CandCNC
Page 9
MAKING CONNECTIONS TO
YOUR PLASMA CUTTER
Hooking Up Your Plasma Machine to the MP3600-DTHC IV/BladeRunnerAIO
DTHC IV LINUX
NOTE: IF you have a Hypertherm with a rear “CPC (14 pin) round connector
you can skip this section.
CAUTION: Portions of this install may include opening your plasma cutter machine and attaching wires.
MAKE SURE THE UNIT IS UNPLUGGED PRIOR TO REMOVING ANY COVER(S) OR MAKING ANY
CONNECTIONS. Plasma units have HIGH VOLTAGES 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 power disconnected from your
plasma unit.
You should determine which type install you will need for your plasma.
There are 3 questions that need to be answered:
1.) Does your plasma unit have an internal ARC OK (dry contact) signal or one on a standard CPC
connector? If not then you will need to purchase and install the Digital Current Probe Option (DCP-01).
it is available separately or as part of the Universal Connection Kit
2.) Does your plasma unit have an internal voltage divider (Automation Interface) with a ratio of 20:1 or
50:1 ? If not you will need to purchase and install the Raw Arc Volts divider card (RAV-01). It is
available separately or as part of the Universal Connection Kit
3.) Are you using a hand torch or machine torch? If using a hand torch (even with a unit that is setup for
automation, you will probably need to tap into the TORCH SWITCH wires from the hand torch to fire
the torch remotely (from the computer). There is a page on how to do that from either the RAV-01 (if
you already have it because of #2 above) or directly from the THC SENSOR PWM connector.
If you have a Plasma unit that needs the RAV-02 card you will need to install that card in your plasma
unit or have it done. See the RAV-02 card section for instructions and warnings. If you are using the
DCP-01 for ARC OK, there is an addendum at the end of this manual on installing and testing the DCP-
01.
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
ARC 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 to
ionize the air and start the plasma.
The DTHC IV 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 IV 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.
DTHCIV1-14_2
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