Plasma THC Mach4

 

__Use__MachMotion_Logo_HiRes_TransBG-update-01-450.png

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