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Texas MicroCircuits – TMC3in1 Hardware & Software Installation

Copyright © 2008-2017 – Texas MicroCircuits www.texasmicrocircuits.com

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Texas MicroCircuits

TMC3in1 – Torch & Motion Controller 3in1 Plasma w/THC-5 Axis Breakout Board - Spindle Controller

Hardware & Software Installation Guide

For use with TMC3in1 Plugin Rev 3.0.x.x Rev B

Updated: January 19, 2017

Author: Randall L Ray Very Sr. Engineer Texas MicroCircuits



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Table of Contents

Revision History ................................................................................................... 6 Hardware Installation of TMC3in1 ....................................................................... 6

TMC3in1 Locations .......................................................................................... 7 General Locations ......................................................................................... 7 TMC3in1 Connection Locations ................................................................... 9

TMC3in1 Mach3 Screen ................................................................................ 12 Definition of New TMC3in1 Mach3 Screen Controls and Indicators ......... 12

TMC3in1 Mach4 Screen ................................................................................ 15 Definition of New TMC3in1 Mach4 Screen Controls and Indicators ......... 15

Installing the TMC3in1 Hardware .................................................................. 16 Ethernet Smooth Stepper (ESS) ................................................................ 16 TMC3in1 General Installation ..................................................................... 17

Connecting the TMC3in1 to the ESS ..................................................... 17 Securing the TMC3in1 to the ESS ......................................................... 18 Adding ESS Ethernet Cable ................................................................... 18 Powering the TMC3in1 and ESS ............................................................ 19

Torch Height Controller .............................................................................. 21 Plasma Manufacturer’s CNC Connection .............................................. 21 Wiring the THC portion of the TMC3in1 ................................................. 22

5 Axis Breakout Board ................................................................................ 23 Spindle Speed Controller ........................................................................... 23

Software Setup for the TMC3in1 ................................................................... 24 You will need to use the recommended version of Mach3 ....................... 24 You will need to use the latest ESS Plugin ................................................ 24 You will need to merge the TMC3in1 File Set ........................................... 24 Start Mach3, and select the ESS Plugin: ................................................... 26

TMC3in1 Plugin .............................................................................................. 26 Enabling the TMC3in1 Plugin ..................................................................... 26 Configuring the TMC3in1 Plugin ................................................................ 27

THC Configuration Window .................................................................... 28 Short Description of THC Configuration Parameters ................................ 29 Detailed Description of THC Configuration Parameters and their use ..... 29

Selecting the Voltage Divider Ratio ........................................................ 29 Selecting the Proper Voltage Input ........................................................ 30 Selecting the Desired Pierce Count ....................................................... 31 Selecting the Arc Voltage Source ........................................................... 32 Selecting the Default Target Tip Volts .................................................... 32 Selecting the Target Band Volts ............................................................. 32 Changing the Target Band Volts Parameter .......................................... 33 Selecting the Linear Response Band Volts............................................ 33



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Changing the Target Band Volts Parameter .......................................... 33 Selecting the THC Offset Volts ............................................................... 34 Selecting the Mode Run Simulator ......................................................... 35 Selecting the M11/M10 Mode ................................................................. 35 Selecting the Delay THC Active after Arc Ok Mode .............................. 36 Selecting the RESET TMC3in1 Off Mode .............................................. 37 Selecting Anti-Dive Options .................................................................... 37 Selecting Cut Out Anti-Dive Mode .......................................................... 38 Selecting the Anti-Dive Mode based on Averaged Tip Volts Settings .. 38 Selecting the ATV Data Points ............................................................... 39 Selecting the % Change in ATV before Anti-Dive Engages .................. 39 Selecting % THC Response when ATV Anti-Dive is Active .................. 39 Selecting the Ceiling above the Target Volts to Disable THC ............... 39 Selecting the Floor below the Target Volts to Disable THC .................. 40 Open Logs ............................................................................................... 40 Explanation of When Changes are Stored and When they are not ...... 40

Enabling THC Mode in ESS Plugin ............................................................... 42 Setting TMC3in1 Mach Ports and Pins .......................................................... 42 Mach Screen Detail ........................................................................................ 43 TMC3in1 Monitor Screen ............................................................................... 45

1- Under Limit Indicator -The under limit indicator lights when the Actual Tip Volts is under 1v. This is normal when the torch isn’t fired and Arc Ok is not on. ...................................................................................................... 45 2- Torch On -This indicator is active when the torch has been fired. .... 45 3- Arc Ok- This indicator is active when Arc Ok is received from the plasma cutter showing that the arc has transferred to the material being cut. 45

TMC3in1 Firmware Update Screen .............................................................. 47 Appendix ............................................................................................................. 48



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Figures Figure 1 – TMC3in1 General Locations 1 ........................................................... 7 Figure 2 – TMC3in1 General Locations 2 ........................................................... 8 Figure 3 - THC Pin Connections .......................................................................... 9 Figure 4 - eStop, Home/Limit, Spindle Control Pin Locations ....................... 10 Figure 5 - Axes (Step/Dir) Pin Connections ..................................................... 11 Figure 6 - TMC3in1 Mach3 Screen New Controls and Indicators ................. 12 Figure 7 - ESS Card from Warp9TD ................................................................... 16 Figure 8 - Installing Standoffs ............................................................................ 17 Figure 9 - Plugging the TMC3in1 into the ESS ................................................ 18 Figure 10 - Securing the TMC3in1 to the ESS .................................................. 18 Figure 11 - Cat5 Cable Install ............................................................................. 19 Figure 12 - Connecting Power to the TMC3in1 ................................................ 19 Figure 13 - All Done ............................................................................................. 20 Figure 14 – Various Manufacturers Plasma Cutter CNC Connections ......... 21 Figure 15 - Wiring ArcOk .................................................................................... 22 Figure 16 - Wiring Divided Volts ........................................................................ 22 Figure 17 - Wiring Torch On ............................................................................... 23 Figure 18 - Select ESS Plugin ............................................................................ 26 Figure 19 - TMC3in1 Plugin is Disabled. ........................................................... 27 Figure 20 - TMC3in1 Plugin is Enabled. ............................................................ 27 Figure 21 - TMC3in1 Config Window ................................................................. 29 Figure 22 - Voltage Divider Selection ................................................................ 30 Figure 23 - Plasma Connections (Single Ended Pins 3 & 4) .......................... 31 Figure 24 - Pierce Counter Selection ................................................................ 31 Figure 25 - Pierce Counter .................................................................................. 31 Figure 26 - Arc Voltage Source .......................................................................... 32 Figure 27 – Default Target Tip Volts Selection ................................................ 32 Figure 28 - Target Tip Volts Display .................................................................. 32 Figure 29 - Target Band Volts Selection ........................................................... 32 Figure 30 - Linear Response Band Selection .................................................. 33 Figure 31 - Voltage Band Example 1 ................................................................. 33 Figure 32 - Voltage Band Example 2 ................................................................. 34 Figure 33 - THC Offset Volts ............................................................................... 34 Figure 36 - Run Simulator Mode ........................................................................ 35 Figure 37 - Ports & Pins ...................................................................................... 36 Figure 38 - ESS Plugin M11/M10 ........................................................................ 36 Figure 39 - Delay After Arc Ok ........................................................................... 37 Figure 40 - RESET THC Run Option .................................................................. 37 Figure 41 - ESS Plugin PWM Selection ............................................................. 37 Figure 42 - Ports & Pins ...................................................................................... 38 Figure 43 - Cutout Below % ............................................................................... 38



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Figure 44 – Enable Anti-Dive Mode based on Averaged Tip Volts ............... 38 Figure 46- Change in ATV before Anti-Dive Engages ..................................... 39 Figure 47 - %THC Response when Anti-Dive Active ...................................... 39 Figure 50 - Open Logs button and Path ........................................................... 40 Figure 51- When Changes are Stored ............................................................... 41 Figure 52 - Ports & Pins ...................................................................................... 42 Figure 54 - Ports & Pins - Mill Options ............................................................. 43 Figure 55 - THC Yellow Status LED ................................................................... 43 Figure 56 - THC Green Status LED .................................................................... 44 Figure 57 - Target Tip Volts - Underlimit .......................................................... 44



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Revision History Changes since version 2.x.x.x:

1. The THC Up and Down signals are now based directly off of the Mach Motor Tuning parameters for Z Axis Acceleration and Velocity.

2. THC Acceleration is no longer used in the THC configurations window. 3. THC Rate is no longer used on the screen set main screen. 4. The THC configuration window has had its layout change some and some names

have become more descriptive. 5. On the screen set, the THC Up and THC Down parameters now indicate the Z axis

velocity commanded. 6. On the Mach3 Diagnostics tab, you may notice the Torch Up and Torch Down LEDs

flashing randomly – this is okay and will not affect performance. This occurs now due to a change in the way the Z axis movement is now being transmitted to the SmoothStepper.

Hardware Installation of TMC3in1 This manual is a subset of the larger TMC3in1 Specification manual. The specification manual completely documents plasma’s theory of operation of, torch height control, the breakout board, and the spindle speed controller. This part of the manual is for those that want to “cut to the chase” and get their TMC3in1 up and running as quickly as possible. However, for in depth explanation and operational detail, please consult the current TMC3in1 Specification on our website.



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TMC3in1 Locations General Locations

Figure 1 – TMC3in1 General Locations 1



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Figure 2 – TMC3in1 General Locations 2



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TMC3in1 Connection Locations The green Phoenix connectors are removable as a group. Gently lift with your hand to remove the group you need, DO NOT PRY with a metal object between the header and the board!. Underneath are the silkscreen names of the specific pin functions. Below are some photos and more information about each pin or pin group.

Figure 3 - THC Pin Connections

The E-Stop should be considered a courtesy signal. Your E-Stop switch(s) should also control a relay that cuts off the power to your motors!

Formatted: Normal



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Figure 4 - eStop, Home/Limit, Spindle Control Pin Locations



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Figure 5 - Axes (Step/Dir) Pin Connections



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TMC3in1 Mach3 Screen There are many changes, mostly additions, to include the THC functions on the Mach screen set. Below is a screenshot of the new TMC3in1 Mach3 screen and below that are definitions of each new function.

Figure 6 - TMC3in1 Mach3 Screen New Controls and Indicators

Definition of New TMC3in1 Mach3 Screen Controls and Indicators

1. Mach Screen Version – “3.0.x.x” indicates that this screen is required for any TMC3in1 plugin versions of 3.0.x.x or possibly higher.

2. Actual Tip Volts – This is the actual plasma arc tip voltage received after being multiplied by the divider ratio selected in the THC Config plugin. When active, the TMC3in1 will try to bring the Z axis (torch) arc to match the Target Tip Volts.

3. Target Tip Volts – This is the target voltage set by the operator that the TMC3in1 will adjust the Z axis (torch) to while cutting. To change the number, click in the box and type in the target voltage and press the “Enter” key.



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4. Increment/Decrement Arrows – Clicking on either of these arrows will increment or decrement the Target Tip Voltage by 1 volt. This can be done when cutting is active to fine tune cut height.

5. TMC3in1 Updating Firmware – Flashing Red This indicator reflects the TMC3in1 is updating its firmware, and is accompanied by a log window showing the update progress. Updates should only happen when changing to a different version of the TMC3in1 plugin.The user should wait until updating is finished and the TMC3in1 Status light (number 7) is Green indicating TMC3in1 is running.

6. TMC3in1 Status – Yellow The Yellow LED indicates that the TMC3in1 hardware and the TMC3in1 Mach3 plugin are not currently communicating. Releasing Mach3 from Reset or changing the target voltage (see numbers 3 and 4) should start the TMC3in1, and turn the status LED Green.

7. TMC3in1 Status – Green These 2 indicators (Green/Yellow) reflect the operational status of the TMC3in1. The Green LED indicates that the TMC3in1 Hardware and the TMC3in1 Mach3 plugin are communicating correctly.

8. Overlimit – The overlimit indicator will turn Red when the Actual Tip Voltage exceeds the measurable voltage range for your divider ratio. The overlimit indicator may turn on when a torch is fired for piercing, but should disappear once Arc Ok is detected. The overlimit indicator may also turn on and stay on if the system is miswired or misconfigured.

9. Underlimit – The underlimit indicator will turn Yellow when the Actual Tip Voltage is below an allowable level. This is usually under 1 volt and is common when the torch is not fired and no arc is detected.

10. Mode: Sim – This indicator shows when the TMC3in1 is in Simulator Mode. More about this later in this document.

11. Up/Dn Indicators – These indicators are showing Torch Up and Torch Down signals sent to Mach. The boxes next to them indicate the commanded Z velocity issued by the TMC3in1. The ESS and Mach3 may or may not honor the commanded Z velocity.

12. THC Active – This indicator reflects when the THC is actively running in the TMC3in1. There are various reasons that the TMC3in1 will shut off THC control (M11, no Arc Okay, stopping Z axis THC response or Delay after Arc Okay).

13. THC CFG – Clicking this button will display the THC Configuration screen. Details of the THC CFG screen will be explained later in this document. Any changes to the configuration will be used for this instance of Mach and not stored in the XML. To store in the XML for later use, go to Mach Config > Config Plugins > Config beside the TMC3in1 plugin. Information on what is displayed is later in this document.



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14. Monitor – Clicking this button will display the Monitor screen. These are extra indicators showing more detailed THC function and is mostly used when debugging and installation.

15. Enable M11/M10 Usage – This indicator shows when the M11/M10 functions are enabled (but not necessarily active) in the THC Configuration.

16. Enable THC Delay after Arc Ok – This indicator shows when the THC Delay after Arc Ok has been enabled (but not necessarily active) in the THC Configuration.

17. Anti-Dive: % Cutout Mode – This indicator shows when the THC Configuration has enabled the Anti-Dive feature of “% Cutout Mode”.

18. Pierce Count – Every time the torch is fired, this indicator increments by 1 showing total number of pierces. The indicator will turn Red to show the operator that this number is at or past the limit set by the operator in the THC Config. No action is taken by the TMC3in1 on this indicator. It is for operator display only and has no effect on plasma operations.

19. M11/M10 Control Active – This indicator shows when the M11/M10 commands are active and being processed.

20. Delay Active after Arc Ok – This indicator shows when a delay of user set time value (set in the THC Configuration) is actually active.

21. Anti-Dive: Linear Mode - This indicator shows when the THC Configuration has enabled the Anti-Dive feature of “Linear Mode”.

22. Mark Log File – This button is pressed when the user sees a possible failure occurring. It puts a special mark in the log file to help specify where a problem occurs in the log.

23. Pierce Count Reset – Clicking on this button will reset the Pierce counter.

More detail on the functions of these indicators is explained later in this document.



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TMC3in1 Mach4 Screen This will be expanded upon once the Mach4 plugin has been released.

Definition of New TMC3in1 Mach4 Screen Controls and Indicators This will be expanded upon once the Mach4 plugin has been released.



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Installing the TMC3in1 Hardware Before installing the TMC3in1 unit, an Ethernet Smooth Stepper card must be installed in the system first. The TMC3in1 plugs directly into the ESS utilizing Port 3 and the expansion port, but leaving Ports 1 & 2 for other user functions. The TMC3in1 also powers the ESS.

Ethernet Smooth Stepper (ESS) The ESS has always been an integral part of the architecture of the TMC3in1 because it takes a lot of the load off the PC and commands THC moves from the Z axis much faster and smoother. Many users mount the ESS in their control enclosure using 6-32” standoffs. We supply extra standoffs to allow the TMC3in1 to plug on top of the ESS and stabilize the TMC3in1.

Texas MicroCircuits does not sell the ESS card, but there are many resellers that do and also www.warp9td.com .

Figure 7 - ESS Card from Warp9TD



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TMC3in1 General Installation

Connecting the TMC3in1 to the ESS The TMC3in1 was designed to mount directly atop the ESS, expanding the footprint as little as possible, yet leave Port 1 and Port 2 completely accessible to the user for additional I/O.

We supply the ¾” nylon 6-32 standoffs with each TMC3in1. If you do not use 6-32 standoffs with your ESS, you will either need to change them, or purchase ¾” standoffs in your size (i.e. 8-32) to be able to properly mount the TMC3in1.

The JP4 5V power jumper (for the ESS port 3 pin 26) can be jumpered or un-jumpered. The TMC3in1 supplies power to the ESS via two pins in the Expansion Port header, so we recommend leaving JP4 un-jumpered.

Figure 8 - Installing Standoffs

The TMC3in1 should plug firmly into the ESS via Port 3 and the Expansion Port. Once safely seated in the Port 3 and Expansion Port sockets, you can insert the 6-32 lockdown screws.



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Figure 9 - Plugging the TMC3in1 into the ESS

Securing the TMC3in1 to the ESS

Secure the TMC3in1 by installing the 4 6-32 screws that came with the TMC3in1. The unit will now be mechanically secure.

Figure 10 - Securing the TMC3in1 to the ESS

Adding ESS Ethernet Cable

The Ethernet cable should be plugged into the RJ45 connector on the ESS, as shown in the photo below. The other end goes to your network or PC network card.

WARNING: Make sure you plug your Ethernet cable into the ESS RJ45 connector and not into the TMC3in1 RJ45 connector. The TMC3in1 RJ45 connector is for communicating with optional future equipment.



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Figure 11 - Cat5 Cable Install

Powering the TMC3in1 and ESS

Last, but not least, make sure that the ESS is NOT being powered by its 5V J6 connector or any break out boards on ports 1 or 2! The TMC3in1 will supply power to the ESS. Connect 10.8V to 26.4V DC power to the TMC3in1 J1 connector.

Figure 12 - Connecting Power to the TMC3in1

All of the basic connections are complete, and now on to wiring the TMC3in1 for the desired functions.



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Figure 13 - All Done



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Torch Height Controller

Plasma Manufacturer’s CNC Connection In the last 15 years, almost 95% of all major plasma supply manufacturers have incorporated (or have an option) for a CNC connection from their machine to CNC electronics. All of the major names such as Hypertherm, Thermal Dynamics (Victor/ThermoDyne), and ESAB do.

The TMC3in1 requires these signals/controls to operate:

- Arc Ok or OK-to-Move (2 wires) - Torch On or Gun Switch (2 wires) - Divided Tip Volts (usually divided by a standard ratio such as 50:1, 30:1,

16.67:1, etc. (2 wires)

Note: The TMC3in1 can NOT receive Raw Tip Volts as it will damage the TMC3in1

Below are examples of some of the connectors used on major plasma brands for CNC connection to the TMC3in1. You will need to consult your own plasma cutter owner’s guide for wiring information or contact your plasma representative. Many offer a “CNC cable option” and it plugs into the back of the plasma power supply. The other end has wires that can be connected to the THC connector of the TNC3in1.

Figure 14 – Various Manufacturers Plasma Cutter CNC Connections



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Wiring the THC portion of the TMC3in1 Though it may seem boring to watch all the photos of wiring the TMC3in1 THC portion, an incorrectly wired input can damage the TMC3in1. Please spend a little time following the installation and wiring photos. The Phoenix (green) connector, when installed, covers the silkscreen markings on the PCB. You can refer back to the locations section of this manual to see them.

Arc Ok or “Ok to Move” is an input to the TMC3in1. It is a closed contact that is sensed by the THC. Being non-polarized, either wire can be installed in pins 1 & 2.

Figure 15 - Wiring ArcOk

Divided volts is very much polarized. Installing reversed can cause damage to the TMC3in1. Install the minus or ground (shown here as a black wire) in pin 3 and the plus or positive (shown here as a red wire) in pin 4.

Figure 16 - Wiring Divided Volts

Pins 5 & 6 are not actively used at this time.



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The Torch On is an output by a relay on the TMC3in1. This is a closed contact that triggers the torch to fire and is non-polarized so either wire can go into pin 7 & 8.

Figure 17 - Wiring Torch On

5 Axis Breakout Board TBC

Spindle Speed Controller TBC



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Software Setup for the TMC3in1

You will need to use the recommended version of Mach3 (3.043.062) available from

http://warp9td.com/index.php/sw/software-mach#MachThree

It is assumed you know how to install Mach3 for use with an ESS (no parallel port driver). If not, please refer to installation instructions on the Mach3 website.

http://www.machsupport.com/

You will need to use the latest ESS Plugin (Released April 2016 –or– newer) from

Both the TMC3in1 plugin and the required ESS version that works with it, will be included in the zip file containing all the required files. The required ESS version may or may not be the current release on the Warp9TD.com website.

The TMC3in1 plugin (version 3.x.x.x and higher will alert you if the required ESS plugin version is not being used:

It is assumed that you know how to install the ESS. If not, please visit the Warp9TD website. Be sure to use the SCU (System Configuration Utility) to make it easy to install.

http://warp9td.com/index.php/sw

You will need to merge the TMC3in1 File Set The TMC3in1 Merge File Set will soon be on our website, but for now you can send an email to:

[email protected]

and we will send you the latest version. This zip file includes:



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- Latest TMC3in1 Plugin - Corresponding ESS plugin - Bitmaps required by the TMC3in1 Screen Set - The TMC3in1 Screen Set - TMC3in1 Scripts Folder with Files - Some miscellaneous files and scripts that may prove useful

It is NOT assumed you know how to install the TMC3in1 or you wouldn’t be reading this manual.



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Start Mach3, and select the ESS Plugin:

Figure 18 - Select ESS Plugin

TMC3in1 Plugin

Enabling the TMC3in1 Plugin Go into Mach3’s Menu -> Config -> Config Plugins.

In the Plugin Control and Activation window, enable the TMC3in1 plugin by changing the RED X to a GREEN check.



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Figure 19 - TMC3in1 Plugin is Disabled.

Figure 20 - TMC3in1 Plugin is Enabled.

Configuring the TMC3in1 Plugin

While you are still in the Plugin Control and Activation window, press CONFIG in the yellow area.

This is the TMC3in1 Config window. These configuration values will be saved to the XML when you press OK, only when you get here from the Plugin Control and Activation window.



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THC Configuration Window Click on “THC CFG” to open the THC Configuration window. These parameters are used to determine the operation of the TMC3in1. Below, each parameter is marked with a number and below that are short and detailed definitions.



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Figure 21 - TMC3in1 Config Window

Short Description of THC Configuration Parameters

1. ‘Reset’ Turns off TMC3in1 – TMC3in1 state controlled by “Reset” button on Mach3 screen 2. Enable Reporting of Negative Tip Volts – If the Divided tip volt wires are connected with

their polarities reversed and this option is enabled, a message will pop up with a warning to check for reversed polarities. If this option is disabled, you will not receive this message.

3. Arc Voltage Divider – This is the divider ratio matching the one set in the plasma power supply

4. Arc Voltage Source – The TMC3in1 has 2 arc voltage sources. Choose “single ended”. 5. Pierce Count Limit – Threshold of pierce counts before the red pierce count exceeded

warning light comes on 6. Target Tip Volts – This is the default set by the user and displays on the Mach screen. 7. Target Band – This is the +/- voltage band that no THC action occurs within. 8. Linear Response Band – This is the +/- voltage band that uses proportionally reduces the Z

axis commanded velocity response 9. THC Offset – Used to “trim” THC tip volts to better match with cut height. This is normally

not needed. 10. Mode: Run Simulator – This will cause the TMC3in1 to simulate up and down motion 30

times with the Z axis. It is used to make sure your configuration settings will allow the ESS and Mach3 to respond to THC commands from the hardware and also to make sure your Z axis is responding smoothly.

11. Mode: M10/M11 – When enabled, the TMC3in1 will need to receive a M11 commands in G-Code before THC response is allowed and an M10 command will disable THC response.

12. Mode: Delay after Arc Ok – Enabling delay after Arc Ok received. 13. Length of delay field – This is the length of delay in seconds after Arc Okay is received

before THC control start, when #12 is enabled. 14. Stop Z axis THC response when the X-Y velocity is less than X % of the commanded

feed rate – This is an Antidive feature to prevent the torch from diving due to slow velocities at the beginning of a cut, the end of a cut, and in corners.

15. Value % - When Z axis decelerates below X%, THC is disabled when #14 is enabled. 16. Enable Voltage Based Anti-Dive – Enable the “anti-dive” parameters in this group. 17. Average Tip Volts – Use average (1 to 128 samples) for tip volts. 18. % Change in ATV – % change in ATV before anti-dive engages 19. % THC Response – % THC response rate when anti-dive active 20. Ceiling Above Tip Volts – voltage point above tip volts when THC is disabled 21. Floor Below Tip Volts – voltage point below tip volts when THC is disabled 22. Open Logs – Opens log folder specified by path shown 23. When Changes are Stored – Shows when changes are store in XML and when not

Detailed Description of THC Configuration Parameters and their use

Selecting the Voltage Divider Ratio While you are still in the TMC3in1 Config window: For the Arc Voltage Divider, select whichever one your machine uses:



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Figure 22 - Voltage Divider Selection

The Voltage Divider Ratio is used to provide the arc voltage to the THC in a form that is not dangerous. The raw tip volts can be anywhere from 100v to over 300v in some models. This voltage can be very dangerous. The voltage divider circuit divides this voltage per a ratio provided by the plasma manufacturer. The output is directly proportional to the raw tip voltage but at a reduced level to provide safe voltages at the THC. It is very important that the divider selection in the THC Configuration window matches that chosen at the plasma cutter so the THC can operate properly.

If your machine allows you to choose a value based on jumper or switch settings, we would recommend using them in this order of preference:

- 50:1 - 40:1 - 30:1 - 20:1 - 16.67:1 - 15:1

DO NOT USE STRAIGHT (RAW) TIP VOLTS, IT WILL DAMAGE THE TMC3IN1!

Selecting the Proper Voltage Input While you are still in the TMC3in1 Config window: For the Arc Voltage Source, select “Single Ended”. This will connect to J7, with the positive wire connecting to Pin 4 of J7 and the ground wire connecting to Pin 3 of J7. The figure below shows the connections to the TMC3in1 for “Single Ended” operation.



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Figure 23 - Plasma Connections (Single Ended Pins 3 & 4) Selecting the Desired Pierce Count The Pierce Count feature counts a pierce every time Arc Ok is established. Many users want to know how many pierces have occurred since the plasma tip and/or electrode was last changed. This helps them determine when next to change the tip/electrode instead of having it “blow out” during a cut because of extended use.

While you are still in the TMC3in1 Config window: The Desired Pierces section is optional, but will keep track of the number of pierces performed. This will help with maintenance of consumables.

Figure 24 - Pierce Counter Selection

The left box lets you set the desired number of pierces to perform before the warning light turns on, flashing Red on the main Mach3 Screen like this:

Figure 25 - Pierce Counter The Reset Pierces button will allow you to reset your current pierces count to 0.



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Selecting the Arc Voltage Source While you are still in the TMC3in1 Config window: Select the “Single Ended” Arc Voltage Source. This is the only choice used at the present

Figure 26 - Arc Voltage Source

Selecting the Default Target Tip Volts While you are still in the TMC3in1 Config window: Target Tip Volts is the tip voltage you want to cut at. This is material and speed dependent. Setting the Default Tip Volts here will cause it to show this setting each time you start Mach3. However, the tip volts can be set or changed on the Mach3 screen by selecting the Target Tip Volts, entering a number, and pressing Enter.

Figure 27 – Default Target Tip Volts Selection As stated above, the Target Tip Volts can also be specified on the main Mach screen.

Figure 28 - Target Tip Volts Display

Selecting the Target Band Volts While you are still in the TMC3in1 Config window: Target Band (Volts) is the voltage band you want to stay within, above your Target Tip Volts or Below Your Target Tip Volts. 0.25V is the recommended value to use, but you may modify it. Example: 0.25 is plus and minus 0.25 for total band width of 0.5 volts. This means that the THC will try and keep the tip voltage at the desired Target Tip Volts, but will give leeway within this band. If the THC did not have this band, it’s possible that the THC would ALWAYS be giving the Z axis commands and “see-sawing” or oscillating.

Figure 29 - Target Band Volts Selection

When you are within the target band, the TMC3in1 will not issue any THC UP or THC DOWN signals.



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Changing the Target Band Volts Parameter - The default is 0.25v - Decreasing this number too much may cause the Z axis to oscillate - Increasing this number too much may cause the Z axis not to respond as quickly to

changes in material height (i.e. warping).

Selecting the Linear Response Band Volts While you are still in the TMC3in1 Config window: The Linear Response Band (Volts) is the area that the THC UP and THC DOWN signals will be generated at less than full strength. One way to think of this is as the nudging region. When you are only a little bit away from your Target Band, you just want to nudge the voltage back. If you are farther away, you move a little harder. If you are outside of the Linear Response Band, you push with full force.

Example: A setting of “20.1” is plus and minus 20.1 volts for total bandwidth of 40.2 volts.

Figure 30 - Linear Response Band Selection

Changing the Target Band Volts Parameter - 20V is the default value. - If your system responds too aggressively or begins to oscillate, increase this

value. - If your system does not follow close enough to the target voltage, decrease this

value. Not tracking the target voltage may also be related to acceleration settings, or THC rate.

Examples of various voltage settings:

i. Settings a. Target Tip Volts = 120.0 b. Target Band (Volts) = 0.25 c. Linear Response Band (Volts) = 20.1

Figure 31 - Voltage Band Example 1



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ii. Settings a. Target Tip Volts = 120.0 b. Target Band (Volts) = 2.0 c. Linear Response Band (Volts) = 5

Figure 32 - Voltage Band Example 2

In these images, the green line represents the Target Band (Volts) above and below our Target Tip Volts. There will be NO THC UP or DOWN signals generated when our Actual Tip Volts is in this region.

The yellow areas represent the Linear Response Band (Volts). When the Actual Tip Volts is near the green line, (but in the yellow area), the THC UP or DOWN signals will just start turning on, weak signals at first. As the Actual Tip Volts moves farther away from the green line, the THC UP or DOWN signals will be stronger. As the Actual Tip Volts approaches the red area (but while it is still in the yellow area), the THC UP or DOWN signals will be very strong.

Once the Actual Tip Volts is outside of the yellow area and in the red area, the THC UP or DOWN signals will be fully on.

Selecting the THC Offset Volts While you are still in the TMC3in1 Config window: THC Offset. This provides an offset adjust for the Actual Tip Voltage. In testing, measurements, and operation, it is not needed, which is why we set it to 0.001 V (1 mV). It is provided merely as a courtesy. The most common usage is to “match” the plasma manufacture user guide on tip voltage/cut height.

Figure 33 - THC Offset Volts



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Selecting the Mode Run Simulator While you are still in the TMC3in1 Config window: Mode Run Simulator will allow you to test your TMC3in1 Hardware to see if the THC Up and THC Down signals are being received and processed by Mach correctly. Your Z axis should respond to the movement they request. If there are any issues with the movement of your Z axis, please adjust your Z Velocity and Z Acceleration settings in Mach’s Motor Tuning. If there is no response whatsoever, then there is likely a problem with your configuration of THC Up, THC Down and THC On pins in Mach3’s Menu -> Ports and Pins -> Inputs.

Figure 34 - Run Simulator Mode You will need to:

Place a check in the Run Simulator box, and press OK to close the Config window to start the Simulator Mode.

Make sure Mach is released from Reset Make sure your equipment can move up and down at least 2 inches in each

direction Have all of your other settings properly configured. Press ok to start the simulation. To exit Simulator Mode, open the Config window again and un-check the

Run Simulator box, and press OK to close the Config window and stop the Simulator Mode.

Selecting the M11/M10 Mode While you are still in the TMC3in1 Config window: Using M11 to Enable THC Up/Down signals from the TMC3in1 and using M10 to Disable THC Up/Down signals from the TMC3in1.

Here is a very good article that explains the operation of M11/M10:

http://warp9td.com/index.php/faq/faq-g-code-m-code#WhatIsMCode

Let’s say that you will assign Output #3 in Mach for this M11/M10 functionality. You would need to Enable it, Use Port 3, Pin14, and use a red X for Active Low (meaning it will be active high).



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Figure 35 - Ports & Pins

In the ESS Main Config, you would also need to set the output number accordingly.

Figure 36 - ESS Plugin M11/M10

In your G-Code file you would then use the commands M11P3 or M10P3 (P3 is for port 3) followed by a move command (G0, G1 etc…).

Selecting the Delay THC Active after Arc Ok Mode While you are still in the TMC3in1 Config window: Delay THC output signals from the TMC3in1 for X.Y seconds after the Arc Ok is received. This will allow your torch time to move away from



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the pierce location before THC Up or THC Down signals are generated. This helps to prevent head crashes and to resolve other pierce related issues. The parameter is measured in seconds. (i.e. 0.6 seconds or 600 miliseconds)

Figure 37 - Delay After Arc Ok

If you are using Anti-Dive correctly, you will most likely not need this delay function, but it may prove helpful when cutting very thin materials at high speed.

Selecting the RESET TMC3in1 Off Mode While you are still in the TMC3in1 Config window: Reset Turns off the TMC3in1. This is typically the desired mode.

Figure 38 - RESET THC Run Option

Selecting Anti-Dive Options Anti-dive requires that the ESS Main Config settings for XY PWM Velocity Output be used. Choose an available output and select it from the drop down box (in this case, Output #2).

Figure 39 - ESS Plugin PWM Selection

In Outputs set #2 to Enable it, Use Port 3, Pin 16, and use a red X for Active Low (meaning it will be active high).



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The output will be a 130 kHz signal that has a PWM duty cycle equal to current XY Velocity / requested Feedrate. This allows the TMC3in1 to know how fast the current XY movement is in respect to how fast it will be at the request Feedrate.

Selecting Cut Out Anti-Dive Mode While you are still in the TMC3in1 Config window: Anti-dive, Cutout (Inhibit) THC Up and THC Down signals if the current XY Velocity / requested Feedrate is below X%. This is the preferred Anti-dive mode, and a very good starting value to use is 97%.

This means that if the requested Feedrate is 100 ipm and the current velocity is less than 97 ipm, then there will be no THC Up and THC Down signals generated. While the current velocity is 97 ipm or greater, then THC Up and THC Down signals would be generated.

Figure 41 - Cutout Below % Selecting the Anti-Dive Mode based on Averaged Tip Volts Settings While you are still in the TMC3in1 Config window: To select and use any of the Voltage Based Anti-Dive features, you must check this box.

Figure 42 - Enable Anti-Dive Mode based on Averaged Tip Volts



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Selecting the ATV Data Points While you are still in the TMC3in1 Config window: Using the ATV (Average Tip Volts) is a method of smoothing out short spikes in the Arc Voltage readings that can make the torch seem to dive unnecessarily. The “smoothing” takes an average of the rolling number of samples from 1 to 128, averages them and uses that number for the Arc Voltage sample. A smaller number (2 or more) will smooth very narrow spikes where a larger number (64 or more) will smooth wider spikes. Since the original sampling is performed hundreds of times a second, no significant response will be lost.

Figure 45 - ATV Data Points

Selecting the % Change in ATV before Anti-Dive Engages This number is the percentage change from the ATV number that must occur before the Anti-Dive action engages.

Figure 43- Change in ATV before Anti-Dive Engages

Selecting % THC Response when ATV Anti-Dive is Active This number (when less than 100), is the percentage of the X/Y motion that the Z axis will move when the ATV Anti-Dive is active. Look at it as THC Rate when Anti-Dive is active.

Figure 44 - %THC Response when Anti-Dive Active

Selecting the Ceiling above the Target Volts to Disable THC The “Ceiling” is a voltage level ABOVE the target volts that, when crossed, will disable the THC. For example, if the target voltage is 115v and the ceiling is 20v, then if a Tip Volts spike occurs that is 135v (115v + 20v) then the THC will become inactive until the Tip Volts comes below the 135v level, then THC will be active again.



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Figure 48 - Ceiling above Target Volts to Disable THC

Selecting the Floor below the Target Volts to Disable THC The “Floor” is a voltage level BELOW the target volts that, when crossed, will disable the THC. For example, if the target voltage is 115v and the floor is 20v, then if a Tip Volts instantaneous drop occurs that is 95v (115v - 20v) then the THC will become inactive until the Tip Volts comes back above the 95v level, then THC will be active again.

Figure 49 - Floor below Target Volts to Disable THC

Open Logs The “Open Logs” button is used to open the folder (specified by the path in the box to the right of the button) that contains the logs for the operation of the THC during a Mach3 run. Though the log is in an Excel “csv” format, it is difficult to examine by the normal user. Special Analyzing software is used by the support people (either the OEM manufacturer or Texas MicroCircuits) to analyze the log and provide insight into any problems reported by the user. A log is produced from the time Arc Ok is acknowledged until the end of the g-code run or Stop has been pressed, even if there are no problems cutting. In the future, we expect the logs will give us predictive information about the operation so that potential problems can be trended before they happen.

Figure 450 - Open Logs button and Path

Explanation of When Changes are Stored and When they are not Though the explanation below may be obvious to some, maybe a e a little more detail will help. When the THC Config screen is invoked by pressing the “THC CFG” button below the “THC On/Off” button on the Mach3 screen, any changes will ONLY be used for that invocation of Mach3. Once Mach3 is closed, those changes will disappear.

However, is the THC Config screen is invoked via the Mach3 Menu->Config->Config Plugins->TMC3in1 CONFIG selection; any changes will be stored to the profile (XML) and will be available next time Mach3 is started.



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Figure 461- When Changes are Stored



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Enabling THC Mode in ESS Plugin There is no longer an ESS setting for this, and it happens automatically.

Setting TMC3in1 Mach Ports and Pins In Ports and Pins -> Outputs, I will use Output #1 for this example. Set your Relay to turn on the torch to use Port 3, Pin17, and use a red X for Active Low (meaning it will be active high).


In Ports and Pins -> Inputs:

THC On is the Arc OK signal coming in.

All 3 of the signals must be set as shown!

Figure 53 - Ports 7 Pins - Input

In Ports and Pins -> Mill Options, you MUST NOT CHECK the box for “Allow THC UP/DOWN Control even if not in THC Mode”.



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Figure 48 - Ports & Pins - Mill Options

Mach Screen Detail This Red flashing LED means the Mach3 is updating the firmware in the TMC3in1.

Figure 49 - THC Red Status LED

This Yellow LED means the Mach3 has no communications with the TMC3in1.

Figure 506 - THC Yellow Status LED



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This Green LED means the Mach3 IS communicating with the TMC3in1.

Figure 517 - THC Green Status LED

The Yellow Underlimit LED means that we are reading a voltage from the Tip that is Underlimit, typically less than a volt. If you don’t currently have an Arc Okay signal, this is normal.

Figure 528 - Target Tip Volts - Underlimit

The Red Overlimit LED means that we are reading a voltage from the Tip that is Overlimit, typically more than 400 volts (depending on Arc Voltage Divider selected). It is common to see this come on at the start of a pierce, but should be gone once an Arc Okay signal is present.

Figure 59 - Target Tip Volts – Overlimit



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TMC3in1 Monitor Screen

Figure 60 - TMC3in1 Monitor Screen The TMC3in1 Monitor Screen is invoked by pressing the “Monitor” button on the Mach3 screen just below the “THC CFG” button. The screen above will pop up. This screen gives more data to the user when Mach3 is in operation.

1- Under Limit Indicator -The under limit indicator lights when the Actual Tip Volts is under 1v. This is normal when the torch isn’t fired and Arc Ok is not on.

2- Torch On -This indicator is active when the torch has been fired. 3- Arc Ok- This indicator is active when Arc Ok is received from the plasma

cutter showing that the arc has transferred to the material being cut. 4 M11/M10 – This indicator shows if the THC is in M11/M10 mode 5 Up – This indicator shows when the command to move the z axis up has

been issued. The amount of acceleration is shown in the number beside the indicator

6 Down - This indicator shows when the command to move the z axis down has been issued. The amount of acceleration is shown in the number beside the indicator

7 Pierce Delay Mode- This indicator shows when the Pierce Delay mode is enabled.

8 Actual Tip Counts – This number is used by the developer for debugging. It has no real meaning to the user.

9 Actual Tip Volts – This number is the actual tip volts being read by the THC from the plasma cutter

10 Simulator – This indicator shows when the z axis exerciser/simulator is running. It is also used to determine z axis performance. (Explained later)

11 12 13 and 14 are developer information of no use to the user. 15 THC Hardware Packet – This is the packet number sent from the

TMC3in1 to the TMC3in1 plugin. It should increment about 10 times a second.



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16 ESS to TMC Plugin Packet # - This is the packet number sent from the ESS/TMC plugin to the TMC3in1. It should increment about 10 times a second.



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TMC3in1 Firmware Update Screen

Figure 61 - TMC3in1 Firmware Update Screen This screen will appear and then go away after the firmware update is complete.

1. Updating – This indicates which processor is being updated. 2. Percentage Complete – The current firmware update percentage. Once you

reach 100% this window will disappear. 3. Serial Number – The serial number of your TMC3in1



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Appendix

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