CandCNC DCP-01 Operating and safety instructions

DTHC-SETUP/INSTALL
MANUAL
CandCNC
For use with the following CandCNC products:
UBOBII Builders Kit + DTHC
UBOB III Builders Kit + DTHC
MP3000-DTHC rev B or later
BladeRunner (all versions) with DTHC option
BladeRunner AIO Dragon-Cut
DCP Digital Current Probe (11/02/2010)
DCP-01 with REV15 THC Sensor (2/23/2011)
Smart-Kut Software Upgrade (10/15/2010)
Use this manual to install and setup a DTHC Expansion
Module in the field for any of the above listed CandCNC
products OR to setup and test the DTHC functions in a
a CandCNC Product that already has the DTHC Module
installed.
REV6
JAN 25th 2011
FEB 2011
+15V -15V
TEST
CAL
ACT
CandCNC
CandCNC
DIGITAL CURRENT PROBE
Model DCP-01
CLAMP
Workclamp
Lead
Plasma
Unit
DC AMPS
20 - 125A
Includes complete setup and testing of the new CandNC
DIGITAL CURRENT PROBE

DIGITAL TORCH HEIGHT CONTROL MODULE (DTHC)
The DTHC is a plug compatible module that will plug into the UBOB Ultimate
BreakOut Board card and with the proper plug-in and profile in MACH, provide
advanced Torch Height Control (including Torch on/off). The following pages go
through the details and setup of the DTHC using the custom screens and plug-ins.
The MP3000-DTHC-UBOBIII Install file on the support CD will automatically setup
MACH3 with the plug-ins and profiles needed to get started. If you are upgrading
an existing UBOB based system (MP3000; BladeRunner; UBOB Builders Kit) to do
plasma cutting you need to verify the UBOB is a UBOB III or newer card.
The DTHC is designed to work with several of our products and it’s possible to field upgrade
those products with a DTHC module. The following pages are intended to cover the details
and setup of the DTHC. For the general setup of your product like the MP3000 you should
refer to the manual for that product. If you do not have the manual or the Support CD you
can find the PDF files on the CandCNC.com website in the section. The support
files are also there as well as on our in the section.
Some complete products from CandCNC may not have the correct version of the UBOB to
do a direct plug of the DTHC and there may not be a slot for the card in the front panel.
Please advise us if you need a new front panel with a slot for the DTHC and which product
you have. If you do not have an MP3000 or BladeRunner in the case then you can get a
special front panel aluminum plate that will mount the components inside your case and
expose the plugs for easy hookup. See our website for details.
DTHC MANUAL REV4 10/16/10
Manuals
CandCNCSupport Yahoo Forum Files
PAGE 2

Programming Headers
(For factory use only)
DB9 Socket for interface
to THC Sensor Card
Test LED
Test Button
16 PIN Header
Plug to UBOB
DC to DC
Power Converter
Units are calibrated
at the factory.
Actual card layout
may vary from the
photo.
The photo shows a top view of the DTHC module card. There are two connections to
make. The first is the 16 pin IDC cable between the DTHC and the UBOB Feature
Connector. It’s the only 16 pin header on the UBOB. Both headers are keyed so the
cable only fits one way. The other connection is to the DB9 socket from the THC
Sensor Card.
INSTALLING THE DTHC INTO AN EXISTING MP3000 or BladeRunner
PRODUCT
1. Locate the UBOB card in the unit. It is the card with the PORT1 and Serial
Port inputs. There is a 16 pin FEATURE CONNECTOR. Use the short 16 pin IDC
cable included with the DTHC and plug one end into the FEATURE CONNECTOR
2. Mount the DTHC to the Front Panel using the jackscrews on the DB9 Socket.
Remove both hex jackscrews and line up the holes for the TEST LED and the
TEST BUTTON. Replace the hex jackscrews through the front into the DB9
Socket and tighten until the board is snug against the inside of the panel. DO
NOT OVERTIGHTEN AND STRIP THE INTERNAL FASTENERS ON THE DB9!
It will make secure mounting difficult. The threads on the jackscrews are 4-40.
3. Hold the back of the DTHC Card and insert the other end of the 16 pin IDC
cable from the UBOB card FEATURE CONNECTOR Header.
4. Proceed to DTHC preliminary testing
PAGE 3

PRELIMINARY TESTING THE DTHC MODULE
Further testing requires you have MACH3 installed, the serial cable attached and the
MP3000-DHTC profile and screen set loaded. See the section on Loading DTHC DRIVERS
Below
:
If you have an MP3000 with the DTHC already installed, power up the MP3000 and using a
small probe (stiff wire, paperclip, etc push the TEST Button that is recessed behind the front
panel. Press and release one time. The yellow LED should start to flash. If it does not check
the AC cord and plug and try again. If the LED lights and flashes it indicates that the DTHC has
power and the on-board processor is working.
.
LOADING DTHC DRIVERS/PLUG-INS
The Following assumes that the auto INSTALL for the MP3000 (MP3000-Install) unit has
been done and the basic profile has been checked and the Basic screens have been tested.
If they have not, refer to the MP3000 User Manual or your Bladeruner AIO manual and perform
those steps. If you are building up a unit (UBOB or UBOB Builders Kit) you need to refer to those
manuals for the base setup. All of the plug-ins will be loaded during the base install but the DTHC
install adds addtional screens, MACH profiles and Icons to use with the DTHC. The
communication drivers need to be configured for DTHC interface. The following steps will take
you through setting up the system to use with the DTHC module.
UPDATE: Any unit shipped after 2/25/2010 has a new auto-installer that puts both the Basic
(router/mill) and the DTHC (plasma) profiles and their related screens and drivers on the PC in
MACH and does NOT need the update install. IF your desktop has both the MP3000-DTHC or
the BladeRunner Dragon-Cut shortcuts then you do not need tho do the DTHC Upgrade install
listed below. All current units being shipped have the updated auto installer. The update for
DTHC procedure is included for users that have an older MP3000, BladeRunner, or UBOB
Builders Kit and are adding a DTHC module for plasma cutting in the Field.
?
?
?
?
?
?
From the Support CD (or a web download locate the MP3000E-DTHC-UBOBIII_INSTALL file.
Run it in Windows with MACH3 NOT RUNNING. It will place two MP3000-DTHC icons on the
desktop that will Start MACH with the correct profile instead of having to use MACH Loader each
time. It will add and configure the MACH com objects (driver). The MP3000-DTHC profile in MACH
will be added along with the matching screen sets and macros.
After the MP3000-DTHC Install, open MACH3 using either the MP3000-DTHC Icon OR
Bladerunner AIO icon from the matching named profile in the MACH Loader.
If you re-install MACH or upgrade, you may need to run the Install again.
Open MACH using the MP3000-DTHC-UBOBiii or BladeRunner AIO profile (for the product you
have) and select CONFIG PLUGINS from the CONFIG menu in the top row. You will see a list of
plugins that are available At the top of the list are the two CandCNC plug-ins. Each one starts with
“ccc_”
Confirm that they are all ENABLED. If you make any changes make sure you close and restart
MACH.
Click the CONFIG (yellow) text next to the ccc_comm plugin and you will see the screen on the
following page: PAGE 4

?Use the screen to select the hardware you are using. The Ubob THC Plugin should be
selected. If you have a ESPC Power supply (part of all RouterPak and PlazPak
products) then be sure to check that as well. Note the COM port selection box. In most
circumstances that will stay on “1”.
A
A
Activate the recessed TEST Button on the front panel of the MP3000-DTHC or
your unit with the DTHC module installed and connected. The TEST LED should
start flashing.The unit goes into a test sequence where the TIP VOLTS DRO is set to
100 and the UP screen LED flashes 5 times. Then the TIP VOLTS DRO is set to
150 and the DOWN LED flashes 5 times. This test sequence repeats until you hit
the Test Button again and the TEST LED stops flashing.
If the test does not show the above results the most probable cause is the serial
communications is not working between the PC and the MP3000. Make sure you
have the right port selected. If you were sent a special serial cable with the RS232
buffer module (see photo) make sure it is installed correctly.
DYNAMIC SELF-TEST of DTHC MODULE
PAGE 5

5
Volts
RV1
R2
Tip Volts
Torch Switch
VR2
Arc OK[V]
THC Sensor
J14
OK
J4
1
TP1 TP2
TP3
TP4
D2
REV 14
D21
J15
HIGH VOLTAGE
PLUG
Electrode
+
Switch
Tip
Torch
L4
J11
J5
D6
36 39
CAUTION!
HIGH VOLTAGE
C2
- [NEG]
Volts
D22
CAUTION!
J1
96
DCP
HIGH VOLTAGE
R6
CAUTION!
J3
R8
Arc
37
R7
38
J16
D13
J17
C1
R1
CandCNC
L1
L2
+ [POS]
Workclamp
ARC OK
J10
TORCH RELAY
DB9 Cable to
Connector on DTHC
Module
TORCH SWITCH
TO ARC XFR
[OK to Move]
Relay Contacts
(DRY CONTACTS)
Spark Gap
For HV Systems
Input Jack
for
Digital Current
Probe (DCP)
NOTE: BOARD Lettering
(silkscreen) on REV14
cards is
For J11 and J10.
J10 is the Torch Switch
Wires
REVERSED
FOR CT (Current
Transformer) Input
Only. See page
information
SENSIVITY ADJUST
FOR ARC OK FROM
CT Transformer ONLY
Not used with other
ARC OK methods
TORCH
ACTIVE
ARC OK
ARC OK LED
ACTIVE ONLY
WHEN CT INPUT
is USED.
To TORCH -
(ELECTRODE WIRES)
TO TORCH POS
(WORKCLAMP WIRE)
TP1 - TP2 Test voltage:
When torch fired = approx
1/7 of Rat TIP VOLTS.
DAMGER
HIGH VOLTAGE
WHEN TORCH
is ON
THC SENSOR CARD
REV 14
NO POLARITY
NO POLARITY
Mount card at least ½”from any
Metal. Use ½”or longer standoffs
above metal case Do not let shell
of DB9 contact metal of
Plasma Case
PAGE 6

WHT
RED
YEL
BLK
J19 Located inside Cabinet on PC Board
HYPERTHERM 1000/1250/1650
Connecting THC SENSOR CARD
FOR OPERATION WITH MP1000C-THC
and MP3000 (all series)
5
RV1
Tip Volts
VR2
Arc OK[V]
THC Sensor
J14
OK
J4
1
REV 14
D21
J15
HIGH VOLTAGE
PLUG
Electrode
Switch
Tip
Torch
J11
J5
D6
36 39
CAUTION!
HIGH VOLTAGE
C2
- [NEG]
Volts
D22
CAUTION!
J1
96
DCP
HIGH VOLTAGE
R6
CAUTION!
R8
Arc
37 38
D13
J17
C1
CandCNC
+ [POS]
Workclamp
J10
TORCH RELAY
DB9 Cable to
Connector on DTHC
Module
Spark Gap
For HV Systems
TORCH
ACTIVE
ARC OK
ARC OK LED
ACTIVE ONLY
WHEN CT INPUT
is USED.
To TORCH -
(ELECTRODE WIRES)
TP1 - TP2 Test voltage:
When torch fired = approx
1/7 of Raw TIP VOLTS.
DAMGER
HIGH VOLTAGE
WHEN TORCH
is ON
START SIGNAL
ARC XFR
Connector for
OPTIONAL DCP
Digital Current Probe
J15
J16
Use 18 or 20ga insulated Hookup wire
Insulation rating to 400V Min
TIP VOLTS CONNECTION
J15 and J16 are Slide-on connectors located on the PCB
PAGE 7

5
Volts
RV1
R2
Tip Volts
Torch Switch
VR2
Arc OK[V]
THC Sensor
J14
OK
J4
1
TP1 TP2
TP3
TP4
D2
REV 14
D21
J15
HIGH VOLTAGE
Electrode
+
Switch
Tip
Torch
L4
J11
J5
D6
36 39
CAUTION!
HIGH VOLTAGE
C2
- [NEG]
Volts
D22
CAUTION!
J1
96
DCP
HIGH VOLTAGE
R6
CAUTION!
J3
R8
Arc
37
R7
J16
D13
J17
C1
R1
CandCNC
L1
L2
+ [POS]
Workclamp
ARC OK
J10
TORCH RELAY
DB9 Cable to
Connector on DTHC
Module
Spark Gap
For HV Systems
FOR CT (Current
Transformer) Input
Only. See page
information
SENSIVITY ADJUST
FOR ARC OK FROM
CT Transformer ONLY
Not used with other
ARC OK methods
TORCH
ACTIVE
ARC OK
ARC OK LED
ACTIVE ONLY
WHEN CT INPUT
is USED.
To TORCH -
(ELECTRODE WIRES)
TO TORCH POS
(WORKCLAMP WIRE)
TP1 - TP2 Test voltage:
When torch fired = approx
1/7th of Raw TIP VOLTS.
(Divide by 7 circuit)
DAMGER
HIGH VOLTAGE
WHEN TORCH
is ON
THC SENSOR CARD
REV 14
Mount card at least ½”from any
Metal. Use ½”or longer standoffs
above metal case Do not let shell
of DB9 contact metal of
Plasma Case
CONNECTIONS FOR SYSTEMS USING CT TRANSFORMER
CT Transformer is an OPTION and must be ordered separately. It is used on Plasma
Cutters that do not have an available ARC OK (Called other names by different
Plasma manufacturers). The ARC OK provides feedback to the control that a valid
pierce has been made and the arc current is at a level where motion can be released
and the cut begun. The ARC OK is used only when the control has the THC enabled
(Screen button). IT IS REQUIRED for Automated cutting with THC. All CandCNC
THC Sensor cards have had the ability to use an external Current Transformer (CT)
placed in the AC line to the plasma. The CT will only sense AC current so cannot be
used on the DC side of the plasma. A new DC Current Probe (DCP) will be
introduced in 2009 (late summer) that will read and sense the actual DC current at the
WorkClamp lead and the REV14 card has the pads for the connector that will
interface the DCP (Digital Current Probe) through the THC Sensor. To use the DCP
you will have to have a DTHC Module Rev 8 or later. You can trade in older DTHC
modules for the upgrade when you purchase a new DCP module.
PAGE 8

5
RV1
R2
Tip Volts
Torch Switch
VR2
THC Sensor
J14
J4
1
TP1 TP2
TP3
TP4
D2
REV 14
D21
J15
HIGH VOLTAGE
Electrode
+
Switch
Tip
Torch
L4
J11
J5
D6
36 39
CAUTION!
HIGH VOLTAGE
C2
- [NEG]
Volts
D22
CAUTION!
J1
96
DCP
HIGH VOLTAGE
R6
CAUTION!
J3
R8
37
R7
J16
D13
J17
C1
R1
CandCNC
L1
L2
+ [POS]
Workclamp
J10
Volts
Arc OK[V]
ARC OK
TORCH RELAY
DB9 Cable to
Connector on DTHC
Module
Spark Gap
For HV Systems
TORCH
ACTIVE
ARC OK
ARC OK LED
ACTIVE ONLY
WHEN CT INPUT
is USED.
To TORCH -
(ELECTRODE WIRES)
TO TORCH POS
(WORKCLAMP WIRE)
TP1 - TP2 Test voltage:
When torch fired = approx
1/7th of Raw TIP VOLTS.
(Divide by 7 circuit)
DAMGER
HIGH VOLTAGE
WHEN TORCH
is ON
THC SENSOR CARD
REV 14
Mount card at least ½”from any
Metal. Use ½”or longer standoffs
above metal case Do not let shell
of DB9 contact metal of
Plasma Case
CONNECTIONS FOR SYSTEMS USING DIGITAL CURRENT PROBE
Digital Current Probe is an OPTION and must be ordered
separately. It is used primarily to read and display the actual cut
current (TORCH AMPS) on the screen and to set fault trip points
and actions. The DCP can also be used as the ARC OK signal
instead of either the internal ARC OK (some plasma units) or the CT
(current transformer covered on the previous page.
You can continue to use the ARC
OK (arc xfr/OK to Move) plasma internal signals connected to J4
and J5 and either one will trigger ARC OK but the signals are
redundant. The ARC OK from the DCP can be adjusted by material
(by Cut Profile) and is more accurate than either the internal or CT
method. See the DTHC settings section on how to set the ARC OK
trip points in the DTHC Cut Profile.
For detailed instructions on how to install, setup and calibrate the
DCP with any DTHC based CandCNC product see the DCP Setup
section at page_________
IF YOU HAVE
THE DCP hooked up as shown YOU DO NOT NEED ANY
OTHER SOURCE OF ARC OK.
+15V -15V
TEST
CAL
ACT
CandCNC
CandCNC
DIGITAL CURRENT PROBE
Model DCP-01
CLAMP Workclamp
Lead
Plasma
Unit
DC AMPS
20 - 125A
1
2
3
4
5
SPECIAL NOTE:
The DCP Digital Current
PRobe can be added to
any CandCNC product
that has a DTHC
expansion module and
was shipped AFTER Jan
15th 2010. The DCP will
not work with REV 12
THC Sensor cards or with
DTHC modules before
REV9. If you have
questions about it’s use
with your unit see the
DCP Setup section to
help identify if your DTHC
can accept the new DCP.
White (if present in cable)
+9 to +12 from DTHC Module
Com (return) for 9 - 12 from DTHC
DCP PWM signal BACK to DTHC
J4
J5
PLASMA WORKCLAMP
LEAD (wire)
PLASMA WORKCLAMP
LEAD (wire)
White or shield hookup is OPTIONAL
Hookups for
DCP-01
PAGE 9

ZD3
5
Volts
RV1
C6
R2
Tip Volts
Torch Switch
VR2
ZD2
Arc OK[V]
THC Sensor
J14
OK
J4
1
TP1
TP2
TP3
TP4
D2
D1
REV 15
D21
J15
HIGH VOLTAGE
PLUG
ZD1
Electrode
Switch
Tip
Torch
L4
J11
J5
D6
-+
CAUTION!
HIGH VOLTAGE
- [NEG]
Volts
D22
C4
CAUTION!
J1
96
DCP
K1
HIGH VOLTAGE
R6
CAUTION!
++
J3
+
C5
R8
Arc
TORCH RELAY
J8
J8
R7
3
3
J16
L3
D13
J17
C1
R1
CandCNC
L1
L2
+ [POS]
Workclamp
ARC OK
J10
1
1
J2
J7
J7
2
2
TO TORCH POS
(WORKCLAMP WIRE)
+15V -15V
TEST
CAL
ACT
CandCNC
CandCNC
DIGITAL CURRENT PROBE
Model DCP-01
CLAMP Workclamp
Lead
Plasma
Unit
DC AMPS
20 - 125A
PLASMA WORKCLAMP
LEAD (wire)
PLASMA WORKCLAMP
LEAD (wire)
Hookups for
DCP-01
To RJ11 Jack
on THC SENSOR
Settings for J7 & J8 when using RJ11
Jack with DCP-01
J3 is a voltage doubler jumper ONLY used
with the CT transformer (see DTHC setup Manual)
CONNECTIONS FOR SYSTEMS USING DIGITAL CURRENT PROBE
THC SENSOR REV15 card WITH RJ11 connector on DCP-01
PAGE 9A (addendum)

HYPERTHERM PowerMAX 45
Connecting THC SENSOR CARD
FOR OPERATION WITH MP3000-DTHC
and BladeRunner Dragon-Cut seris
5
RV1
Tip Volts
VR2
Arc OK[V]
THC Sensor
J14
OK
J4
1
REV 14
D21
J15
HIGH VOLTAGE
PLUG
Electrode
Switch
Tip
Torch
J11
J5
D6
36 39
CAUTION!
HIGH VOLTAGE
C2
- [NEG]
Volts
D22
CAUTION!
J1
96
DCP
HIGH VOLTAGE
R6
CAUTION!
R8
Arc
37 38
D13
J17
C1
CandCNC
+ [POS]
Workclamp
J10
TORCH RELAY
DB9 Cable to
Connector on DTHC
Module
Spark Gap
For HV Systems
TORCH
ACTIVE
ARC OK
ARC OK LED
ACTIVE ONLY
WHEN CT INPUT
is USED.
To TORCH -
(ELECTRODE WIRES)
TP1 - TP2 Test voltage:
When torch fired = approx
1/7 of Raw TIP VOLTS.
DAMGER
HIGH VOLTAGE
WHEN TORCH
is ON
START SIGNAL
ARC XFR
Connector for
OPTIONAL DCP
Digital Current Probe
J21
J19
Use 18 or 20ga insulated Hookup wire
Insulation rating to 600V Min, Twist wires
along the length of the run.
TIP VOLTS CONNECTION
J19 and J21 are Screw connectors located on the PCB inside the
PowerMAX 45. See the location drawing next page. Detailed
instructions for making these connections are in
https://www.hypertherm.com/library/files/Manuals/Service%20Manual%
20%28SM%29/806110r0.pdf
J12 connector
located on rear
of unit.
IMPORTANT:
Do not open the case with power
on the AC line.
When making any connection inside
the PowerMAX
THERE ARE DANGEROUS
VOLTAGES present in the unit anytime it is connected
to an AC source EVEN IF IT IS TURNED OFF.
disconnect the unit from the AC
Line (unplug it).
NOTE: Hypertherm START (remote torch fire) DOES
NOT WORK with the Hand Torch. You must find the
Switch wires from the Hand torch and splice into them
to be able to fire the torch remotely. See the following
page to help identify the correct wires.
3
4
12
14
IF YOU HAVE THE DCP SEE
PRIOR PAGE FOR ARC XFR
HOOKUP
PAGE 10

Use ScotchLoc IDC Splices (RED) to tie Torch Switch output on
THC Sensor (J10) Screw Terminals. Locate Orange and Violet
wires at J10 in the PowerMAX box and tap each wire as shown.
To test short two screw terminals on J10 THC Sensor and torch
should fire (Plasma Unit on)
IMPORTANT:
Do not open the case with power
on the AC line.
When making any connection inside
the PowerMAX
THERE ARE DANGEROUS
VOLTAGES present in the unit anytime it is connected
to an AC source EVEN IF IT IS TURNED OFF.
disconnect the unit from the AC
Line (unplug it).
Connect to Screw
terminals J10 1 & 2 on
the THC Sensor Card
FROM HAND TORCH CABLE
CONNECTING HAND TORCH TO THC SENSOR CARD
PAGE 11

SIGNAL NAME(s) POWERMAX
REF
THC
SENSOR
REV14 REF
NOTES WIRE Type
TORCH SWITCH;
START - MECH
TORCH
PINS 3 & 4
J12
J10 Screw
Term 1 & 2
For use with mechanical
Torch ONLY.
18-22Ga stranded low
voltage insulated
TORCH SWITCH
HAND TORCH
ORG & VIO
wires at J10
J10 Screw
Term 1 & 2
Parallel taps where Torch
Cable Plugs into J10 in
PowerMax
18-22Ga stranded low
voltage insulated
ARC VOLTS; RAW
TIP VOLTS
J19 & J21
inside
Powermax45
J14 (neg) ,
J15 (pos)
This is NOT the 50:1
divided voltage at J12.
See detailed instructions
18-22 PVC stranded ,
insulted, twisted pair min
600V rated insulation
ARC OK ; ARC
XFR
PINS 12 & 14
J12
J4 & J5 ARC
OK Switch
Input
Dry Contact ouput from
PowerMAX (no voltage)
18-22Ga stranded low
voltage insulated
TP 19
W
-
+-
+
TP 18
R
TP 17
B
192 VDC 192 VDC
J21 (work lead)
J19 or J18
(white wire)
FRONT
To THC SENSOR CARD J14
NEG input terminal
To THC SENSOR CARD J15
POS input terminal
CAUTION: Make sure wires
and terminals do not touch
anything but the screws for
J19 and J21. HIGH
VOLTAGE IS PRESENT
WHEN TORCH IS ON.
Drawign not to scale
HYPERTHERM PowerMAX 45
Connecting THC SENSOR CARD
FOR OPERATION WITH MP3000-DTHC
and BladeRunner Dragon-Cut series
LOCATION OF J19 and J21
Inside PowerMAX 45
PAGE 12

THIS SECTION RESERVED FOR POWERMAX 65.85 HOOKUP DATA
PAGE 13

THC SENSOR CARD TESTING
and PC.
using a 25ft
DB9 Extension cable (all wires straight through).
and make
sure you can come out of RESET and that the CP (Charge Pump) LED on the front of the
UBOB/MP3000 is ON.
You should see the LED above the TORCH
button on MACH turn on and there will be a click on the THC Sensor card and one of the
small LED’s on the card will light. That indicates the TORCH ON relay is working.
The next check is to confirm the ARC OK circuit is working.
The ARC OK LED on the
MACH3 Screen should light. If it does you can proceed to the actual hookup of the THC
SENSOR card.
All of the cables we ship with any Package Deal are all
“Extension”type cables with all pins straight through.
All cards are checked at least twice and most three times before they leave the factory.
It’s unusual for a THC SENSOR 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 (>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
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 (REV10 and up) is protected from HF and most
High Voltage start circuits. The REV 14 card has been introduced to work with any units
including units that use both HF , HV and CD start.
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 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
ionize the air and start the plasma.
The DTHC 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 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.
Before you make connections to the plasma unit you may want to do some testing
on to confirm proper operation of the THC SENSOR with the DTHC Module.
Set the THC SENSOR card on an insulated surface close to the DTHC
Connect the THC SENSOR to the DB9 connector on the DTHC Module
Load MACH and the MP3000-DTHC (or BladeRunnerAIO DTHC) Profile
On some products you may have to have the Motor DC on to come out of RESET
Click on the TORCH icon on the screen.
Short across the J4 and
J5 Terminals with a small screwdriver or jumper wire.
If any of the tests fail make sure you have the cables firmly attached and that
they are the correct type.
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PAGE 14

Hooking Up Your Plasma Machine to the MP3000-
DTHC/BladeRunnerAIO DTHC
CAUTION: Portions of this install may include opening your plasma cutter
machine and attaching wires.
. Plasma
units have 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 are to be
done with the
You should decide if you want to mount the THC Sensor PCB inside your plasma unit
or in a small external box on the outside of the unit. You will need access to the DB9
connector on the THC Sensor card so if you mount the card inside, it should be
so that the DB9 is exposed. If you cut a small square in the cover or front panel
so that the connector frame wil pass through and drill two holes for the connector
mounting holes you can use the connector mounting jack screws to hold the
board in place. If you use an external box you will need to provide holes for the
signals listed in the following steps. I there is a
trigger level adjustment pot onthe front of the card (VR1) to adjust the level of current
that trips the ARC GOOD signal . Drill an access hole to be able to adjust that pot.
External connectors, hookup wire and external enclosure are not provided.
I
Normally the torch
handle wil have at least one set of small wires coming from the torch head cable
and attaching to a screw terminal post inside the box. Find the point where the
torch cable enters the box and identify any small pair(s) of wires that travel up the
torch head cable. Most machines are setup to be able to change out the entire
torch head and cable assembly and will have screw terminals (or a plug) inside to
make that operation easier. Some machines have different types of special
connectors to make changing the torch out easier so you may have to trace back
where the wires make attachment to a terminal strip or an internal card. If you
modify any wiring or circuitry be aware it may void your warranty on the plasma
machine.
MAKE SURE THE UNIT IS UNPLUGGED PRIOR
TO REMOVING ANY COVER(S) OR MAKING ANY CONNECTIONS
THC SENSOR PCB INSTALL:
f your plasma unit does not have an external activate (remote) torch
switch, you must find the torch activate switch connections.
HIGH VOLTAGES
power disconnected from your plasma unit
f you are using the CT for ARC OK,
PAGE 15

1. Most plasma units have connection terminals where wires from the torch or
panel connectors attach to the internal 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. 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 THC Sensor PCB on the other side of the chokes from
their torch head connection (end closest to the internal logic card).
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 THC Sensor 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 nearby components.
3.
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.
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.
To identity the correct pair for the Torch Switch
The THC Sensor 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.
If your plasma unit 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).
does not
PAGE 16

4. If your plasma unit does not have an “arc ok” signal jack AND you are NOT
using DCP module you will need the external CT (current transformer). D
:
A.)
B.) one hot leads
C.)
5 If you are using the CandCNC Digital Current Probe (DCP),
6. If you have a plasma unit that DOES have an Arc Good signal or you have the
DCP module
7. chassis
o the
following
Make SURE the cord to the plasma unit is disconnected from
any voltage source.
If you have room inside the unit disconnect of the AC prior or
following the Main switch and slide the wire through the center of the current sense
transformer like a finger through a donut. (for low power plasma units less than 50A
rating you may need to take more than one wrap of the single AC wire through the
center hole)
There are two connections on top of the transformer and the large power
resistor supplied needs to be connected with one lead on each
connection. In addition you need to connect a twisted pair wire between
the two connections and the terminal on the board marked “ARC
Good”(J6). No polarity. The transformer is a current transformer and
forms its voltage across the power resistor. This is an AC voltage that we
rectify and use to trip the Arc Good circuit /relay on the THC Sensor PCB
and use the isolated relay contacts to signal the parallel port and
MACH2/3. A good way to mount the current transformer inside the unit is
to use a plastic cable tie and secure it to a nearby bundle of wires or
bracket.
. you need not hook up
any ARC OK signals. The ARC OK signal is derived from the TORCH AMPS (cut
current) feedback. ARC OK trip point is set in the CUT PROFILES in MACH3. See the
section on installing and calibrating the DCP-01/02 on how to set the ARC OK trip point.
, you do not need to install the Current Transformer and power resistor.
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.
NOTE: IT is ESSENTIAL that the of the plasma unit have a good
earth ground. Refer to the suggested grounding section of the diagrams
(#####) 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!
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
PAGE 17

35 to 100A range Plasma units
Less than 35A Units
Pass one conductor from the AC line straight
through the center of the Current Transformer
Take a full wrap with one wire from
the AC line.
Wires to ARC OKAY
screw terminals on
THC Sensor Card
Wires to ARC OKAY
screw terminals on
THC Sensor Card
Provided Power Resistor
across terminals
Provided Power Resistor
across terminals
INSTALLATION OF CURRENT TRANSFORMER
Used for plasma units that do not have
Arc Good (Arc Xfer) signal or DCP
PAGE 18

Digital Current Probe Model DCP-01
DCP-01 Digital Current Probel uses the
existing THC SENSOR (rev14 or above)
and slips over the Plasma System
Workclamp lead wire to provide DC amp
feedback to the DTHC and to the MACH
screen. The following series of photos
shows the DCP being hooked up to a
plasma cutter.
Start by removing the ground clamp from
your plasma workclamp. If it has a large ring
terminal on the end where it attaches to the
clamp you will need remove the ring terminal
and replace it with a new one after you push
it through the DCP unit.
Loosen the cable strain relief/clamps on each
end of the box by twisting the retainer nut
counterclockwise viewed from the end. The
Strain relief has an internal collar that clamps
down on the wire the more it is tightened.
Straighten the wire as much as possible and
start feeding it from the right hand side.
Push the wire through gently. If it hangs try
rotating the wire and pushing but do not
force it. There is a round hole in the Hall
probe inside the box that the wire has to
pass through. It is located close to the right
side of the unit. If you have problems getting
the wire to go though pull the wire out and
remove the 4 screws holding the top and
remove the top and the PCB with the Hall
Probe (see next page). Thead the wire
though the right side strain relief and pull
enough through so you can thread the Hall
Probe on the card and then over and out of
the left side strain relief.
Right hand Strain Relief
Left hand Strain Relief
Cable passes through center of DCP-01
Clamp End
Clamp End
Plasma Unit End
Plasma Unit End
Physical install and hookup
PAGE 19