📄 MACH4 Configuration for THC-2 Rev.5 on C82 or C25XP Ver.2
Sign in

MACH4 Configuration for THC-2 Rev.5 on  C82 or C25XP BETA


The files on this version only work with Firmware FF5V11.

Used software: Mach4 4.2.0.5920.

https://www.machsupport.com/ftp/Mach4/DevlopmentVersions/Mach4Hobby_Installer-4.2.0.5920.exe

https://warp9td.com/files/Plugins/ESS/Mach4/ESS_Mach4_v320.zip *

Screen and Macros:

https://cnc4pc.com/attachment_file/m/4/M4_THC-2_V3.zip * 

💡

* There is no need to manually download the plugin and files if running the installer found below, as the installer will copy those into your installation.


THC-2 Rev 5.1 FIRMWARE: FF5V11 

These wiring samples for connection can be used:

1. Connection C25XP Rev.5 and THC-2 Rev.5.

2. Connection C25XP Rev.5 and PTS-1.

3. Connection C25XP Rev.5 and Plasma Floating Head.



Start by making a backup of the existing installation:

Make a backup of the configuration and file installation. We recommend creating a backup of the current installation by right-clicking in the current installation folder and zipping it. 

Before configuring the THC make sure you have wired and configured, and tested the initial probing. This could be done with the Plasma Touch Sensor or a Floating Head.


💡

Complete the configuration stages



1. Installation. 

You can choose between running an automatic installer that copies all the files and the ESS Plugin and configures Mach4, or you can copy the files and make all the configuration changes manually

  • 1.1. Bluetooth Configuration.

                            


  • 1.2 Installing files and configuring Modbus, Mach4, and the ESS Plugin.

    • 1.2.1 Automatic Installation. 

                      Download, extract, and run the installation program as shown in the video.

                      https://cnc4pc.com/attachment_file/m/4/M4_THC-2_V3.0.0.0.zip




    • 💡

      Note:

      If you choose the automatic installation option, go to 1.3—Verify Communication and Functions. The screenshots in the Manual Installation Instructions can be used to validate the configuration.


    • 1.2.2 Manual Installation.

                  Enable Modbus Plugin
                   Determine the COM assigned during the Bluetooth installation to set it in the Modbus later 
                   configuration.

Control Panel \ All Control Panel Items \ Devices and Printers

💡

Note:

The COM port assigned by Windows would need to be set in the Modbus configuration.


Configure\Control\Plugins

  •  Create a new Modbus Connection


  • Configure Modbus Communications

  • Configure Modbus Communications

  • Enabled Modbus Plugin


  • Create the Modbus Receive Functions


  • Modbus Receive Functions


  • Create Modbus Receive Functions:


  • Create Modbus Send Functions:


  • 1.3 Verify Communication and functions

Diagnostic / Modbus


2. Screen Description.

  • 2.1. SETPOINT 
    It is the target voltage to be achieved.

  

  • 2.2. ARC VOLTAGE
    Limit from 40 to 400VDC, True Voltage measured by the THC unit.


  • 2.3. V-RANGE (HY)
    It is the tolerance or (+/-) voltage range used to generate an adjustment. The torch height is not commanded to adjust if the true voltage is within the specified range.  It can be between 2 to 32VDC


  •  2.4. TEST MODE
    The test mode simulates the plasma operation and signals, allowing you to observe how the controller reacts without having to power the plasma.
  1. Select the test mode button on the screen, and the test LED will turn on, indicating the THC-2 is in test mode.
  2. Activating the DN or UP should adjust the Z-axis.  You can observe the signals received and the Z-axis adjusting accordingly.
  3. To exit test mode, Press the test mode button again.
  4. Z-axis correction will start after the DT seconds you set after the ACR OK signal is sensed. 


  • 2.5. AUTO SETPOINT
    Automatically establishes the SetPoint based on the set cutting height.


  • 2.6. THC-DELAY
    Torch motion starts the number of seconds you set as DT after the ARC signal is determined. This can be a value between 0.1 and 9.9 seconds. This allows for piercing without adjusting the Z axis and also allows the voltage to stabilize before adjusting the height.


  • 2.7. DIVIDER.
    This divider ratio matches the one set in the plasma power supply. It can be a value between 1 and 100; select decimal values (finer resolution). This can also be used to fine-tune or calibrate the voltage reading. 


  • 2.8. ANALOG SMOOTHING.
    This data smooths the voltage reading, which can be a value between 1 and 200. The analog voltage can be noisy or jumpy, so this setting will allow for a more stable reading. 


  • 2.9. ANTI-DIVE
    If the plasma torch moves over space, the THC will see it as a voltage spike and will cause the Z axis to plunge or dive looking for the plate.  Setting a max value will allow the THC to ignore the voltage spike and prevent the torch from diving.  This can be a value between 10 and 100 %.  

  • 2.10. Z_TOP
    Set Z_Top is the safe position from which rapid movements are allowed. 


  • 2.11. OFFSET_Z
    This is the offset distance between a switch's position and the material. It is used while probing and is very useful when using Floating Heads, which have a travel distance to the probing switch. 


  • 2.12. PROBING FEED RATE
    It is the speed at which probing is executed.


  • 2.13. Z MIN. HEIGHT
    Set how low you want the Z-axis to go while probing. 


3. Probing and THC.








4. Testing and Calibrating:

Testing and Troubleshooting Considerations:

  • Test wiring and Configuration using TEST MODE on the THC


Test Probing with a PTS-1 or Floating head:

  • Note that all the position values assume that work Z zero is the plate position, and we recommend setting this before executing the g-code.

  • For the initial testing, ensure the plasma machine is off, and you can observe the plasma relay activating and deactivating accordingly. 

  • Do the initial testing using the G31 Z-40 F20 command in the MDI screen, and you should be able to see the torch start probing.

  • You can observe the probe enable LED on the screen, the Enable LED on the PTS-1 unit when it starts probing, and the touch LEDs on the screen and the PTS-1 unit.


Test that the Touch Relays Start/Stop the Plasma

M62 should start the plasma, and M63 should stop it. Observe the action on the screen LEDs and the output pins of the breakout board, relay, and plasma cutter.

Test THC action:

  • Press the knob three times to enter test mode in the THC and observe the ARC OK signal activate.
  • Turn the knob up or down to move the axis and observe the Torch UP and Torch Down LEDs activate when moving in each direction.  The Z-axis should also move to adjust the position.
  • To exit test mode, press the knob once.

Test the complete sequence, which includes probing, piercing, and cutting with THC.

Configure the THC parameters according to the manual:

Run this G code that does not use macros:

N0050 F20               (Set the Probing Speed 20mm/sec)
N0060 G31 Z10       (Start probing axion on the Z-axis to a depth of up to 10mm)
N0070 G92 Z3         (Set work zero for the z axis using an offset of the switch)
N0080 G00 Z2         (move the Z-Axis 2mm up. initial pierce )
N0090 M62 P5        (Start the Torch)
N0100 G04 P2         (Set a Pause of 2 seconds to allow the pierce time.)
N0110 G00 Z3         (move the Z-Axis 3mm up. Cut height)
N0120 G01 X5         (Cut a 5mm square.)
N0130 Y5
N0140 X0
N0150 Y0
N0160 M63 P5        (Turn off the Plasma)
N0170 G0 Z5           (move the Z-Axis 5mm up. Z_top)

Feel free to adjust it to your units or other preferences.


RECOMMENDATIONS:

  • If the height adjustment is not smooth or overshoots the position, lower the % of correction speed.  If set too fast, you will see a sewing machine effect. Usually, correction does not need to be too fast if cutting through relatively flat surfaces. 

                                 

  • Make sure MACH4 is appropriately licensed, and THC does not work in DEMO Mode.

  • If you do not see action on the signals coming from the THC, try tracing them by measuring them at the output of the THC, the input of the breakout board, the LEDs of the breakout board, the Software Diagnostics, the software function, etc...  You need to understand where you are losing them.

5. Macros.

  • 5.1. Parameters Update Macros.

    Descriptions of Macro:

    These allow for adjusting the parameters on the fly via G-code.  This is useful for automating the parameters directly from the post-processor or for cutting different areas with different parameters without having to stop and manually adjust the parameters. 

    Macro 20300

    Q     – Set the Height parameter
    P - Set the Delay parameter (0 - 10)
    H - Set the V Range parameter (2 - 32)
    E - Set the Set Point (40 - 265)
    A-1 = Auto Setpoint parameter active.  
    0 = Auto Setpoint parameter disabled.

    Syntax:
    “M20300 Q2 P2 H2 E120”

    This will set the pierce height to 2mm, the delay (time before adjusting the height) to 2 seconds, and the setpoint (target voltage) to 120 volts.

    NOTE:
    Not all the parameters need to be called, just the ones you need to adjust.


  • 5.2. No Z Axis Macros.



N0090 M3          (Probes, pierces, moves to cutting position, and starts the torch)
N0100 G01 X5    (Cut a 5mm square.)
N0110 Y5
N0120 X0
N0130 Y0
N0150 M5          (Turn off the Plasma and move the Z axis to Z_Top)



6. Setting up the Post Processor.

Post for SheetCam: 

 

  • Load the postprocessor to be used: Select the "Mach4 CNC4pc THC-2 with Z and Macro M20300" postprocessor in Options/Machine.


  • Click on "Set a post-processor variable".

                                      


  • Enter the values of the variables to be used on probing: Steps 2 and 3 may need to be repeated for each variable.  these can be: switchoffset (offset of the floating head switch), zminheight  (how low the Z axis goes while probing), V_Range- set the range of setpoint, Set_Point- set the set point for the job, Auto_Setpoint - 0 disable auto set point and 1 enable auto set point,  and probingfr (Velocity at which probing will be executed).

                                  


  • Create Cut Feature:  After having entered all the variables, we proceed to do the cutting operation.