Ohmic Sensor Install-Setup Manual
Contents
1. TABLE 1 0 REV 8 w Ohmic Sensor Interface Card Table I O REV 6 8 versions Earlier versions will work as well Remove factory jumper To UBOB III Card A Home if used End view 35 ft UTP Cable 2 pin blocked TO FT 01 Ohmic Sensor module Strip wives and attach plug as Shown This connection changed from previous manual to use old touch off switch in NC mode to E Stop the system To 9 14VDC power source The 35 ft UTP cable is shipped with the 6 wide IDC connector attached and the other end of the cable unterminated The 5 pin Mini Eurostyle plug is shipped un attached to the cable so the cable is easier to thread down exiting cable routes Cut the cable to length then Strip the wires on the unterminated end and carefully wire the wire colors as shown It is important that you get the wires oriented as shown the 5 pin and jack are keyed so it only fits one way Plug it in the jack first to determine the orientation NOTE in the cable there are 8 wires but only 5 are used The White Green wire and the Brown and White Brown are NOT used TABLE 1 0 REV2. THIS SETUP PUTS THE LIMITS in the STRING INTO the E STOP circuit and they operate as part of the ESTOP and no longer just limits They will NOT be ignored durign a Homing Move End of Limit Beginning of Limit String String 8 3 2 1 654321 27 BED N W 83 286 Limit Z s String IN Switch Tip Flate 1 Take Limit string loose from Table I O card 2 Remove jumper on limit string 3 Put two ends of limit string into the LIMIT STRING terminals 4 Connect the LIMITS OUT wire white in this manual as shown to LIMITS input terminal 5 Make sure your Z switch is wired Normally Closed NC 6 See previous pages for connection to Table I O card
3. i l 4 Ohmic Retaining Cap a4 l T H2 1 l Hypertherm Part 220953 FineCut Consumables Ohmic Shield Hypertherm Part 220948 220930 Fine Cut Nozzle Normal Fine Cut uses unshielded ring Will not work with Ohmic Touch aa Torch Holder part of table structure ae 1 Insulated Barrel Retaining Cup I Ohmic Connection Tab Shield Sense Tab Mechanized Shield TIP Requires special Ohmic Consumable See your torch vendor for ordering 4 Wide Pluggable Screw terminal Touch Switch COM Touch Switch NC Common J Stranded Insulated Wire size 24 to 16ga o TERM 1 Ohmic Tab 1 Attach the Ohmic Sensor module close to the torch mount on the Z carriage Use a Velcro strip 2 BE CAREFUL of POLARITY when making the connections If the PLATE and TIP leads are connected backwards and the torch is fired possible damage to the Ohmic Sensor Module is possible Units are not repairable NOTE SOME REV1 UNITS HAD THE TERMINALS MARKED WRONG ON THE LABEL SEE THE DIAGRAM ON PAGE 1 3 The PLATE lead must be connected to metal that is part of the cutting grid where the metal to be cut is placed Most tables are electrically connected between the gantry and fable parts and the cutting grid If your table has a separate table for cutting make sure it is attached to the gantry superstructure and torch holder via a strap or you will have to extend the PLATE wire Te
4. 10 w Ohmic Sensor Interface Card REV 10 Table I O was released to production 2 15 13 O 4PANGER O 9 14VDC ta Floating cy wallplug Remove factory jumper Strip wires and l attach plug as Shown is connection changed from previous Most walpiugsupphes Rave ag Aqual to use old touch off swtich in NC the Positive lead with a stripe it is best to test the leads with ea eee a meter for and neg DC VOLTS If the leads get reversed it will not damage 35 ft UTP anything but the FT 01 will not Cable power up This change is not needed on the rev 12 2 and later cards see the Note at the bottom of the page and the next page Shown Above New Table I O REV 10 table I O card This card is a redesign The PORT 2 inputs are removed not used Jack for Ohmic Sensor is added along with the floating power input for the Ohmic Sensor Module It uses the same cable as the previous REV 8 model with the Ohmic Sensor Interface Card The normal Port 1 inputs and outputs are the same as the previous Table I O cards although thg exact position on the cards has changed The card is smaller and easier to get into tight spaces The 35 ft UTP
5. cable is shipped with the 6 wide IDC connector attached and the other end of the cable unterminated The 5 pin Mini Pluggable Termial is shipped un attached to the cable so the cable is easier to thread down exiting cable routes Cut the cable to length then Strip the wires on the unterminated end and carefully wire the wire colors as shown It is important that you get the wires oriented as shown the 5 pin and jack are keyed so it only fits one way Plug it in the jack first to determine the orientation NOTE in the cable there are 8 wires but only 5 are used The White Greg wire and the Brown and White Brown are NOT used Cut them off If you have enough length you ca use them for the wires to connect your Tlp and Material plate wires and or your old touch off switch NOTE THE REV 12 2 CARDS RELEASED 4 15 14 HAVE THE LIMITS NOW CONNECTED TO THE EPO ON THE CARD YOU DO NOT NEED TO REMOVE THE GREEN WIRE FROM THE CONNECTOR TABLE I O REV 12 w Ohmic Sensor Interface Card BY PASS OPTION SWITCH FOR E STOP C not included in FT 01 kit 9 14VDC Floating wallplug Strip wires and i 39NYA WODON th Z O attach plug as Shown Most wallplug supplies have the Positive l
6. connector TABLE 1 0 REV 12 2 wi Ohmic Sensor Interface Card BY PASS OPTION SWITCH FOR E STOP l not included in FT O11 kit You can setup a bypass switch and locate it close to O 2 the operator so you can 9 14VDC oll Laas Ma OK bring MACH out of RESET ign a E and manually jog the axis off wafplug 3 the switch to clear the condition The switch needs to be a MOMENTARY type so it won t be left on and defeat the E STOP from the R Z Safety and any LIMITS oy connected through the FT Strip wires and S act s sO Q oF attach plug as if Shown XVWAOPzwoi iM4aDNVG WODON Normally Open Momentary Switch Press to Bypass Most wallplug supplies have E STOP the Positive lead with a stripe itis best to test the leads with FROM Z Safety a meter for and neg DC VOLTS If the leads get reversed it will not damage anything but the FT 01 will not Using 250 quick connect crimp on terminals crimp the wires from both sides of the Bypass Switch around the green wire and then crimp the pair into the fresh crimp on terminal The type of switch used for the Bypass is not critical as long as it is Normally Open and closed when you push it When you release it should
7. switch into the existing limits string of NC switches 1 Using the screw access on top Remove the jumper from the LIMIT STRING INPUT 2 Remove the ends of the limit string from the limit terminals on the Table I O card and re route them to the LIMIT String Input 3 Wire your Touch off switch on the Floating Holder as Normally Closed NC by using the COM and NC terminals on the switch 4 The Touch Off switch is now in the limit string and ANY switch that is activated including the Touch off should cause MACH to go into reset You no longer need to define any LIMITS or inputs since the old limit string is now part of the E STOP EPO string OPTION TWO Use the limit string wire directly to the LIMIT input on the Table I O You can setup your LIMITS as shown in the Ports amp Pins Ports amp Pins setup screen from Ether Cut systems that have a PORT2 set of inputs to allow the LIMITS input tab on the table I O board to be used This is ONLY if you want separate LIMITS and E_STOP Engine Configuration Ports amp Pins Enabled 0 10 O O e O Ore NN WN RRA RRA RA Pins 10 13 and 15 are inputs Only these 5 pin numbers may be used on this screen Automated Setup of Inputs ox ewer FOR SETUPS THAT HAVE EXISTING SEPARATE LIMITS ON OTHER AXIS USING a NC STRING OF SWITCHES if you do not have this setup then disregard this page Note Your switch pinout may be different SEPARATE LIMIT SWITCHS Normally Closed
8. CandCNC Ohmic Sensor Feather Touch Ohmic Sensor for CandCNC BladeRunner Plazpak and MP3000 DTHC II units For REV1 amp REV2 Units FRONT SIDE NIE MANUAL RELEASE 5 rA r IN Switch Piate Tip The CandCNC FeatherTouch Ohmic Sensor Module is designed to work with all existing CandCNC plasma controls including all MP1000 THC MP3000 DTHC DTHCIl BladeRunner Dragon Cut and Plazpak systems It uses an active circuit to sense the tip of the torch touching the plate material to be cut It is totally isolated from the normal inputs to the Table I O The inputs on all CandCNC interface and BoB products have always been isolated from the PC ground to both prevent spikes and surges from harming sensitive port inputs on the PC and to reject noise that might come through sharing a dirty ground The Table I O inputs all use the same input common and it is designed to float and not be attached to a circuit that has a ground connection to the table i e switches and devices not connected to the table electrically If you allow one side of the Table I O circuit to be connected to the table side ground than the isolation is partially or completely defeated Noise from plasma cutting is exponentionally higher than from routing or milling setups and needs to be considered in any input or sensor feed to the controls The Ohmic Touch circuit is operated from it s own stand alone power source 9 to 14VDC wallplug and
9. MUST have the LIMIT STRING jumper in place on the FT 01 module of LIMIT STRING or you must have a string of Normally Closed switches connected in series into these inputs 10 The previous LIMIT switches on your system will become E STOP switches when wired in through the FT 01 If you want to keep them as LIMITS you will need to wire the two ends of the string with one end tied to any of the Table I O common TABS inside row and the other end into the old LIMITS input center terminal on the 5 pin connector You will need to setup you LIMITS as before using the X X limits input 11 It is highly recommended that you get your system moving and cutting using the Z switch wired as a touch off switch per the user manual of the controller model you are using BEFORE you add the FT 01 into the mix and start changing the E Stop connections 212 732 212 733 219 676 226 763 212 724 212 734 B Note Your ohmic sensor for your torch may be different that those shown here The objective is to have a connection to the shield at the tip of the torch and it is not connected to the body of the torch or touching the frame of the torch holder r Shield sense tab provides feedback to a compatible torch height controller before starting the cutting process Place the shield sense tab between the cup and shield Newer 45 65 85 105 consumables for Machine Torch 3 l 1 4 1 l z l
10. ead with a stripe it is best to test the leads with a meter for and neg DC VOLTS Ifthe leads get reversed it will not damage anything but the FT 01 will not power up See notes for 12 2 and later cards You can setup a bypass switch and locate it close to the operator so you can bring MACH out of RESET and manually jog the axis off the switch to clear the condition The switch needs to be a MOMENTARY type so it won t be left on and defeat the E STOP from the Z Safety and any LIMITS connected through the FT 01 Normally Open Momentary Switch Press to Bypass E STOP FROM Z Safety You will need to crimp two wires into the EPO Tab that has the green wire Cut off the crimp terminal on the Green wire and strip back the insulation on both wires and carefully warp the wire from one side of the Bypass Switch around the green wire and then crimp the pair into the fresh crimp on terminal The type of switch used for the Bypass is not critical as long as it is Normally Open and closed when you push it When you release it should return to Normally Open Most pushbutton switches are configured this way Because the circuti is NC most of the time noise on the Bypass Switch or wires has no effect NOTE This can be used on any Table I O version shown if the EPO is used for other E STOP inputs See the next page to wire the 5 wide green connector on the rev 12 2 and later versions of the card The green wire is left the
11. it s output is opto isolated so it can maintain the integrity of the noise canceling and isolated inputs of the Table I O It s sensor input is surge and voltage protected so normal plasma start and run voltages do not effect it It offers a fairly low sense impedance and filtering to prevent false triggering Here is a list of rules to follow to get good results 1 Always use the Ohmic Touch with a backup sensing system that will stop down motion if the sensor fails to work This can happen on dirty oily rusty or painted metal The Floating Torch Holder mechanical Touch off acts as both a mechanical shock absorber and a limit switch to protect the torch from damage DO NOT RUN WITHOUT A BACKUP MOTION LIMIT 2 Keep the tip of the nozzle on your torch clean and free from trash and slag If you start to have contact problems on material that is rusty or dirty keep a spray bottle of water handy and wet down the surface for better conduction 3 Be careful to observe polarity when hooking up the Inputs to the Torch Tip and Plate ground terminals A reversed connection can result in a false signal and possible damage if left connected wrong 4 The DC power terminals are marked for polarity Do NOT reverse connect a source of DC or you will damage the module If in doubt meter it out The must go in the side marked on the label 5 Make sure to go though the hookup and calibration to test the proper functions of the Ohmic touch and the back
12. llustration Measure so the remaining wires in the UTP will reach the header fo the 5 pin connector and cut them off 6 Unplug the Limits wire and strip each wire in the UTP cable so about 3 16 is exposed and insert them in the screw terminal openings in the 5 pin connector as shown It is important that the insulation is off back far enough that the exposed wires are making good contact with the metal contacts in the screw terminal but that the bare wires do not stick out far enough that they can touch each other Poor wiring on this plug is the leading cause of problems with the FT 01 not working 7 Once you have the 5 wide plug wired insert it into the header on the board as shown and reconnect the Green Limits wire over to the OUTSIDE EPO TAB closest to the edge with the other TABS tab as shown To test the EPO part of the install power everything up and take MACH out of RESET IF you cannot get MACH to come out of reset and you have an External E STOP Event error flash in the diagnostics screen than the Z safety is either not wired as Normally Closed or there is a wiring problem with the 5 wide connector Connecting up the Z Safety Switch CONT 8 To test if the EPO is still working temporarily short across the two EPO pins and make sure you can come out of RESET In systems with an ESP or ESPII power supply from CandCNC BladeRunners Plazpaks the Motor DC Power MUST be ON before you can come out of RESET 9 You
13. onnector but is connected as shown UPDATE 4 15 14 The above modification is now part of the new REV 12 2 version card and does not need to be done to get the FT O11 and the old Z switch to trigger an E stop You can disregard the instructions to remove the green wire from the connector To check the REV level of your card please see the drawing below ia CandCNC label Part name and REV Level located on top of card in the area shown white on green prinitng IPIN Connecting up the old TOUCH OFF switch Z Safety Switch 1 You should check your Z safety switch and make sure it can be wired as Normally Closed That means there is conduction between the COM and the NC terminal when the switch is not activated and it OPENS no conduction when the switch is activated Tripped Use an ohmmeter or continuity tester to check the switch THE E STOP INPUT SIGNAL IN MACH CANNOT BE CHANGED to make it work with a Normally open There are other switches in the EPO circuit in series 2 When you strip jacket off the UTP cable to expose the individual wires take off enough so you can make the green LIMIT wire about 3 to 4 inches longer than the others 3 Strip back about 1 4 of insulation off the green wire and apply a 250 Crimp on terminal to the exposed wires 4 Remove the factory supplied jumper wire across the EPO E Stop tabs on the Table I O card 5 Temporally plug the LIMITS wire to the EPO terminal as shown in the i
14. return to Normally Open Most pushbutton switches are configured this way Because the circuit is NC most of the time noise on the Bypass Switch or wires has no effect NOTE This can be used on any Table I O version shown if the EPO is used for other E STOP inputs NOTE THE REV 12 2 CARDS RELEASED 4 15 14 HAVE THE LIMITS NOW CONNECTED TO THE EPO ON THE CARD YOU DO NOT NEED TO REMOVE THE GREEN WIRE FROM THE CONNECTOR Put the green wire into position 3 center SETUP AND TESTING 1 Make the connections between the Ohmic Sensor and the Table I O card as shown on page Provide DC power to the module Modules ship with a DC wallplug power supply that should be used unless you have access to a source of FLOATING ground neg side is not tired to any other circuit See the section power hookups and options 2 Make sure the wire jumper is in place at the location indicated The jumper is applied at the factory and only should be removed if you are going to integrate the LIMIT for the touch off in with existing limits on your table see section on hooking to existing limit string 3 Use the section on hooking up the touch off switch not part of the Ohmic Touch kit on your Floating Torch Holder 4 Plug in the power to the Ohmic Sensor Confirm that the power LED Green is on If it is not unplug it immediately and locate the cause of the lack of power to the module using a DVM 5 Check the settings on your Limits input The limit inp
15. rm 2 down to the actual plate you are cutting 4 3 654321 214 A Jumper MUST be in place on installs a A A R g p that do not have a string of LIMITS a already setup See the instructions 2 IN Z fe detail p E te Tip or more details These Wires are not part of the ie ippen cable bundle and umpere M See a to use are not supplied as part of string of limits Limit String bwitch 5 o P OPa ag Existing Touch off Switch on Floating Torch Holder wire as NORMALLY CLOSED Table I O REV 6 8 versions Earlier versions will work as well O COOMOOOCOCOCOCOCO O00000W000000 or OOOCOm HOOO0OO ob p E dn 0 1318YL SNOB a NOTE The indicators ql on the Table I O card will light when the signal is active ON between the input terminal and the Common terminal across from it inner Table I O Card row It will give you Located inside visual indication that BladeRunner and the signal is getting to newer Plazpaks_ the inputs and that the Table I O is connected to the UBOB card in the controller LI OS pr C_O O El 3 QuO m AHome 0 0 3 E d Ou C0 01 BT QO ZHom QuOl Qu O
16. up limit to stop the motion 6 Do not attempt to use ohmic touch with unshielded consumables it won t work Some consumables may need special shields like the Hypertherm Fine Cut with a special Ohmic shield 7 The ohmic touch is designed for use with automated plasma cutting using controls from CandCNC We cannot support other uses or interface to outer users systems FT O1 FeatherTouch Ohmic Sensor for use with CandCNc BladerRunner Dragon Cut BladeRunner Ether Cut MPSOOO DTHCI MP3100 DTHCIV MP3500 and Plazpak REV 6 Manual 4 15 14 CandCNC Ohmic Sensor To Torch Tip Ohmic tab To PLATE Machine Frame Old Touch Switch COM Old Touch Switch NC yA ing IN Switch Rets Tip This manual contains new connection suggestions for the FT 01 based on previous manuals If you already have an FT 01 installed and working you should review this manual and determine if you should make changes to the installation IMPORTANT INFORMATION It has been brought to our attention that with the old touch off swtich wired to the table I O limits input as per the previous manuals the swtich does NOT stop motion if the Z is a homing move and the FT 01 fails to sense In this manual we have changed where the Z safety switch is connected so it now functions as an E stop rather than a limit The previous labeled LIMITS wire Green in the UTP cable is now no longer connected to the 5 wide c
17. ut is port 8 pin 11 in all most UBOB based systems new Ether Cut system is an exception At least one of the or signal usually X needs to be Enable green check if you are using it for just the touch off It has to be set different than if you are using other limits in a normally closed string THIS SECTION HAS BEEN SUPERCEDED BY USING THE Z SAFETY SWITCH AS AN E STOP THIS IS INCLUDED ONLY IF YOU WANT TO CONTINUE TO USE AN EXISTING STRING OF LIMITS WIRED DIRECTLY TO THE TABLE I O Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Signal Enabled Port Pin Nu Active Emulated Hotkey bey X 11 x 8 K 0 0 x X Home 1 Ti 0 0 1 Y 0 enabled for LIMIT INPUT to y 0 work Active Low setting detemines YHome 12 if it trips on NO or ee 0 0 x NC switch action east HI Coe 1k Go Oo c Pins 10 13 and 15 are inputs Only these 5 pin numbers may be used on this screen Automated Setup of Inputs Use this setup if you have no limits setup and are connecting the LIMITS up directly to the table i o and NOT through the FT 01 IF they are connected through the LIMITS STRING input terminals on the FT 01 they are Np longer Limits and become part of the E STOP chain What to do if you already have a string of LIMITS OPTION ONE add the Z Safety touch
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