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)