TMC3in1 Torch & Motion Controller 3in1. Vol. 01: Hardware and Software Setup Guide

TMC3in1 Torch & Motion Controller 3in1 Plasma THC - 5 Axis Breakout Board Spindle Controller Vol. 01: Hardware and Software Setup Guide For use with TMC3in1 Plugin Rev: 4.2.x.x Author: Randall L Ray Very Sr. Engineer Texas MicroCircuits www.texasmicrocircuits.com Page 1 of 47

Table of Contents 1. Revision History... 6 2. TMC3in1 Requirements... 7 3. TMC3in1 Software Development Updates... 7 4. About the Manuals... 8 5. TMC3in1 Locations... 9 5.1 General Locations... 9 5.2 TMC3in1 Connection Locations... 10 6. TMC3in1 Mach3 Screen... 13 6.1 Definition of New TMC3in1 Mach3 Screen Controls and Indicators... 13 7. TMC3in1 Mach4 Screen... 16 8. Definition of New TMC3in1 Mach4 Screen Controls and Indicators... 16 9. Installing the TMC3in1 Hardware... 16 9.1 Ethernet Smooth Stepper (ESS)... 16 9.2 TMC3in1 General Installation... 17 Connecting the TMC3in1 to the ESS... 17 9.3 Securing the TMC3in1 to the ESS... 18 9.4 Adding ESS Ethernet Cable... 18 9.5 Powering the TMC3in1 and ESS... 19 10. Torch Height Controller... 21 10.1 Plasma Manufacturer s CNC Connection... 21 10.2 Wiring the THC portion of the TMC3in1... 22 11. The 5 Axis Breakout Board... 24 12. Isolated Input Signals... 25 13. The Spindle Speed Controller... 27 14. Software Setup for the TMC3in1... 27 14.1 Mach3... 27 14.2 ESS Plugin... 27 14.3 You will need to merge the TMC3in1 File Set... 28 14.4 Start Mach3, and select the ESS Plugin:... 28 14.5 Enabling the TMC3in1 Plugin... 29 14.6 TMC3in1 Firmware Update Screen... 30 14.6 Configuring the TMC3in1 Plugin... 31 14.7 Short Description of THC Configuration Parameters... 32 14.8 Detailed Description of THC Configuration Parameters... 33 i. Selecting the Tip Voltage Divider Ratio... 33 ii. Selecting the Tip Voltage Source... 34 iii. Selecting the Desired Pierce Count... 35 iv. Selecting the Default Target Tip Volts... 35 v. Selecting the Target Band Volts... 36 vi. Selecting the Linear Response Band Volts... 36 vii. Selecting the THC Offset Volts... 38 viii. Selecting the Mode Run Simulator... 38 ix. Selecting the M11/M10 Mode... 39 x. Selecting the Delay THC Active after Arc Ok Mode... 40 www.texasmicrocircuits.com Page 2 of 47

xi. Selecting the RESET TMC3in1 Off Mode... 40 xii. Selecting Velocity Based Anti-Dive Options... 41 xiii. Selecting Velocity Based Anti-Dive Mode... 41 xiv. Selecting the Anti-Dive Mode based on Averaged Tip Volts Settings... 42 xv. Selecting the ATV Data Points... 42 xvi. Selecting the % Change in ATV before Anti-Dive Engages... 42 xvii. Selecting % THC Response when ATV Anti-Dive is Active... 42 xviii. Selecting the Ceiling above the Target Volts to Disable THC... 43 xix. Selecting the Floor below the Target Volts to Disable THC... 43 xx. Open Logs... 43 xxi. Explanation of When Changes are Stored and When they are not 44 14.9 Enabling THC Mode in ESS Plugin... 45 14.10 Setting TMC3in1 Mach Ports and Pins... 45 15 TMC3in1 Monitor Screen... 46 www.texasmicrocircuits.com Page 3 of 47

Figures Figure 1 TMC3in1 General Locations 1... 9 Figure 2 TMC3in1 General Locations 2... 10 Figure 3 - THC Pin Connections... 11 Figure 4 - estop, Home/Limit, Spindle Control Pin Locations... 11 Figure 5 - Axes (Step/Dir) Pin Connections... 12 Figure 6 - TMC3in1 Mach3 Screen New Controls and Indicators... 13 Figure 7 - TMC3in1 Mach3 Screen New Controls and Indicators... 14 Figure 8 - ESS Card from Warp9TD... 17 Figure 9 - Installing Standoffs... 17 Figure 10 - Plugging the TMC3in1 into the ESS... 18 Figure 11 - Securing the TMC3in1 to the ESS... 18 Figure 12 - Cat5 Cable Install... 19 Figure 13 - Connecting Power to the TMC3in1... 19 Figure 14 Assembly Completed... 20 Figure 15 Various Manufacturers Plasma Cutter CNC Connections... 21 Figure 16 - Wiring ArcOk... 22 Figure 17 - Wiring Divided Volts... 23 Figure 18 - Wiring Torch On... 23 Figure 19 5 Axis Break Out Board... 24 Figure 20 ESS Plugin Error Message... 27 Figure 21 Zip File Contents... 28 Figure 22 - Select ESS Plugin... 29 Figure 23 TMC3in1 Plugin is Disabled... 29 Figure 24 TMC3in1 Plugin is Enabled... 30 Figure 25 Firmware Update Screen... 30 Figure 26 TMC3in1 Config Window... 32 Figure 27 Voltage Divider Selection... 33 Figure 28 Tip Voltage Source Selection... 34 Figure 29 - Wiring Tip Voltage... 35 Figure 30- Plasma Connections (Single Ended Pins 3 & 4)... 35 Figure 31 Default Target Tip Volts Selection... 36 Figure 32 - Target Tip Volts Display... 36 Figure 33 - Target Band Volts Selection... 36 Figure 34 - Linear Response Band Selection... 37 Figure 35 - Voltage Band Example A... 37 Figure 36 - Voltage Band Example B... 38 Figure 37 - THC Offset Volts... 38 Figure 38 - Run Simulator Mode... 39 Figure 39 M11/M10 Mode... 39 Figure 40 - Ports & Pins... 39 Figure 41 - ESS Plugin M11/M10... 40 Figure 42 - Delay After Arc Ok... 40 Figure 43 - RESET THC Run Option... 41 Figure 44 - ESS Plugin PWM Selection... 41 Figure 45 - Ports & Pins... 41 www.texasmicrocircuits.com Page 4 of 47

Figure 46 - Cutout Below %... 42 Figure 47 - Enable Anti-Dive Mode based on Averaged Tip Volts... 42 Figure 48 ATV Data Points... 42 Figure 49 - Change in ATV before Anti-Dive Engages... 42 Figure 50 - %THC Response when Anti-Dive Active... 43 Figure 51 Ceiling Above Target Volts to Disable THC... 43 Figure 52 Floor Below Target Volts to Disable THC... 43 Figure 53 Open Logs Button and Path... 44 Figure 54 - When Changes are Stored... 44 Figure 55 - Ports & Pins Outputs... 45 Figure 56 - Ports & Pins Inputs... 45 Figure 57 - Ports & Pins - Mill Options... 46 Figure 58 Monitor Screen... 46 www.texasmicrocircuits.com Page 5 of 47

1. Revision History Texas MicroCircuits Vol. 01 Hardware and Software Setup Guide Changes from version 4.1.x.x to 4.2.x.x: a. Screenset Changes i. Significant overhaul of the screenset to use all of the available space and to streamline the layout. ii. Fixed the incorrect positioning of the X, Z and A offsets in the offsets tab. iii. Added the underlimit indicator back into the screenset. b. TMC3in1 Plugin Window Changes i. Cleaned up the monitor window and shrunk it down. 6 fields moved to the Advanced Monitor window ii. Advanced Monitor window was cleaned up, and it also shows the Hardware Rev on it now too. c. TMC3in1 Plugin Core Software Changes i. Added the ability to set underlimit Voltage in the config (Below this value, the THC will shut off and the torch won't rise. d. ESS Plugin Changes i.added the ability to have THC Z Max and Z Min run off of Work Coords instead of Machine Coords (like they always have been). This option is in the ESS Spindle, THC & Laser Config window. ii.added Splash Screen so we can see that the ESS plugin loaded (and its version) iii.added a check that warns you if your Mach3 License file is not present (and displays the limitations of Demo Mode) Changes from version 3.1.x.x to 4.1.x.x: a. Support for negative polarity tip voltage measurement with B-2 versions of the TMC3in1 hardware has been added. b. The screenset now indicates when Voltage based Anti-Dive is actively inhibiting THC. c. We now allow for Macro calls to set the following parameters from G-Code: i. Target Tip Volts ii. Target Band Voltage iii. Linear Response Band Voltage iv. THC Offset Voltage v. Enabling/Disabling M11/M10 vi. Enabling/Disabling Delay after ArcOkay before THC starts vii. Setting Delay Time after ArcOkay before THC starts viii. Enabling/Disabling Stop THC Response when velocity drops below specific percentage of commanded feedrate. ix. Stop THC Response when velocity drops below N% of commanded feedrate. x. Enabling/Disabling Voltage Based Antidive. xi. N (1 to 128) Data Points for Voltage Based AntiDive. xii. Voltage Based Antidive Activates after N% voltage change. xiii. Voltage Based Antidive THC Response Percentage xiv. Voltage Based Antidive Disables THC when N Volts Above Target Tip Volts www.texasmicrocircuits.com Page 6 of 47

xv. Voltage Based Antidive Disables THC when N Volts Below Target Tip Volts Changes from version 3.0.x.x to 3.1.x.x: a. There are now RED LED indicators next to THC Z Max and THC Z Min to indicate that your Z axis has reached its maximum THC adjusted height or minimum THC adjusted height respectively. b. Mark Log File and Mode Simulator moved in the screen set. c. Several descriptors and locations were changed to make the screen set more readable. Changes from version 2.x.x.x to 3.0.x.x: a. The THC Up and Down signals are now based directly off of the Mach Motor Tuning parameters for Z Axis Acceleration and Velocity. b. THC Acceleration is no longer used in the THC configurations window. c. THC Rate is no longer used on the screen set main screen. d. The THC configuration window has had its layout change some and some names have become more descriptive. e. On the screen set, the THC Up and THC Down parameters now indicate the Z axis velocity commanded. f. 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. 2. TMC3in1 Requirements To use the TMC3in1, you will need to meet at least these requirements: a. An Ethernet SmoothStepper (ESS) b. A licensed copy of Mach3 R3.043.062 (Mach4 support is in development). THC will NOT work in demo mode of Mach3. c. A Windows based PC capable of running Mach3. Here are some general PC requirements. d. A 12 V to 24 V DC (10.8 V min to 26.4 V DC max) power supply for the TMC3in1 (the TMC3in1 will power the ESS, so the ESS will not need its own power supply). e. A tip Volts signal that has a divider of 50:1, 40:1, 30:1, 20:1, 16.67:1 or 15:1. If your Plasma unit only has 1:1 (non divided or RAW) tip volts, you will need to obtain a voltage divider, since the TMC3in1 cannot work with RAW tip volts. 3. TMC3in1 Software Development Updates The TMC3in1 is a software defined product that has its hardware controlled by software (firmware). The software of the TMC3in1 is updated automatically when you switch to a new TMC3in1 plugin version, so additional features and updates may be provided. Here is the current software feature status: www.texasmicrocircuits.com Page 7 of 47

a. The THC features of the TMC3in1 are stable and functional. b. 4 axes of motion are available on the breakout board (X, Y, Z and A) However, the 5th axis (B) has been temporarily borrowed to support some THC features. The B axis should be available in the next major release of the TMC3in1 plugin. c. The X axis Home/Limit switch has been temporarily combined with the Y/Z axes Home/Limit switch (all of this is being sent to the Port 3 Pin 11 input of the ESS). The X axis Home/Limit switch and the Y/Z axes Home/Limit switch should have two unique pin numbers in the next major release of the TMC3in1 plugin. d. The Spindle Relay and the Spindle 0V to 10 V DC output are currently disabled. This should be available in the next major release of the TMC3in1 plugin, or the one just after it. e. Mach4 plugin support for the TMC3in1 is in development. It has and anticipated release of summer 2017. f. Bug fixes Updates will be released to address bugs as they are found. 4. About the Manuals This is manual 01, the Hardware and Software Setup Guide, which will help you get your TMC3in1 up and running as quickly as possible. Manual 02 covers Plasma and THC basics which is very helpful if you are new to this field. Manual 03 covers specific Macros available to you through the TMC3in1. Manual 04 covers Frequently Asked Questions and Troubleshooting. Most of this information is also available on the Forum portion of our website. www.texasmicrocircuits.com Page 8 of 47

5. TMC3in1 Locations 5.1 General Locations Figure 1 TMC3in1 General Locations 1 www.texasmicrocircuits.com Page 9 of 47

Figure 2 TMC3in1 General Locations 2 5.2 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. www.texasmicrocircuits.com Page 10 of 47

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! Figure 4 - estop, Home/Limit, Spindle Control Pin Locations www.texasmicrocircuits.com Page 11 of 47

Figure 5 - Axes (Step/Dir) Pin Connections www.texasmicrocircuits.com Page 12 of 47

6. 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 6.1 Definition of New TMC3in1 Mach3 Screen Controls and Indicators a. Mach Screen Version 4.2.x.x indicates that this screen is required for any TMC3in1 plugin versions of 4.2.x.x or possibly higher. b. 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. c. 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. d. 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. e. Tip Voltage 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 www.texasmicrocircuits.com Page 13 of 47

disappear once Arc Ok is detected. The overlimit indicator may also turn on and stay on if the system is miswired or misconfigured. f. Tip Voltage Underlimit The underlimit indicator will turn Yellow when the Actual Tip Voltage is lower than the allowed voltage. This will usually turn on if your plasma unit is turned off. This indicator should turn off as soon as your torch fires. g. V In Reversed This indicator will turn Yellow when the Divided Tip Voltage wires are Reversed, based on your Tip Voltage Source selection in THC Configuration. Please correct your wiring. This may turn on if your plasma unit is turned off. Figure 7 - TMC3in1 Mach3 Screen New Controls and Indicators h. 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. i. Torch Button: This will turn the torch On or Off manually. The Red LED above it will indicate torch activity. j. THC ON/OFF Button: This will Enable/Disable Torch Height Control for your system. If the Green LED above it will not turn on, then you are likely in demo mode. You must have Mach3 licensed for this to turn on. If it is not on, your Z axis will not respond to simulation mode or actual commands to move the Z axis while cutting. k. ARC OK: This Green LED will illuminate when the Arc Okay signal is being received. l. 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). m. THC Up Indicator This indicator shows the presence of a Torch Up signal sent to Mach3 from the TMC3in1. The box to the right indicates the commanded Z velocity issued by the TMC3in1. The ESS and Mach3 will not honor the commanded Z velocity if THC ON/OFF is not lit or if the THC Z Max value has been exceeded. n. THC Down Indicator This indicator shows the presence of a Torch Down signal sent to Mach3 from the TMC3in1. The box to the right indicates the commanded Z velocity issued by the TMC3in1. The ESS and Mach3 will not honor the commanded Z velocity if THC ON/OFF is not lit or if the THC Z Min value has been exceeded. o. THC Config Clicking this button will open the THC Config window to make temporary changes to the THC Configuration. To make permanent changes, you will need to go Menu -> Config-> Config Plugins, and click on the Yellow Config in the TMC3in1 s row. p. 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. www.texasmicrocircuits.com Page 14 of 47

q. 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. Clicking on the Reset Pierce Count button to the right will reset the Pierce counter. r. TMC3in1 Status Active Communications 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. No Communications 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. 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 (letter h) is Green indicating TMC3in1 is running. Simulation Active This indicator shows when the TMC3in1 is in Simulator Mode. More about this later in this document. 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. THC Z MAX This will illuminate when you have exceeded your Z Max elevation, and will prevent the Z axis from going any higher via THC. The value is controlled in the box to the right. THC Z MIN This will illuminate when you have exceeded your Z Min elevation, and will prevent the Z axis from going any lower via THC. The value is controlled in the box to the right. s. Using Mode Indicators -These LEDs will illuminate when you are using the corresponding Mode in the THC Config: Using M11/M10 Affects THC This indicator shows when the M11/M10 functions are enabled (but not necessarily active) in the THC Configuration. Using 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. Using X-Y Velocity Affects THC This indicator shows when the THC Configuration has enabled the Anti-Dive feature of % Cutout Mode. www.texasmicrocircuits.com Page 15 of 47

Using Voltage Mode AntiDive This indicator shows when the Voltage Mode AntiDive has been enabled (but not necessarily active) in the THC Configuration. t. Inhibiting Indicators - These LEDs will light up when the corresponding mode is actively INHIBITING Torch Height Control. More detail on the functions of these indicators is explained later in this document. 7. TMC3in1 Mach4 Screen This will be expanded upon once the Mach4 plugin has been released. 8. Definition of New TMC3in1 Mach4 Screen Controls and Indicators This will be expanded upon once the Mach4 plugin has been released. 9. Installing the TMC3in1 Hardware Before installing the TMC3in1 unit, an Ethernet Smooth Stepper card must be connected 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. 9.1 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. www.texasmicrocircuits.com Page 16 of 47

Figure 8 - ESS Card from Warp9TD 9.2 TMC3in1 General Installation Connecting the TMC3in1 to the ESS The ESS port 3 pin 26 5V power pin is controlled by the power jumper JP4 which should be un-jumpered (i.e. do not short out the JP4 pins with the jumper). The TMC3in1 supplies power to the ESS via two pins in the Expansion Port header. DO NOT power the ESS with its J6 power jumper. 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. Figure 9 - Installing Standoffs www.texasmicrocircuits.com Page 17 of 47

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. Figure 10 - Plugging the TMC3in1 into the ESS 9.3 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 11 - Securing the TMC3in1 to the ESS 9.4 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. www.texasmicrocircuits.com Page 18 of 47

Figure 12 - Cat5 Cable Install 9.5 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 13 - Connecting Power to the TMC3in1 All of the basic connections are complete, and now on to wiring the TMC3in1 for the desired functions. www.texasmicrocircuits.com Page 19 of 47

Figure 14 Assembly Completed www.texasmicrocircuits.com Page 20 of 47

10. Torch Height Controller 10.1 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 15 Various Manufacturers Plasma Cutter CNC Connections www.texasmicrocircuits.com Page 21 of 47

10.2 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 pin 1 and pin 2. Figure 16 - Wiring ArcOk The Tip Voltage is polarized. Installing reversed may cause damage to the TMC3in1 or your plasma unit. Please make sure you select the appropriate Tip Voltage Source in the THC Config window. If you are using: A Positive Tip Voltage System (like Thermal Dynamics), install the minus or ground (shown here as a black wire in the picture below) in pin 3 and the plus or positive (shown here as a red wire) in pin 4. www.texasmicrocircuits.com Page 22 of 47

Figure 17 - Wiring Divided Volts A Negative Tip Voltage System (like Hypertherm), install the minus or ground in pin 4 and the plus or positive in pin 3, which is the opposite of the picture above. Pins 5 & 6 are not actively used at this time. 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 18 - Wiring Torch On www.texasmicrocircuits.com Page 23 of 47

11. The 5 Axis Breakout Board Figure 19 5 Axis Break Out Board Jumper J10 allows you to select which voltage reference you wish to use for the three COM (commons) provided on the left hand side header of the 5 Axis Breakout Board. Please note that currently the B axis Step and Dir pins are being used for other functions, and will not be available for a B axis until the next major plugin update. a. You can tie all of the commons to ground at J10, at which point the ESS will need to Drive Active Highs for all of the Step and Dir Pins. www.texasmicrocircuits.com Page 24 of 47

b. You can tie all of the commons to +5 V DC at J10, at which point the ESS will need to Drive Active Lows for all of the Step and Dir Pins. c. You can leave J10 un-jumpered, at which point you will have erratic functionality from your Step and Dir Pins. The COMs are located so that each pair of axes adjoining them can share the same terminal (i.e. the two common wires will both need to go into the same COM screw terminal). 12. Isolated Input Signals There are 3, identical, isolated input signals available. They can be used for anything that you wish, but we have them identified as: EStop (currently Port 3 Pin 12, but it will be moving to a virtual port in a future software release). X Home or Limit (currently Port 3 Pin 11, but it will be moving to a virtual port in a future software release). Y and Z Home or Limit (currently Port 3 Pin 11, but it will be moving to a virtual port in a future software release). (Yes, this shares the same input pin as X Home above.) Since these are isolated inputs, you will need to use your Vin source (12V to 24 V DC) to generate a current through the opto-isolator, the current through the optoisolator will generate the input signal to Mach3. Here are example schematics for wiring Normally Open and Normally Closed switches into the pins: www.texasmicrocircuits.com Page 25 of 47

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13. The Spindle Speed Controller This section will be completed once the Spindle Software Update has been released. 14. Software Setup for the TMC3in1 14.1 Mach3 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/ 14.2 ESS Plugin Both the TMC3in1 plugin and the required ESS plugin version are included in the zip file containing all the required TMC3in1 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: Figure 20 ESS Plugin Error Message It is assumed that you know how to install the ESS. If not, please visit the Warp9TD Getting Started page for Mach3. Be sure to use the SCU (System Configuration Utility) to simplify installation. www.texasmicrocircuits.com Page 27 of 47

14.3 You will need to merge the TMC3in1 File Set The current TMC3in1 Merge File Set is on our website. The zip file includes: a. Bitmaps required by the TMC3in1 Screen Set b. Macro scripts specific to TMC3in1 features c. Latest TMC3in1 Plugin and corresponding ESS Plugin in the Plugins folder d. TMC3in1 Screenset Scripts Folder with Files e. A generic TMC3in1 profile as a starting point for your system f. The TMC3in1 Screen Set When you open the Zip file, it will look like this: Figure 21 Zip File Contents Highlight and select all of the files inside the Zip file, and then drop or paste then into your C:\Mach3\ folder. It may ask you if you want to overwrite some files, and click yes. If you are not using the provided TMC3in1 profile, the macros in the macros folder will need to be moved into your profile s macro folder if you wish to run them. 14.4 Start Mach3, and select the ESS Plugin: www.texasmicrocircuits.com Page 28 of 47

Figure 22 - Select ESS Plugin 14.5 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. Figure 23 TMC3in1 Plugin is Disabled www.texasmicrocircuits.com Page 29 of 47

Figure 24 TMC3in1 Plugin is Enabled 14.6 TMC3in1 Firmware Update Screen Figure 25 Firmware Update Screen If the firmware in the Master, Spindle and THC processors, on the TMC3in1, is not the same version as required by the TMC3in1 plugin, the plugin will automatically update your firmware. This screen will appear and then go away after the firmware update is complete, on each processor. Depending on which plugin version you were using, when you switch to a new version, you may need to update the firmware on 1, 2, all 3 or none of the processors. Each g represents a good line of data being transmitted. If there is a corrupted data packet, the transmission will be www.texasmicrocircuits.com Page 30 of 47

aborted and the restarted. This may take several minutes to update, so it may be best to ignore the computer during that time. a. Updating - This indicates which processor is being updated. b. Percentage Complete - The current firmware update percentage. Once you reach 100% this window will disappear. (A new window may appear for a different processor s firmware). c. Serial Number - The serial number of your TMC3in1 14.6 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. 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. www.texasmicrocircuits.com Page 31 of 47

Figure 26 TMC3in1 Config Window 14.7 Short Description of THC Configuration Parameters a. Reset Turns off TMC3in1 TMC3in1 state controlled by Reset button on Mach3 screen b. Tip Voltage Divider This is the divider ratio matching the one set in the plasma power supply c. Tip Voltage Source The TMC3in1 has two tip voltage polarities. Choose Positive Tip Volts or Negative Tip Volts based upon your plasma system. www.texasmicrocircuits.com Page 32 of 47

d. Pierce Count Limit Threshold of pierce counts before the red pierce count exceeded warning light comes on e. Target Tip Volts This is the default set by the user and displays on the Mach screen. f. Target Band This is the +/- voltage band that no THC action occurs within. g. Linear Response Band This is the +/- voltage band that uses proportionally reduces the Z axis commanded velocity response h. THC Offset Used to trim THC tip volts to better match with cut height. This is normally not needed. i. 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. j. Mode: M11/M10 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. k. Mode: Delay after Arc Ok Enabling delay after Arc Ok received. The field to the right is the length of delay in seconds after Arc Okay is received before THC control start, when k is enabled. l. Enable Velocity Based Anti-Dive Mode This is a velocity based 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. The field to the right allows you to specify the lower end velocity % at which point THC will be inhibited if i is enabled. m. Enable Voltage Based Anti-Dive Enable the anti-dive parameters in this group. n. Average Tip Volts Average (1 to 128) tip voltage data points. o. % Change in ATV % change in ATV before anti-dive engages p. % THC Response % THC response rate when anti-dive active q. Volts Above Target Tip Volts voltage point above target tip volts when THC is inhibited. r. Volts Below Target Tip Volts voltage point below target tip volts when THC is inhibited. s. Open Logs Opens log folder specified by path shown t. When Changes are Stored Shows when changes are store in XML and when not 14.8 Detailed Description of THC Configuration Parameters i. Selecting the Tip Voltage Divider Ratio While you are still in the TMC3in1 Config window: For the Arc Voltage Divider, select whichever one your machine uses: Figure 27 Voltage Divider Selection www.texasmicrocircuits.com Page 33 of 47

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! ii. Selecting the Tip Voltage Source The Tip Voltage is polarized. Installing reversed may cause damage to the TMC3in1 or your plasma unit. Please make sure you select the appropriate Tip Voltage Source in the THC Config window. If you are using: Figure 28 Tip Voltage Source Selection A Positive Tip Voltage System (like Thermal Dynamics), install the minus or ground (shown here as a black wire in the picture below) in pin 3 and the plus or positive (shown here as a red wire) in pin 4. www.texasmicrocircuits.com Page 34 of 47

Figure 29 - Wiring Tip Voltage A Negative Tip Voltage System (like Hypertherm), install the minus or ground in pin 4 and the plus or positive in pin 3, which is the opposite of the picture above. Figure 30- Plasma Connections (Single Ended Pins 3 & 4) iii. 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 27 - 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 28 Reset Pierce Counter The Reset Pierces button will allow you to reset your current pierces count to 0. iv. 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 www.texasmicrocircuits.com Page 35 of 47

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 31 Default Target Tip Volts Selection As stated above, the Target Tip Volts can also be specified on the main Mach screen. Figure 32 - Target Tip Volts Display v. 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 33 - Target Band Volts Selection When you are within the target band, the TMC3in1 will not issue any THC UP or THC DOWN signals. Changing the Target Band Volts Parameter: The default and minimum value is 0.25 V Larger values may cause the Z axis not to respond as quickly to changes in material height (i.e. warping). Also you may have rougher cuts Small values may cause the Z axis to oscillate if you have a slow Z axis vi. 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 www.texasmicrocircuits.com Page 36 of 47

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 34 - Linear Response Band Selection Changing the Linear Response Band 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 Z axis acceleration settings Examples of various voltage settings: Voltage Band Example A o Target Tip Volts = 120.0 o Target Band (Volts) = 0.25 o Linear Response Band (Volts) = 20.1 Figure 35 - Voltage Band Example A Voltage Band Example B o Target Tip Volts = 120.0 o Target Band (Volts) = 2.0 o Linear Response Band (Volts) = 5 www.texasmicrocircuits.com Page 37 of 47

Figure 36 - Voltage Band Example B 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. vii. 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 37 - THC Offset Volts viii. 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 and the ESS 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. www.texasmicrocircuits.com Page 38 of 47

Figure 38 - Run Simulator Mode You will need to: Make sure Mach is released from Reset In the THC Config window, check in the Run Simulator box, and press OK to close the Config window to start the Simulator Mode. 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. Simulator Mode will exit automatically after it completes its simulation. ix. 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. Figure 39 M11/M10 Mode 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). Figure 40 - Ports & Pins www.texasmicrocircuits.com Page 39 of 47

In the ESS Main Config, you would also need to set the output number accordingly. Figure 41 - 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 ). x. 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 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 milliseconds) Figure 42 - 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. xi. 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. www.texasmicrocircuits.com Page 40 of 47

Figure 43 - RESET THC Run Option xii. Selecting Velocity Based 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 44 - 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). Figure 45 - Ports & Pins 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. xiii. Selecting Velocity Based Anti-Dive Mode While you are still in the TMC3in1 Config window: This is the simplest Antidive 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. www.texasmicrocircuits.com Page 41 of 47

Figure 46 - Cutout Below % xiv. Selecting the Anti-Dive Mode based on Averaged Tip Volts Settings While you are still in the TMC3in1 Config window: This is the more advanced Anti-dive mode. To select and use any of the Voltage Based Anti- Dive features, you must check this box. Figure 47 - Enable Anti-Dive Mode based on Averaged Tip Volts xv. 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 48 ATV Data Points xvi. 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 49 - Change in ATV before Anti-Dive Engages xvii. 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 www.texasmicrocircuits.com Page 42 of 47

when Anti-Dive is active. Typically you would set this to 0.0 in order to prevent the tip from crashing. Figure 50 - %THC Response when Anti-Dive Active xviii. 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. Figure 51 Ceiling Above Target Volts to Disable THC xix. 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. xx. Figure 52 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. www.texasmicrocircuits.com Page 43 of 47

Figure 53 Open Logs Button and Path xxi. Explanation of When Changes are Stored and When they are not Though the explanation below may be obvious to some, 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. Figure 54 - When Changes are Stored www.texasmicrocircuits.com Page 44 of 47

14.9 Enabling THC Mode in ESS Plugin There is no longer an ESS setting for this, and it happens automatically. 14.10 Setting TMC3in1 Mach Ports and Pins a. 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). Figure 55 - Ports & Pins Outputs b. In Ports and Pins -> Inputs: All 3 of the input signals must be set exactly as shown. THC On is the Arc OK signal coming in. Figure 56 - Ports & Pins Inputs c. In Ports and Pins -> Mill Options You MUST NOT CHECK the box for Allow THC UP/DOWN Control even if not in THC Mode. www.texasmicrocircuits.com Page 45 of 47

Figure 57 - Ports & Pins - Mill Options 15 TMC3in1 Monitor Screen Figure 58 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. a. TMC3in1 Status Indicator - This is a multipurpose LED, with the following color codes: Black No Communications are present with the TMC3in1 Red The voltage is currently Overlimit Yellow The Input Tip Voltage is Reversed Green The TMC3in1 is Active and communicating properly with none of the above exceptions. b. THC Active This is Green when THC (Torch Height Control) is allowed, and Grey when THC is not allowed by the TMC3in1. c. Torch On Black when the Torch relay is Off and Green when the Torch Relay is On www.texasmicrocircuits.com Page 46 of 47