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Burny 1100 CD Owner's Operation And Maintenance Manual

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BURNY
REPLICATOR
1100 CCD
Operation and
Maintenance
Manual
CE Compliant
Revision: 7-July-2000
AO-70160-0 (A)
®

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Summary of Contents for Burny 1100 CD

  • Page 1 BURNY REPLICATOR 1100 CCD Operation and Maintenance Manual CE Compliant Revision: 7-July-2000 AO-70160-0 (A) ®...
  • Page 2 This documentation may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine-readable format without explicit written permission from CLEVELAND MOTION CONTROLS, INC. Cleveland Motion Controls, Inc. 7550 Hub Parkway Cleveland, Ohio 44125-5794 Telephone: 216 / 524-8800 Fax: 216 / 642-2199 ©...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS WARRANTY PART 1 SYSTEM OVERVIEW ................3 INTRODUCTION ................... 3 SPECIFICATIONS..................5 TEMPLATE PREPARATION..............16 1.3.1 INTRODUCTION ................16 1.3.2 INSTRUCTIONS FOR TEMPLATE PREPARATION ..... 16 PART 2 SYSTEM OPERATIONS................19 INTRODUCTION ..................19 OPERATOR CONTROLS ................20 2.2.1 INTRODUCTION ................
  • Page 4 3.5.1 INTRODUCTION ................38 3.5.2 LAMP REPLACEMENT ..............39 3.5.3 TOOLS ....................40 3.5.4 PARTS ....................40 PART 4 TRACER CALIBRATION ................ 41 INTRODUCTION ..................41 LOGIC BOARD MO-12199 CALIBRATION AND TESTING....41 4.2.1 POWER SUPPLY CHECKOUT............41 4.2.2 LOGIC BOARD ADJUSTMENTS:............ 42 4.2.3 MAXIMUM SPEED SETTING............

  • Page 5: Part 1 System Overview

    The Replicator® 1100 CCD is an optical tracing system complete with scanner assembly, operator control panel, two-axis servo amplifier, and scanner cable. Also available are motor gearbox assemblies and cables. When integrated with a Burny® CNC, the Replicator 1100 CCD can be configured for external two-axis and three axis (drive synchronized) servo amplifier applications.
  • Page 6 On units with an internal two-axis servo amplifier, the output of this card is then sent directly to both of the axis servo motors. The Operator Control Panel contains switches and controls that allow the operator to utilize all of the features of the tracing head. In addition, manual jog control of each axis is also provided.

  • Page 7: Specifications

    PART 1 – SYSTEM OVERVIEW SPECIFICATIONS 1.2.1 ENVIRONMENTAL SPECIFICATIONS ENVIRONMENT: Operating Temperature 0-50°C (32°-120°F) Relative Humidity 5%-95% Non-condensing 1.2.2 FEATURE SPECIFICATIONS KERF COMPENSATION: Kerf compensation is applied electronically and is available for tool diameter up to 12 mm. Kerf Compensation values range: –1 mm (-0.039 in) to +6 mm (0.236 in) + is away from the template TRACING SPEED:...
  • Page 8 1.2.3 ELECTRICAL SPECIFICATIONS MYX-12383 REPLICATOR 1100 (for AC lifters) “PWR” connector I/O ratings PIN # DESCRIPTION RATINGS Line HOT input for Replicator power supply. 115 or 230 V max AC, 50/60 Hz, 1.6 A max, protected by FU1 on rear panel. CAUTION:Set internal jumper according to voltage to be used.
  • Page 9 PART 1 – SYSTEM OVERVIEW MYX-12383 REPLICATOR 1100 (for AC lifters) “SOL” connector I/O ratings Note: All solenoids are served by the same fuse, FU2, 6.3 A, on the rear panel. Maximum total current of the solenoids is limited by this fuse.
  • Page 10 “LIFT” MYX-12383 REPLICATOR 1100 (for AC lifters) connector I/O ratings Note: All lifters are served by the same fuse, FU3, 6.3 A maximum, on the rear panel. Maximum total current of the lifters is limited by this fuse. PIN # DESCRIPTION RATINGS Lifter 1 up switched output...
  • Page 11 PART 1 – SYSTEM OVERVIEW Lifter 4 Hot un-switched output Un-switched 24 V max AC Line, 50/60 Hz, max 2 A See note above. Lifter 4 Neutral un-switched output Un-switched 24 V max AC Neutral, 50/60 Hz, max 2 A See note above.
  • Page 12 “PLAS” MYX-12383 REPLICATOR 1100 (for AC lifters) connector I/O ratings PIN # DESCRIPTION RATINGS 1, 2 Plasma Start relay normally closed contacts 30 VDC or 230 VAC, 2 A 1, 3 Plasma Start relay normally open contacts 30 VDC or 230 VAC, 2 A 4, 5 Plasma Stop relay normally closed contacts 30 VDC or 230 VAC, 2 A...
  • Page 13 PART 1 – SYSTEM OVERVIEW “PWR” MYX-12384 REPLICATOR 1100 (for DC lifters) connector I/O ratings PIN # DESCRIPTION RATINGS Line HOT input for Replicator power supply 115 or 230 V max AC, 50/60 Hz, 1.6 A max CAUTION: Set internal jumper according to voltage to be used.
  • Page 14 “SOL” MYX-12384 REPLICATOR 1100 (for DC lifters) connector I/O ratings Note: All solenoids are served by the same fuse, FU2, on the rear panel. Maximum total current of the solenoids is limited by this fuse. PIN # DESCRIPTION RATINGS Input - Solenoid Hot 24 V max AC, 50/60 Hz, or 24 V max DC, 6.3 A max Input - Solenoid Neutral or common Neutral or common for pin 9...
  • Page 15 PART 1 – SYSTEM OVERVIEW “LIFT” MYX-12384 REPLICATOR 1100 (for DC lifters) connector I/O ratings Note: All lifters are served by the same fuse, FU3, on the rear panel. Maximum total current of the lifters is limited by this fuse. PIN # DESCRIPTION RATINGS...
  • Page 16 Lifter 6 down output 24 VDC @ 1 A See note above. DC Lifter supply (+) Same as pin 19, except fused by FU3 DC Lifter supply (-) Same as pin 20, except fused by FU3 Chassis Ground 18 AWG wire “PLAS”...
  • Page 17 PART 1 – SYSTEM OVERVIEW MYX-12384 REPLICATOR 1100 (for DC lifters) “CMTR” connector I/O ratings PIN # DESCRIPTION RATINGS 3, 5 Clutch Switch on front panel 24 V max, 3 A max 2, 8 Cross axis Motor ± 30 VDC, 4 A 1, 4 Cross Axis Tach 20 V, 5 mA Max...

  • Page 18: Template Preparation

    TEMPLATE PREPARATION 1.3.1 INTRODUCTION The Replicator CCD tracing system uses a template, a full-scale drawing of the part or hole to be cut. The system can trace a line drawing or a silhouette. See the figure below showing these two drawing types. Silhouette Template Line Template Figure 1.2 –...
  • Page 19 PART 1 – SYSTEM OVERVIEW SPEED For speeds less than 1000 mm/min (40 in/min) a corner radius of 2.5mm (0.1 in.) is recommended. For speeds above 1000 mm/min the radius should be increased based on the machine performance. This will be directly related to the drives selected and the frame weight and stability.
  • Page 20 Figure 1.3 – Slowdown Marker...

  • Page 21: Part 2 System Operations

    PART 2 – SYSTEM OPERATIONS PART 2 SYSTEM OPERATIONS INTRODUCTION The operator has a choice of two modes available to control machine motion: • Manual Mode • Tracing Mode In Manual mode, the machine is moved (jogged) with the arrows on the directional keypad.

  • Page 22: Operator Controls

    Edge tracing or centerline tracing can be done on a line template. Only edge tracing can be done on a silhouette template. When the tracer is combined with a Burny CNC Control, the Burny must be out of "NC RUN" in order to operate the tracer functions.

  • Page 23: Tracer Panel Controls

    PART 2 – SYSTEM OPERATIONS 2.2.3 TRACER PANEL CONTROLS Figure 2.1 – Replicator 1100 CCD Upper Front (Tracer) Panel TRACER FUNCTION KEYS At the upper left of the Tracer Panel are the Tracer Function Keys and Indicators, shown in Figure 2.2 below. The three LED indicators give information about the tracing mode selected and its status by changing colors and blinking rates.
  • Page 24 JOG KEYS Start motion by pressing the red center stop (0) button on the Direction Keypad, then pressing the desired direction key. Press the red center Stop button to stop the motion. Figure 2.3 – Jog Keypad SPEED POT The SPEED POT (also referred to as the FEEDRATE knob) controls both the cut and jog speed.
  • Page 25 PART 2 – SYSTEM OPERATIONS In the pictures below, the circle represents the amount of material that the cutting device will remove during the cutting process, kerf. (This is sometimes thought of as tool diameter.) The diameter determines the kerf compensation value (e.g.

  • Page 26: Cut Process Controls

    CORNER SPEED The Corner Speed potentiometer sets the speed for Automatic Corner Slowdown. The Corner Speed potentiometer uses the speed switch high setting value. It must be turned down to give a speed value below the main cutting speed or it will have no effect. When this tracing mode is selected, the tracer slows down at corners and small radius areas of the template If the corner speed is set greater than the main cutting speed, there is no slowdown.
  • Page 27 PART 2 – SYSTEM OPERATIONS PLASMA/GAS SWITCH The Plasma/Gas control is a two-position toggle switch defined as follows: Down Maintained On: Oxygen cutting mode selected Maintained On: Plasma cutting mode selected GAS CONTROLS PREHEAT GASES This PREHEAT GASES switch is used to control the fuel gases and can supply power to a torch ignition circuit, if the machine is so equipped.

  • Page 28: Manual Mode

    PLASMA CONTROLS PLASMA START BUTTON This pushbutton is used to start plasma cutting. It activates the Plasma Control and Plasma Start relays and deactivates the Plasma Stop relay. The Plasma Start relay can be configured to have momentary or maintained contacts.

  • Page 29: Replicator Ccd Tracer Operation

    6. When the desired point is reached, press the red Stop button to halt motion If the Replicator is connected to a Burny control, CNC must be Off to make a manual move using the tracer controls. To make a straight cut using manual mode, proceed as follows: 1.

  • Page 30: Setting The Tracer Function Keys

    2.4.4 SETTING THE TRACER FUNCTION KEYS INTRODUCTION At this point, the template has been positioned, the machine has been moved to the desired starting point, and the Tracer Panel controls have been set. Now the tracing option must be chosen with the tracer Function Keys. Figure 2.5 –...
  • Page 31 PART 2 – SYSTEM OPERATIONS REPLICATOR TRACE FUNCTION ACTIVATION TABLE Power Up Mode Activation Keys LED Status Notes Power On Emergency Stop LED1, 2 and 3 Solid All 3 LED’s on GREEN — Switch Released GREEN—no flashing also when in Stop/Standby Edge Line Tracing Functions Mode Activation Keys...
  • Page 32 Centerline Tracing Functions Mode Activation Keys LED Status Notes Center line tra ce Step 1- Press F2 LED2 solid GREEN. LED2 solid GREEN to show mode LED1 and LED 3 fast blinking centerline mode selected. GREEN to indicate that one of the LED1 and LED 3 fast blinking directions must be pushed.

  • Page 33: Making The Pierce

    PART 2 – SYSTEM OPERATIONS 2.4.5 MAKING THE PIERCE The next step is to manually make the pierce. Set the Cut Process Controls as detailed in Section 2.2.4 and make the pierce. 2.4.5 STARTING LEADIN The starting position was chosen to provide the desired distance and direction to the template, where lock-on will occur and cutting of the part will begin.
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  • Page 35: Part 3 Installation And Maintenance

    PART 3-INSTALLATION AND MAINTENANCE PART 3 INSTALLATION AND MAINTENANCE WARNING ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT SHOULD INSTALL, ADJUST, OR SERVICE THIS EQUIPMENT. READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEEDING. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN INJURY OR DEATH.

  • Page 36: Installation Steps

    Line Conducted Emission and other portions of the EC directive is then the responsibility of the drive or other equipment manufacturer. All motors used with the Replicator must be supplied by Burny- Etek to insure compliance with the EMC Directive. If other than Burny-Etek...
  • Page 37 PART 3-INSTALLATION AND MAINTENANCE 3.3.2 All pieces should be carefully inspected for shipping damage, loose parts, and, most importantly, exposed uninsulated electrical parts. Contact Burny immediately if any problems occur. 3.3.3 Set the AC line voltage jumper as described in this installation section.

  • Page 38: Checking The Installation

    four mounting bolts, lockwashers, and nuts of 1/4-20 or M6 size. Use the hole pattern shown in the cabinet drawing of the 1100. 3.3.6 Route the Tracer cable from the Tracer to the Replicator. Be sure that the 360 degree grounding clamps are installed properly at both ends and that connector screws are tight.
  • Page 39 • Wire size for AC and DC mains should be AWG 18 or larger. • Each cable is supplied by, designed by, or approved by Burny • The system and all other electrical devices associated with and in the proximity of the system have been properly grounded.

  • Page 40: Service And Maintenance

    Service must only be performed by trained, authorized personnel. Generally, components for the 1100 system are not repairable by the user. In the case of malfunction of the system, Burny service personnel shall be consulted to assist in isolating the component(s) causing the problem. If a component has sustained damage, the involved assembly is usually returned to the factory and a replacement assembly shipped to the user.

  • Page 41: Lamp Replacement

    PART 3-INSTALLATION AND MAINTENANCE The on-site person can be most valuable in diagnosing problems: • Being familiar with equipment and user manual. • Knowing conditions and events at time of failure. • Being familiar with normal operation. • Observing and reporting damage accurately. 3.5.2 LAMP REPLACEMENT WARNING...

  • Page 42: Tools

    TOOLS Special tools are not required for installation and maintenance of the 2.5RS. In the unusual event that a user is to construct or repair a Burny supplied cable, proper crimping and extraction tools will be specified by Burny .

  • Page 43: Part 4 Tracer Calibration

    The GND Reference for all measurements is "0V" and can be located on the metal chassis of connector “J10” on the logic card. If the REPLICATOR CCD is connected to a Burny CNC, make sure the Burny is not in "NC RUN". 4.2.1 POWER SUPPLY CHECKOUT 1.

  • Page 44: Logic Board Adjustments

    4. Check for +12V (+/- 0.5) on output side (right lead) of 7812 regulator “U18”. 5. Check for +3.3V (+/- 0.07) on + lead of capacitor “C91”. 6. Check for +1.5V (+/- 0.04) on + lead of capacitor “C85”. 4.2.2 LOGIC BOARD ADJUSTMENTS: 1.

  • Page 45: Maximum Speed Setting

    PART 4-TRACER CALIBRATION with thick lines (greater than 4mm). Adjust the internal corner speed pot (P2) until the desired speed is achieved. 4.2.3 MAXIMUM SPEED SETTING Determine the maximum speed of the machine, either in millimeters per minute (mm/min) or inches per minute (in/min), using the following procedure.
  • Page 46 Dipswitch Max Speed Inches/min mm/min 26.5 29.7 32.9 36.1 39.4 1000 42.6 1082 45.8 1163 1245 52.2 1327 55.5 1409 58.7 1491 61.9 1573 65.2 1655 68.4 1737 71.6 1819 74.8 1901 78.1 1983 81.3 2065 84.5 2147 87.8 2229 2311 94.2 2393...
  • Page 47 PART 4-TRACER CALIBRATION Dipswitch Max Speed Inches/min mm/min 103.9 2638 107.1 2720 110.3 2802 113.5 2884 116.8 2966 3048 3429 3810 4191 4572 4953 5334 5715 6096 6477 6858 7239 7620 8001 8382 8763 9144 9525 9906...
  • Page 48 Dipswitch Max Speed Inches/min mm/min 10287 10668 11049 11430 11811 12192 12573 12954 13335 13716 14097 14478 14859 15240 NOTE: If your machine falls in between speeds listed above, choose the setting for the closest speed. If your machine falls very close to exactly between two settings, you may want to experiment with the two settings to see if one gives better tracing results than the other.

  • Page 49: Camera Rotation Adjustment

    PART 4-TRACER CALIBRATION 4.2.4 CAMERA ROTATION ADJUSTMENT INTRODUCTION The Camera Rotation Adjustment performed at the factory will usually be sufficient for a field installation. In the event that the camera is removed from the unit or the head assembly mounting plate is not parallel to the “Y” axis, then this adjustment must be performed.
  • Page 50 ADJUSTMENT Turn the unit off. Remove the nose cone per the “tracer head camera rotation alignment detail” in Figure 4.2 and loosen the two mounting plate screws. Place a sheet of white paper in front of the illumination lamp to reduce the light reaching the camera.
  • Page 51 PART 4-TRACER CALIBRATION Figure 4.2 – Camera Rotation Alignment...

  • Page 52: Special Key Functions

    4.2.5 SPECIAL KEY FUNCTIONS Mode Activation Keys LED Status Notes Display Software F1 + STOP Blink software version number Short blink = 0, long blink = Version together (in binary) on LED1. Light On / Off F1 + F3 Toggles halogen light on together and off.

  • Page 53: 120W Pwm Drive Calibration

    The GND Reference for all measurements is "0V" (TP1) located on the I/O power assembly MO-10773 or MO-12565. If the REPLICATOR CCD is connected to a Burny CNC, make sure the Burny is not in "NC RUN". 4.3.1 POWER SUPPLY ADJUSTMENTS (I/O power assembly MO-10773 or MO-12565) 1.

  • Page 54: Jumper Settings (I/O Assembly Mo-10773 Or Mo-12565)

    Offset Adjustment (P4, P5): To turn on both drive enables, push the yellow center button on the keypad and the red “0” stop button simultaneously. Adjust "XO" (P4) to remove any drift in the rail motor, Then adjust "YO" (P5) to remove any drift in the cross motor. Push the red “0”...
  • Page 55 PART 4-TRACER CALIBRATION OPTION PLUG (PL2) JUMPER SETTINGS Configuration Pl2 Jumper Settings No Notch Filters Jumper: 1-3, 2-4, 5-7, 6-8 With Notch Filters Jumper: 1-3, 5-7, 13-14, 15-16...
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  • Page 57: Part 5 Index

    Manual Mode ........26 AUX 1 Switch........24 Maximum Speed Setting..... 43 AUX3 SWITCH........25 O2 (Oxygen) Switch ......25 Burny CNC.......... 41 Operation..........27 Camera Rotation Ad justment....47 Operator Control Pane l ......4 Camera Rotation Adjustment....47 Operator Controls........
  • Page 58 Tools............ 40 Tracer Function Keys....21, 28 Torch Lifter Controls ......26...

  • Page 59: Part 6 Replacement Items

    PART 6– REPLACEMENT ITEMS PART 6 REPLACEMENT ITEMS 6.1 REPLACEMENT ASSEMBLIES ITEM: MYX-12384 REP 1100 CCD, 120W, 6 DC LIFTER ITEM DESCRIPTION MO-12631 1100/1300 POWER HARNESS MO-07308 1100/1300 TRACER CONTROLS HARN MO-08112 REP. 1000 SERIES CLUTCH OPTION MO-08648 REP 1100/1300 RELAY CARD 6 DC MO-08671 1100/1300 6 TORCH CUT HARNESS MO-08672...
  • Page 60 ITEM: MYX-12383 REP 1100 CCD, 120W, 6 AC LIFTER ITEM DESCRIPTION MO-12631 1100/1300 AC POWER HARNESS MO-07308 1100/1300 TRACER CONTROLS HARN MO-08112 REP. 1000 SERIES CLUTCH OPTION MO-08647 REP 1100/1300 RELAY CARD 6 AC MO-08671 1100/1300 6 TORCH CUT HARNESS MO-08672 1000 120W TACH HARNESS MO-08675...

  • Page 61: Replacement Parts

    PART 6– REPLACEMENT ITEMS 6.2 REPLACEMENT PARTS ITEM: MYX-12384 REP 1100 CCD, 120W, 6 DC LIFTER ITEM DESCRIPTION A16-21477 SWITCH,TOGGLE, ON-NONE -MOM A16-21479 SWITCH,TOGGLE, ON-OFF-MOM, A16-21480 SWITCH,TOGGLE, ON-OFF-ON, .25QC A16-21605 SWITCH,TOGGLE, ON-NONE -ON .25QC TRANSFORMER, 1000 CCD MAIN, 115/230V PRI, DUAL C14-32290 SECONDARY,44CT @ 3A (132VA) AND 12V @ 2.5A (30VA) C44-21838...
  • Page 62 ITEM: MYX-12384 REP 1100 CCD, 120W, 6 AC LIFTER ITEM DESCRIPTION A16-21477 SWITCH,TOGGLE, ON-NONE -MOM A16-21478 SWITCH,TOGGLE, MOM-OFF-MOM A16-21479 SWITCH,TOGGLE, ON-OFF-MOM, A16-21480 SWITCH,TOGGLE, ON-OFF-ON, .25QC A16-21605 SWITCH,TOGGLE, ON-NONE -ON .25QC TRANSFORMER, 1000 CCD MAIN, 115/230V PRI, DUAL C14-32290 SECONDARY,44CT @ 3A (132VA) AND 12V @ 2.5A (30VA) C44-21838 KEYBOARD, 1000 SERIES TRACER X01-31357...

  • Page 63: Part 7 Drawings

    PART 7-DRAWINGS PART 7 DRAWINGS...
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