Mach3 and ESS Plugin Configuration for THC on 
C82 or C25XP

Used software:
Mach3 Version 3.043.062 with Win 10 Fix

Mach3  ESS Plugin v180220 u4f1L

Used hardware:
C25XPR1 and ESS V4.0.

This configuration shows how to configure a standard Mach3 Plasma profile.

STEP 1: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. 


STEP 2: Configure Mach3 and ESS Plugin according to the screenshots below or download and install this XML.


Make sure that you assign the pins that you have wired for each function.





STEP 3: Under Plugin Control Configure the Ethernet Smooth Stepper Plugin:


STEP 4: Download the Screen and paste.

Download the compressed file containing the macros and screen that work with the macros:  

You will need to install the screen found in the download folder and place the macro in the macros directory for the profile folder.




View/Load Screen: 

STEP 5: Configurations Screen


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 to 9.9 seconds.




Set the height.



Set the Cut height.


Set the OFF SET_Z of the switch of a floating head as a probe when using a probe signal to determine the material position.

Z Top
Set the safety height, the Z axis will move to this height with the M2015 macro for ending the cut.

Probing FR

Set the velocity/FeedRate at which the probing is executed.

Z Min Height

Set the travel height when probing.


STEP 6: Macros: 

M03: Probes, does the initial pierce, and sets the head at the cutting height:

  • Run G31 Z “Z min. height” F “Probing FR”
  • Move the Z Offset Z and set Z0
  • Move the Z Height
  • Torch on
  • Wait for Pierce_Delay
  • Move the Z Cut_Height
  • Activate THC


M05: Ends cutting.

  • Torch Off
  • Deactivate THC
  • Move Z to Z_Top


M62: Start Cutting.

  • Torch On

M63: Ends Cutting.

  • Torch Off

STEP 7: Test the Wiring and Configuration: 



  • 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.



  • If the height adjustment is not smooth or overshoots the position, lower the % of correction speed.

  • Make sure MACH3 is properly licensed, and THC does not work on 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.



STEP 8: Post for SheetCam: 


  • 8.1 Mach3 CNC4pc plasma no Z CNC4pc plasma no Z

This post-processor works with all the data on the screen and uses the M3 and M5 macros.


  • 8.2 Mach3 CNC4pc plasma with Z CNC4pc plasma with Z

This post processor does not use the M3 and M5 macros or the parameters set on the screen but sends all the actions via gcode and starts and stops the plasma using the  M62 and M63 macros.

The variable for the post-processor will need to be set up as internal variables:

switchoffset = Z Offset

zminheight = Zmin. height

probingfr = Probing FR


The function of these instructions is to show the operation of the postprocessor for sheet cam with Z for MACH3


Load the postprocessor to be used: Select the "MACH3 CNC4pc plasma with Z" 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), 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.