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CandCNC DCP-01, Setup And Installation Manual, Page: 7 / 54

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CandCNC DCP-01 Setup And Installation Manual Download Page 7

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

V

olts

VR2

Arc

OK[V]

THCSensor

J14

OK

J4

1

REV14

D21

J15

HIGH VOLTAGE

PLUG

Electrode

Switch

Tip

Torch

J1

1

J5

D6

36

39

CAUTION!

HIGH VOLTAGE

C2

-[NEG]

V

olts

D22

CAUTION!

J1

9

6

DCP

HIGH VOLTAGE

R6

CAUTION!

R8

Arc

37

38

D13

J17

C1

CandCNC

+[POS] W

orkclamp

J10

T

ORCHRELA

Y

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

Summary of Contents for DCP-01

Page 1: ...3 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 functi...

Page 2: ...ducts 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 produ...

Page 3: ...T 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 int...

Page 4: ...ill 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 sho...

Page 5: ...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...

Page 6: ...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...

Page 7: ...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 USE...

Page 8: ...ase 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 diff...

Page 9: ...vered 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...

Page 10: ...orkclamp 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 WORKCLA...

Page 11: ...lation 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 Det...

Page 12: ...r 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...

Page 13: ...ons 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 i...

Page 14: ...THISSECTIONRESERVEDFORPOWERMAX65 85HOOKUPDATA PAGE 13...

Page 15: ...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 boa...

Page 16: ...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...

Page 17: ...herm 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 rat...

Page 18: ...e 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...

Page 19: ...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 P...

Page 20: ...al 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 rotat...

Page 21: ...es loose the DCP setup section has the wire colors and hookup for the cable When you have the Workclamp lead wire threaded through the box hand tighten the outside nuts on each strain relief until it...

Page 22: ...a unit keep the DCP interface cable at least 1 away from an high voltage cables in the unit Do not cable tie the Interface cable to other cables in the box unless you know they are low voltage cables...

Page 23: ...e DB9 female plug on the front of the DTHC module at the MP3000 or the BladeRunner side panel Secure it with the remaining two 4 40 machine screws and washers 4 Uncoil the 25 ft RJ45 cable and plug on...

Page 24: ...e Stored Settings Button to preset some values for the DCP It s important that you have gone through the DTHC setup in this manual FIRST and that you have confirmed using the DTCH self test button tha...

Page 25: ...n Module Refer to your product manual to identify and access the DTHC module It is the small PCB card behind the panel on all CandCNC units where the DB9 cable from the THC Sensor plugs in In most cas...

Page 26: ...der plug for DTHC to UBOB Cable DTHC Self Test LED DB9 connector for cable to THC SENSOR CARD TORCH VOLTS Calibration Unit is calibrated at the factory DO NOT ADJUST THIS POT NO DCP Calibration POT AD...

Page 27: ...a valid arc and you do not see the Current displayed on the TORCH AMPS DRO on the MACH screen then go back through the test and calibration section If you see cut current out of range or get a Curren...

Page 28: ...etal Chassi Do Ground PC or Controllers to Earth Ground Rod Conrollers will reference themselves to power ground through their AC lines NOT Note THC Sensor Card shielded cable is not connected to any...

Page 29: ...ns and that you have attached re attached any wires mentioned in the above guidelines Replace all covers and safety devices on the plasma unit and plug the plasma unit into power with the unit switche...

Page 30: ...ial If it moves in the wrong direction STOP the move and use the CONFIG HOMING LIMITS in MACH to change the polarity of the To change it click on the symbol green check or red X and it will change to...

Page 31: ...own when you did the tests on the previous page b Mach 3 provides added THC functionality and has inputs for pierce height initial cut height etc At this point we have not tested those features so the...

Page 32: ...PAGE 30...

Page 33: ...he control fully counterclock wise and determine it if lights the ARC GOOD led on the MP3000 DTHC Screen when firing the torch against the metal doing a normal pierce If it does not light it is possib...

Page 34: ...hen it is illuminated the signal is being sent to the Mp3000 to turn on the torch Anytime the Torch is on or should be on through manual OR software activation that LED should will be on is a indicato...

Page 35: ...e activity of the DTHC The UP and DOWN LED s also function as feedback when the MP3000 DTHC Self Test is activated Please see the setup and testing section for more information The UP and DOWN signals...

Page 36: ...light and the torch will Auto Learn on every cut Pressing the button while in Continuous Mode turns the Mode OFF NOTE It is not a good idea to use the Continuous Mode on a job with mixed types of cuts...

Page 37: ...S DRO value It has the same effect as lowering the torch and decreasing the Tip Volts This button is provided in the event you enter a value directly into the PRESET VOLTS DRO and then need to update...

Page 38: ...t Profile see CUT PROFILE Functions and setup a manual cut so you position the cut gap manually above the material and make a line cut Observe the TORCH VOLTS and establish a voltage average and use t...

Page 39: ...has passed all of the self tests then setup and make a manual cut at a constant height the recommended Cut gap and watch the TORCH AMPS DRO While cutting it should be close to the value you have set...

Page 40: ...C module via a serial connection from the PC to the UBOB and up to the DTHC module The Current Values are what is in the DTHC memory Values are transferred when you hit OK NOT when they are just displ...

Page 41: ...omponents are the feedrate set in the G Code and CAM program and the Tip Volt Preset Since both values vary between machines it s best to run a series of tests Even the cut gap distance from the tip t...

Page 42: ...e from the CAM program The operator can use the Feedrate Override controls on the Program Run Screen to adjust the feedrate Memo field to remind the operator what size tip nozzle to use for cutting Ty...

Page 43: ...p Volts Study the section on Proper Plasma Cutting and understand the relationship of Preset and Actual tip volts VOLTS This is the tolerance range in which the DTHC is satisfied with the match betwee...

Page 44: ...te volts It s in Tip Volts rather than a percentage It s the highest volt reading you will allow before the fault triggers one or more of the Since a high voltage would indicate a large gap and the po...

Page 45: ...y based mainly on the specific nozzle size you are using This is how much you will allow the actual current as measured by the DCP and displayed on the TORCH AMPS DRO from the Cur Current Setting abov...

Page 46: ...d After the DTHC turns on with the automatic option you can turn if off and back on at any point in the cut If you want to run with no THC MACH ignores UP DOWN commands from the DTHC you can de select...

Page 47: ...ositive or negative since each one is relative to the previous position The THC Moves DRO reflects a register in MACH that is used to update the Z DRO At intervals along the cut the THC Moves is total...

Page 48: ...sary Make sure you have a GOOD Workclamp connection to the Material not just the table or cut grid e If the DTHC software goes into head lock Tip Saver during the test cut open the CUT PROFILE stored...

Page 49: ...djustments to the PRESET VOLTS one volt at a time using the UP arrow or DOWN arrow buttons on the DTHC screen 3 Remember that each tip nozzle size and material type thickness needs different settings...

Page 50: ...result in voltage spikes that will confuse the DTHC and cause the TIP saver to lock on or the torch to plunge Whatever the recommended pierce delay is on your chart make sure you subtract the cycle t...

Page 51: ...tuning wrong THC RATE setting in MACH too high THC Corrections Max and Min are set too low high settings tab in MACH NOTE MAX and MIN settings are in units If you are running in MM units you need to...

Page 52: ...the problem is with a connection torch switch terminals or a problem at the torch Do s and Don ts run the manual cut test and record the conditions you see including the LED indications make sure you...

Page 53: ...e 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 c...

Page 54: ...e Clamp Good connection to the workpiece with clamp is essential for proper operation of the THC RAW ARC VOLTAGE TORCH SWITCH DCP Interconnect cable DCP PLASMA UNIT DB9 to DTHC Senosr Input connector...

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