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

Connect the 15 pin D-type socket test socket cable to the PH10 PLUS test socket

The original probe signal of the 7-pin DIN socket is directly connected to the probe interface (when the internal interface is not used)

DC power socket power input connected to the accompanying 24Vdc power adapter

Equipotential connection of equipment grounding point is used for system grounding

Reset button to reset the controller and restart after pressing

Detailed explanation of PICS interface signals (for real-time control)

PICS (Product Interconnection System) is a real-time signal standard defined by Renishaw. The key signals are as follows:

STOP (pin 1): Low level active. When PHC10-3 PLUS detects overload, blockage, disconnection or USB cable removal of the test seat, it will actively lower this signal. The CMM controller can also urgently stop the movement of the measuring seat by lowering the STOP.

POFF (pin 2): Low level active, used to turn off the probe power. POFF has a lower priority than STOP.

PDAMP (pin 7): Low level active, used to reduce the sensitivity of strain gauges (such as SP25M) and suppress false triggering during rapid movement.

LED anode (pin 4): Constant current input, used to light up the LED on the measuring socket.

Probe signal (pin 5) and probe return (pin 9): transmit probe trigger signal (when using non multi wire cables). At this point, the length of the PICS cable must be less than 0.5 meters, otherwise the signal is susceptible to interference.

Comprehensive analysis of configuration switches (DIP switches)

4.1 Communication related (switches 1-6)

Baud rate (switches 1-3):

Baud rate SW1, SW2, SW3

300 DOWN DOWN DOWN

600 UP DOWN DOWN

1200 DOWN UP DOWN

2400 UP UP DOWN

4800 DOWN DOWN UP

9600 UP DOWN UP

19200 DOWN UP UP

Stop position (switch 4): UP=2 stop position, DOWN=1 stop position.

CTS protocol (switch 5): UP=requires CTS signal to send, DOWN=ignores CTS (it is recommended to short circuit CTS and DTR when connecting).

LF protocol (switch 6): UP=append line break after each message, DOWN=do not add.

Note: Switches 4-6 are only valid in the basic command set (switch 9 down). In the extended command set mode, the data format is fixed as: 1 start bit+7 data bits+1 even check+1 stop bit, and CTS is always required.

4.2 Interface and Function Switches (Switches 7-13)

Switch function up (UP) and down (DOWN)

7. PPOFF behavior: PPOFF is valid during the seat index period, only PDAMP is valid during the seat index period

8 HCU2 probe damping/reset button enabled/disabled

9 Command Set Extended Command Set Basic Command Set

10 probe reset time extension (applicable to long extension rods) standard

11 probe connection methods PICS or 7-pin DIN, only 5-pin DIN

12 output configuration PICS DIN

13 probe wire isolation machine cable mode Multiwire mode

Important: When using a multi wire scanning probe (such as SP25M), switch 13 must be set to DOWN, and switches 11 and 12 also need to be set accordingly (usually 11=DOWN, 12=DOWN).

RS232 and USB communication configuration

5.1 Definition of RS232 connector pins (25 pin D-type)

Pin signal description

Shielding layer of shielded cable

2 TxD sent to CMM computer

3 RxD received from CMM computer

4 RTS send request (maintain+12V after initialization)

5 CTS clear sending (from CMM computer); If CMM does not provide this signal, pins 5 and 20 need to be short circuited

7 SG signal ground

20 DTR indicates that PHC10-3 PLUS has been powered on

Wiring suggestion: The simplest three wire connection method is to connect 2-3-7 and short-circuit 4-5-20 on the CMM side (or 5-20 on the controller side). But a more reliable way is to use a full handshake.

5.2 USB Communication Points

The driver program (signed) from the accompanying CD must be installed.

The maximum cable length is 5 meters, which can be extended to 30 meters through cascading USB hubs.

Avoid sharing the same USB root hub with high data bandwidth devices such as cameras and hard drives to prevent communication delays that may cause the test socket response to timeout.

If the USB cable is unplugged during operation, PHC10-3 PLUS will immediately assert the PICS STOP signal, triggering a safe shutdown.

5.3 Differences between Two Command Sets

Basic Command Set (Switch 9 DOWN):

Compatible with existing PHC10-2 communication protocols and software commands.

Adjustable stop position, CTS, LF and other parameters.

Suitable for most traditional CMM control systems.

Extended Command Set (Switch 9 UP):

Fixed protocol (7 data bits, even parity, 1 stop bit).

Support software control of HCU2 and PICS functions (such as probe damping, POFF, LED OFF).

Support advanced functions such as TP200 probe reset.

Introduce product identifiers and device numbers for future multi interface control.

CMM software needs to support extended command sets.

Selection suggestion: Unless you need special features to expand the command set (such as multi interface collaboration), you should usually choose the basic command set for maximum compatibility.

Diagnostic table for front panel LED indicator lights

The front panel of PHC10-3 PLUS provides 10 LEDs to reflect the system status in real-time. The following table is the basis for rapid on-site diagnosis:

The name and color of the LED light up indicate its meaning

POWER green power supply is normal

The STOP red controller is asserting PICS STOP; Flashing indicates that PI 200-3 is asserting STOP

HEADREADY green test seat is ready and can accept commands

HEAD ACTION yellow measuring seat is indexing (moving)

DATUM ERROR Red measurement base origin error (needs to be reinitialized)

OBSTRUCT ERROR The red measuring seat movement is obstructed or cannot be locked in place

OVERLOAD ERROR Red test seat overload (unlocked due to excessive force during locking)

TP7 green detected TP7 probe

TP200 green detected TP200 probe

STD green detected TP2/TP6/TP20 probe

SEATED green probe is in place (trigger mechanism reset)

DAMPED yellow probe damping activated

Typical abnormal combination:

DATUM ERROR is constantly on: The measuring seat has lost its origin point and needs to send a "return to zero" command or power off and restart.

OBSTRUCT ERROR is constantly on: Check if there are any obstacles on the movement path of the test seat or if the extension rod has collided.

STOP constantly on: There may be an external STOP signal (check CMM emergency stop circuit) or an internal fault in the controller.

The LED of the probe type does not light up: the probe is not connected correctly or the probe cable is damaged.

Common troubleshooting process

On site engineers encountering integration or operational issues with PHC10-3 PLUS can troubleshoot in the following order.

Fault 1: Controller power LED does not light up

Check the main power cord and IEC socket.

Measure whether the output of the power adapter is 24Vdc (allowable ± 5%).

Confirm that CMM is not in emergency stop state (some systems may cut off the power supply to the controller).

Fault 2: The test seat does not move in automatic mode

Communication failure: Verify that the RS232 baud rate is consistent with the CMM computer; Check if the CTS signal is raised (if using hardware handshake).

Command set mismatch: Ensure that the position of switch 9 is consistent with the expected CMM software.

Cable fault: Measure the internal resistance of the test seat cable (PHC side), and the maximum resistance of a single core should not exceed 2.5 Ω.

Check the HEAD READY LED: If it doesn't light up, it means the measuring seat is not ready and the origin may not have been found.

Fault 3: No response in manual mode (HCU2)

Check if the HCU2 cable is connected to a 9-pin D-type socket.

Confirm whether switch 8 (HCU1 button enabled) is in the UP position (if HCU2 is used, this switch also affects).

In manual mode, the measuring seat should be able to respond to slow jogging. If there is no response, try pressing the "emergency stop" release button on HCU2.

Fault 4: CMM computer cannot receive probe trigger signal

Check the probe cable: When using a standard two-wire trigger probe, a Multiwire bypass connector must be installed, otherwise the signal cannot pass through the internal relay of the controller.

Multi wire probe configuration: If using a scanning probe such as SP25M, it is necessary to confirm that switch 13=DOWN (Multiwire) and that the cable is correctly connected to the measuring socket and computer interface.

Measurement trigger output: When the probe triggers, check for any on/off changes between pins 5-9 of PICS (or measure directly from pin 7-DIN).

Fault 5: Poor measurement repeatability or decreased accuracy

Mechanical looseness: Check whether the mounting screws of the measuring seat and the connection between the measuring seat and the CMM spindle are tightened.

Probe damping incorrect activation: Confirm that the DAMPED LED is not lit during the measurement process (damping will reduce trigger sensitivity). If it lights up incorrectly, check if the CMM software incorrectly asserts the PDAMP signal.

Cable interference: Ensure that the measuring seat cable, PICS cable, and power line are routed separately and shielded and grounded as a whole.

Special case: XON/XOFF flow control under extended command set

If the extended command set is enabled, CMM computers can pause controller data transmission by sending XOFF (0x13) and resume by sending XON (0x11). Attention: If the output buffer overflows, the controller will lose response. Therefore, it is recommended not to frequently use XON/XOFF, but to achieve reliable transmission through CTS/RTS hardware flow control.

Maintenance and spare parts recommendations

There are no user repairable parts inside PHC10-3 PLUS. Any faulty unit should be returned to a Renishaw authorized service center for repair. Daily maintenance only requires:

Cleaning: Use soft and dry non-woven fabric to wipe the shell and interface, do not use solvents.

Cable inspection: Regularly check whether the measuring seat cable (especially coiled cable) has cracked outer skin or broken core wire.

Dial switch record: It is recommended to record the current switch setting value on the device label for quick recovery.

Recommended spare parts (for quick replacement):

A pre configured PHC10-3 PLUS controller (A-5863-0100 standard version, or A-5863-0200/0300 integrated PI 200-3 version)

A 6-meter PLM6 test seat cable (spare part)

A DP4024N3M power adapter