Operation manual – THC3T-04

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: sales@robot3t.com

 Website : www.robot3t.com

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 Operation manual – THC3T-04

1. Device information

1.1 Introduce

The unit is a modern analogue - microprocessor plasma torch height controller that
operates by analyzing voltage changes in the plasma source due to variations in height between
the torch tip and the material being cut. The microprocessor makes determinations to raise or
lower the torch based off of the strength of the voltage signal being read. It is equipped with an
easy to read LCDs display and three user friendly keys making operation simple and does not
require any additional measuring instruments. The device has patented solutions made with the
highest quality components to ensure a safe, durable, and reliable long-term operation.

Simplified block diagram: LCD INPUT BLOCK

DISPLAY (step/dir,
start/stop,
INTERFERENCE
home/limit…)
PLASMA DIVIDER FILTERS THC3T-04 CONTROLLER
CUTTER BOARD CIRCUITS
OUTPUT BLOCK
(step/dir,
KEYBOARDs relays)

The main parameters of the master board:

Parameter name Acceptable

Supply voltage 24 - 36V DC
Maximum input voltage of 1:50 divider 10VDC
Duty cycle 100%
Weight 150g
External Dimensions (L * W * H) 118x108x40[mm]

The THC3T-04 package includes:

 1 main board;
 1 LCD display board;
 1 cable RS232 and 1 potentiometer 10K;
 Operation manual (this book);
 1 metal detector sensor;
 1 divider board;

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 Operation manual – THC3T-04

1.2 Function block diagram main board

Fig1. Block diagram main board

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 Operation manual – THC3T-04

Fig2. Block diagram main board

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 Operation manual – THC3T-04

1.3 LCD display board

Name/Application Refer to
Display
LCD 16x2 show the THC3T- 1
04 master status.
1
Keyboards
 Enter: Used to change
the mode and set 3
mode. 2 2
 Up & Down: Used to

PULSE_X
change the display or

PULSE_Y
OUT_DIR

DIR_IN
PULSE_IN
OUT_PULSE
DISABLE
OUT_5VDC
GND
data in each mode.
Rs232 & power cables
Connect between main board
3
and display board via RS232
interface. Fig3. LCD display board

1.4 Divider board

Fig4. Divider board

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 Operation manual – THC3T-04

1.5 How THC3T-04 works

 When IN_START is not activated, THC3T-04 operated on manual mode. Z-

axis was jog up/down by MACH3 or 2-buttons connected to
JOG_UP/JOG_DOWN signals.
 When IN_START is activated (connected to 0V_EXT), and area arc-voltage
divider board from ARC_OK_MIN to ARC_OK_MAX (parameter on LCD
display board), then THC3T-04 will switch to auto mode.
- First, the torch goes down, touch the work piece by metal detector sensor;
- Second, torch goes up by about setting value START_DISTANCE
(parameter on LCD display), allows exporting out OUT_FIRE signal and
waited some time for priming hole;
- Next, send OUT_ARC signal to breakout board to control the automatic
cutting operations.
- In the end, IN_START is not activated, OUT_FIRE and OUT_ARC signals
will off and move up the original STOP_DISTANCE (parameter on LCD
display).

THC3T-04 have 3-switchs on board to select mode operations:

Fig5. Switch select mode

ON OFF DESCRIPTION
 To enable receive pulse X, pulse Y to adjusted response
SW1
 Use to RUN SPEED on LCD (not connect PULSE X, PULSE Y)
To receive ARC_VOLTAGE from Divider board (in case of plasma

cutter haven’t divider)
SW2
To receive ARC_VOLTAGE from plasma cutter (Plasma cutter have

divider 1:50)

SW3 Logic-Dir inversion


Table1. Select mode operation

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 Operation manual – THC3T-04

2 Configuration LCD display board

 Work Screen

- Tip V: Arc-voltage from plasma cutter

through divider board to main board.
- Set V: Voltage from potentiometer, was
change to control height torch.
- In the Bottom right corner display the up
or down arrow correspond to the Z-axis
motion.
Fig6. Work Screen
 Mode Screen

Press Enter on LCD display board to change Mode Screen.

No Mode Value Description

This parameter determines the value
1 Sensitive 0 to 250
respond of Z axis motion
2 ARC OK MAX 0 to 300 ARC OK MAX = TIP V + 40
3 ARC OK MIN 0 to 300 ARC OK MIN = TIP V - 40
Distance to start turn on plasma, from
4 Start distance 0mm to 99mm
torch to the material surface
Distance to move up when finish the
5 Stop distance 0mm to 99mm cutting, from torch to the material
surface
6 Wait time 0 to 9.9s Wait time after ignition
Velocity of Z axis when move down to
7 Home speed 0% to 99%
detect the surface of material
Velocity of Z axis in automatically torch
8 Run speed 0% to 99%
height control mode
9 Ratio 0 to 5000 pulse/mm Ratio of mechanical drive of Z axis
Go back Press Enter button to go back work
10 none
screen
Table2. Parameters on LCD display

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 Operation manual – THC3T-04

3 Signals summary of THC3T-04

3.1 Power supply

24-36V
GND
Fig7. Power
3.2 Power external
Supply

GND_EXT

24V_EXT

Fig8. Power external

Note:
- For stability and better noise rejection, the external power should been
supplied, after detachable 2-jumper inside the device;
- In case the user does not want to use any other power source, can be used from
2-pins GND_EXT and 24V_EXT. By default 2-jumper has been setup in the
device.

3.3 Connect LCD display board

Fig9. Connect main board and LCD display board

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 Operation manual – THC3T-04

3.4 Connect potentiometer

Potentiometer to change value

set V on LCD display board.

Fig10. Connect potentiometer

35 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.

Fig11. Connect Acr-voltage from divider board

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 Operation manual – THC3T-04

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
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.

Fig12. Connect Acr-voltage from plasma cutter

3.6 Input IN_DETECT

BROWN
BLUE
BLACK

Fig13. Connect metal detector sensor

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 Operation manual – THC3T-04

3.7 Input IN_START (active LOW)

BREAKOUT BOARD

IN_START
NO
OUTPUT
RELAY

NC
GND_EXT
COM
Fig14. In_start signal

3.8 Input TOP_LIMIT & BOT_LIMIT (active LOW)

NC TOP_LIMIT
COM

BOT_LIMIT
GND_EXT

Fig15. Top_limit & Bot_limit signals

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 Operation manual – THC3T-04

3.9 Input JOG_UP & JOG_DOW (active LOW)

JOG_UP

JOG_DOWN
GND_EXT

Fig16. Jog_up & Jog_down signals

3.10 Input Pulse/Dir

shield
PULSE_Z

PULSE_X
PULSE_Y
DIR_Z
+5VDC

BREAKOUT BOARD

Fig17. Pulse/dir from breakout board

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3.11 Input Disable (Active LOW)

GND_EXT

DISABLE

Fig18. Disable signal

3.12 Output Pulse/Dir

shield
STEP+
DIR+
STEP-
DIR-

DRIVER Z-AXIS

Fig19. Output Pulse/Dir to driver Z

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3.13 Output OUT_FIRE & OUT_ARC

BREAKOUT
BOARD

RELAY 24VDC
RELAY 24VDC OUT_FIRE
ARC OK
ect…
INPUT

PIN12
PIN13
PIN15

Fig20. Output Out_fire & Out_arc signals

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4. Fast connect

 Step 1: Connect power supply (fig.7-page.8), LCD display board (fig.9-page.8)

and potentiometer (fig.10-page.9)
 Step 2: Connect input pulse/dir from breakout board (fig.17-page.12)
 Step 3: Connect output pulse/dir to driver Z (fig.19-page.13)
- Jog up/down on MACH3 software to control Z-axis (OKStep4);
- In case of Z-axis can’t goes up/down, should be strictly adhered to:
 Checking power supply of THC3T-04, breakout board and driver Z;
 Checking input pulse/dir from BOB (route and configure for a
software);
 Checking step/dir of driver Z.
 Step 4: Connect input In_detect (fig.13-page.10)
 Step 5: Connect input In_Start from breakout board (fig.14-page.11)
- When output relay of breakout board is turned on, In_start signal is
activated. The torch goes down and touch the workpiece  metal detector
sensor is activated. Torch goes up to Start_distance (parameter on LCD
display board) (OKStep 6)
- In case of, Z-axis can’t goes down, should be strictly adhered to:
 Checking power supply of THC3T-04, breakout board and driver Z;
 Checking output relay of breakout board (route and configure for a
software);
 Checking led status of metal detector sensor. Led off when sensor
touch workpiece.
 Step 6: Connect output Out_fire and Out_arc (fig.20-page.14)
- Turn off power plasma cutter;
- Turn on power supply THC3T-04, breakout board and driver Z;
- Setup parameters on LCD display board:
 ARC_OK_MAX: 300
 ARC_OK_MIN: 0
 Set V: 10 (potentiometer value on Workscreen)
- Turn on output relay of breakout board, In_start is activated. Z-axis goes
down, touch workpiece and goes up to Start_distance  Relay Out_fire &
Out_arc is turned on  Step 7

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 Operation manual – THC3T-04

- In case of, relay Out_fire or Out_arc isn’t turned on. Checking relay
24VDC and line from signal to relay.
 Step 7:
- Turn on power plasma cutter;
- Turn on output relay of breakout board and read acr-voltage TIP_V on
LCD display board  Turn off output relay.
- Setup parameters on LCD display board:
 ARC_OK_MAX = TIP_V + 40;
 ARC_OK_MIN = TIP_V - 40;
 Set V: the same as torch height (potentiometer value on
Workscreen)
 Step 8: Configure on MACH3

5 Operation with MACH3 software

To integrate THC3T-04 with Mach3 software, customer need to config some

parameters in software.

4.1 Macro “m3.m1s”

DoSpinCW()

Sleep(100)

While (IsActive(INPUT1))

Sleep(10)

Wend

sleep(100)

While (IsActive(INPUT1))

Sleep(10)

Wend

4.2 Macro “m5.m1s”

DospinStop()

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4.3 Config input for ARC_OK signal

Fig21. Config input

User can use any input, just check this input have to same in macro M3

4.4 Select OUTPUT

Fig22. Config output

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