CandCNC THC Sensor PWM Setting Up

THC SENSOR PWM MODULE

SETTING UP THE THC SENSOR PWM MODULE

IF you already have a working PWM Module with your DTHCIV
of either REV number and you are just upgrading to the DTHC IV
for CommandCNC you can skip this section of the setup

.

PWM MODULE
REV 21 and later

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This update is to cover the newer PWM rev 21, PWM Mod2 and the
soon to be released PWM II

UPDATED for PWM, newerPWM MOD2

and PWM II

10/22/17

CandCNC

Page 1

SETTING THE THC SENSOR PWM PRESCALE

DIVIDER RATIO( REV21)

THIS MUST BE DONE TO MATCH YOUR INSTALL

UNITS ARE SHIPPED TO MATCH THE RAV-01 (7:1)

RATIO. USE THE CHART BELOW IF YOU ARE USING

THE MODULE WITH A PLASMA WITH AN INTERNAL

VOLTAGE DIVIDER. SEE THE SECTION ON

CONNECTING A PLASMA WITH AN INTERNAL

VOLTAGE DIVIDER TO DETERMINE TE PROPER RATIO

To set PWM SENSOR ratio divider option:

1. Turn case over. There is a small access slot for the
Prescale Jumpers

2. Determine the proper setting for the type setup you have.

3. Set the small option jumper to match.

Prior MODEL

PWM

Shown

THC Sensor PWM REV21

For use with

Hypertherm

TD & Others

RAV-01/02

(Factory Default)

50:1
20:1

Not Used XX

Check jumper settings

to match plasma divider ratio

Remove back to access jumper

7:1

DTHC II

VOLTS

Press and release
Volts Test. Front panel

will light

settings

TEST

DTHC IV

ARC

OK

LED Test Active

Rear

Press and
Hold for
ARC OK
TEST

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Volts

Volts

SCALE

SCALE

50:1 Scale (Hypertherm and

50:1
20:1

some others) Recommended
for Hypertherm with CPC

7:1

Volts

Volts

SCALE

SCALE

50:1

50:1

20:1 Standard on some

20:1

20:1

Thermal Dynamics, others

7:1

7:1

Volts

Volts

SCALE

SCALE

50:1

30:1 Divider

20:1
30:1

(Not ON Sensor PWM)

7:1

Volts

Volts

SCALE

SCALE

7:1 Divider

50:1
20:1

(from CandCNC RAV-01

N/A

7:1

Card )

DEFAULT

CandCNC

IMPORTANT:
The Hypertherm 45 has an
internal voltage divider. It
cannot be changed from the
50:1 ratio. Set your PWM
Sensor jumper to the 50:1
position if you are using the
MIC-01 Direct Connect
Cable.

Page 2

CandCNC

Page 3

THC SENSOR PWM MODULE VOLTS

TEST/CAL

THC SENSOR PWM MODULE TEST/CAL

Front

SENSORSENSOR

PWM PWM

Digital Plasma Module

MOD 2

To DCP-01

To DCP-01

CandCNC

Torch

+5

ON

+12 PWR

Test

Active

Arc OK

Input JACK

Input JACK

Divided Volts

Divided Volts

To DTHC
Module

To DTHC
Module

Digital Plasma

TORCH

SWITCH

ARC OK

ARC OK

To Plasma

Arc OK

Module

(Transfer)

CandCNC

To Plasma

To CPC or RAV-02

Cable

THC Sensor PWM REV21

For use with

Hypertherm

TD & Others

RAV-01/02

(Factory Default)

50:1
20:1

Not Used XX

7:1

Check jumper settings

to match plasma divider ratio

DTHC II

DTHC IV

TEST

VOLTS

Press and release
Volts Test. Front panel

will light

ARC

OK

LED Test Active

Press and
Hold for
ARC OK
TEST

E

THC PWM Module (Plasma Pickup Module) can be put in TEST/CAL mode
without removing the card from the case.

 Turn the case over and look on the back. There are two recessed test buttons

find the button marked VOLTS.

 Unplug the Divided Volts (from the plasma) either the 2 pin plug or the stereo

plug. Leaving the Divided Volts plugged in will Skew the reading.

 Push and release Volts Test, this puts the unit in test/cal mode. The yellow

Test Active on the front will flash. You should see 126 to 128 volts displayed on
the TORCH VOLTS in the CommandCNC screen

 Pushing the button again will take the unit out of test/cal mode and the LED will

stop flashing and the TORCH VOLTS reading will return to Zero.

 In TEST mode the PWM signal to the DTHCIV is tested. If you unit passes the

Volts Test then the Cat5 cable and DTHCIV module are operating properly. If
the voltage is still wrong or zero when the torch fires then the cable to plasma is
bad or the voltage divider in the plasma is bad.

The test is based on a simulated PWM from the circuit so if the prescale divider

setting is wrong the calibration will show correct but when the torch is fired
the voltage will be wrong.

CandCNC

Page 4

THC SENSOR PWM MODULE VOLTS

TEST/CAL

Test

Active

THC SENSOR PWM II MODULE TEST/CAL

Front

SENSORSENSOR

PWM PWM

To DCP-01

To CPC or RAV-02

Arc OK

(Transfer)

To Plasma

Cable

IIII

Volts IN

+5

ACT

+12 PWR

TORCH

SWITCH

Torch

ON

Arc OK

Input JACK

Divided Volts

To DTHC
Module

Digital Plasma

Module

CandCNC

ARC OK

THC Sensor PWM REV21

For use with

Hypertherm

TD & Others

RAV-01/02

(Factory Default)

50:1
20:1

TD/Victor 30:1

7:1

Check jumper settings

to match plasma divider ratio

DTHC IV

DTHC V

TEST

VOLTS

Press and HOLD
Volts Test. Front panel

will flash

ARC

OK

blue LED Volts ACTive

Press and
Hold for
ARC OK
TEST

E

THC PWM II Module Rev 1.4 (Plasma Pickup Module) can be put in TEST/CAL
mode without removing the card from the case.

 Turn the case over and look on the back. There are two recessed test buttons

find the button marked VOLTS.

 Unplug the Divided Volts (from the plasma) either the 2 pin plug or the stereo

plug. Leaving the Divided Volts plugged in will Skew the reading.

 Push and hold Volts Test puts the unit in test/cal mode. The blue Volts IN ACT

LED on the front will flash. You should see 126 to 128 volts displayed on the
TORCH VOLTS in the CommandCNC screen

 Releasing the button will take the unit out of test/cal mode and the LED will stop

flashing and the TORCH VOLTS reading will return to Zero.

 In TEST mode the PWM is completely tested. If you unit passes the Volts Test

but the voltage is still wrong or zero when the torch fires then the cable to
plasma is bad or the voltage divider in the plasma is bad.

The test is based on a simulated PWM from the circuit so if the prescale divider

setting is wrong the calibration will show correct but when the torch is fired
the voltage will be wrong.

CandCNC

Page 5

THC SENSOR PWM MODULE VOLTS

TEST/CAL

Depress and Hold TEST button
to test PWM circuit back to
DTHCIV. Volts ACT LED on
front will flash and DTHC
screen in CommanCNC should
display a voltage. Calibrated
units (see DTHC calibration
section) should display 126 to
128 volts during test.

CandCNC THC SENSOR
PWM and PWMII

E

SENSOR

PWM

THC Sensor PWM REV21

For use with

Hypertherm

TD & Others

TD/Victor 30:1

RAV-01/02

(Factory Default)

Check jumper settings

to match plasma divider ratio

50:1
20:1

7:1

DTHC IV

VOLTS

Press and HOLD
Volts Test. Front panel

will flash

CHECKING ARC OK SIGNAL BACK TO DTHCIV

CARD:

1. Turn case over.
2 With RJ45 (UTP cable) connected to DTHCIV and
unit powered up, depress the ARC OK TEST
BUTTON on the card. The ARC OK LED on the
MACH screen should light. The ARC OK test LED
on the front of the case will light.

Case not shown for clearity

DTHC V

TEST

ARC

OK

blue LED Volts ACTive

Press and
Hold for
ARC OK
TEST

CandCNC

Screen may be different

Page 6

THC SENSOR PWM MODULE VOLTS

TEST/CAL

Before you make connections to the plasma unit you may want to do some testing
to confirm proper operation of the THC SENSOR PWM with the DTHC II/ IV Module.

 Connect the THC SENSOR PWM (or Sensor PWM II MODULE ) to the RJ45

(CAT5) connector on the DTHCIV Module. Be careful! Do not connect the CAT5

from the DTHCIV module to ANY OTHER RJ45 jack. It has voltages that can
damage other modules (like the USB to RS485 4 port hub or the Ethernet jack on
the controller or your PC

 Start CommandCNC using the Desktop Icon Plasma Profile and make sure you

can come out of RESET and that the CP (Charge Pump) LED on the front of the
MP3600/ BladeRunner is ON.

 On full controller products you have to have the Motor DC on to come out of

RESET.

Click on the TORCH icon on the screen. You should see the LED above the

TORCH button on CommandCNC turn on and there will be a click in the THC Sensor
PWM card and the small LED on the front labeled TORCH ON will light. That indicates
the TORCH ON relay is working.

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The next check is to confirm the ARC OK circuit is working. Follow the instructions

for the THC SENSOR PWM section and open the back and use the ARC OK Test
button. The ARC OK LED on the MACH3 Screen should light. If it does you can

proceed to the actual hookup of the THC SENSOR PWM Module to your plasma unit.

If any of the tests fail make sure you have the cables firmly attached and that

they are the correct type.

All cards are tested at least twice and most three times before they leave the factory. It’s
unusual for a THC SENSOR PWM to be bad or fail in no load testing. If you have
checked all of the connections, cables and MACH setup and you still cannot get the THC
SENSOR to work contact us at 903-364-2740 or via e-mail at [email protected]

NOTE: Some Larger (>100A) plasma units or older smaller models use various methods
to start the initial ARC. Most common is HF (High Frequency) start. HF Start presents
several challenges. It uses the concept that higher frequency waves travel through air
(and arc) easier than DC voltage. The HF is normally combined with a higher voltage and
it starts an ARC that the plasma uses to ignite the air. Once the arc fires, if a conductive
part is close, the arc will transfer to the material. The HF start causes a lot of noise and
current spikes. The other form of High Voltage start is the CD (Capacitor Discharge)
method. It is basically a high current version of an Automotive ignition 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 board. The THC Sensor PWM (REV18 and up) is protected from HF and
most High Voltage start circuits.

CandCNC

Page 7

MAKING CONNECTIONS TO

YOUR PLASMA CUTTER

1. You need the proper CandCNC Plasma Connection Kit to make the interface to
your plasma cutter.

2. Different types of plasma cutters can be used. Some have everything needed
terminated to one connector (e.g. Hypertherm 45/65/85/105/125) with rear CPC.
Others may have the same or no external connectors. We can only cover a few
specific types.

NOTE: Some plasma cutters use a manual contact start (TAP start) when the end
of the torch has to touch the metal then be retracted to start the arc. These types
of cutters WILL NOT WORK for plasma CNC cutting.

A note about HF start plasma cutters and the DTHCIV.
The DTHCIV is highly isolated from the plasma side and the noise from an HF
start plasma will not enter the controlls thought the PWM module or the
DTHCIV. Most problems from HF start are from having a common
connection to the control side (motor power supply, PC or monitor, etc)
The table and plasma chassis needs a good local earth ground (rod) close to
the table. You need to separate the Plasma cutter and its cables as far as
possible from the controls. You should NOT tie the control side to the same
ground rod as the plasma or table is connected to. The AC safety grounds
between the two systems need to connect at one common point (only) and as
physically separated as possible. In severe cases you may need to provide a
separate clean ground to the control side or even place the control equipment in
a shielded metal enclosure NOT connected to the plasma ground. Even earth
grounded wires with high currents running through them will induct some noise
into anything tied to the same ground. Just a few volts of noise on a shared
ground can disrupt the operation of some PC’s. If you fire your torch and the
PC locks up , CommandCNC stops responding, or the controller does weird
things, you need to start separating the source of the noise (the plasma cutter
and the torch leads) away from the PC control side and break any LOCAL
common connections...even grounds.

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CandCNC

Page 8

MAKING CONNECTIONS TO

YOUR PLASMA CUTTER

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.

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.

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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.

DTHCIV1-14_2

CandCNC

Page 9

SELECT PLASMA CONNECTION KIT

NOTE: IF you have a Hypertherm or Thermal Dynamcis “A”

series with a rear “CPC (14 pin) round connector you can skip

this section.

1. Most plasma units have connection terminals where wires from the torch or panel connectors
attach to the internal PC Boards. The terminals provide a convenient place to do your connections.
Use crimp-on spade or round terminals to attach the wires to the terminal strips. Make sure the new
wires you install do not touch adjacent metal objects. On some machines there may be more than
one set of small wires and are used for sensing tip shorts and other conditions. To identity the
correct pair for the Torch Switch use an ohmmeter or continuity checker across each pair while
you manually push the torch head button. When you identify the pair make note of where they
attach. Use #22 to #18 stranded wire (twisted pair) to connect between the two screw terminals on
the THC Sensor PCB marked “Torch Switch” to the two switch terminals in the plasma unit.

There is no polarity. NOTE: IF your unit has noise filter chokes from the
torch switch wires up to its internal logic card, it is recommended you place
the two wires to the RAV-02 PCB on the other side of the chokes from
their torch head connection (end closest to the internal logic card).

2. If your unit has a Raw Arc Voltage connection point (i.e. like the Hypertherm
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 RAV-02 card.
Just make sure you use wire that has insulation rated for at least 400 V.
Small signal wire like telephone wire (UTP) is not rated that high and can
arc to nearby components. The RAV-02 card is designed to take the

full tip voltage and divide and filter it. Open circuit full tip voltage can be
as high as 300VDC in some machines.

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3. If your plasma unit does not have a designated tip voltage measurement point, you will
need to locate a place inside the unit where
you can get one wire onto the WORK CLAMP lead and another on the heavy
lead(s) that connects to the torch tip (ELECTRODE).

a. Note: some machines like the Hypertherm 380 do not have a single

heavy wire to the Torch tip and instead have a set of parallel smaller
wires that all terminate into one connector. In the case of the 380 the
WHITE wires are the tip volts negative.

b. You can identify both locations by visually tracing the two leads as
they come into the box. You should find several locations/terminal strips that have connections to
these two points and you can use those for your sense wire connections. Use unshielded stranded.

c. Make a connection between the locations you have identified that tie directly to the two
leads (workclamp and torch tip) to the two “TIP Volts” terminals. Make sure that these wires are
routed where they cannot come into contact with hot or moving components. The TIP VOLTS inputs
on the RAV-02 card have a polarity. The + side is the Workclamp and the - side is the Electrode

CandCNC

Page 10

MAKING CONNECTIONS TO

YOUR PLASMA CUTTER

5. If you are using the CandCNC Digital Current Probe (DCP) with a
plasma that does not have an ARC OK signal , the DCP01 provides a

current feedback to CommandCNC and the ARC OK trip point is set and
provides a software based ARC OK

6. If you have a plasma unit that DOES have an Arc Good signal and
you have the DCP module, either signal will trip the ARC OK.

Note: The term Arc Good is interchangeable with Arc Ok , Arc Xfer and OK
to MOVE.

7. NOTE: IT IS ESSENTIAL that the chassis of the plasma table have a
good earth ground. Refer to the suggested grounding section of the
diagrams and provide for a good earth ground close to the table. A
safety ground back to a breaker panel many feet away may be a good
ground for AC frequencies (60hz) but poor for higher frequencies like
plasma noise.

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CandCNC

Page 11

USING RAW ARC VOLTAGE CARD

DISCLAIMER AND LEGAL NOTICE

The following section covers the installation of a Voltage Divider card inside the plasma unit.
There are dangerous and possibly lethal voltages present in a plasma power supply/unit.
ALWAYS UNPLUG THE UNIT FROM THE AC POWER BEFORE REMOVING ANY COVERS.
ALWAYS REPLACE ALL COVERS AND SAFETY BARRIERS BEFORE TURNING THE
POWER BACK ON.

You do any install of a card inside of your Plasma Power Unit AT YOUR OWN RISK. If you
do not wish to do the procedure either find a person qualified to do so OR contact us for
options.

CandCNC/Fourhills Designs (hereafter referred to as “CandCNC”) nor any of its
resellers or agents will be responsible for any damage to any plasma unit or the loss of
any income resulting from using any of our electronics or using our instructions written or
verbal to connect to any electronics. While we take care to provide accurate and concise
information, we will not be responsible for any damages to equipment, personnel, or
surrounding equipment, structures or land resulting from the direct or indirect use of our
products.

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The entire liability of CandCNC or any of its agents or employees is to replace or
repair products provided by CandCNC. Under no circumstances will we be liable for any
damages or loss exceeding the value of the actual products provided by us regardless if the
products are used as described and in the proper manner. All CandCNC products carry a
warranty that covers repair or replacement ONLY. Any labor, travel expense or costs to
replace a component or product outside the CandCNC factory is NOT COVERED by
warranty.

If you do not accept the terms of this notice DO NOT OPEN OR INSTALL THE
RAV-01 CARD. Return the card for a full refund and seek an alternative way to sense
the voltage.

CAUTION: Some plasma units use a very high voltage spark (Capacitor Discharge
or CD) arc starting system. While the RAV-01 card is protected from high voltage inputs
CD type systems can cause arcing in the connecting wires or to nearby components.
If you have a CD start unit and do not have experience working with high voltage systems
SEEK PROFESSIONAL HELP to do any install.

CandCNC

Page 12

CONNECTING to YOUR PLASMA

RAV-012 Raw Arc Voltage Divider Option

For Plasma Units WITHOUT Internal Voltage Divider

NOTE this card comes in most of the Connections Kits including

the UNIVERSAL CONNECTION KIT

RAV-02 Raw Arc Volts CARD

Module

E

Plexglas
Insulator
Base
(safety shield)

SHIELDED ANALOG CABLE

36” Nom

Part# SAC-01

ScotchLOC™

IDC Splices (RED)
2 pieces

RAV to THCSensorPWM Interconnect

1

PART # CCAB-31

1

36” (min)

CandCNC

Page 13

CONNECTING to YOUR PLASMA

RAV-02 Raw Arc Voltage Divider Option

Later version RAV-02

IF YOU HAVE AN INTERNAL ARC OK SIGNAL:
Connect one wire to Terminal 4 and Terminal 3
above (left two terminals)

IF YOU DO NOT HAVE AN INTERNAL ARC OK
SIGNAL: You will need to purchase a DCP-01
Digital Current Probe.

RAV-02 PREFACE: General Information

RAV-02 Raw Arc Volts CARD

IMPORTANT: When making any connection inside

Module

the Plasma Unit, disconnect the unit from the AC
Line (unplug it). Do not open the case with power
on the AC line. THERE ARE DANGEROUS
VOLTAGES present in the unit anytime it is
connected to an AC source EVEN IF IT IS
TURNED OFF.

TORCH SWITCH Terminals.
If you have a plasma unit with a Machine Torch you
will need to locate the two torch fire connection
points. in some units it is called START. IT is a
REMOTE Fire set of wires.

IF YOU HAVE A HAND TORCH you will need to
identify the two Torch Switch wires that come from
the Hand torch and

E

The RAV-02 can be used several ways so it can get confusing about making the connections.
The primary use of the RAV-02 is to take Raw Arc Volts (undivided volts and divide it by a
precise ratio so it can be used by the THC SENSOR PWM module to generate a digital signal
to send volts data to the DTHCII Digital Torch Height Module. In some circumstances that is all
that you will use the card for. Examples are on the Hypertherm 1000/1250/1650 series and the
Older Thermal Dynamics “A” series. Both types have a rear CPC connector (14 pin) that has
the Torch Fire and ARC OK signals available and are used with the CandCNC MIC-02 interface
cable so ONLY the Shielded Analog Cable (SAC-01) is used between the RAV-01 and THC
SENSOR PWM.

On other types of Plasma cutters that have no external connectors for ANY of the required
signals the RAV-01 can become a connection board for accessing those signals internally and
passing them to the THC SENSOR PWM Module via the CCAS-01 4 wire cable. The following
pages will cover how to first use the RAV-02 as a voltage divider card in a unit that does not
have an integrated voltage divider. If you have a plasma unit with no external connectors than
the next section shows how to use the RAV-02 to fire the torch from the software. Finally if
your plasma has an internal access to the Torch fire for a mechanical torch and an internal ARC
OK (OK to MOVE). REMEMBER: the RAV-02 is just a pass-through (place to make
connections) for ARC OK and TORCH FIRE. It does not sense or provide those signals.

There are added pages on some Plasma Cutters and how to connect them; sometimes there is
more than one way. If there is a way to access the proper signals externally than that method
with a cable is recommended. In each case the objective is to get the signals in and out of the
THC SENSOR PWM Module.

CandCNC

Page 14

CONNECTING to YOUR PLASMA

RAV-01 Raw Arc Voltage Divider Option

RAV-02 Mounted inside Plasma UNIT.

CandCNC RAW ARC VOLTS Voltage divider card

Later version RAV-02

E

Plexiglas

Safety

Shield

Module

1

RJ45 (Cat5) cable to

DTHCII Module

To CPC or RAV-01

Note: Same wire colors
are used on the PWM II

THC SENSOR PWM MODULE
Mounted outside plasma unit

+12 PWR

Arc OK

To DCP-01

ARC OK

SWITCH

TORCH

(Transfer)

Arc OK

To Plasma

Cable

To DTHC

Module

Digital Plasma Module

SENSORSENSOR

PWM PWM

CandCNC

+5

Torch

ON

Active

Test

Divided Volts

Input JACK

Front

Divided volts from
CandCNC Raw Arc
Volts card

Connections for PWM II MODULE are the SAME

CandCNC

Page 15

CONNECTING to YOUR PLASMA

RAV-02 Raw Arc Voltage Divider Option

For Plasma Units that have NO external connector for the required
signals OR do not have an internal voltage divider.

Mounting the RAV-02 Card inside your Plasma Cutter:
Do any mounting or modification with the
Power cord DISCONNECTED to the plasma unit

The mounting location for the card will vary from one type/brand of plasma
unit to another. Pick a location and mount the RAV-01 using the Plexiglass shield
using small self tapping screws (not furnished) or adhesive Velcro strips. Mount
the card at least 1 inch away on all sides from any internal cards, terminals or bare
wires. The standoffs of the card are insulated and so the card can be mounted
with the plexiglass shield against the chassis. There is high voltage present when
the torch fires at the end of the card where the RAW ARC VOLTS (tip Volts) is connected.
Keep that end of the card away from ANY conductive object closer than 2 inches.

Once you have the RAV-01 Card mounted in a safe location you will need
to make provisions to connect the two low voltage cables (CCAB-31 and SAC-01).
You need to provide holes on the rear or side of the unit (BE CAREFUL DRILLING
METAL IN YOUR UNIT. TINY SHAVINGS CAN FALL ON PARTS THAT COULD
SHORT.) Ream the holes smooth or drill them oversized and use a rubber
grommet to protect the wires. Clean up with a magnet or blow the cabinet out
with air. One hole needs to be able to pass the diameter of the SAC-01 Plug. The
other needs to pass the diameter of the cable for the CCAB-31. NOTE: The
4 wide plug on the CCAB-31 cable is removable. You will need to remove the
end that passes into the enclosure to fish the wire through for the RAV-01 Connection.
BE SURE TO FOLLOW THE COLOR CODE TO REATTACH THE CONNECTOR.
THE COLORS ON BOTH ENDS WILL GO ONTO THE SAME TERMINAL/PIN
NUMBER. Connect the two cables where the diagram shows to the RAV-01 Card.

E

Making the connections

A WORD ABOUT ARC OK SIGNALS: “ARC OK” is our terminology of a signal coming back

from the plasma unit that signals the unit has fired the torch and has a valid arc. Most plasma
units made for manual cutting DO NOT HAVE an ARC OK (also known as ARC XFR;
TRANSFER; OK to MOVE and other similar terms). It is a circuit that closes (relay contacts or
sometimes called “dry contacts”) on a valid arc. Units that do have the signal will have it
labeled, on a connector or covered in their manual. IF YOU HAVE DOUBTS, assume the unit
does NOT have ARC OK and follow the guidelines below.

IF YOUR PLASMA HAS AN ARC OK CONNECTION POINT: There will be two connection points.
Run a small gauge (18-24 ga) pair of wires from the internal ARC OK points to the two screw
terminals on the edge of the RAV-01 Card. This wire carries no high voltage or current. Follow the
diagram on Page ____. There is a board labeling program on some cards where the white printing
is WRONG! USE THE PICTURES IN THIS MANUAL to make the connection. Make sure the
connection is secure and that no stray wires are outside the opening of the screw terminals.

IF YOUR PLASMA DOES NOT HAVE AN ARC OK CONNECTION POINT: Turn to the section on
the DCP-01 Digital Current Probe option. You will need to purchase and install this option to
provide a reliable ARC OK signal to your DTHCII system.

CandCNC

Page 16

CONNECTING to YOUR PLASMA

RAV-01 Raw Arc Voltage Divider Option

Finding the correct connections.

The first signal you need to identify and locate is the Raw Arc Volts (Raw Tip Volts). This is
the voltage between the Electrode and the Workclamp. The Hypertherm 1000 thru 1650
series have two spade terminals (J15 and J16) that are for easy connection of Raw Arc Volts.
On later models (45/65/85/105/125) WITHOUT the internal voltage divider, the location of the
Raw Arc Volts is not as obvious but they have Field Service Bulletins where they give detailed
directions on finding the Raw Arc Volts. Our manual covers connection to the PowerMax
1000, 1250 and 1650 as well as the PowerMax 45 and PowerMax 65/85/105 with the optional
CPC connector.

https://www.hypertherm.com/Xnet/library.jsp/null is a search page where you can enter your

model number and then search the FSBs. The files are in PDF format.

For other brands of plasma units or a model not designed to be automated the search for
connection points may be a little more difficult but not impossible. The key is the leads going
to the torch cable. On most plasma units you can locate these signals by opening the unit
(POWER DISCONNECTED!) and visually tracing the wires coming from the plasma torch.
The Workclamp will be connected to a stud or terminal inside and is pretty easy to identify. It
is the POSITIVE (+) side of the circuit. The Electrode side goes up the plasma cable to the
torch head. It will be one heavy wire or a series of smaller gauge (12ga or larger) stranded
wires of the same color and they will all connect to the same electrical spot (bus) inside the
plasma. In a lot of units these wires are all solid WHITE in color but do not use color as your
clue. Some plasma manufacturers provide block level schematics in their use or service
manual that give wire colors (and in some cases terminal numbers and locations).

E

WHEN YOU HAVE LOCATED THE WORKCLAMP AND ELECTRODE WIRES IN THE UNIT:

Using a two conductor wire (18-22 ga) [not supplied] with insulation rated to 400V or more
crimp on two ring or fork terminals. USE WIRES OF TWO DIFFERENT COLORS and long
enough to reach the RAV-02 Card using an indirect route (give yourself extra wire). Run the
first color wire (red or the brightest color) to where the WORKCLAMP attaches. Normally that
will be a heavy bus bar with other smaller wires attached. If it is a single large stud you will
need a ring terminal that will fit over the stud. That will be your positive (+) wire.

Use the other wire color and run a connection using a ring or fork terminal to where the
ELECTRODE wires attach.

Carefully route both wires from their connection points over to where they will attach at spade
inputs on the edge of the RAV-01 Card. Keep the wires away from other high voltage wires or
components on the circuit board. Use nylon wire ties to secure the wires to other wire bundles
or to the chassis. DO NOT WIRE TIE THEM TO COMPONENTS ON THE PC BOARDS. DO
NOT USE LOW VOLTAGE WIRES LIKE THOSE USED FOR WIRING PHONES OF
NETWORKS.

DTHCIV1-14_2

CandCNC

Page 17

USING THE RAV-01 TO FIRE THE TORCH

(for plasam units with no external connector

to fire the torch or with a hand torch)

The next internal signal you need to locate is the TORCH SWITCH. If you are connecting
to a unit with a Hand Torch you will need to find and tap into the two wires coming from the
torch switch in the hand piece. How will you know? First the wires will be smaller and
different colors than the ELECTRODE or PILOT ARC (more about that later) wires. In most
cases there will be four smaller wires. Two will be the torch switch and two will be the PIP
or CIP (Consummables-In-Place) wires. Once again the manufacturers documents can be
of service here identifying colors and even connection points. If you do not have the
manufacturers service information with schematics and cannot find them on-line you will
need to do a little detective work to identify the torch switch wired.

The first thing your should do is get an Ohmmeter, and with it set to low ohms, short the
leads together and make sure the meter shows the change and displays low (close to zero)
ohms. If your meter has a “squaker” continuity tester position then use that as a tone
indication. Clip across two of the four smaller wires. If you get no reading or tone (or an
OV or OL indication) the circuit is open. Activate the torch switch on the hand piece and if
the reading goes to a low value of ohms (<100) or the tone sounds, it is the switch
contacts. Confirm the reading by pushing the torch switch several times. Keep testing
wires until you find the pair that changes the meter. Note the colors. Use your meter to
test the other wires. You may well find a pair that causes the meter to go to low ohms as
soon as you touch them, but working the torch switch WILL NOT change the meter. Those
are NOT the torch switch pair. Once you have identified the Torch Switch pair study the
diagram on page ____ and using the two ScotchLOC connectors slide one over each of
the two wires connect them to the Torch Switch pair.

E

That concludes the internal connections you will have to make for your unit.
Make sure all leads are insulated and away from possible physical damage.
Double check to make sure there are no loose connections 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 switched off. Turn the unit on, and make sure the
unit works correctly in manual mode. (i.e. cut a piece of metal by hand). If you
have a machine torch manually fire the torch from the Torch On button in MACH3

CandCNC

Page 18

USING THE RAV-01 TO FIRE THE TORCH

(for plasam units with no external connector

to fire the torch or with a hand torch)

NOTE : Some models of plasma cutters that have a CNC connector (CPC
connector) have a safety lockout to prevent firing the hand torch remotely. The
listed connection will fire the torch the same as pulling the trigger. Both the
trigger and the software can fire the torch. There may be a way to bypass the
lock-out and use the CPC connector to fire the torch. Contact us via e-mail for
other possible solutions on plasma cutters that have a CPC connector.

Use ScotchLoc IDC Splices (RED) to tie Torch Switch output on THC Sensor
(J10) Screw Terminals. Locate Orange and Violet wires at J10 in the
PowerMAX box and tap each wire as shown. To test short two screw
terminals on J10 THC Sensor and torch should fire (Plasma Unit on)

CONNECTING HAND TORCH TO THC SENSOR CARD

E

Connect to Screw
terminals J10 1 & 2 on
the THC Sensor Card

IMPORTANT: When making any connection inside

the Plasma Unit, disconnect the unit from the AC
Line (unplug it). Do not open the case with power

on the AC line. THERE ARE DANGEROUS

VOLTAGES present in the unit anytime it is connected
to an AC source EVEN IF IT IS TURNED OFF.

Wire colors will vary
by brand

FROM HAND TORCH CABLE

CandCNC

CandCNC

Page 19

USING THE RAV-01 TO FIRE THE TORCH

(for plasam units with no external connector

to fire the torch or with a hand torch)

NOTE the RAV-01 Card has been updated and designated the RAV-02. Its functions and
connections remain the same but some locations for connectiosn have been moved. Any
reference to the RAV-01 on new systems should be replaced with the RAV-02

RAV-01 Raw Arc Volts CARD

CONNECTION (+)

TO WORKCLAMP

TO ELECTRODE

CONNECTION (-)

CAUTION: High Voltages Present
When TORCH is ON.

CAUTION: High Voltages Present
When TORCH is ON.

J15

Tip

Volts

Workclamp

+ [POS]

CAUTION!

- [NEG]
Tip
Electrode

J14

HIGH VOLTAGE

WHEN TORCH is ON

Volts

D13

CAUTION!

HIGH VOLTAGE

CAUTION!

R1

HIGH VOLTAGE

C1

REV 18

THC

CandCNC

L2

R6

PICKUP

PLASMA

4

ARC
OK

Volts

1

1

SW1

MANUAL

SW3

1

1

Local Connections

3

ARC OK

Out

VOUT

TORCH FIRE

FIRES

CAUTION

2

TORCH SWITCH

TORCH

SWITCH

TORCH

Volts

Divided

+

Divided

-

TP1

+

+

-

TP2

-

SW2

ARC OK

1

TORCH SWITCH

1

Module

Volts

to Torch Sensor PWM

SAC-01 Shieilded Cable

J5

1

1

TO THC SENSOR PWM

TO THC SENSOR PWM

MODULE use CCAB-31

PART # CCAB-31

E

1

Torch Fire wires
see previous page for
connecting to Hand torch
models without CPC
connectors

Electrode (-)

WORK clamp (+)

The RAV-01 card has been
redesigned but the connection points
are the same and similar in location.

Later version RAV-02

Torch

ARC OK

Switch

PAIR

Pair

Divided Volts OUT
to PWM Module

3.5mm stereo plug

1

CandCNC

PART # CCAB-31

1

Page 20

Connection to THC SENSOR PWM

Module

USING THE RAV-01 TO FIRE THE TORCH

(for plasam units with no external connector

to fire the torch or with a hand torch)

RAV-02 Raw Arc Volts CARD

Later version RAV-02

RAV-02

CONNECTING TO HAND TORCH SWTICH
WIRES FROM RAV-01

E

SWITCH WIRES FROM
PLASMA HAND PIECE

RJ45 (Cat5) cable to

DTHCIV Module

Use the same two wires on the 4 pin connector for
the PWM Module REV 21

ALTERNATE METHOD TO FIRE HAND TORCH IF NOT

USING RAV-01 CARD

Digital Plasma Module

To DCP-01

SENSORSENSOR

PWM PWM

CandCNC

To DTHC

Module

+5

ON

Active

Torch

Test

Divided Volts

Input JACK

+12 PWR

Arc OK

1

ARC OK

SWITCH

TORCH

(Transfer)

Arc OK

To Plasma

Cable

Volts card

CandCNC

CandCNC

Page 21

HYPERTHERM 1000/1250/1650

Connecting THC SENSOR PWM CARD

J15

J16

This is for units with a hand torch that do not have the rear CPC connector

TIP VOLTS CONNECTION

J15 and J16 are Slide-on connectors located on the PCB

+

-

Use 18 or 20ga insulated hookup wire
insulation rating to 400V minimum.

F

J19 Located inside Cabinet on PC Board

YEL

BLK

RED

WHT

ARC XFR

START SIGNAL

1

PART # CCAB-31

To PWM Module

Connect to THC SENSOR PWM VIA
CAB-31 Cable

internal
connections

RAV-02

To TORCH ­(ELECTRODE WIRES)

Arc OK

Torch

Fire

1

Arc OK

Torch

Fire

(THC SENSOR Rev17)

RAV-02 Version

DANGER
HIGH VOLTAGE
WHEN TORCH
is ON

V

MO

R3

Test

Test

Volts Cal

Arc OK

Torch Fire

DIVIDED

VOLTS OUT

Apprx 7:1

Stereo cable to PWM module

To PWM

CandCNC

Page: 75

Page 22

HYPERTHERM 1000/1250/1650 and Thermal Dynamics units

with rear CPC connector and no Arc Voltage Divider

Raw arc volts connection points
vary from one model to another.
Refer to manufacturers manuals
for locations.

+

-

Use 18 or 20ga insulated hookup wire.
Insulation rating to 400V minimum.

OPTIONAL RAV-02
MOUNTED INSIDE PLASMA

CONNECTION (+)

TO WORKCLAMP

TO ELECTRODE

CONNECTION (-)

CAUTION: High Voltages Present
When TORCH is ON.

CAUTION: High Voltages Present
When TORCH is ON.

J15

Tip

Volts

Workclamp

+ [POS]

CAUTION!

- [NEG]
Tip
Electrode

J14

HIGH VOLTAGE

WHEN TORCH is ON

Volts

D13

R1

CAUTION!

C1

HIGH VOLTAGE

REV 18

CAUTION!

HIGH VOLTAGE

CandCNC

THC

PLASMA

L2

MANUAL

R6

PICKUP

4

ARC OK

ARC
OK

Volts

Out

1

1

VOUT

SW1

TORCH FIRE

SW3

1

1

CAUTION

Local Connections

3

TORCH SWITCH

TORCH

SWITCH

FIRES

2

TORCH

F

Volts

Divided

+

Divided

TP1

+

+

-

TP2

-

SW2

ARC OK

1

TORCH SWITCH

1

Volts

-

to Torch Sensor PWM

SAC-01 Shieilded Cable

J5

1

TO THC SENSOR PWM

TO THC SENSOR PWM

MODULE use CCAB-31

Module

Route shielded cable
through rear bulkhead

TO CPC CONNECTOR ON REAR

OF PLASMA

MIC-02

For units with CPC but NO
Internal Voltage Divider

RJ45 (Cat5) cable to

DTHCII Module

METHOD TO CONNECT TO UNIT
WITH MACHINE TORCH USING
REAR CPC CONNECTOR FOR
TORCH FIRING AND ARC OK

Digital Plasma Module

To DCP-01

SENSORSENSOR

PWM PWM

CandCNC

+5

Torch

ON

Active

Test

ARC OK

SWITCH

TORCH

(Transfer)

Arc OK

1

To Plasma

Cable

To DTHC

Module

Divided Volts

Input JACK

Divided volts from
CandCNC Raw Arc
Volts card

CandCNC

Page 23

HYPERTHERM 1000/1250/1650 and Thermal Dynamics units

with rear CPC connector and no Arc Voltage Divider

Raw arc volts connection points
vary from one model to another.
Refer to manufacturers manuals
for locations.

+

-

Use 18 or 20ga insulated hookup wire.
Insulation rating to 400V minimum.

OPTIONAL RAV-02
MOUNTED INSIDE PLASMA

CONNECTION (+)

TO WORKCLAMP

TO ELECTRODE

CONNECTION (-)

CAUTION: High Voltages Present
When TORCH is ON.

CAUTION: High Voltages Present
When TORCH is ON.

J15

Tip

Volts

Workclamp

+ [POS]

CAUTION!

- [NEG]
Tip
Electrode

J14

HIGH VOLTAGE

WHEN TORCH is ON

Volts

D13

R1

CAUTION!

C1

HIGH VOLTAGE

REV 18

CAUTION!

HIGH VOLTAGE

CandCNC

THC

PLASMA

L2

MANUAL

R6

PICKUP

4

ARC OK

ARC
OK

Volts

Out

1

1

VOUT

SW1

TORCH FIRE

SW3

1

1

CAUTION

Local Connections

3

TORCH SWITCH

TORCH

SWITCH

FIRES

2

TORCH

F

Volts

Divided

+

Divided

TP1

+

+

-

TP2

-

SW2

ARC OK

1

TORCH SWITCH

1

Volts

-

to Torch Sensor PWM

SAC-01 Shieilded Cable

J5

1

TO THC SENSOR PWM

TO THC SENSOR PWM

MODULE use CCAB-31

Module

Route shielded cable
through rear bulkhead

+12 PWR

Arc OK

To DCP-01

ARC OK

Digital Plasma

Module

CandCNC

To DTHC

Module

+5

ACT

ON

Volts IN

Torch

SENSORSENSOR

PWM PWM

IIII

(Transfer)

To Plasma

Cable

SWITCH

Divided Volts

Input JACK

Arc OK

TORCH

METHOD TO CONNECT TO UNIT
WITH MACHINE TORCH USING
REAR CPC CONNECTOR FOR
TORCH FIRING AND ARC OK

TO CPC CONNECTOR ON REAR

OF PLASMA

MIC-02

For units with CPC but NO

Front

Internal Voltage Divider

T

o CPC or RAV-02

1

CandCNC

Divided volts from
CandCNC Raw Arc
Volts card

Page 24