Installation and troubleshooting of Renishaw PHC10-3 PLUS controller

Renishaw PHC10-3 PLUS Motor Seat Controller: A Complete Technical Guide from Replacement to Integration

In coordinate measuring machines (CMM) and precision measurement systems, the Renishaw PH10 PLUS series motor gauge has become the industry standard for its flexible probe orientation capability. The PHC10-3 PLUS controller that drives the test bench is the "nerve center" of the entire system - it is responsible for parsing instructions from the upper computer, managing the movement of the test bench, coordinating probe signals, and communicating with external devices such as automatic replacement racks. For equipment integrators and maintenance engineers, correctly installing, configuring, and diagnosing PHC10-3 PLUS is a prerequisite for ensuring efficient operation of measurement systems.

This article is based on the installation guide of the controller, combined with common on-site issues, providing a complete technical manual covering hardware upgrades (replacing PHC10-2), dip switch settings, interface wiring, RS232/USB communication configuration, LED status analysis, and troubleshooting.

PHC10-3 PLUS Overview: Core Features and Applicable Scenarios

PHC10-3 PLUS is a controller designed specifically for the PH10 PLUS series motor test bench. It manages all positioning functions of the test bench, including A-axis (pitch, range 0 ° to 105 °) and B-axis (rotation, range ± 180 °) position control, and supports signal switching for the probe interface. However, please note that the controller itself does not process probe trigger signals; It only provides channels to transmit probe signals (such as from TP200, TP20, or scanning probes) to the CMM controller.

Compared with the previous generation PHC10-2, PHC10-3 PLUS has made three important improvements:

Remove IEEE interfaces and add USB ports (B-type sockets) to meet the communication needs of modern computers.

Rearrange the rear panel connectors, but retain the same type of interfaces and labels for easy replacement in place.

Simplified and reorganized the configuration switches (DIP switches), removing unused switches and consolidating the remaining switches into a single row.

Key compatibility warning: PH10 PLUS system components are completely incompatible with PH9 or PH20 systems. It is absolutely forbidden to connect the PH10 PLUS test socket to the PH9 controller, otherwise it may cause hardware damage.

Typical system composition

PH10 PLUS motor measuring socket (such as PH10T, PH10M)

PHC10-3 PLUS Controller

Probe (TP2/TP6/TP20/TP200, etc.)

Probe interface (such as PI 200-3, or using the controller's built-in interface version)

Hand control unit (HCU2, optional)

CMM computer (via RS232 or USB communication)

Power adapter (Emerson DP4024N3M, 24Vdc output)

Upgrading from PHC10-2 to PHC10-3 PLUS: Switch Mapping and Precautions

For older systems using PHC10-2, PHC10-3 PLUS is designed as a plug and play alternative, but the definition of the rear panel switch has changed. The following table shows the key mapping relationships (in basic command set mode):

PHC10-2 switch PHC10-3 PLUS switch function up/down position meaning

1, 2, 3 1, 2, 3 baud rates (300-19200) refer to the baud rate table below

4 (unused) 4 (original 6) Stop bit Up=2 bits, Down=1 bit

5 (unused) 5 (original 7) CTS protocol upper=CTS enabled, lower=CTS disabled

6 (original 4) 6 (original 8) LF protocol+LF added, below=no LF added

7 (original 11) 7 PPOFF configuration: PPOFF is valid during the seat index period, and only PDAMP is valid

8 (original 12) 8 HCU1 probe damping/reset button up=enabled, down=disabled

9 9 Command Set Up=Extended Command Set, Down=Basic Command Set

10 probe reset time up=extended (Level 2), down=standard (Level 1)

11 (original 17+18) 11 interface connection up=PICS or 7-pin DIN, down=only 5-pin DIN

12 Output Configuration Up=PICS, Down=DIN

13 (new) 13 probe wire isolation: machine cable on top, multi wire on bottom

Key points for replacement operation:

Physical connection: The PHC10-3 PLUS uses the same 15 pin D-type head as the PHC10-2 to connect the test socket cable (via PLM6 or PLM7 cables, etc.), as well as the same 25 pin RS232 plug.

Switch migration: Set the original switch position to the new switch according to the table above. Note that switches 4, 5, 13, 14, 15, and 16 on PHC10-2 are no longer in use or merged.

After changing any switch, the "Reset" button on the back panel must be pressed, otherwise the new settings will not take effect.

During USB communication, switches 1-6 are ignored (can remain in the default down position), but switches 7-13 still function as intended.

Detailed explanation and connection guide for the rear panel interface

The rear panel of PHC10-3 PLUS provides the following interfaces (from left to right):

Interface type function

19 pin D-type plug PICS output connected to CMM controller, transmitting real-time status signals (STOP, POFF, PDAMP, etc.)

9-pin D-type socket HCU2 connected to manual control unit

25 pin D-type plug RS232 communication connection to CMM computer

USB Type-B socket for communication with CMM computer (requires driver installation)

DIP switch group configuration switch, see the previous section