ROBOT3T THC3T-02 User manual

Operation manual –THC3T-02 with Step/Dir
1
Notes on safety:
Improper use or disregard of these warnings may result in the injury or death of
people.
Do not, in any manner, process, take apart, or make changes to this product.
When installing this product, we recommend that if technical knowledge
becomes necessary please consult a qualified mechanic.
Do not operate this product with wet hands, wet gloves, or any wet clothing.
Provide adequate protection for all risks associated with plasma cutting.
Before turning the unit on, secure the safety of others, and read and
understand all instructions. If you have any questions or concerns, do not
continue.
After assembly, secure protection of contact terminals from operator's touch.
Here are the addresses where you can get help if you encounter problems:
E-mail: [email protected]om
Website : www.robot3t.com
Thank you for purchasing ROBOT3T product.
Please read this manual carefully and keep it for future reference.

Operation manual –THC3T-02 with Step/Dir
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1. Device information
1.1 Introduction
Compact THC3T-02 with Step/Dir output uses arc voltage to maintain a consistent
distance from the plate while the torch is cutting. This allows the system to maintain proper
torch height regardless of variations in the material, of flatness of the cutting bed.
Simplified block diagram:
The THC3T-02 package includes:
1 main board;
1 divider board;
1 potentiometer + cable.
1.2 Specifications
-Using potentiometer to set height’s torch;
-Voltage divider and noise to obtain the raw signal from the plasma cutting;
-Using signal processing algorithms to derive the voltage stability of the plasma;
-Apply a algorithm to support smooth motion, this is a advantage of Compact
THC3T-02;
-Auto calib the arc voltage with any plasma cutter;
-Auto detect ARC OK;
-Integrated voltage divider 1:50;
-Control directly the Z axes driver with Step/Dir signal, give high
performance and more accuracy.
Fig1. Block diagram
Output
Pulse/Dir

Operation manual –THC3T-02 with Step/Dir
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Fig2. Connection diagram

Operation manual –THC3T-02 with Step/Dir
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1.3 Main board
The main parameters of the master board:
Parameter name
Acceptable
Supply voltage
24 -> 36V DC
Maximum arc-voltage
660VDC
Maximum input voltage of 1:50 divider
+6.6VDC
Maximum current of output relays
150mA/100VDC
Weight
300g
External Dimensions (L * W * H)
95x110x45[mm]
Table1. Main parameter
Buttons:
- Menu: To change mode
-
Up, Down: To change the
display or data in each mode.
LEDs Status:
-
Power red LED; Run yellow LED (THC ready); Height
green LED (Torch height OK);
-
LED1 display “Up”, “Down”, “Height” status of Z-axis;
- LED2 is arc-voltage value from plasma cutter.
Fig3. Main board
LED2
LED
1

Operation manual –THC3T-02 with Step/Dir
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1.4 Divider board
SW MODE
DIVIDER
SW 1
SW 2
Discription
100:1
ON
ON
Voltage divide ratio 1:100
50:1
OFF
ON
Voltage divide ratio 1:50
ON
OFF
EXT-
50:1
OFF
OFF
Voltage input of 1:50
divider EXT(extension)
2Setup parameters
Press “menu”button to choice mode need to set:
No
Mode
Value
Description
1
U
Set-height
U10 to U300
To set height from torch to material in
auto mode by potentiometer.
Fig4. DIVIDER board

Operation manual –THC3T-02 with Step/Dir
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2
A
Area for control
A001 to A050
Device will change to auto mode when
the arc voltage from:
[Voltage Set - Area for control] to
[Voltage Set + Area for control]
3
S
Sensitive
S100 to S800
This parameter determines the value
respond of Z axis motion.
4
P
Arc-voltage
P000 to P300
Display the arc voltage value from
plasma cutter.
Addition of the new version (From 01/06/2017)
No
Function
Value
Description
1
Add paramer d on
the display menu
Delay time
d001 to d099
The delay time to send ARC_OK from
0.1 to 10s: THC will sent ARC_OK
signal after this delay, the main purpose
is Z axis not move down at the first time
of cutting.
2
Add paramer s on
the display menu
Run speed
s001 to s099
Change speed of motor from 0 to 100%
of max speed. This parameter only affect
in STEP/DIR version.
3
Add state of
Switch SW1
ON and OFF
Change the direction of Z motor.
Table2. Parameters on LED display

Operation manual –THC3T-02 with Step/Dir
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3 Signals summary of THC3T-02
3.1 Power supply
3.2 Arc-voltage
When connecting directly, use the shortest possible cables for connecting the plasma
cutter with THC controller - it is recommended the THC controller to be mounted directly
at the plasma cutter.
Fig5. Power Supply
24-36V DC
GND

Operation manual –THC3T-02 with Step/Dir
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Fig 6. Connect Arc-voltage from DIVIDER board

Operation manual –THC3T-02 with Step/Dir
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While being a universal THC, accepting full raw arc voltage for most any
plasma cutter on the market, an exciting new standard feature of this unit is the
addition of a 1:50 divider for an extremely fast, simple installation on most major
brands. There will most likely be a direct connection for this on the outside of the
plasma cutter's unit. Please refer to your plasma cutter owner's manual.
An example of how to connect the THC controller's measurement input with
the output of the very popular Hypertherm Powermax45® - The THC comes
Fig 7: Connecting the plasma source with DIVIDER

Operation manual –THC3T-02 with Step/Dir
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standard equipped with a low voltage output of 1:50 divider. This ratio is the
most commonly used division in most major brands and there will most likely be
a plug for this connection on the outside of the cutter's unit.
3.3 Potentiometer
To set height from torch to material by potentiometer. (U mode on LEDs display)
Fig9. Connect potentiometer
Fig 8. Plasma cutter with voltage divider 1:50 output

Operation manual –THC3T-02 with Step/Dir
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3.4 Input Step/Dir (opto)
3.5 Output ACR_OK (OPTO)
If the device operated at auto mode, ARC_OK signal is activated.
Fig10. Step/dir from breakout board
BREAKOUT BOARD
DIR_Z
shield
STEP_Z
+5VDC
BREAKOUT
BOARD
EXT_COM
ARC_OK
INPUT
GND
Fig11. Arc_Ok output

Operation manual –THC3T-02 with Step/Dir
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3.6 Output Step/Dir to Driver-Z
4. Fast connect
Step 1: Turn off plasma cutter.
Step 2: Connect power supply.
-After switching power on, red LED is turn on, the THC controller's display
shows "thc" message, a flashing voltage value is presented for 2 seconds and
then run yellow LED blink Turn off THC power and go to Step 3.
-In case of, power LED, run LED or LED 4 digit 7 segment display not turn on
Error.1-page.16
Fig12. Output Step/Dir to driver Z
DRIVER Z-AXIS
DIR-
DIR+
STEP-
STEP+
shield
Fig13. Power Supply
24-36V DC
GND

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Step 3: Connect input pulse/dir from breakout board.
Step 4: Connect output pulse/dir to driver Z
-Turn on THC3T-01 and wait yellow LED blink Jog up/down on MACH3
software to control Z-axis OK Turn off THC3T-02 and go to Step5;
-In case of Z-axis can’t goes up/down Error.2-page.16
Step 5: Arc_Ok output.
BREAKOUT BOARD
DIR_Z
STEP_Z
+5VDC
Fig14. Connect with
breakout board
Driver-Z
Dir-
Dir+
Step-
Step+
Fig15. Connect with
driver-Z
BREAKOUT
BOARD
EXT_COM
ARC_OK
INPUT
GND
Fig16. Arc_Ok output

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Step 6: Connect Arc-voltage (page.8&9)
-Turn on THC3T-02 and wait yellow LED blink. Press “menu” button 4-times
to select “P” mode (fig.17-page.14).
-Turn on plasma cutter and read arc-voltage area on LED display (example:
Arc-voltage area from 110 to 120) Turn off plasma cutter and go to step
7.
-In case of, THC don’t have arc-voltage Error.3-page.16
Step 7: Press “menu” button to select “U”mode and using potentiometer to set “set-
height” parameter value (fig.18-page.14)
-Example: If arc-voltage area on “P” mode from 145 to 155 then:
Set-height = (145+155)/2=150.
Step 8: Press “menu” button to select “A” mode (fig.19-page.15). This parameter
value set about 30. Device will change to auto mode when:
[Set-height –Area for control] < Arc_voltage < [Set-height + Area for control]
Example: “U” mode: Set-height = 150;
“A” mode: Area for control = 30.
Fig17. ARC-voltage parameter
Fig18. Voltage set-point parameter

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Device will change to auto mode and turn on relay ARC_OK when:
120 < Arc_volatge < 180.
Arc_voltage = Set-height
Height green LED turn on
Arc_voltage > Set-height
Z-axis goes down
Arc_voltage < Set-height
Z-axis goes up
Step 9: Press “menu” button to select work-screen (fig.20-page.15) and turn
on plasma cutter to using.
All parameters updated online during operation.
Fig19. Area for control parameter
Fig20. Area for control parameter

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5. Fault processing
No.
Code
Name
Causes
Countermeasures
1
Error.1
Power fault
-The THC is broken;
-The power is not
connected;
-The line of power
supply is broken;
-Replace the THC;
-Connect the power
supply;
-Check that the power
line are wired correctly;
-Replace the power cable
2
Error.2
Step/dir
fault
-The power of breakout
board and drive Z are not
connected;
-The line of step/dir from
breakout board to THC
is broken or not
connected;
-The line of step/dir
from THC to drive is
broken or not connected;
-Configuration on
MACH3 is not
corrected;
-The breakout board or
drive-Z are broken;
-The THC is broken;
-Check that the power
line are wired correctly;
-Check that the step/dir
line are wired correctly
or replace;
-Check that the step/dir
line are wired correctly
or replace;
-Check that
configuration on
MACH3;
-Replace breakout board
or drive-Z;
-Replace the THC.
3
Error.3
Arc-voltage
fault
-The power of plasma
cutter is not connected;
-The line of arc-voltage
from divider board to
THC is broken or not
connected;
- The THC is broken;
-Connect the power
supply;
-Check that the step/dir
line are wired correctly
or replace;
-Replace the THC.