CNC Router Parts PRO 4824 Series Installation Instructions Manual

Plasma upgrade kit

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Assembly instructions manual (9 pages)

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CNC R

Plasma Upgrade Kit

Version 2016Q3.1

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Summary of Contents for CNC Router Parts PRO 4824 Series

Page 1 CNC R Plasma Upgrade Kit Version 2016Q3.1...
Page 2 Plasma Upgrade Instructions CONTENTS Contents 1 TMC 3-in-1 Installation 2 Software Conﬁguration Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 6 Plasma Upgrade Instructions • Unplug the indicated ribbon cable from Ethernet Smoothstepper (ESS) as shown Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 7 Plasma Upgrade Instructions • Unbolt and remove grounding wire assembly as shown and set the grounding nut aside Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 8 Plasma Upgrade Instructions • Unplug the indicated Phoenix connectors from ESS and CRP560 card Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 9 Plasma Upgrade Instructions • Remove the 8 indicated screws retaining gland plate and set aside • Gently pull gland plate away from CRP800 case Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 10 Plasma Upgrade Instructions • Cut indicated cable tie to relieve strain on wire bundle and create access to SP/THC port wiring Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 11 Plasma Upgrade Instructions • Remove the indicated 4 screws holding ESS to CRP560 and set aside Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 12 Plasma Upgrade Instructions • Install the provided 4 nylon standoﬀs into the aluminum standoﬀs at the corners of the ESS • Fold CRP560 to ESS ribbon cable as shown Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 13 • Place the TMC Card on the previously installed nylon standoﬀs Note: Be sure the TMC’s connectors ﬁt securely into both port 3 and the expansion port of the ESS. Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 14 Plasma Upgrade Instructions • Reinstall 4 screws from step 2.1 into nylon standoﬀs as indicated Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 15 Plasma Upgrade Instructions • Remove the indicated multi-piece Phoenix connector from the THC Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 17 Plasma Upgrade Instructions • Isolate the white/black, white/green, red/black, red/white, orange/black, green/black wires for installation into the TMC card Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 18 • Install the white/black wire from the CRP860-03E into position 1 • Install the white/green into position 2 • Install the red/black wire into position 3 • Install the red/white wire into position 4 Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 19 Note: While it is possible to install bare conductors into Phoenix type connectors, please use crimped ferrules or tinned wires if possible. Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 20 Plasma Upgrade Instructions • Install orange/black wire into position 7 • Install green/black wire into position 8 • Reinstall Phoenix connector onto THC board Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 21 Plasma Upgrade Instructions • Remove the indicated Phoenix connector from the 12v harness and set aside Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 22 Plasma Upgrade Instructions • Remove indicated red, black, blue and blue-white wires from the 12v and 5v power supplies Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 23 Plasma Upgrade Instructions • Remove the existing 4 wire harness and replace with the supplied 12v harness Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 24 • Install the new 12v harness as shown Note: Double ferrules of the new 12v harness should be positioned at the "bottom" of the control unit near the CRP560 card and ESS Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 25 Plasma Upgrade Instructions • Install the double-ferrules of the new (supplied) 12v power harness into the previ- ously set aside phoenix connector of the CRP560 card as shown Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 26 • Install the remaining black and red wires of the 12v harness into the negative and positive (respectively) positions of the J1 phoenix connector of the TMC card Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 27 • Reinstall ribbon cable into ESS • Reposition gland plate and secure with 8 screws removed in step 1.6 • Reinstall grounding wire assembly and secure with nut • Reconnect motor drivers Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 29 Be sure to use the SCU (System Conﬁguration Utility) to make it easy to install. • http://warp9td.com/index.php/sw For information on installing the TMC3in1 plugin for Mach3 see the CNC Router Parts Software Setup and Usage guide. This is required for proper function of your torch height controller.
Page 30 In Mach3’s Ports and Pins menu make the following changes: • (Under Output Signals) Enable Outputs 4, 5 and 6 and set them as shown (Port 3 Pins 14, 16 and 17 respectively) Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 31 Plasma Upgrade Instructions • Enable THC On, Up, and Down and set them as shown (Port 3 Pins 10, 13 and 15 respectively) Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 32 Plasma Upgrade Instructions • (Under Spindle Setup) Change Clockwise (M3) and CCW (M4) Output# to 6 Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.
Page 33 In Mach3’s Plugin Control Menu, select "ESS - Spindle, THC and Laser Conﬁg" and then make the following changes • Set the XY PWM velocity to Output 5 Plasma Upgrade Instructions Version 2016Q3.1 Copyright©2016 CNC Router Parts LLC. All Rights Reserved.

This manual is also suitable for:

Pro crp800-4824