safety ground back to a breaker panel many feet away may be a good ground for AC frequencies 60hz but poor for higher frequencies like plasma noise Since we are bypassing any high frequency noise to the plasma chassis if it has a poor noise ground it can actually put noise back into the tip volts rather than shunting it away CandCNC Page 63 THC SENSOR PWM MODULE VOLTS TEST CAL
9. 013IHS 031 SYfY m Yellow TORCH ON Green Power LED C on when Torch fire Should be ON signal is active RJ45 connector for CATS cable to PWM Module qdT1oH asa z sdais NO oHa YO Xy DTHC IV Digital Torch Height CandCNC Page 43 D TFICIV MODULE PRELIMINARY TESTING THE DTHC MODULE The only preliminary tests of the DTHC IV module are for power getting to the board and to test the RESET button and check for the initializations sequence on the front panel LED s 42 Of 20 1 Power up the Bladerunner MP3000 MP3100 Plazpak and watch the front LED s on the DTHC IV They should turn on one at a time from right to left starting with the ARC OK LED then all LEDS should flash twice This indicates the microprocessor in the DTHC IV is alive and working 2 An integral part of the DTHC IV communications too and from MACH are dependant on the C3Bus USB to RS485 4 port Hub A lot of testing and DTHCIV settings are done via the HUB UTILITY through the C3BUS They will be covered later after the other components and cards have been installed and tested aqiOH asa z sdais NO oHa YO OHV DTHC IV Digital Torch Height Se FUNCTION What it means Shows the torch is on and that there is a valid arc so automated ARCOK YEL from Plasma PWM Module or from DCP 01 current reading The DTHC can be turned on and DTHC ON BLU off in software
10. Al OHLG 24 Aq p llonuoo lno iuip oue uonoui pue SUO I OUNS OHLG Sixe Z BU JO O4JUOD PoseYUs piiq u e sBultiq pue JOHLG DY Jo s in1e J DY Jo je s ye1 A OHLA ONODBUEO M N PUL 13 N9 4940 1 49 N0Y SOB HOM 047409 OHLA S9rSui sxe Z 1103 I pIAID a6e JOA ue SAeY JOU OP ey sjiun uo pesn pue Ajjeusejul psyunoy uodo LO AVY E O I 99811971U1 IONUO S uuo gt I eee JADU OAZUOD 1 O LAH s e 1 qoiq SPWI SOWOH luo uii u1i d H sii ySoUo NOILdO waynojnau apina BelloA Od S8VSUy SOA DEKNE 943 JOdd J A14G Q 1 ui una xx ISN JOON PNO oeJi 1u S uuo2o eSo MO duly pue 4O199uuoo yonms YoJoL Odd O YyALLNO VINSV 1d SHOA p p A q DAOW 0 Aeyo ysbHulyas pue s jney w4 yz d H Bulipnjou synopesy OHLG pue uonouu e Jo yoeqp sj u ios suonounj OH LG uonoNW w h a 1 noye ig sixe Z sjeuBis 41g 9 d 1s JI3 YOIOL JBAIIG JOJO 0 d 1S Z suojdo N OHLG uolno uuo2o uinb u pue suyod uono uuoo slonuoo oeJi 1u ulouij days Z SNOpueo Bunsix 104 Ieu19 x SAeY si no ewsejd P JON Sueno ewsejd Ju l Jjip 0 suolndo 2EBJiJ lul JO SLIM NOILOANNOO ONOPUED 89S JNOXNNIT CHOVIN NOILVYNSDIANOO GASVE Al OHLG MAN Page CandCNC 8 9 SIMPLIFIED SETUP STEPS SETUP OUTLINE Install or update and verify Mach3 version 3 043 067 on CD Use Master Installer II to install
11. CONNECTING to YOUR PLASMA RAV 01 Raw Arc Voltage Divider Option RAV 01 Raw Arc Volts CARD INSTALL PWM MODULE tp MANUAL TORCH FIRE G Aas Y aa ee TORCH SWITCH Terminals IF YOU HAVE AN INTERNAL ARC OK SIGNAL If you have a plasma unit with a Machine Torch you Connect one wire to Terminal 4 and Terminal 3 will need to locate the two torch fire connection above left two terminals points in some units it is called START IT is a REMOTE Fire set of wires IF YOU DO NOT HAVE AN INTERNAL ARC OK SIGNAL You will need to purchase a DCP 01 IF YOU HAVE A HAND TORCH you will need to Digital Current Probe It plugs identify the two Torch Switch wires that come from the Hand torch and RAV 01 PREFACE General Information The RAV 01 can be used several ways so it can get confusing about makint the connections The primary use of the RAV 01 is to take Raw Arc Volts undivided votls and divide it by a precise ratio so it can be used by the THC SENSOR PWM module to generate a digital signal to send volts data to the DTHCII Digital Torch Height Module In some circumstances that is al that you will use the card for Examples are on the Hypertherm 1000 1250 1650 series and the Thermal Dynamics A series Both types have a rear CPC connector 14 pin that has the Torch Fire and ARC OK signals available and are used with the CandCNC MIC 02 interface cable So ONLY the Shielded Analog Cable SAC 01 is used between t
12. GiGi CACI ria Mounts at PC for USB to R5485 Module mounts at the Plasma cutter s DTHC IV mounts in Controller or MP3100 box The following pages will cover the identification hookup setup and testing of the DTHCII Digital Torch Height Control System Each card mosule has a specific function and set of tests A minimum system will consists of a DTHC II Expansion Module interfaced to a CandCNC UBOB III Universal Breakout Board and the THC Sensor PWM Module The DTHC IV is a later version of our popular DTHC II that was introduced in 2011 and is the 3rd generation DTHC and the 4th generation of Digital THC s from CandCNC The DTHC line has always been a feature rich product with advanced technology based on powerful embedded processor chips and modern surface mount components From the innovative Total Isolation including the analog Arc Volts readings to the Self test and built in Tip Saver anti dive the DTHC has earned a reputation for being solid reliable and user friendly while offering the operator a wide range of options for precise cutting with plasma and all at a very effective price The DTHC IV builds on that success by making the product faster with more features and the first ever Shared Z design for MACH3 for access Automation control signals in the plasma Using the same PWM Module as the DTHCIl it takes a divided Arc Volts signal available as an option on several plasma models or fr
13. LAN From PowerLtt Low Power State Link Speed WakeOnL4N From PowerL tt CandCNC Page 32 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN XP m Control Panel File Edit View Favorites Tools Help lt Back a pe Search Wey Folders Address gt Control Panel ETHER CUT Name L Accessibility Options Add or Remove Programs 4a Administrative Tools Display Add Hardware Folder Options Fonts P Internet Options akeyboard Vg Control Panel lt gt Switch bo Category view See Also to windows Update a Help and Support Printers and Faxes eas Network Connections Per a File Edit View Favorites Tools Adwanced Help pack O a pa Search Falders E Address Connections Mame LAN or High Speed Internet Network Tasl Gs i Create a new connection J Local Area Connection 2 Set up a home or small office network Change Windows Firewall settings See Also a Network Troubleshooter Make sure the Local Area Connector does not show it is disabled It may show it is not CONNECTED but if it is missing or disabled you will need to get the problem resolved before you can proceed with the install Other Places gt Control Panel a My Network Places My Documents P My Computer Details Metwork Connections System Folder CandCNC Page INSTALL SETTING UP THE ETHERNET P
14. The switches are small tactile switchs that require light pressure z One push puts the unit in test cal mode The Test LED will flash 126 to 127 ewill display on the TORCH VOLTS DRO zs A second push will take the unit out of test cal mode and the LED will stop flashing and the TORCH VOLTS reading will return to Zero es Once in TEST mode you can calibrate the DTHC II module to display the correct TORCH VOLTS on the screen See the DTHCII module section to in the front part of this manual to find the calibration points The THC SENSOR PWM is factory calibrated Do not try to set the calibration if the test voltage is MORE THAN A FEW VOLTS OFF THE TARGER OF 126 It will not fix problems with reading the torch volts or if it displays wrong when the torch is fired The calibration is based on a simulated PWM from the circuit so if the prescale divider setting is wrong the calibration will show correct but when the torch is fired the voltage will be wrong CandCNC Page 56 THC SENSOR PWM MODULE VOLTS TEST CAL THC SENSOR PWM MODULE TEST CAL E L Front Input JACK Divided Volts Press and Hold for ARC OK TEST Digital Plasma Module Pr ass and release V olts Test Front panel To DTHC Module To Plasma will light er 0 To DCP 01 TORCH Arc OK SWITCH Transfer l Remove b ck to access jumper settings To CPC or RAV 01 THC PWM MOdule Rev 21 Plasma Pickup Modulg can be
15. air is not flowing When the unit is triggered the starts a few milliseconds after the current starts to flow in the electrode circuit As the air flows it pulls the electrode away from the nozzle and creates an ARC That is used to ionize the air and start the plasma INSTALL ul J m m o 2 gt n The DTHC IV can be used with all types of plasma units The HF units tend to be very noisy and some even have large amounts of RFI The total isolation of the DTHC IV circuit from any low level PC logic including any common ground stops any conducted noise The internal circuits are protected from RFI with proper layout and careful attention to bypass components on all active circuits Hooking Up Your Plasma Machine to the MP3100 DTHC IV BladeRunnerAlO DTHC IV NOTE IF you have a Hypertherm with a rear CPC 14 pin round connector you can skip this section CAUTION Portions of this install may include opening your plasma cutter machine and attaching wires MAKE SURE THE UNIT IS UNPLUGGED PRIOR TO REMOVING ANY COVER S OR MAKING ANY CONNECTIONS Plasma units have HIGH VOLTAGES present that can be dangerous or lethal IF YOU ARE NOT EXPERIENCED WORKING WITH HIGH VOLTAGES DO NOT ATTEMPT TO INSTALL THIS OR ANY OTHER DEVICE INSIDE YOUR PLASMA UNIT YOURSELF SEEK PROFESSIONAL HELP In order to control your plasma unit there are three main connections that need to be made to the plasma unit itself All of the following operations a
16. from the G Code at run time The Cut Profile in MACH now allows multiple levels of settings and is a better place to do the setup and testing under MACH Page 24 HUB MANAGMENT HUB UTILITY E CandCNC Hub Utility alla MISC File TP About Opens choice to PN200 Pendant Rev 1 update firmware DTHC N aot s Hypertherm plasma This is the first step in updating Device Code b the HUB Address b F RMWARE Firmware Version b Device Status m a I ty m m CanacNc Hub connected Firmware version 1 6 Current Firmware Version File Misc About Devices Device Details PN200 Pendant Rev 1 DTHC IV Hypertherm plasma Device Code b Address b Firmware Version b Select hub firmware file Look in Baigent 2 E usb485hub_1 2 ucccx E usb485hub_1 S ucccx My Recent usb 8Shub_1 6 uccex Documents Desktop ey Select the highest release number My Documents new firmware can be found on the Candcnc website manuals page My Computer My Network File name usb48Shub_1 6 ucccx Places Files of type CandCNC Hub Fimware Files v CandCNC Page 25 HUB MANAGMENT HUB UTILITY To update the USB RS485 Hub Firmware you must 1 Download a designated file from the CandCNC Website Product Support Tab and place it in a named folder on the machine that has the hub attached Select the MISC tab at the top and you will have an Update Hub Firmware choice
17. other choices for other functions may be added later 2 Click on the Update Hub Firmware and a File Navigation window will open and you can navigate to the file in the folder you have downloaded the new firmware to The file extension for all Firmware updates will be ucccx Highlight the file to use and hit the OPEN button The Hub Utility will automatically update the hub firmware m CandCNC Hub Utility AmE Update Hub Firmware PN200 Fendant Few 1 Device Details Device PN200 Fendant Rev 1 Device Code h Choose firmware file Look in usb hub gt SEE My Recent Documents Desktop May Computer My Hetwork Places File name usb485hub ucecx Files of type CandENC Hub Firmware Files ki Cancel CandCNC Page 26 HUB MANAGMENT HUB UTILITY DEVICE TESTING PN200 48 Function Hand Control IF YOU DO NOT HAVE THE PN200 the device will not show up in your devices list and this screen will not appear Joystick shows XY Calibration Ear positionwhen stick x o on the PN200 is b ar deflected Confirms b operation or Joystick Gal Cal C3BUS HUB ROTARY ENCODER HaT o Campa TEST are Indicators You can Enc1 DTHC clcik on the L numbers PRESET encoder i to turn on an indicator status Rotating the on the PN200 to test s oe Checking the box under the count clockwise aga l ld G s counie it will
18. part is close the arc will transfer to the material The HF start causes a lot of noise and current spikes The other form of High voltage start is the CD Capacitor discharge method It is basically a high current version of an Automotive ignition system Up to 30 000 volts can be generated If the THC Sensor is not protected the high voltage and high frequency can cause component failure on the card or worse in the THC unit and even burn the board The THC Sensor PWM REV18 and up is protected from HF and most High Voltage start circuits CandCNC Page 59 MAKING CONNECTIONS TO YOUR PLASMA CUTTER 1 You need the proper CandCNC Connection Kit to make the interface to your plasma cutter 2 Different types of plasma cutters can be used Some have everything needed terminated to one connector e g Hypertherm 45 65 85 105 125 with rear CPC Others may have the same or no external connectors We can only cover a few specific types NOTE Some plasma cutters use a manual contact start TAP start when the end of the torch has to touch the metal then be retracted to sart the arc These types of cutters WILL NOT WORK for plasma CNC cutting CandCNC Page 60 THC SENSOR PWM MODULE VOLTS TEST CAL The smaller Hypertherm and other modern brand units use a low noise method called blowback arc start The electrode is mounted against a spring that keeps it pushed against the inside of the Nozzle as long as
19. put in TEST CAL mode without removing the card from the case zs Turn the case over and look on the back There are two recessed test buttons find the button market VOLTS One push puts the unit in test cal mode The Test active on the front LED will flash You should see 126 to 128 volts displayed on the TORCH VOLTS in the MACH screen A second push will take the unit outRsaest cal mode and the LED will stop flashing and the TORCH VOLTS reading will return to Zero ze Once in TEST mode you can calibrate the DIHC iV module to display the correct TORCH VOLTS on the screen See the DIHCII module section to in the front part of this manual to find the calibration points The THC SENSOR PWM is factory calibrated Do not try to set the calibration if the test voltage is MORE THAN A FEW VOLTS OFF THE TARGET OF 126 It will not fix problems with reading the torch volts or if it displays wrong when the torch is fired The calibration is based on a simulated PWM from the circuit so if the prescale divider setting is wrong the calibration will show correct but when the torch is fired the voltage will be wrong CandCNC Page 57 INSTALL ul J m m o 2 gt al THC SENSOR PWM MODULE VOLTS ST CAL INSTALL ul J m o 2 gt al Enter Value Depress and release TEST button to test PWM circuit back to DTHC Il Test LED qn front will flash and DTHC screen in MACH should display a volt
20. that covers repair or replacement ONLY Any labor travel expense or costs to replace a component or product outside the CandCNC factory is NOT COVERED by warranty If you do not accept the terms of this notice DO NOT OPEN OR INSTALL THE RAV 01 CARD Return the card for a full refund and seek an alternative way to sense the voltage CAUTION Some plasma units use a very high voltage spark Capacitor Discharge or CD arc starting system While the RAV 01 card is protected from high voltage inputs CD type systems can cause arcing in the connecting wires or to nearby components If you have a CD start unit and do not have experience working with high voltage systems SEEK PROFESSIONAL HELP to do any install CandCNC Page 64 CONNECTING to YOUR PLASMA RAV 01 Raw Arc Voltage Divider Option For Plasma Units WITHOUT Internal Voltage Divider NOTE this card comes in most of the Connections Kits including the UNIVERSAL CONNECTIONKIT RAV 01 Raw Arc Volts CARD INSTALL W J m o 2 2 n LU L pan h LI COD Divided Volts AE Plexglas Insulator Base safety shield YLE aea CU CAUTION TORCH SWITCH NEG D Volts ectrode co TPN ARC O TORCH SWITCH SHIELDED ANALOG CABLE 36 Nom Part SAC 01 cos ScotchLOC IDC Splices RED 2 pieces RAV to THCSensorPWM Interconnect PART CCAB 31 o 36 min s a CandCNC Page 65
21. the proper setting for the type setup you have 3 Set the small option jumper to match NEW MODEL REV 21 Press and Hold for ARC OK TEST Press and release Volts Test Front panel LED will light Remove back to access jumper settings s1 90 1 Scale Hypertherm and 2 1 some others Recommended IMPORTANT The Hypertherm 45 has an internal voltage divider It cannot be changed from the 50 1 ratio Set your PWM Sensor jumper to the 50 1 Om 5 1 20 1 Standard on some Thermal Dynamics others Volts 7 1 Divider lB 50 1 position if you are using the MIC 01 Direct Connect Cable 20 1 from CandCNC RAV 01 Card DEFAULT CandCNC Page 55 THC SENSOR PWM MODULE VOLTS TEST CAL Test LED Flashes in TEST Mode TORCH ARC TEST 5V 12V CY UO OD THC SENSOR PWM AR Plasma Pickup Module d for DTHC Il Divided volts from USE CAT5 UTP RJ45 Cat5 cable to DTHCII Module T CandCNC Raw Arc CABLE Advanced PM Volts card remove back cover for e nology access to test buttons THC SENSOR PWM Plasma Pickup Module can be put in TEST CAL mode without removing the card from the case Turn the case over and remove the 4 corner screw holding the back on and carefully pry off the back panel It will expose the back of the PC board and there are two small momentary pushbuttons and a dual row of option jumpers
22. 5 UTP up to On g LEDS y When a device is plugged into a port on the hub the LED will light if it has proper communications It does not mean the device is operating correctly see later pages for using the Hub Utility The Activity Monitor shows CandCNC Electronic Controls for CNC z sdais NO OHLG YO 28y DTHC IV Digital Torch Height Port1 INPUT CP PWREET e Bae Ch reunited ey CandCnNncc DTHC IV parallel port system shown Page 15 CandCNC CONNECTION EXANIPLES The CandCNC C3BUS USB to RS485 4 Port Hub CONTROLLER PC TM ae Mount close to PC 6ft Port Hub S m O CATS on up to Sort gq C lar 48 function Hand Controller O c o p 1 10 z EU aly O gt oO CandCNC p RS485 Fl CandCNC a 4X4 Driver gt a Cards card RS485 m Card uj S 0 aras TOW Spindle T IY x SSpeed n 9 c Mark IV 1 a T 2 NOTE Example ONLY some of the examples are not available yet Only ones in Yellow are currently available Names may change and release dates are not yet scheduled CandCNC Page 16 RS485 4 PORT HUB HARDWARE INSTALL 4 Plug the USB RS485 4 Port Hub wall plug power supply into an AC outlet NOTE While the wall plug power supply has pins for standard US AC 120VAC sockets the power supply will work and run from any AC power source from 100 to 240VAC 50 60HZ You can purchase plug adapters from several on line m
23. 6 HT 45 20ga Steel 036 DTHC Delay sec 3 HT 45 zzaa Stainless 030 HT 45 22ga Steel D3D Preset Cut Current AMPS z HT 45 26ga Steel 018 i HT 45 26ga Stainless 018 Preset Air Pressure 70 HT 45 3 16 Stainless 188 HT 45 3 16 Steel 188 HT 45 3 4 Stainless 750 HT 45 3 8 Stainless 375 These are default settings using the CUT PROFILE in MACH3 HT 45 3 8 Steel 375 They are used UNLESS they are overwritten from a G Code file HT 45 5 8 Steel 625 gt with new settings You should check all OTHC settings when Add E prompted From the actual G Code DTHL V Firmware version a Peel This is the opening TAB of the CUT PROFILE MENU The DTHCII version of this screen only has one level and is used to set the DTHC parameters for a cut There are STORED SETTINGS and they are listed in the Current DTHC Settings window The DTHC cut values can be changed on the screen and Save applies them to the DTHC memory You can add new profiles with different presets OTHE Settings marked settings are only active in Full Automation TAF installs NOTE The DCC function provided by using SheetCAM TNG and the POSTS that support DCC WILL OVERRIDE THESE SETTINGS when the G Code is loaded and the RUN button is hit The operator can choose to override the base settings via the screen Preset Volts DIHC Delay etc OR override the entire profile by opening the CUT PROFILE and hitting SAVE after the G code has stopped on the tool CAUT
24. Active Low Device ready for use Acceleration units second 2 h 25 Down This setting MUST be exactly the same as the Steps Per Unit in Z Motor Tuning in MACH3 Note Max Velocity and Acceleration may be higherthan the Z axis settings in MACH These values will vary widely based on the type Z motor slide friction torch weight and linear drive ratios Send Motor Config Use this Hub Utility to test and set these values using the Z scroll buttons and the actual Z setup you 9 will be using Values set here cannot be changed in MACHS Cut Profile tabs DTHC Settings Setup Test Device Arc Volt Preset h 31 V DTHC Enable M Tip Save ON imi Tip Saver 4 DTHC Delay sec 0 1 Upper volts Fault Limit 200 Update Device Firmware y sec pp Arc OK Current fi Lower Volts Fault Limit 50 Volt Tracking Tolerance fo CanaCNC Hub connected Firmware version 1 6 Slowest Z Velocity 0 DTHC Sensitivity 8 DTHC Tracking o These settings are for testing and reflect the actual values stored in the DTHC IV local memory They may be ovenwritten during MACH Cut Profile changes or from G Code settings during run time Send THC Config DTHC SETTINGS These are the same as using the CUT PROFILE when MACH is running and serve to be able to test the RS485 communication to from the DTHC IV and to test the DTHC IV memory and interface In normal cutting these settings are provided by the Cut Profile and or the DCC values
25. C SETTINGS TAB CandCNC DTITHE IV Settings DTHC Motor Tuning Cut Settings INSTALL DTHC IV DTHC Responsiveness Preset Tuning g Stepper Servo e Slow ka RS a ae oR Ca CRS a 3 Sn Sr fy Medium Fast Custom ED m SELECTING DTHC RESPONSE PRESETS There are six DTHC Response presets for different types of cutting conditions There are three for Stepper and Three for Servo based Z axis Slow Preset Is for general flat sheet cutting of material that does not tend to warp more than about a 1 2 rise over 2 inches or more of length Slow does not mean the motion is slow but rather it slows down the response to voltage change during a cut and dampens over response to brief spikes or dips in arc gap arc volts Medium Preset Is for cutting thinner material that can warp more intensely and allows respones to cut up to about a 30deg rise at rates up to about 200 IPM XY rates Select this Preset if you cut 16ga and thinner and you see a lot of warping and vertical changes Fast Preset Is for very aggressive cutting on severe warps corrugated or at very high cut rates This setting will function to cut up to a 45 deg slope at 180 IPM and smaller slopes at 350 IPM It will cut thin corrugated Some other DTHC settings may need to be adjusted Stepper setting VS Servo setting Servos present different dynamics and tuning issues than steppers They typically have much faster top velocity rates and a wider range o
26. CH3 before running the Hub Utility Steps per unit 10000 Max Velocity 250 F Acceleration 125 OTHE Firmware wersion 1 Cancel END OF OTHC IV MODULE INSTALL CandCNC Page 52 THC SENSOR PWM MODULE SETTING UP THE THC SENSOR PWM MODULE IF you already have a working PWM Module with your DTHC Il of either REV number and you are just upgrading to the DTHC IV you can skip this section of the setup INSTALL ul J m m o 2 2 al THC SENSOR PWM REV 17 CANDCNC Model Mod A to REV THC SENSOR PWM 20 Plasma Pickup M ule for DTHC II DMWIDED ARG VOLTS lt MAK R TO OTHC Il 36v DG Module USE CATS UT a Aevenoed ARCVOLTs danced Tere beth Gover Par Ag s lo iest bui iai VM MODULE vV 21 and later The THC SENSOR PWM MODULE PWM Module has been redesigned to fit into a smaller case The function and settings are EXACTLY THE SAME If you have a working REV 20 or sooner module your DO NOT need to upgrade it to a newer REV 21 This manual is written for using either module and the setup and testing is the same Certain indicators and button locations have been moved CandCNC Page 53 SETTING THE THC SENSOR PWM PRESCALE DIVIDER RATIO THIS MUST BE DONE TO MATCH YOUR INSTALL UNITS ARE SHIPPED TO MATCH THE RAV O1 7 1 INSTALL PWM MODULE RATIO USE THE CHART BELOW IF YOU ARE USING THE MODULE WITH A PLASMA WITH AN INTERNAL VOLTAGE DIVIDER SEE T
27. CandCNC Page 37 CABLE CONNECTIONS for DTHCIV C3 BUS amp ETHER CUT C To PWM os Module O y K ETHER CUT Connections Guide 54 04 T wg F z lll CandCNC DTHC IV Digital Torch Height I lt thernet Electronic Controls for CNC CP PWR UBOB III Technology Green Cat5 from Ethernet Jack on Ether Cut front panel TO Ethernet jack on PC Up to 25ft length BLUE CAT5 cable for RS485 from UP TO 25ft C3BUS Jack on Ether Cut to Ethernet Jack CAUTION All cables are CAT5 UTP 8 conductor and will plug into any CAT 5 RJ45 jack We have color coded the cables to help keep them from being mis connected If you use other CAT cables be sure to label them on each end Connecting cables wrong could damage modules UP TO 25ft CandCNC C3BUS RS485 4 Port Hub PWR Con ACT 9 USB PORTS HHI CandCNG RS485 4 PORT HUB mage AOTIVITY MONITOR lt py w Z hn HUB is REQUIRED for DTHC IV CONTROLLER PC RUNNING MACH3 CandCNC Page 38 SETTING UP THE ETHERNET PORT FOR ETHER CUT OP TIONAL TESTING OF THE ETHERNET PORT TESTING Your IP address ETHER CUT INSTALL To do this test you must have the Ether Cut connected to the Ethernet jack on the PC You should see the yellow LED on the JACK RJ45 of the Ether cut come on steady as soon as the two are plugged in together and both powered up This LED indicates there is a physical connection the ca
28. DTHC IV SETUP INSTALL MANUAL _ Jan 2014 For use with the following CandCNC products MP3000E DTHCIV or later BladeRunner all versions with DTHC IV option Plazpak Series all versions with DTHC IV option Ether Cut Upgrades all series DTHC IV Options DCP 01 Digital Current Probe 11 02 2010 Dcc Dynamic Cut Control HyT Connect Hypertherm Connection Kits TAP Total Automation Plasma Use this manual to install and setup a DTHC IV Expansion Module in the field for any of the above listed CandCNC products OR to setup and test the DTHC IV functions in a CandCNC Product that already has the DTHC IV Module installed Includes complete setup and testing of the new CandNC DIGITAL CURRENT PROBE CAL TEST 20 125A DC AMPS and CNC Model DCP 01 CandCNC Page 1 TABLE OF CONTENTS Introduction 2 3 DTHCIV Features List THC Basics II Overview 4 8 Module ID Correct Block Diagram Expanded Block Diagram Outline Steps Ill Software Install 9 10 Master Installer II IV Hardware Install 11 25 A C3 BUS 4 Port Hub 1 Introduction 2 Install B Hub Management Setup 1 Hub Utility 2 Z Motor Settings C Hub Management Setup cont 1 2 3 Firmware Upgrade 4 Device Testing V Setting up Ethercut 26 38 A Install 1 Screen Sets for DTHCIV and Ethercut 2 Ethercut Hardware Ethernet Port XP a Network Adapters b Network Connections c TCP IP Address 3 Ethercut Hardware IP Eth
29. DTHC control You will find that the Max Velocity and Acceleration will be much higher than your settings in MACH for the Z motor tuning This is normal because of the DTHC IV controlling the motion directly under THC You should set this as high as possible Move the settings up and test the Z motion using the Full Speed Jog buttons on the screen The motor should move smoothly and rapidly both up and down Lose steps or faults on a servo system back the numbers off by 25 The settings here are for a stepper system with a 620 oz in motor running a 5 TPI leadscrew You settings will vary but you should be able to hit about double the velocity and acceleration of the Z motor tuning in MACH IT IS IMPORTANT THAT THESE SETTINGS BE OPTIMIZED for best response under DTHC control They will effect the Gain and Tracking settings for the DIHC THIS IS THE ONLY PLACE TO SET THE Z TUNING FOR DTHC IV AMINUMUM INSTALL REQUIRES YOU PREFORM THIS ONE FUNCTION IN THE HUB UTILITY E DTHC Settings CandCNC Hub Utility Bae DTHC Information Devices Device Details DTHC Enabled UP i Hypertherm plasma Arc DOWN PN200 Pendant Rev 1 Device Torch ON DTHC HOLD DTHC V Tip Save ON DTHC es WD coon Tip Save Active DTHC Fault Test Mode P evice Cod Z Motor Settings for DTHC g atas i Units Full Speed Jog Firmware Version Pana perua LO C Dir Active Low Max Velocity units minute 250 mm Up Device Status I inch M Step
30. EDRATE y OUTPUT if SBU m NEXT CUT OVERRIDE tH Ganaration Auto Learn Nm CONTINOUS FEEDRATE 4 OUTPUT 3 DTHC ONLINE Digital Torch Height Control I Operation of OiHO RE Click to Display Loc PERCENT 100 pera Stored Setting 0 00 5 NETLA FAULT PROFILE ERROR Driver Successfully initialised vv DTHC IV Screen Set with DCC TAP flyout using TAB key NOTE Screens change as we upgrade certain features and your screen may not look exactly like this one but it should be similar _Mach3 CNC Licensed To CandCNC Serial 11011006 File Config Function Cfg s View Wizards Operator Plugin Control Help Setup Test Settings Diagnostics Use TAB to OPEN CLOSE this panel Note Using DCC the G Code sets most of these parameters Automatically Cut Current AMPS Currer eat HIGHLIGH PRESET AMPS Enter Value Set Value Hit ENTER 100 a of Preset AMPs s DTHC DELAY Enter Value m ACTIVE v Anti Dive i PAUSE G CODE EEN TIP SAVER ON OFF El Load G Code ar B Edit G Code 4 ll HT ONLINE Close G Code DTHC I BAONE FEEDHOLO HT ONLINE indicates RS485 connectio FIRE Rewind Cut cot Dasa OM OFF WR Fine RUN G CODE STOP G CODE Load Material DCC 0 lt E pm s J REGEN RESET DISPLAY cove d a c i m UP p a DTHC a D N y mop ic s i FEEDRATE 6 00 TAVANE ON OFF rT A Feeorate 6 0 t DTHC ONLINE L a aenershion e Must be ON for pro Digital Torch Height Control w Stored Setting PERCEN
31. HE SECTION ON CONNECTING A PLASMA WITH AN INTERNAL VOLTAGE DIVIDER TO DETERMINE TE PROPER RATIO To set THC SENSOR PWM ratio divider option 1 Remove rear cover of THC SENSOR PWM Case 2 determine the proper setting for the type setup you have 3 Set the small option jumper to match O VOLTS TEST OLDER MODEL K 3 Qo 0O REV 17 REV 20 Shown t 20 1 i a e 50 1 No jumper UO Back of THC SENSOR PWM SCALE Cover removed ae 20 1 Scale Hypertherm and 71 some others ee IMPORTANT vots The Hypertherm 45 has an Om 201 16 1 Standard on internal voltage divider It 0 11 Thermal Dynamics others cannot be changed for the un mpu 50 1 ratio Set your THC IVIQer om from CandCNC RAV 01 e ae Card the 50 1 position if you are J B using the MIC 01 Direct w en 50 1 Standard on Connect Cable 16 1 1 1 Hypertherm pa Lej Thermal Dyamics others Page 54 CandCNC SETTING THE THC SENSOR PWM PRESCALE DIVIDER RATIO Ta THIS MUST BE DONE TO MATCH YOUR INSTALL UNITS ARE SHIPPED TO MATCH THE RAV O1 7 1 RATIO USE THE CHART BELOW IF YOU ARE USING THE MODULE WITH A PLASMA WITH AN INTERNAL VOLTAGE DIVIDER SEE THE SECTION ON CONNECTING A PLASMA WITH AN INTERNAL VOLTAGE DIVIDER TO DETERMINE TE PROPER RATIO INSTALL P WVIVI MODULE To set PWM SENSOR ratio divider option 1 Remove rear cover of THC SENSOR PWM Case 2 determine
32. ION The code stops on each tool used and the settings are updated The last set of parameters to be loaded to the DIHC memory will be the one used during the cut CandCNC Page 46 INSTALL DTHC IV DTHC IV MACHS CONTROL DTHC SETTINGS TAB l CandCNC DTHC IV Settings 4 2 Cut Settings OTHE Motor Tuning n I m DTH Responsiveness 2 n Preset Tuning Stepper Serva Slow r Medium Fast Custom EN m Other OTHE Settings Upper Volks Faulk Limit 160 Arc OK Current YY 10 Lower Volks Fault Lirik 75 Current Tolerance a20 e marked settings will cause the OTHE IV to Fault and stop mowing the Z during a cut iF the Torch alts Falls outside of the Upper and Lower settings marked settings are only used with the GCP 01 Current Probe General Settings Stop on Fault Stop on Current Fault Raise Head on Fault Torch OFF on Arc Loss Mote settings on this page are GLOBAL settings For all Cut Profiles and are not overridden by any settings in the G CODE Use them carefully OTHE Firmware version 1 Cancel DTHC SETTINGS TAB opens up a screen with 3 sections Each one has specific functions that will be covered in the following pages The DTHC Settings effect the Operation of the DTHC IV and are global and not by Cut Profile previous TAB These settings remain in effect until they are changed in this menu CandCNC Page 47 DTHC IV MACHS CONTROL DTH
33. ORT FOR ETHER CUT WIN XP Network Connections File Edit View Favorites Tools Advanced Help lt Back gt pi z Search Folders Hel Find the Local Area network there may be wireless networks INSTALL m Q n W I m lll Address e Network Connections TA Name Network eee Ba Ancor Gich lt Sneed Internet shown too Ether Cut mead a needs a DEDICATED Siesta a lew MERTE network connection connection mas 5 Set up a home or small from the ehternet port office network status on the pc directly to the Change Windows Repair EtherCut connector Firewall settings a Disable this network device Bridge Connections Right click and select Repair this connection Create Shortcut PROPERTIES from the mi Rename this Delete List Box The Ha fae _ Rename Properties window will connection lt display Change settings of this connection Local Area Connection 2 Pro x General Advanced Other Places Er Control Panel aj My Network Places My Documents ag My Computer Connect using BS NVIDIA nForce Networking Controller f Configure This connection uses the Following items Scroll to the 21 O05 Packet Scheduler Internet 4 AEGIS Protocol IEEE 802 1 v3 7 5 0 Protocol device we internet Protocol TCF IP and hit the usss PROPERTIES button Install Uninstall Description Details Transmission Control P
34. T Operation of D SMART KUT HC CETLE FAULT E J avo team Aieinous ERROR Driver Successfully initialised j CandCNC Page 29 DTHC IV Ether Cut Screen Set with DCC TAP fly out using TAB key between Hypertherm and MACHS is val ACTION SETTING UP THE ETHERNET PORT FOR ETHER CUT Windows XP System Properties AA Automatic Updates Remote Computer Hame Hardware Advanced System Restore General THER CUT INSTALL System hlicrosaft Windows gt P Professional Verston 2002 Service Pack 3 Registered to TOMC Computer AMD Athlon tm 64 42 Dual Core Processor 5900 301 GHz 2 00 GB of RAM Physical Address Extension System Properties 2 gt x System Restore Automatic Updates Remote General i Computer Name Hardware Advanced Device Manager The Device Manager lists all the hardware devices installed on your computer Use the Device Manager to change the properties of any device Drivers compatible with Windows Windows Update lets you set up how Windows connects to Windows Update for drivers Hardware Profiles Driver Signing lets you make sure that installed drivers are Hardware profiles provide a way for you to set up and store different hardware configurations Hardware Profiles CandCNC Page 30 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN XP
35. age Calibrated units see calibration section should display 126 to 128 volts durning test J CandCNC THC SENSOR PWM Card REV 20 PWM CandCNC PWM SENSOR Carg REV 21 Case not shown for clearity Press and Hold for ARC OK TEST Press and relea Volts Test oa AEL will light Remove back to accessll mper settings CHECKING ARC OK Card IGNAL BACK TO DT 1 Remove case bottom rev 20 version 2 With RJ45 UTP cable connected to DTHCII and unit powered up depress the ARC OK TEST BUTTON on the card The ARC OK LED on the MACH screen should light The ARC OK test LED on the front of the case will light NOTE rev 21 module has rear access holes for test hie oe the back must be removed for setting the Screen may be different CandCNC Page 58 THC SENSOR PWM MODULE VOLTS TEST CAL Before you make connections to the plasma unit you may want to do some testing to confirm proper operation of the THC SENSOR PWM with the DTHC II Module INSTALL v Connect the THC SENSOR PWM or PWM MODULE REV 21 to the RJ45 CAT5 connector on the DTHC IV Module ul J m m o 2 2 n V Start MACH3 using the Desktop Icon for DTHCIV or EtherCut Profile and make sure you can come out of RESET and that the CP Charge Pump LED on the front of the UBOB MP3000 MP3100 BladeRunner is ON V On some products you may have to have the Motor DC on to come o
36. and from the screen it shows when the DTHC is active Cutting can begin Signal comes STEPS Z Shows Z motion activity from both DTHC and MACH control RESET button resets the DTHCIV RESET Button processor and does an initilization Pattern for self check Indicates the DTHCIV has issued a HOLD command back to MACH HOLD to prevent motion DTHCIV POWER INDICATOR vas aT GRN Ca S ustin DICATOR Rae LET TORCH ON Shows torch FIRE signal from MACH3 CandCNC Page 44 CUT PROFILES i Use TAB ta OPENVELOSE this panel How to access the CUT PROFILES Stored Settings in MACH Use the TAB key on your keyboard and the Flyout screen will pop upon the right side of your normal Program Run Screen You canslide the separator bar over to uncover the Program run screen if you wan tot have both open at the same time NOTE It is best to run your video screen resolution at 1280 X 1024 or higher so the program run screen does not take up all of the monitor and you have some room left for the flyout Most video drivers and monitors will handle 1280 X 1024 and 49 gt a of Preset anal AMPS 44 ocou Enter Value E KETE later ones have other resolutions higher The MACH screens we supply are 1024 X 768 The higher the resolution you run in s sus TEN windows the smaller portion of the monitor the MACH scrren takes up Set your system up to your preference with the tab flyout in mind Most of t
37. ave the radio button set on the Install the software fe If your hardware came with an installation CD lt ar floppy disk insert it now Next Button the driver has already What do you want the wizard to do been installed in the earlier steps so you do Install the software automatically Recommended Install from a list or specific location Advanced Click Next to continue Hardware Update Wizard This completes the software and driver install for the CandCNC USB to RS485 4 port Hub Completing the Hardware Update eS Wizard The wizard haz finished installing the software for k CandCNC USE to RS385 hub See the following pages for checking the install and to use the CandCNC Hub Utility Admin Click Finish to close the wizard Back Cancel CandCNC Page 18 RS485 4 PORT HUB HARDWARE INSTALL 7 To confirm that your USB RS485 4 PORT HUB drivers have been installed open the System Application in Control Panel and then the Hardware Tab and the Device Manager You will see a Tree Structure of hardware devices Scroll to the bottom and Find the UNIVERSAL SERIAL BUS DEVICES and under it you should see the CandCNC USB to RS485 hub device IF YOU DO NOT then unplug the USB connector either end and wait 5 sec and plug it back in You should NOT get the Hardware Install or Update Wizard The Device manager should update and show you the screen below T
38. ble is good and both ends are connected and have power it DOES NOT indicate the two are actually talking sending data The Green LED does indicate activity both send and receive so it may confirm there are packets going one way it does not indicate Type the name of a program Folder document or vim Internet resource and Windows will open it For you Open cmdl C WINDOWS system32 cmd exe Microsoft Windows AP Version 5 1 2600 lt C Copyright 1985 2661 Microsoft Corp C o Documents and Settings tonmmy gt ping 180 9 9 9 Pinging 16 6 6 1 with 32 bytes of data Reply from 9 9 bytes 32 time 28ms ITL 249 Reply from Oo 9 bytes 32 time 30ms IIL 249 Reply from g butes 32 time 26ms IIL 249 Reply From go 9 bytes 32 time 2Z ms IL 249 Ping statistics for 16 9 9 9 Packets Sent 4 Hece ived 4 Lost H iHz lossi Approximate round trip times in milli seconds Minimum 26ms Maximum 3Bms Average 28ms Cos Documents and Settingsstommu gt CandCNC Page 39 SETTING UP THE ETHERNET PORT FOR ETHER CUT Motion Control Hardware Plugin sensed Your system is showing more than one control device Please pick the one you would like this profile to use Mormal Printer port Operation ESS vilUpldile Mo Device Mo Device Moa Device Dont ask me this again When you open the Ether Cut Profile for the first time you should see the dialog box above MACH should recognize the ESS Ethe
39. cause it to flash clockwise Multicolor LEDS will change colors if you Enc2 FeedRate x click the L button again Does the same LED Fast Flash changes 5 X 5 keypac reflects button pushes on the PN200 keyboard and displasy key number in the Last Key DRO IF YOU DO NOT HAVE THE HyT Connect RS485 options the device will not show up in your devices list and this screen will not appear CandCNC Page 27 Setting Up EtherCut Systems with Ethernet and IP Address CandCNC Page 28 MACH SCREENS FOR DTHC IV amp ETHERCUT _ Mach3 CNC Licensed To CandCNC Serial 11011006 File Config Function Cfg s View Wizards Operator Plugin Control Help Setup Test Settings Diagnostics Use TAB to OPEN CLOSE this panel OTHC VGunerTHO IF O 0000 BBM 0 0000 ee H Cut Current Box JE 0 0000 AF 0 0000 ereser 45 usr Hit ENTER Enter Value of Preset Volts al AMPs 190 TORCH INSTAL r a DTHC DELAY TORC J i VOLTS 1 0 W THC Button MUST b ON too for THC Control IVE rir SAVER _ON OFF l Anti Dive WB HT ONLINE Hypertherm RS485 HT ONUNE indicates R5485 connection between Hypertherm and MACH3 is valid ree N cise cou E DTHC 7i RUN a STOP Pes ewind cow _ Sata oA FINKE s55 ACTION THC MOVES Set Ref Point EEE Load Material i 0 0 00 Goto Ref Point REGEN CODE Incremental P 1 Single Step J i TA TAE z SMART KUT i FE
40. ction button that Displays current opens a new Update Device Firmware firmware of the HUB dialog window This allows you to update This MUST show You must have a each module with new connected status device firmware New firmware before any other of the highlighted in the will be designated by a functions will display Devices List to REV number Firmware updates will be available for down load in a special download section of the CandCNC website and on the Yahoo CandCNCSupport Forum The Hub Utility is an application provided to manage the C3BUS USB to Rs485 4 Port Hub and the devices attached to it With the utility you can Updte the Hub Firmware Firmware is the program that runs the hub Update Firmware in the Devises attached like the DTHCIV Test basic communications Test device functions Device level diagnostics set some device settings What you CANNOT DO Run MACHS3 Both applications trying to talk to the same device does not work CandCNC Page 23 HUB MANAGMENT HUB UTILITY DTHC INFORMATION is direct feedback from the DTHC IV module and indicates the current status of the unit You cannot make changes or do inputs from this section Since you cannot run MACH and the Hub Utility at the same time these settings are primarily used for off line diagnostics at the factory CSBUS HUB Z MOTOR SETTINGS This section is the most important because it sets the base motor settings for the Z motor under
41. ction to the PowerMax 1000 1250 and 1650 as wall as the PowerMax 45 and PowerMax 65 85 105 with the optional CPC connector ul J m m o 2 2 al https www hypertherm com Xnet library jsp null is a search page where you can enter your model number and then search the FSBs The files are in PDF format For other brands of plasma units or a model not designed to be automated the search for connection points may be a little more difficult but not impossible The key is the leads going to the torch cable On most plasma units you can locate these signals by opening the unit POWER DISCONNECTED and visually tracing the wires coming from the plasma torch The Workclamp will be connected to a stud or terminal inside and is pretty easy to identify It is the POSITIVE side of the circuit The Electrode side goes up the plasma cable to the torch head It will be one heavy wire or a series of smaller gauge 12ga or larger stranded wires of the same color and they will all connect to the same electrical spot bus inside the plasma In a lot of units these wires are all solid WHITE in color but do not use color as your clue Some plasma manufacturers provide block level schematics in their use or service manual that give wire colors and in some cases terminal numbers and locations WHEN YOU HAVE LOCATED THE WORKCLAMP AND ELECTRODE WIRES IN THE UNIT Using a two conductor wire 18 22 ga not supplied with insulation rated to 400V or more
42. ed It may show it si not CONNECTED but if it is missing or diabled you will need to get the problem resoved before you can proceed with the install CandCNC Right click and select Properties Page 36 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN 7 INSTALL ETHER CUT This connection uses the following items o amp Client for Microsoft Networks Bl QoS Packet Scheduler Bl File and Printer Sharing for Microsoft Networks Intemet Protocol Version 6 TCP IPv6 1 Highlig ht Internet l intemet Protocol Version 4 TEP IP v4 Protocol Version 4 4 Link Layer Topology Discovery Mapper 1 0 Driver TCP IPv4 Link Layer Topology Discovery Responder Click Properties Button wide eso Con protocol that rie r across diverse interconnected networks H Inv ork Conn Internet Protocol Version 4 TCP7IPv 3 Properice ES ea x ces Fol lowi ng Add ress You can get IP settings assigned automatically if your network supports this capability Otherwise you need to ask your network administrator li for the appropriate IP settings Enter the address exactly as shown Obtain an IP address automatically Use the following IP address 10 9 9 1 IP address E la SE 5 255 255 Enter the Subnet Default gateway E Mask exactly as nem shown 255 255 255 0 Leave all other settings blank no DNS servers Click OK to save
43. erchants including Amazon com for less than 2 00 No voltage conversion is necessary 5 Using the included USB A to B adapter cable plug the B plug into the matching jack at the end of the hub and the other end into any open USB jack on the control PC Note for testing you can load the drivers and CandCNC Hub Utility on any PC or Laptop but for operation you need to have the hub installed and working in the PC that runs MACH and controls you machine INSTALL 6 Windows will see the new hardware and will launch the Hardware Install Wizard Use the following screens to finish the hardware install Hardware Update Wizard Welcome to the Hardware Update Wizard First Screen of Hardware Install Update Wizard Windows will search for current and updated software by looking on Your computer on the hardware installation CD or on the Windows Update Web site with your permission Leave the radio button set on the No Not this time option and hit the Next Button Can Windows connect to Windows Update to search for software O Yes this time only O Yes now and every time connect a device No not this time Click Next to continue CandCNC Page 17 RS485 4 PORT HUB HARDWARE INSTALL aol a Y lt Hardware Update Wizard Next Screen of Hardware eS Install Update a Wizard This wizard helps you install software for CandCNC USBrs485hub Le
44. ernet for WIN7 a Local Area Connection b TCP IP Address 4 Connection Schematic 5 Optional Ping Test of Ethernet B Modules Setup 39 42 1 DTHCIV Module a Install DTHCIV b ID of DTHC Plugs and Indicators c Front Panel Indicator Chart 2 DTHCIV Cut Profiles 43 50 a Accessing Cut Profiles via Mach3 Screen b Basic Cut Profile Display 1 Current DTHC Settings c DTHCIV Settings Tab 1 Preset tuning DTHC Sensitivity DTHC Tracking 2 Other DTHC Settings 3 General Settings d DTHC Motor Tuning 1 Display Info Only 3 PWM Module Setup 1 57 a Older Model Divide Ration Settings b New Model 21 Divide Ratio Settings c Test Calibration 1 Older Module Volts Test 2 Newer Module Volts Test d ARC OK Test CandCNC Page 2 TABLE OF CONTENTS cont C Making Connections to your Plasma Cutter 58 67 1 Connecting using Universal Connection Kit 2 Making Connections to Plasma a Finding the Correct Connections b Firing to Torch c Testing Troubleshooting RAV 01 d Hypertherm 1000 1250 1150 Connection Points e Connection to Hypertherm 45 3 Making Connections via External Connections a Thermal Dynamics 1 CPC Pinout 2 Automation Interface PC Board 3 A Series Pin Outs b Hypertherm 1 CPC Pinout 45 65 85 105 125 2 Divider Switch Settings VI Setting Up and Plasma Cutting with DTHCIV A Setting Up the Z Axis for Automatic Touchoff 1 Modifying SheetCam Post for Switch Offset and Ref Difference B Z Motor Tuning fo
45. ess Since USB is a common port on most PC s it is a logical choice for communications that do not depend on precise timing You will note that the USB RS485 4 Port Hub has four in dependant channels ad each channel can talk to multiple devices Because of different Baud Rates or special signals the 4 port hub has two special jacks 1 Hypertherm RS485 Port This channel runs at a much slower speed and can only talk to a Hypertherm Plasma Cutter equipped with an RS485 port optional and through our HyT Connect RS485 interface If you already have the HyT Connect RS485 SIM Kit installed and have the older single port dual jacks RS485 module you need to unplug the existing setup and plug the RJ45 Cat5 cable FROM the port on the rear of the Hypertherm into the jack 1 marked To Hypertherm Rs485 PORT CandCNC Page O USER MANUAL RS485 4 PORT HUB Plugging RS485 Hypertherm into RS485 PORT on back of Hypertherm 65 85 105 J A n BN See HyT Connect Manual for details on installing and using the RS485 remote control for the Hypertherm and the DCC Dynamic Cut Control CandCNC Page 211 al lt i lt USER MANUAL RS485 4 PORT HUB 2 PN200 Hand Control The PN200 hand control uses normal high speed baud rates but the special dead man E Stop to the EPO of any CandCNC controller requires a special jack The PN200 MUST be plugged into the PN200 jack to be able to use the E STOP safety recommended
46. f torque Only slect this mode is your Z is a servo motor Itis important to understand that the above settings and suggestions are based on typical leadscrew type Z mechanisms with average pitch of 2 5 mm for stepper and 1 2 54 mm for servo The settings may need to be adjusted for courser or finer pitches Use the CUSTOM setting if the presets do not product smooth response CandCNC Page 48 DTHC IV MACHS CONTROL DTHC SETTINGS TAB CandCNc DIHC IV Settings OTHE Motor Tuning DTH Sensitivity J Cut 5ettngs 42 0 E 20 OTHE Responsiveness Preset Tuning fe Stepper Servo Slow Medium Fast f Custom Slowest Velocity z Voltage Tracking Tolerance l SETTING DTHC RESPONSE USING CUSTOM Settings If you select CUSTOM in the Preset Tuning buttons the DTHC Sensitivivy and DTHC Tracking will no longer be grayed out and can be used to custom tune the Z for a given condition You may find that custom tuning is needed if your Z mechanics are either very course or very fine DTHC Sensitivity determines the response RATE how quickly the Z responds to small changes in the ARC VOLTS Setting the DTHC Sensitivity higher will force the DTHC IV and the Z to increase the rate that it responds DTHC Tracking determines how close to the PRESET VOLTS the DTHCII will try and hold the changes dampening The resolution of the DTHC IV is 1 16 VDC It uses a
47. for example so use only the motor tuning VALUES in the new Profiles NOTE MACH keeps backup copies of the XML profiles any time you make changes They are stored in a folder under MACH named XMLBACKUPS In that folder you will find Files like ETHER CUT TAP xb11 the suffix after the dot are xb the version To recover you can find the highest ver number and rename it with the xml suffex First copy it to the main MACH folder as the xb extension and then rename it If you have one already named that it will refuse so first remane the XML file if that name to something like default than rename the file you copied in CandCNC Page Using the Auto Installers for CandCNG DTHC IV and EtherCut Controls a m i 4 f H HEI BHHER IR KYE JEEE Etertsut New PROFILES ICONS will be added to your desktop You may have other CandCNC profiles from earlier installs If you do not have at least one of the new ICONS as shown above after running the DIHCIV EtherCut_Install it was not done correctly Do the install again CandCNC Page 12 USER MANUAL RS485 4 PORT HUB INCLUDED IN THIS KIT USB to RS485 4 Port Hub Module Universal WallPlug Power Supply 100VAC to 240VAC in 5V DC out USB Ato USB B interface fable 6ft Installer driver CD User Manual PDF May be on Master Support CD in RS 485Hub4 Folder IRANA Version 1 0 DATE 10 30 2012 See www CandCNiC c
48. ges in the Voltage Fault Volts out of range error code trigger and two inputs for use if the DCP 01 is being used NOTE the ARC OK CURRENT needs to be set to some value above 0 of it will false trigger on system that DO NOT use the DCP 01 42 0 E 20 Other DTHC Settings Upper Volts Fault Limit 160 Arc OK Current 5 Current Tolerance 30 marked settings will cause the DTHC IV to Fault and stop moving the Z during a cut if the Torch Volts Falls outside of the Upper and Lower settings marked settings are only used with the DCP 01 Current Probe Lower Volts Fault Limit Upper Volts Fault Limit Set this value to about 10 below the open circuit voltage of your plasma torch voltage when fired in the air It will prevent DTHC signals from moving the torch too far down in the event the torch runs off the material or hits a void Lower Volts Fault Limit Set this value to a number that triggers a fault if the voltage is below the normal cutting voltage of the torch with the consumables you use If you change consumables that have different settings you may need to adjust the parameters or you can set the lower limit to reflect the lowest voltage used with ANY type consumable Arc OK Current This setting is used when the plasma unit you are using DOES NOT HAVE an ARC OK OK to MOVE Arc Xfr TRANSFER Etc signal The UNIVERSAL CONNECTION KIT from CandCNC has the DCP 01 Digital Current Probe that reads A
49. he Plug In Control List Box DO NOT OPEN THE SELECTIONS in the list and make ANY changes The IP address WILL NOT display right even if you have communications There are indicators on the front of the Ether Cut clustered around the Ethernet Jack that can be used to confirm connection and valid communications see the chart in this manual W l m J 0 l 4 0 e Do some preliminary motion checks If this is a new install and you have no motor tuning numbers to go from refer to the Motor Tuning Section of the BladeRunner AIO User Manual even if you have just the MP3100 DTHCIV MP3500 DTHCIV EtherCut version or a Plazpak e Continue through the DTHC IV Setup and Contig Manual to do the testing and fine tuning of the DTHC IV There are settings and tuning requirements for the DTHC IV that are different than the DTHC Il IMPORTANT IF you are moving from a DTHC or DTHCII to the DTHCIV it is a radically different system and requires the tuning steps outlined in Chapter of this manual If you skip this than your results will be less than optimal CandCNC Page 10 Using the Auto Installers for CandCNG DTHC IV and EtherCut Controls MENU SCREEN FROM Masterlnstallerlll exe RUN THIS FIRST SELECT THE PRODUCTS TO INSTALL YOU HAVE Setup Master Installer for all Products lis x Select Components Which components should be installed Select the components you want to install clear the components you do
50. he CandCNC USB to RS485 hub device will only show up when it is plugged in Device Manager ox File Action Wiew Help se 2 a gt Keyboards l Machs Pulseing Engine 9 Mice and other pointing devices Monitors 88 Network adapters vay NVIDIA Network Bus Enumerator a Ports COM amp LPT e Processors Sound video and game controllers se Storage volumes A System devices Universal Serial Bus controllers Serial Bus devices CMC LSB to RS4e5 7 Page 19 CandCNC l a Y lt RS485 4 PORT HUB DEVICE CONNECT The USB Active ACT LED only comes on when there is a valid USB connection to the PC Drivers have to be loaded and active INSTALL USB ACTIVE LED PWR Con ACT USB B plug to PC USB CandCNC al ACTIVITY MONITOR To Hypertherm C amp C 1 C amp C 2 PN200 RS485 PORT L INSTALLING CandCNC RS485 Devices to the USB RS485 4 PORT HUB The USB RS485 4 PORT HUB has an advanced processor than can communicate with several RS485 devices RS485 is a robust and noise immune communications standard used in industrial electronics for years Because of its differential signal methods it is unaffected by external or ground based noise and reliable communications of several hundred feet are common RS485 is a multi drop topology meaning there can be multiple devices on the same pair of wires as long as all of the devices operate at the same speed BAUD RATE and have a unique addr
51. he RAV 01 and THC SENSOR PWM On other types of Plasma cutters that have no external connectors for ANY of the required signals the RAV 01 can become a connection board for accessing those signals internally and passing them to the THC SENSOR PWM Module via the CCAS 01 4 wire cable The following pages will cover how to first use the RAV 01 as a voltage divider card in a unit that does not have an integrated voltage divider If you have a plasma unit with no external connectors tha the next section shows how to use the RAV 01 to fire the torch from the software Finally if your plasma has an internal access to the Torch fire for a mechanical torch and an internal ARC OK OK to MOVE REMEMBER the RAV 01 is just a pass through place to make connections for ARC OK and TORCH FIRE It does not sense or provide those signals There are added pages on some Plasma Cutters and how to connect them sometimes there is more than one way If there is a way to access the proper signals externally than that method with a cable is recommended In each case the objective is to get the signals in and out of the THC SENSOR PWM Module CandCNC Page 66 CONNECTING to YOUR PLASMA RAV 01 Raw Arc Voltage Divider Option RAV 01 Mounted inside Plasma UNIT CandCNC RAW ARC VOLTS Voltage divider card Plexiglas Safety Shield INSTALL ul J m o 2 gt al
52. he settings on the tab flyout are not done while you are cutting x To access the following setting screens you have to click on the CUT PROFILES Button located on the tab flyout on most screen sets WARNING If you do not have the C3BUS Hub setup and working and the DTHIC IV shows up in the device list THIS BUTTON DOES NOTHING Without communication between MACH and the DTHC IV you cannot read or change settings NOTE DTHCII and older screen sets only have one level of tabs to select edit and choose a CUT PROFILE Your old CUT PROFILES from earlier installs will still be there but now you have additional tabs and settings available This is an important thing to note in the DIHC IV setup and interface CandCNC Page 45 DTHC IV MACH3 CUT SETTINGS TAB CandCHC D IHC IV Settings DTHC Settings OTHE Motor Tuning Current DTH Settings Information HT 45 1 4 Steel 250 Profile Name Current Settings HT 45 44 Steel SOO l o HT 45 34 Steel 750 Material HT 45 1 2 Stainless 500 HT 45 1 4 Stainless 250 suggested Feed Rate HT 45 1 Steel 1 000 rete HT 45 10ga Stainless 135 s HT 45 10ga Steel 135 these values are For reference only and do not change anything HT 45 12qa Stainless 105 in the OTH or the Cut File HT 45 1294 Steel 105 HT 45 14ga Stainless 075 HT 45 14ga Steel 075 HT 45 16ga Stainless 060 an ee ae Arc volt Preset 147 Tip Saver i HT 45 20ga Stainless 03
53. he torch Up or Down to correct the error Under normal cutting conditions the voltage stays constant with height but certain conditions that effect the arc gap voltage can skew the gap volts and case the THC circuit to overreact The feed rate how fast the tip is moving across the material determines the current density and the Gap Volts A slower feed rate will cause an increase in Torch Volts if no THC servo is there to correct With THC engaged the circuit will sense the higher voltage and based on the error created lower the torch to try and compensate This occurs if the arc crosses a void or existing kerf or at the end of a cut when the scrap drops out The DTHCII includes an adjustable Anti Dive Tip Saver that senses a rapid voltage spike and locks down motion Arc Gap Arc volts Torch Volts volt change approx 015 change ze gt Arc volts gt Arc Gap greater the Arc Gap the greater the Arc Volts Z moves opposite Arc Volts based on Preset Volts Torch Volts Above Preset LOWERS torch Torch Volts below Preset RAISES torch zs Control has window Span Volts where no UP or DOWN occurs prefect cut height Anything inside the Span or from the Preset generates NO change SPAN VOLTS is set in 1 4V increments in the Cut Profile CandCNC C3BUS USB to RS485 4 Port Hub See text for details Pra diri CandCNne ACTIVITY MONITOR Ta yun tem an
54. ke provisions to connect the two low voltage cables CCAB 31 and SAC 01 You need to provide holes on the rear or side of the unit BE CAREFUL DRILLING METAL IN YOUR UNIT TINY SHAVINGS CAN FALL ON PARTS THAT COULD SHORT Ream the holes smooth or drill them oversized and use a rubber grommet to protect the wires Clean up with a magnet or blow the cabinet out with air One hole needs to be able to pass the diameter of the SAC 01 Plug The other needs to pass the diameter of the cable for the CCAB 31 NOTE The 4 wide plug on the CCAB 31 cable is removable You will need to remove the end that passes into the enclosure to fish the wire through for the RAV 01 Connection BE SURE TO FOLLOW THE COLOR CODE TO REATTACH THE CONNECTOR THE COLORS ON BOTH ENDS WILL GO ONTO THE SAME TERMINAL PIN NUMBER Connect the two cables where the diagram shows to the RAV 01 Card Making the connections A WORD ABOUT ARC OK SIGNALS ARC OK is our terminology of a signal coming back from the plasma unit that signals the unit has fired the torch and has a valid arc Most plasma units made for manual cutting DO NOT HAVE an ARC OK also known as ARC XFR TRANSFER OK to MOVE and other similar terms It is a circuit that closes relay contacts or sometimes called dry contacts on a valid arc Units that do have the signal will have it labeled on a connector or covered in their manual IF YOU HAVE DOUBTS assume the unit does NOT have ARC OK and follow the guideline
55. nearby components The RAV 01 card is designed to take the full tip voltage and divide and filter it Open circuit full tip voltage can be as high as 300VDC in some machines 3 If your plasma unit does not have a designated tip voltage measurement point you will need to locate a place inside the unit where you can get one wire onto the workclamp lead and another on the heavy lead s that connects to the torch tip electrode a Note some machines like the Hypertherm 380 do not have a single heavy wire to the Torch tip and instead have a set of parallel smaller wires that all terminate into one connector In the case of the 380 the WHITE wires are the tip volts negative b You can identify both locations by visually tracing the two leads as they come into the box You should find several locations terminal strips that have connections to these two points and you can use those for your sense wire connections Use unshielded stranded twisted wire of 22 to 18 ga rated for at least 400V insulation CandCNC Page 62 THC SENSOR PWM MODULE VOLTS TEST CAL c Make a connection between the locations you have identified that tie directly to the two leads workclamp and torch tip to the two TIP Volta terminals Make sure that these wires are routed where they cannot come into contact with hot or moving components Starting with the REV 14 THC Sensor card the TIP VOLTS inputs have a polarity The side INSTALL ul J m
56. not wank to install Click Next when vou are ready to continue Custom installation x MP3000 DTHCII or Plazpak RouterPak Install 3 4 MB MP3100 DTHCI or Plazpak RouterPak DTHCI Install F MP3500 DTHCIY ETHER CUT or Plazpak RouiterPak ETHER CUT Install 2 4 ME BladeRunner AIO DTHCII Install 4 7 ME MB SladeRunner AIO DTHCTY Install BladeRunner 410 ETHER CUT Install USE485 4 Port Hub Installer Update ONLY Current selection requires at least 6 5 MB of disk space IF you are upgrading an older setup make sure you first backup your MACHS folder to a memory stick and THEN upgrade MACH to version 3 043 067 or later and run the Master Installer lll FIRST Do not select products you don t have or that you used to have Either install the proper DTHC IV product or the Ether Cut product you have but NOT BOTH After you have installed the Master installer and have the icons for the products and can open the profile to indicate you got a successful install You can come back and install again but it will put any profiel back to defautl values and any cahnges you have made like motor tuning and axis settings in MACH will be abck to the default values If you need to recover your motor tuning simply open the MACH folder off your memory stick and copy your old working profile back into the MACH folder on your computer Most of the settings are totally different Ports amp pins
57. nternal PC Boards The terminals provide a convenient place to do your connections Use crimp on spade or round terminals to attach the wires to the terminal strips Make sure the new wires you install do not touch adjacent metal objects On some machines there may be more than one set of small wires and are used for sensing tip shorts and other conditions To identity the correct pair for the Torch Switch use an ohmmeter or continuity checker across each pair while you manually push the torch head button When you identify the pair make note of where they attach Use 22 to 18 stranded wire twisted pair to connect between the two screw terminals on the THC Sensor PCB marked Torch Switch to the two switch terminals in the plasma unit There is no polarity NOTE IF your unit has noise filter chokes from the torch switch wires up to its internal logic card it is recommended you place the two wires to the RAV 01 PCB on the other side of the chokes from their torch head connection end closest to the internal logic card INSTALL ul J m m o 2 gt n 2 If your unit has a tip voltage connection point i e like the Hypertherm 1000 series you will need to use their manual and suggestions as to how to connect to the two points and run those wires to the RAV 01 card Just make sure you use wire that has insulation rated for at least 400 V Small signal wire like telephone wire UTP is not rated that high and can arc to
58. om Manuals htm for updates Copyright notics All content is protected by copyright Any reuse or reproduction in whole or part witout permission is prohibited Any user manual may be reprinted in part or whole by the owner of the products covered by the manual for their own private use Any trademark or logo used in this manualis the property of the the trademark owner CandCNC Page 13 USB RS485 4 PORT HUB Plug Locations and Layout C3BUS USB to RS485 4 PORT HUB Handles all secondary backside communications too and from the DTHC IV to MACH3 All screen readouts and all settings to the DTHC IV are handle by the C3BUS The HUB UTILITY uses the same C3BUS to communicate with all the R8485 modules including the DTHC IV Itis essential the C3BUS be installed and running BEFORE you attempt to setup the RS485 4 PORT HUB TOP VIEW PWR Con ACT RS485 4 PORT HUB USB END VIEW CandCNC ACTIVITY MONITOR To Hypertherm C amp C 1 C amp C 2 PN200 RS485 PORT L RS485 4 PORT HUB FRONT VIEW C amp C C amp C PN200 HyT Connect CandCNC Page 14 USER MANUAL RS485 4 PORT HUB niversal AC power Plug OOVAC to 240VAC 50 60HZ USB ACT LED shows is ee hour Valid connection to PC on USB channel PWR Con ACT CandCNC E ACTIVITY MONITOR To Hypertherm o EPO on ESP front panel Rs485 PORT only C amp C1 C amp C2 PN200 igi y y T or EPO on Table I O ACTIVITY MONITOR Standard CAT
59. om our Optional RAV 01 card and changes the small analog signal to a constant level PWM signal that is many times more immune to external noise and EMF problems Designed to work with your existing equipment including HF and CD start units or the most modern plasma units in built in Automation Interfaces it sets a new standard for Torch Height Control You can pay MORE for a THC but cannot get more features or accuracy than the DTHC IV offers CandCNC w AA aA l ArT BLOCK DIAGRAM TYPICAL DTHC IV HOOKUP for Automation Interface g N DCP 01 option OVERVIEW Used for ARC Current Readout NOT Required Cat5 UTP c UP to 25 ft PWM MODULE Located in the control Plasma Pickup Module the UBOB III Located external and car close to the Plasma cutter MIC 01 Custom Cable gt CPC Plug Single cable on Plasma Hookup to Unit Plasma Unit Page 7 CandCNC FULL SYSTEM BLOCK DIAGRAM PAY aY at ah ewsejd In smoye i s pue suoijdo dV1 pue 990 paoueapy pue oeJi 1u 1ol1eJ1 do Jano uBiu awes y si JJo Ins s1ndul Jo yas paads ysy s nssi uun Ie 4 e 104 JOU HOVN U 0160 y 104 1u uu uinb i s ou qi ssod 0 np sile1su OND i Pai ie Sion ewsejd 10 puUswWWO0994 LON JHLG 24 3e pasojo mou s doo sjonpod SEJ4J 1ul UONOW ASN xx OHL PUL qeun1 pue sajyseyj yonw sue nso e se pue
60. onfirm proper communication with each device and to be able to do some base level testing You cannot run the Hub Utility at the same time as MACH is running The following screens show the CandCNC Hub Utility displaying information about different devices connected to it The Hub is smart and automatically detects any compatible device connected to it Review the screens that follow and understand what each section of the screen is used for CandCNC Page 22 C3 HUB MANAGEMENT HUB UTILITY EE CandCNC Hub Utility ae DEVICE DETAILS Device Details Provides the PEDO Pandin Rev 1 Device Name Hypertherm plasma Device Code Each CLASS type of device Device Code has a different Device DEVICES 3BUS HUB Shows a list of connected Address b CODE Codes can be from devices Asa Firmware Version b 1 to 99 device Is Device Address The Device Status connected and unique address of a device sensed by the within a class values from hub it will appear 1 to 8 Devices of the in the list If you same type must have a connect a device different Device Address and it does not Future cards will have show up address jumpers to allow immediately multiple cards of the same stop close the type to work on the same application and hub restart CandCNe Hub connected Firmware version 1 Firmware Version This displays the current Hub Connected TEST DEVICE to USB on PC A
61. r Best Performance C DTHC Screen Buttons and DRO Functions 1 Base DTHC Screen Elements 2 TAB Fly out on DTHC Screens 3 DCP Option a Indicators b Cut Current Troubleshooting D Cut Profiles Screens 1 Define Terms 2 Adding Profiles E Final Testing 1 Startup Test Manual Cut 2 Using SheetCam to Generate Code VII Addendums A Adding Digital Current Probe B Grounding Practices C Adding HYT Connect Rs485 for Hyperterm D Troubleshooting DTHCIV Problems E Adding FT 01 Feather Touch Ohmic Sensor CandCNC Page 3 FEATURES GUIDE FOR DTHCIV This document describes a product from CandCNC that provides a new approach to Automated Torch Height Control The DTHC MARK IV system is backwardly compatible with earlier CandCNC controllers using the DTHCII The DTHC MARK IV is a 4th generation design using a faster more complex microprocessor and is the culmination of over 10 years of THC designs from the engineering team at CandCNC and is the pentacle of high performance low cost digital torch height control The DTHC IV has the following features new features in RED 2 gt Compact Surface Mount Design High Speed Processor Boot Loader on chip for easy firmware updates gt Uses ECC Electronic Cut Chart for stored settings 2 gt RS485 C3Bus communication using standard UTP cabling CAT 5 2 gt Isolated external HOLD circuit No other inputs on BoB used or needed Works with MACH3 and LinuxCNC 3
62. rc Current amps flowing in the Workclamp lead and is used to trigger the ARC OK signal If you have the DCP 01 connected and in use either in the Universal Connection Kit or as part of the TAP Advanced Interface Kit you should set the Arc OK value to about 1 2 of the lowest cut current you use It is important to understand that the ARC OK can be triggered by EITHER the hard signal reading currfrom the plasma or from the DCP 01 reading current greater than the Arc OK Current setting Current Tolerance This setting is a percentage of the indicated Cut Current and works in conjunction with the ARC OK CURRENT and has to have the DCP 01 to monitor the actual cut current It triggers a current fault and there are General Options that control what happens if a current fault uses the PRESET CURRENT CandCNC Page 50 DTHC IV MACHS CONTROL DTHC SETTINGS TAB INSTALL DTHC IV General Settings Stop on Fault Stop on Current Fault Raise Head on Fault Torch Off on Arc Loss Note settings on this page are GLOBAL settings For all Cut Profiles and are not overridden by any settings in the G CODE Use them carefully DTHE IV Firmware version Cancel General Settings are options to do specific functions in the event of a Fault Faults come from two sources Voltage outside the range of the Upper Volts Fault Limit or the Lower Volts Fault Limit OR if you are running with a DCP 01 module and have actual cut current reado
63. re to be done with the power disconnected from your plasma unit You should determine which type install you will need for your plasma There are 3 questions that need to be answered 1 Does your plasma unit have an internal ARC OK dry contact signal or one on a standard CPC connector If not then you will need to purchase and install the Digital Current Probe Option DCP 071 2 Does your plasma unit have an internal voltage divider Automation Interface with a ratio of 20 1 or 50 1 If not you will need to purchase and install the Raw Arc Volts divider card RAV 01 3 Are you using a hand torch or machine torch If using a hand torch even with a unit that is setup for automation you will probably need to tap into the TORCH SWITCH wires from the hand torch to fire the torch remotely from the computer There is a page on how to do that from either the RAV 01 if you already have it because of 2 above or directly from the THC SENSOR PWM connector If you have a Plasma unit that needs the RAV 01 card you will need to install that card in your plasma unit or have it done See the RAV 01 card section for instructions and warnings If you are using the DCP 01 for ARC OK there is an addendum at the end of this manual on installing and testing the DCP 01 CandCNC Page 61 THC SENSOR PWM MODULE VOLTS TEST CAL 1 Most plasma units have connection terminals where wires from the torch or panel connectors attach to the i
64. rnet device and ask you if you want to use it instead of the Parallel Port You DO If you DO NOT see the dialog box and MACH opens than it may have already been set If the ESS fails to load and you cannot get the screens in the Plug in Control menu than use the top menu bar and the Functions Cfg s menu and select the Reset Device Set option Stop and restart MACH If you get an error message like ESS_v10p1idite CTftn WakeUpcClient Board does not reply Select YES to retry No to config Cancel to quit Yes Ko Cancel MACH does not see the ESS Ethernet Device and you need to go back through the IP setup and the tests to make sure the card is communicating with the PC Ehternet port CandCNC Page 40 THE FOLLOWING SECTIONS DEAL WITH SETTING UP EACH MODULE IF YOU HAVE A CandCNC Product you may not need to use one or more of these sections since some products have theses modules already installed tested and calibrated IF you have a BLADERUNNER AIO Dragon Cut or any MP3000 DTHCII based product Plazpaks than YOU CAN SKIP THE SECTION ON INSTALLING AND SETTING UP THE DTHCIV Module CandCNC Page 41 Digital Torch Height DTHC IV Module 42 Of 20 E a a k gt _ ma n a ee a pi es i J f a j i ea S 4 E pe T p i ai fh a ae k 1 i a a p w ien r ki J i j M m z m 7 1 a J m5 7 P oo Rg ovo n a D KI L re F a w A 1
65. rong card drivers Page 31 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN XP NVIDIA nForce Networking Controll x Aq General Advanced Driver Details Power Management NOTE the screens shown cr q The following properties are available For this network adapter Click are for an NVIDIA Network lll f the property you want to change on the left and then select its value card and may have T 2 chee different option scrrens Property Value andsettings Most cards Enable have default settings that IEEE S021 Support are correct and do not need Low Power State Link Speed Network Address to be changed Optimize For Speedduplex settings WLAN Id WYLAN Support Wake on Magic packet Wake on pattern wWake nLAN From Power ok NVIDIA nForce Networking Controll When running MACH3 on a computer you General Advanced Driver Details Power Management MUST turnoff all Power Saving options in NVIDIA nForce Networking Controller Windows and make sure the communications device is not set to turn off to save power This option may not appear on all Ethernet Cards Allow the computer to turn off this device to save power Property Value Property Value Flow Control Full autonegotiation Enable k IEEES02 1P Support IEEES02 1F Support Low Power State Link Speed Network Address Optimize For Speedduples settings VLAN Id VLAN Support Wake on Magic packet Wake on pattern Wake
66. rotorcol pterret Protocol The default Wide area network protocol that provides communication across diverse interconnected networks Show icon in notification area when connected Notify me when this conmection has limited or no connechyity CandCNC Page 34 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN XP Internet Protocol TCP IP Properties AE The TCP IP Properties window will appear Make the following changes JOTE General ou can get IF settings assigned automatically I your network supports this capability Otherwise you need to ask your network administrator For the appropriate IF settings 4 0 Select Use the following IP Address m Q n L I m lll Obtain an IP address automatically e Use the following IP address IP address 0 9 9 1 lt Subnet mask 255 255 255 Default gateway Type in the IP address exactly as shown 10 9 9 1 Type in the Subnet mask exactly as shown 255 255 255 0 Do not assign a Default Gateway blank Use the following DNS server addresses Prefered ONS server Do not assign any DNS servers blank Alternate DNS server Do not use the Advanced button A NOTE ABOUT THE TCP IP Address and the Ether Cut The Ether Cut uses a modified version of the ESS Smooth Stepper and the manual for that product should NOT be used for this installation We have all of the settings incl
67. s below IF YOUR PLASMA HAS AN ARC OK CONNECTION POINT There will be two connection points Run a small gauge 18 24 ga pair of wires from the internal ARC OK points to the two screw terminals on the edge of the RAV 01 Card This wire carries no high voltage or current Follow the diagram on Page _ _ There is a board labeling program on some cards where the white printing is WRONG USE THE PICTURES IN THIS MANUAL to make the connection Make sure the connection is secure and that no stray wires are outside the opening of the screw terminals IF YOUR PLASMA DOES NOT HAVE AN ARC OK CONNECTION POINT Turn to the section on the DCP 01 Digital Current Probe option You will need to purchase and install this option to provide a reliable ARC OK signal to your DTHCII system CandCNC Page 68 ul J m m o 2 2 n CONNECTING to YOUR PLASMA RAV 01 Raw Arc Voltage Divider Option Finding the correct connections INSTALL The first signal you need to identify and locate is the Raw Arc Volts Raw Tip Volts This is the voltage between the Electrode and the Workclamp The Hypertherm 1000 thru 1650 series have two spade terminals j15 and J16 that are for easy connection of Raw Arc Volts On later models 45 65 85 WITHOUT the internal voltage divider the location of the Raw Arc Volts is not as obvious but they have Field Service Bulletins where they give detailed directions on finding the Raw Arc Volts Our manual covers conne
68. s in the head Confirm switch pair with an ohmmeter while operating the switch Plasma Unit power OFF Air and or tip voltage Hi Volts Workpiece Clamp Good connection to the workpiece with clamp is essential Toren Si eh NISS for proper operation of the THC HOW DTHC THC AVC DTHC WORKS Automatic Torch Height Control often called just THC works by reading the Arc Gap Voltage while cutting Plasma uses constant current cutting If the current stays constant and you vary the gap either by moving the torch or moving the material UP or DOWN then the voltage will change in proportion to the change in arc gap Much like the altimeter on a plane that measures barometric pressure to determine altitude the Arc voltage indicates the RELATIVE distance from the end tip of the nozzle to the top of the material The change in voltage for a change in height is a small percentage of the overall cutting voltage A 1 change in voltage 100 to 101 volts is equal to several thousands typically 015 or more of arc gap change so the THC must be able to see and act on a small change in a large number The THC control must take the actual cut voltage and compare it to a preset target and move the Torch Up or Down to try and correct the height based on it s arc voltage The process forms a servo loop where an error voltage from a preset is used to physically move t
69. t address and settings on Windows 7 for the Ether Cut are very simialr to those for Windows XP show in the previous pages The process of getting to the Network Connections is a little different A NOTE ABOUT USING WIN 7 with MACH3 You must use a 32 bit version of Windows 7 to run MACH3 and the Ether Cut You cannot use WIN 7 64 bit running in 32 bit emulation i mer 54 04 rf wg F z lll Select Control Panel Windows Explorer from Start Menu Mozia Thunderbird poins Select Network and f Pitre Sharing Center from the Gating started Control Panel Full Music Menu Connect to a Projector me C Al caular ae You will get a graphical Control Ponel representation of your network and installed Devices and Frnters links Default Programs On the left you will see Help and Support the Change Adapter Settings menu choice All Programs Search programs ond piles ET down P i _ i _ ma ma k Control Panel k All Control Panel Items Network and Sharing Center te k Control Panel Control Panel Home Manage wireless networks e Change adapter settings lt Change advanced sharing settings Wireless Network Connection linksys_house Intel R PRO Wireless 2200BG Net Local Area Connection Network cable unplugged af Broadcom 440x 10 100 Integrated Make sure the Local Area Connector does not show it is disabl
70. the products you have W l F J 0 l q 0 Install C3 BUS Hub and test that hub utility works and uses the hub Update the hub firmware if needed For Ethercut products follow the IP setup and testing procedures Plug all components together per diagram Use Motor Tuning section in BladeRunner AlO User Manual to setup motors Test JOG and Simple G Code MDI motion commands Use DTHCIV Setup and Config Manual section to test and calibrate the Z tuning for DTHC operation 10 Use DTHCIV to install the Connection Kit Modules and run tests to confirm operation 11 Make connections to plasma cutter 12 Run simple tests with DTHC OFF cutting metal to get baseline numbers and confirm configurations 13 Install SheetCam TNG can be same PC on Ethercut systems 14 Install SheetCam CandCNC Support file 15 Generate simple shapes files using correct post in SheetCam TNG and perform test cuts CandCNC Page 9 LIST of STEPS to SETUP DTHC IV and ETHER CUT SYSTEMS e Open MACH with either the DTHC IV or the Ether Cut profile Icon depending on which product s you have For Just DTHCIV parallel port setup skip the next step e For the Ether Cut install which includes the DTHC IV Check that the ESS plug in is working in MACH3 The Plug In Control tab top menu in MACH should have several ESS choices in the list If the Ether Cut was not working you would not see the selections in t
71. uding the IP address of the ESS card preset and tested at the factory as part of the final system tests we do on all our products The address of the ESS is 10 9 9 9 It is STRONGLY advisable that you DO NOT run this through a hub or have it ona network with other devices If you need network or wireless connectivity you need to install another device and set that up separately with its own address and settings You can run multiple Ethernet cards in the same computer For the Ether Cut setup there is NOTHING you need to change or setup other than the Ethernet port on your control PC If you cannot get the proper indications or the ping response on the tests and have done all of the CandCNC Ether Cut installation than it is most likely a PC related Hardware problem A lot of PC s Dells in particular from refurbishers or that have been used with the parallel port version may have the Ethernet disabled or the proper drivers not loaded We have found that if you load the wrong driver you may get an indication in the Device Manager the Ethernet card is OK but it still won t communicate Windows does no testing for functionality of ANY device It just confirms it is there If you cannot get your Ethernet port to function properly than you should check and see if there are driver updates for your PC and the Ethernet Card you have CandCNC Page 35 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN 7 The procedure for setting up the Ethene
72. unique non linear averaging algorithm developed specifically for Torch Height Control Typically the two settings are interactive If you increase one you may need to decrease the other or vice versa Too much DTHC Tracking will cause Z oscillation the Z will move up and down rapidly as it cuts Zero tracking is a valid setting in some circumstances When making changes to either setting does so in small increments Once you have a good setting make note write it down for both values Over time we will develop numbers for different configurations of Z mechanics and motors and make them available in a chart Slowest Velocity Default value 10 is the slowest speed in IPM that Z will travel while under DTHC control It the DIHC moves based on an error voltage this is the MINIMUM speed it can move at it moves faster the greater the error It effects the lower end of the response curve to give better response to small amounts of change Voltage Tracking Tolerance This is the voltage range that the DIHC works across from minimum to maximum velocity It is the allowable error This works in combination with the DTHC tracking value to establish the response curve of the DTHC The value is in VOLTS of error and the default 1 volt setting is appropriates for most applications CandCNC Page 49 DTHC IV MACHS CONTROL DTHC SETTINGS TAB OTHER DTHC SETTINGS Located in the Center of the DTHC SETTINGS TAB the 4 input boxes allow for chan
73. ut and parameters set for Arc OK Current and Current Tolerance Current that falls outside the parameters you have set Stop on Fault Stops motion in MACH if there is a VOLTAGE fault Raise Head on Fault Does a quick retract of the Z up to Safe Height on a VOLTAGE fault Stop on Current Fault Stops motion in MACH if there is a CURRENT FAULT Torch Off on Arc Loss This turns off the OUTPUT in MACH that fires the torch Most torches will turn off If they lose arc typically they lose arc because they have turned off but the OUTPUT will stay on in MACH DEFAULT SETTINGS All boxes unchecked off It is recommended that you leave them unchecked until you have the system setup and cutting well Only turn any one of there if there is a specific problem that needs to be fixed The cause of a the fault is more important to resolve than what happens after If you have faults while cutting there is usually a reason and it needs to be investigated and fixed CandCNC Page 511 DTHC IV HUB CSBUS CONTROL DTHC Motor Tuning This screen is INFORMATIONAL ONLY You must set the DTHC Motor Parameters in the HUB UTILITY The values shown may not be the ones your system uses 42 0 D CandCNC D IHC IV Settings Cut Settings OTHE Settings DTHE Motor Tuning x Use Hub Utility bo test and set these values The Hub Utility will mot run if MACH3 is running Close this dialog and close MA
74. ut of RESET MCclick on the TORCH icon on the screen You should see the LED above the TORCH button on MACH turn on and there will be a click in the THC Sensor PWM card and the small LED on the front labeled TORCH ON will light That indicates the TORCH ON relay is working The next check is to confirm the ARC OK circuit is working Follow the instructions for the THC SENSOR PWM section and open the back and use the ARC OK Test button The ARC OK LED on the MACHS3 Screen should light If it does you can proceed to the actual hookup of the THC SENSOR PWM Module to your plasma unit Mit any of the tests fail make sure you have the cables firmly attached and that they are the correct type All cards are checked at least twice and most three times before they leave the factory It s unusual fora THC SENSOR PWM to be bad or fail in no load testing If you have checked all of the connections cables and MACH setup and you still cannot get the THC SENSOR to work contact us at 903 364 2740 or via e mail at Tom CandCNC com NOTE Some Larger gt 100A plasma units or older smaller models use various methods to start the initial ARC Most common is HF HIgh Frequency start HF Start presents several challenges It uses the concept that higher frequency waves travel through air and arc easier than DC voltage The HF is normally combined with a higher voltage and it starts an ARC that the plasma uses to ignite the air Once the arc fires if a conductive

DTHC IV -SETUP/INSTALL MANUAL

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