Plasma Retrofit Guide¶

Before Beginning¶

Before beginning this installation, determine your electronics version and intended machine use. This information will assist you in following the correct installation steps.

Plug and Play CNC Controller Version

Some retrofit steps differ for revision 22.1.1 and newer CNC Controllers. These are identifiable by the serial number sticker (located inside the controller's lid) that reads:

CRP800 - 00E - N(motors) - D(drives) - EX - 22.1.1 or newer

More information can be found on the System Identification page in our Plug and Play CNC Controller Technical Manual.

Dual Purpose Plasma / Spindle Machines

• For revision 22.1.1 and newer Plug and Play CNC Controllers, follow the steps for setting jumpers on the CRP850-00E breakout board.

• For previous revisions of Plug and Play CNC Controllers, we recommend upgrading the CRP850-00E breakout board to maintain functionality of the spindle/VFD fault signal when using new Hypertherm Powermax torches. Please Contact Us for more information about this.

Plasma Only Machines

• For revision 22.1.1 and newer Plug and Play CNC Controllers, follow the steps for setting jumpers on the CRP850-00E breakout board.

• For previous revisions of Plug and Play CNC Controllers, follow the steps for disconnecting fault wires.

1. WarpRunner Installation¶

1.1¶

• Unplug the power cable from your CNC Controller and open the lid.

1.2¶

• Identify the 5 volt power supply and remove the adhesive cable tie mount from the side. This will be reinstalled in a future step.

1.3¶

• Remove the ferruled wires from both sides of the 5 volt power supply.

1.4¶

• Insert a small flat tip screwdriver into the retaining clip at the base of the 5 volt power supply.

1.5¶

• Push the screwdriver towards the power supply to un-clip and remove from the DIN rail.

1.6¶

• Install the new 12 volt power supply onto the DIN rail, positioned with the DC output on the right side as shown in the picture.

1.7¶

• Reinstall the ferruled wires into the 12 volt power supply.

• 120V Input (left side in picture)
  • Ground: Green
  • Neutral: White
  • Line: Black

• 12V Output (right side in picture)
  • V Positive: Blue
  • V Negative: Blue/White

• Reattach the adhesive cable tie mount to the side of the new power supply.

1.8¶

• Remove the indicated connectors on the motor drivers.

1.9¶

• Remove the screws attaching the gland plate and set aside.

1.10¶

• You should now be able to tilt the gland plate enough to gain access to the SP/THC port wiring bundle indicated in the picture.

1.11¶

• Remove the two ferruled wires from the indicated Phoenix connector on the ESS.

1.12¶

• Remove the indicated screws attaching the ESS to the CRP850-00E and set aside.

1.13¶

• Remove the ethernet cable from the ESS.
• Remove the indicated ribbon cables from the CRP850-00E breakout board.
• Remove the ESS from the standoffs and carefully set aside.

1.14¶

• Remove the remaining ribbon cable and wires from the CRP850-00E breakout board.
• Remove the indicated screws attaching the CRP850-00E breakout board to standoffs and set aside.
• Remove the CRP850-00E by pulling straight out of the motor drive connections.

1.15¶

• Flip the old CRP850-00E over and remove the standoffs by removing the screws.
• Transfer the standoffs to the new CRP850-00E-F04 breakout board.

1.16¶

• Locate the JPFault jumpers on the CRP850-00E-F04.
• Set both jumpers to the Open position as shown. This will leave one pin exposed for each jumper.

1.17¶

• Install the CRP850-00E-F04 straight down onto the motor drives. Press down firmly at each connection to ensure it is fully seated.
• Reinstall the mounting screws you removed earlier.
• Reinstall the small ribbon cable.
• Reinstall all previously removed wires. Pay careful attention to the connecting terminals. (see next page)

1.18¶

• Mount the ESS on the standoffs and install the provided standoffs into the ESS mounting hole locations.
• Connect the ethernet cable to the ESS if previously removed.

1.19¶

• Reconnect the ESS ribbon cables to the CRP850-00E-F04. Note the connection location for each port above.

1.20¶

• Place the WarpRunner card on the previously installed standoffs.

1.21¶

• Secure the WarpRunner card to the standoffs using the four screws you removed earlier from the ESS (in Step 1.13).

1.22¶

• Install the other end of the power wires you connected to the 12V power supply in Step 1.7 into the indicated Phoenix connector on the WarpRunner.
• Blue is positive (left side of connector) and White/Blue is negative/GND (right side of connector).

1.23¶

• From the SP/THC port wiring bundle you exposed in Step 1.11, clip the cable tie and isolate out the White/Black, White/Green, Red/Black, Red/White, Orange/Black, and Green/Black wires.

1.24¶

• If the Orange/Black and Green/Black wires have quick disconnects on them, trim these off and replace with ferrules or tinned leads.

1.25¶

• Install these select wires from the SP/THC bundle into the Phoenix connector on the WarpRunner card in the positions indicated in the picture. (see table on next page)

1.26¶

• Find the two JPFault jumpers on the CRP850 breakout board. Set both jumpers to the open position as shown above.

1.27¶

• Find the blue and white wires in the FAULT SIG and GND terminals on the CRP850-00E breakout board.
• Remove both wires from the terminals. Secure and tape the exposed ferrules to prevent contact with metal in the controller.

1.28¶

• The remaining wires from the SP/THC port wiring bundle can be coiled with a cable tie as shown.

1.29¶

• Carefully reattach the gland plate using the screws you removed in Step 1.9.

1.30¶

• Reconnect the motor driver connections you removed in Step 1.8.

2. Software Configuration¶

• Mach4 Users:

  • It is recommended to download and install the latest Avid CNC Mach4 installer that includes any updates and new features.
  • The PRO CNC Plasma Software Setup and Usage Guides contain instructions for configuring and using Mach4 with your Avid CNC Plasma system.

• Mach3 Users:

  • You will need to use the Avid CNC Mach3 installer that includes the latest Plasma Compatible ESS Plugin. Follow the the steps in the Mach3 PRO CNC Plasma Instructions.
  • If you have customized any features in Mach3, it is recommended to make a backup of your .xml profile settings file. This can then be used in your new install of Mach3.