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1000 Series Plasma (Mach4) Setup Manual

 

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1 Introduction

After mounting the electrical enclosure and the MachMotion CNC control, follow the steps below to setup the MachMotion Torch Height Control.

Verify the following components:

  • Torch Height Control Enclosure
  • Torch Slide
  • Voltage Divider Board (if applicable)
  • Ohmic Box (if applicable)
  • Cables
    • Torch Slide Cable
    • Plasma Interface Cable
    • Apollo III Interface Cable
    • THC Power Cable
    • THC Ethernet

2 Mount Enclosures

Mount the Torch Height Control Enclosure to the gantry.

Mount the Torch Slide to the gantry and mount the torch to the slide.

Mount the Voltage Divider Board inside the plasma power supply (if applicable).

Figure-1-Voltage-Divider-Board.JPG

Figure 1 Voltage Divider Board

Mount the Ohmic Box on the gantry close enough to the Torch Height Control Enclosure so the Ohmic Cable can reach it (if applicable).

Figure-2-Ohmic-Box.JPG

Figure 2 Ohmic Box

3 Route Cables

Run the following cables from the electrical enclosure to the Torch Height Control Enclosure:

  • Apollo III Interface Cable
  • THC Power Cable
  • THC Ethernet Cable

Run the Torch Slide Cable from the Torch Height Control Enclosure to the Torch Slide Enclosure.

Run the Plasma Interface Cable from the Torch Height Control Enclosure to the Plasma Power Supply.

Run the Ohmic Cable from the Torch Height Control Enclosure to the Ohmic Box as shown above (if applicable).

Run the black wire from Ohmic Box to the Ohmic connector on the actual torch (if applicable).

WARNING

To avoid electrical noise, keep all the above signal cables as far away as possible from the Plasma Torch cables. The Plasma Torch cables and the signal cables should be at opposite ends of the cable trough throughout the entire machine. 

4 Wiring

4.1    Option 1: Without A MachMotion Enclosure

Without a MachMotion enclosure, you should receive the following components:

Figure-3-Without-MachMotion-Enclosure.JPG

Figure 3 Without MachMotion Enclosure

Connect the Apollo III Interface Cable into the terminals in the enclosure as shown below:

Figure-4-Apollo-III-Interface-Cable.JPG

Figure 4 Apollo III Interface Cable

Note: The blue wire GND connects to the blue 0V terminal block shown on the bottom terminal above.

Next run your own wires from these terminal blocks to the Apollo III motion controller.

Figure-5-Apollo-III-Motion-Controller-Outputs.JPG

Figure 5 Apollo III Motion Controller Outputs

Connect the THC Power Cable into the F9 fuses and the PE terminal block.

Figure-6-THC-Power-Fuse-and-Terminal-Block.JPG

Figure 6 THC Power Fuse and Terminal Block

Next run wires from F9 and the PE terminal to the machine L1, L2, and PE (earth ground).

Connect the THC Ethernet Cable into the Ethernet Switch as shown below:

 

Figure-7-THC-Ethernet-Cable.JPG

Figure 7 THC Ethernet Cable

Connect the Apollo III Ethernet Cable from the Apollo III Motion Controller into the Ethernet Switch. Make sure the Apollo III Ethernet Cable is connected into Ethernet #1 as shown below:

Figure-8-Ethernet-1-On-Apollo-III-Motion-Controller.JPG

Figure 8 Ethernet #1 on Apollo III Motion Controller

 

4.2    Option 2: With A MachMotion Enclosure

Connect the Apollo III Interface Cable into the terminals in the enclosure as shown below:

Figure-9-Apollo-III-Interface-Cable.JPG

Figure 9 Apollo III Interface Cable

Note: The blue wire GND connects to the blue 0V terminal block shown on the bottom terminal above.

Connect the THC Power Cable into the terminal blocks in the enclosure as shown below:

Figure-10-THC-Power-Cable.JPG

Figure 10 THC Power Cable

Connect the THC Ethernet Cable into the Ethernet Switch in the enclosure as shown below:

Figure-11-THC-Ethernet-Cable.JPG

Figure 11 THC Ethernet Cable

4.3    Torch Slide

4.3.1 Option 1: Torch Slide Enclosure with Ohmic

Remove the Torch Slide Enclosure cover and connect the ground terminal to machine ground. Run the wire through the grommet with the other wires. Place the cover back on the Torch Slide Enclosure.

 

 Figure-12-Ground-Lug-on-Torch-Slide-Enclosure.JPG

 

Figure 12 Ground Lug on Torch Slide Enclosure

Connect black wire coming out of the Torch Slide Enclosure to the end of the torch. This wire is used for Ohmic Height Sensing.

Figure-13-Ohmic-Height-Sensing-Black-Wire.JPG

Figure 13 Ohmic Height Sensing Black Wire

4.3.2 Option 2: Torch Slide Only

Connect the Torch Slide Cable to the slide as described below:

  • The gray M12 cable to the breakaway proxy on the slide.
  • The two other cables to the Motor Power and Motor Encoder connectors.

 Figure-14-Torch-Slide.JPG

Figure 14 Torch Slide

Figure-15-Motor-Power-and-Motor-Encoder-Cables.JPG

Figure 15 Motor Power and Motor Encoder Cables

4.4    Plasma Power Supply

Wire the Voltage Divider Board up to the plasma power supply.

WARNING! Unless you purchased a voltage divider board with your system, DO NOT connect raw voltage to your system. Severe equipment damage will occur.

Terminal Name

Function

Description

Torch Arc Volts

 

 

J36

Raw Voltage (-)

 

J37

Raw Voltage (+)

 

J35 (+)

Divided Voltage (+)

 

J35 (-)

Divided Voltage (-)

 

 

 

 

Outputs

 

 

J38

Start

Relay output

 

Hold*

Relay output

 

 

 

Inputs

 

 

J34

Arc Transfer

Dry contact input (Connect both pins together to activate output)

 

Plasma Error*

Dry contact input (Connect both pins together to activate output)

*Optional

 

 

WARNING

Do NOT connect any DC or AC voltage to the inputs on J34. Just connect the two terminals together to activate the input. It could blow out the THC. 

 

 Figure-16-Voltage-Divider-Board.JPG

 

Figure 16 Voltage Divider Board

4.5    Oxy Torches

Wire the oxy torches up to the Click PLC inside the electrical enclosure. Note all outputs are 0.3A.

vhbFigure-17-Click-PLC.JPG

Figure 17 Click PLC

Click PLC

Manual Height Control

Output Number in Mach Settings†

C3

Common Voltage (17 – 240V)

  

Y1

Oxy Enable 1*

Output 10

Y2

Oxy 1 up

Output 11

Y3

Oxy 1 down

Output 12

Y4

Oxy Enable 2*

Outpu t13

C4

Common Voltage (17 – 240V)

  

Y5

Oxy 2 up

Output 14

Y6

Oxy 2 down

Output 15
     

Click PLC Option Card 1

    

C1

Common Voltage (17 – 240V)

  

Y101

Ignition Relay*

Output 16 

Y102

Cutting Gas / Fuel

Output 18

Y103

Oxygen Ignition*

Output 17

Y104

Preheat Oxygen*

 Output 19

C2

Common Voltage (17 – 240V)

  

Y105

Cutting Oxygen 1

 Output 20

Y106

Cutting Oxygen 2*

 Output 21 

Y107

Cutting Oxygen 3*

 Output 22 

Y108

Optional Hardware Enable*

  
     

Click PLC Option Card 2*

 

  

C1

Common Voltage (17 – 240V)

  

Y201

Oxy Enable 3*

Output 23

Y202

Oxy 3 up

Output 24

Y203

Oxy 3 down

Output 25

Y204

Oxy Enable 4*

Output 26

C2

Common Voltage (17 – 240V)

  

Y205

Oxy 4 up

Output 27

Y206

Oxy 4 down

Output 28

Y207

Not Used

Output 29

Y208

Not Used

Output 30

 *Optional

†The outputs are configured in the machine configuration outputs tab for modIO interface. This should already be setup by default, but can be changed or setup as needed.

 The outputs are turned on according to the sequence shown below:

Oxy-Torch-Height-Sequence-Support-Version.jpg

 

4.6    Other Inputs / Outputs

Connect any other outputs into the blue relays in the electrical enclosure.

Apollo III

Relay Name

Function

Outputs

R2

Scribe
 

R3

Drill Up
 

R4

Drill Down

 

R5

 

 

R6

 

 

Figure-18-Relays.JPG

Figure 18 Relays

For Servo Height Control wire the Oxy I/O cable according to the following chart.

Output

Servo Height Control

Relay

Out 1

Cutting Gas Valve

11CR

Out 2

Preheat Oxygen Ignition Valve

12CR

Out 3

Preheat Oxygen Valve

13CR

Out 4

Cutting Oxygen Stage 1 Valve

14CR

Out 5

Cutting Oxygen State 2 Valve

15CR

Out 6

Cutting Oxygen State 3 Valve

16CR

Out 7

24V Ignitor ON

17CR

 

5 Calibrate Torch Height Control

5.1  Raw Voltage

If using raw volts from the torch, no calibration should be needed.

If settings were changed from the manufacturer and you need to calibrate the Torch Height Control for Raw Voltage, follow Steps 1 through 6 as defined in section 5.2 Divided Voltage with the exception of Step 4, calibrate the pot to the following:

Desired Ratio

Voltage Display

RAW

59.25

5.2    Divided Voltage

To setup the Torch Height Control to use divided voltage, follow the procedure below.

  1. Take off the cover of the Torch Height Control Enclosure. Identify the board circled below.

Figure-19-Torch-Height-Control-Enclosure.JPG

Figure 19 Torch Height Control Enclosure

  1. Locate the voltage jumpers, the red SW1 switch, and the blue pots on the boards shown above.

Voltage jumpers

SW1 Switch

Figure-20-Calibration.JPG

Figure 20 Calibration

  1. The default calibration for divided voltage is 20:1. If this is the divided voltage needed, continue with this step. Otherwise jump to the next step.
    Move the voltage jumper from X:1 to 20:1.
  2. If 20:1 is not the divided ratio needed, follow this step. Leave the voltage jumper on X:1. Move the red SW1 switch to the CAL selection. Power on the control and monitor the voltage. Adjust the X:1 pot until the voltage reads the correct value based on the table below. Call MachMotion Support for more information.

Desired Ratio

Voltage Display

10:1

50

16.67:1

83.35

20:1

100
  1. Move the SW1 switch to WORK if it isn’t already in that position.
  2. Place the cover back on the Torch Height Control Enclosure.

5.3    Ohmic Sensor Calibration

Not all systems use ohmic sensors for torch height touch off. If you have ohmic torch sensing and need to adjust the calibration, follow the procedures in this section:

  1. Remove the cover of the Ohmic Sensor Board enclosure.

Ohmic-Sensor-Calibration-Step-1.JPG

  1. Make sure that Ohmic sensor is enabled in the Neuron plugin.

Ohmic-Sensor-Calibration-Step-2.JPG

  1. Enable Mach4.
  2. Verify that ohmic cable is connected to the torch tip and that the torch tip is NOT touching
    the table.


Ohmic-Sensor-Calibration-Step-4.JPG

  1. Verify that the Ohmic Sensor Board is operational by turning the potentiometer adjustment screw clockwise until the blue ohmic LED turns on, then turn it counter-clockwise until it turns off. If the LED is already on turn the adjustment screw counter-clockwise until it turns off.  (Mach4 must be enabled for the sensor board to work)


Ohmic-Sensor-Calibration-Step-5.JPG

  1. Lower the torch until the torch tip is making contact with the table or workpiece.Ohmic-Sensor-Calibration-Step-6.JPG
  2. If the LED is on then turn the adjustment counter-clockwise until the LED goes out. Slowly turn the adjustment screw clockwise until the LED lights, then continue turning clockwise one half additional turn.
  3. Raise the torch to verify that the LED turns off. If the LED does not turn off, turn the adjustment counter-clockwise until the LED just turns off.  Verify that lowering the torch to the table turns on the LED.

NOTE:   Turn adjustment counter-clockwise if LED is not turning off.

              Turn adjustment clockwise if LED is not turning on.

6 Software Settings

THC Locking

If the torch is diving around corners, check the Head Safety Lock checkbox in the Neuron plugin under the Plasma Cutting Profile tab. 

Then lower the Level, %Vtip to change how quickly the THC will lock. A lower % will make the THC lock faster and prevent the torch from diving around a corner.

Ventilation Control

To enable ventilation control, check the Enabled checkbox in the Neuron plugin under the Plasma Cutting Profile tab. 

Ramp up is the time the torch will wait before firing for the ventilation system to start and post flow is the time it will keep the ventilation system on after the torch stops. 

The ventilation relay is a 24V output inside the Black THC box. Wire it up to VENT and GND on the connector shown below. 

 

7 Appendix

Warranty Information

MachMotion warranty policy is subject to change. Updated information is available at our website:
https://machmotion.com/warranty

 

The MachMotion Team
http://www.machmotion.com
14518 County Road 7240, Newburg, MO 65550
(573) 368-7399 • Fax (573) 341-2672

 

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