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“ADVANCED PLASMA”

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CR Electronic – Advanced Page 2
1. PRELIMINARY REQUIREMENTS AND WARNINGS ________________________________ 6
1.1. GENERAL _______________________________________________________________________ 6
1.2. PRELIMINARY REQUIREMENTS _________________________________________________________ 6
1.1. WARNINGS _________________________________________________________________________ 7

2. DESCRIPTION OF THE MACHINE AND GENERAL PRINCIPLES OF RUNNING. ___________ 8


2.1. IDENTIFICATION DATA OF THE MACHINE, AND SCHEDULED USE. _________________________________ 8
2.1.1. Technical Particulars of the Machine: _____________________________________________ 8
2.1.2. Electrical Input of the Machine __________________________________________________ 8
2.1.2.1. Required outlets __________________________________________________________________ 9
2.1.3. Scheduled Use of the Machine ___________________________________________________ 9
2.1.4. Operator Workstation _________________________________________________________ 10
2.2. TECHNICAL DESCRIPTION OF THE CONSTITUTING PARTS OF THE MACHINE _________________________ 11
2.2.1. Cutting Plotter ______________________________________________________________ 11
2.2.2. The Electric Board/Console ____________________________________________________ 17
2.2.3. Equipments for Preparing the Cutting “Planes” _____________________________________ 19
2.2.4. Plasma Generator ____________________________________________________________ 20
2.2.5. The Exhauster_______________________________________________________________ 20
2.2.6. Protections and Safety Devices _________________________________________________ 21
2.3. GENERAL RUNNING PRINCIPLES OF THE MACHINE __________________________________________ 23
2.4. REMOTE CONTROLS (EMERGENCY STOP BUTTON)___________________________________________ 24

3. HANDLING AND MOVING THE MACHINE AND ITS COMPONENTS___________________ 25


3.1. HANDLING AND MOVING THE MAIN UNITS ________________________________________________ 25
3.1.1. Moving the work station ________________________________________________________ 25
3.1.2. Electric Board/Console Handling.__________________________________________________ 25
3.1.3. Cut Plotter Handling____________________________________________________________ 26
3.1.1.1. NAME of the COMPONENT_________________________________________________________ 28
3.1.2. Plasma Generator Handling ____________________________________________________ 29
3.1.3. Exhauster Handling __________________________________________________________ 29
3.2. ASSEMBLY, INSTALLATION, ADJUSTEMENTS, COMMISIONING AND DISMANTLING _____________________ 30
3.3. PLACING AND INSTALLING THE SYSTEM’S OFFICE EQUIPMENT. __________________________________ 31
3.3.1. Placing ____________________________________________________________________ 31
3.3.2. Installation._________________________________________________________________ 31

4. PLACING AND SETTING THE MACHINE UP IN THE WORKSHOP ____________________ 33


4.1. PLACING THE MACHINE_____________________________________________________________ 33
4.1.1. Positioning the units constituting the machine _____________________________________ 33
4.1.1.1. Cutting Plotter Positioning _________________________________________________________ 33
4.1.1.2. Cable and Pipe Positioning_________________________________________________________ 35
4.1.1.3. Electric Board/Console Positioning___________________________________________________ 35
4.2.3.1. Positioning of protections and protection devices: photelectric cells ___________________________ 35
4.2. SETTING THE MACHINE UP __________________________________________________________ 36
4.2.1. Connecting and Setting the Plasma Generator Up __________________________________ 36
4.2.2. Connecting and Setting the Machine Exhaust System Up _____________________________ 36
4.2.3. Connecting Transmission Cables and Pipes to the Several Machine Units ________________ 36
4.2.4. Electrical connections and installation ____________________________________________ 37
4.3. MAIN SETTINGS _________________________________________________________________ 38
4.3.1. Settings to make during assembly or re-assembly and before commisioning the machine ___ 38
4.3.1.1. Squaring the plotter ______________________________________________________________ 38
4.3.1.2. Setting the Plasma cutting unit _____________________________________________________ 40
4.4. STARTING THE MACHINE____________________________________________________________ 41
4.5. DISASSEMBLY AND PACKING OF THE MAIN GROUPS OF THE MACHINE______________________________ 42

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5. USE __________________________________________________________________ 46
5.1. ORIENTING THE AXES AND PHYSICAL HOME _______________________________________________ 46
5.2. COMPUTER NUMERICAL CONTROL: STRUCTURE, USE AND COMMANDS. ____________________________ 46
5.2.1. Keyboard commands._________________________________________________________ 47
5.2.2. NUMERICAL CONTROL: structure and use ________________________________________ 51
5.2.2.1. Switching on the machine and START-UP MENU _______________________________________ 52
5.2.2.2. MAIN MENU ____________________________________________________________________ 52
5.2.2.3. MAIN MENU: Setting the cutting parameters __________________________________________ 55
5.2.2.4. MAIN MENU: Moving the torch with manual controls and the TORCH UP or TORCH DOWN functions
56
5.2.2.5. MAIN MENU: LOCK HEIGHT or UNLOCK HEIGHT (block or release torch height) ______________ 57
5.2.2.6. MAIN MENU: PLANES MENU _______________________________________________________ 58
5.2.2.7. MAIN MENU: IMPOST MENU _______________________________________________________ 61
5.2.3. Cutting in the manual mode____________________________________________________ 73
5.2.3.1. Manual mode cutting procedure ____________________________________________________ 73
5.3. INITIALIZING/PREPARING THE MACHINE AND THE WORKING CYCLE _______________________________ 74
5.3.1. Initializing/preparing the machine _______________________________________________ 74
5.3.2. Cutting PLANES _____________________________________________________________ 76
5.3.3. Unloading cutting scrap manually _______________________________________________ 80
5.3.4. Unloading cutting scrap automatically ____________________________________________ 81
5.3.5. Unloading plate scraps and parts manually ________________________________________ 82
5.4. SEQUENCE OF STEPS PERFORMED BY THE CNC TO START CUTTING _______________________________ 83
Z is the height of the Z-axis________________________________________________________ 84
5.5. RESETTING THE MACHINE AFTER AN EMERGENCY STOP _______________________________________ 87
5.6. EXITING THE EMERGENCY MODE DUE TO UNITS EXCEEDING THEIR STROKE __________________________ 88

6. SAFETY INSTRUCTIONS AND SAFETY/WARNING SIGNS _________________________ 89


6.1. SAFETY INSTRUCTIONS_____________________________________________________________ 89
6.2. SAFETY AND WARNING SIGNS ________________________________________________________ 90
6.2.1. SAFETY SIGNS ______________________________________________________________ 90
6.2.2. WARNING SIGNS ____________________________________________________________ 91

7. RISK, SAFETY AND PROTECTION ___________________________________________ 93


7.1. INTRODUCTION __________________________________________________________________ 93
7.2. ANALYSIS AND EVALUATION OF THE SYSTEM’S HAZARDS ______________________________________ 93
7.2.1. Operator intervention on the system _____________________________________________ 94
7.2.2. Warnings for Operator ________________________________________________________ 94
7.2.3. Noise emissions _____________________________________________________________ 94
7.2.3.1. Principal significant noise sources in the system________________________________________ 94
7.2.3.2. Notes on the noise emitted by the machine in a closed environment _______________________ 95
7.2.3.3. Intervention and attempts at intervention at the main noise sources _______________________ 95
7.2.3.4. Fire Prevention __________________________________________________________________ 95
7.2.3.5. Electromagnetic compatibilità ______________________________________________________ 95
7.2.5. Risk analysis and evaluation._____________________________________________________ 96

8. TROUBLESHOOTING ____________________________________________________ 113


8.1. PROBLEMS CONCERNING THE PLOTTER MACHINE AND CUTTING ________________________________ 113
8.1.1. LEDs on the control cards ____________________________________________________ 116
8.1.1.1. Layout of the height control card (Z-AXIS) ___________________________________________ 116
8.1.1.2. Layout of the axis control card (PHOENIX II) _________________________________________ 118
8.1.1.3. Layout of the I/O card (NC-PLASMA INTERFACE ) _____________________________________ 119

9. MAINTENANCE, CLEANING, INSPECTIONS, CHECKS____________________________ 120


9.1. LUBRICATOR POINTS MAP – BELTS POSITION ____________________________________________ 124

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9.2. HOW TO REPLACE BELTS __________________________________________________________ 124

10. TAKING THE MACHINE OUT OF SERVICE AND DISMANTLING __________________ 126
10.1. DIFFERENTIATED WASTE DISPOSAL ___________________________________________________ 126

11. SPARE PARTS – OPTIONALS – TECHNICAL SERVICE _________________________ 127


11.1. PLASMA CONSUMABLES____________________________________________________________ 127
11.2. RECOMMENDED SPARES ___________________________________________________________ 127
11.3. OPTIONALS ___________________________________________________________________ 127
11.4. TECHNICAL SERVICE _____________________________________________________________ 127

12. ATTACHMENTS ______________________________________________________ 128


12.1. DESIGN SECTION _______________________________________________________________ 128
12.2. ELECTRIC DOCUMENTATION SECTION _________________________________________________ 129

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1. Preliminary Requirements and Warnings

1.1. General
• This manual contains the instructions on how to use the ADVANCED PLASMA machine.
These instructions were developed and drafted in compliance with section 1.7.4 of the Machine
Directive and section 5 of UNI EN 292/2: Machine Safety - Basic Concepts and General
Engineering Principles - Technical Principles and Specifications.
NOTE: The instruction manual for the plasma source is also enclosed.
We also supply the manuals for the Personal computer and accessories, the Software and the Dust
extractor unless you decide to purchase these items from sources other than CR Electronic.

1.2. Preliminary Requirements

• READ THE INSTRUCTIONS CAREFULLY before using the machine.

• The instruction manual delivered with the machine is an integral part of the machine itself.
You must read it before doing any work with the machine and you must keep it for future
reference. You must keep the manual until you dispose of the machine definitively.

• Every other manual delivered with the machine must also be considered an integral part of the
machine. You must read these manuals before doing any work with the machine and keep
them for future reference.

• CR Electronic s.r.l. shall not accept any liability for problems, breakage, or accidents due to
the fact that instructions and guidelines contained in this manual are not followed or not
appropriately applied.

• The machine needs ONLY ONE OPERATOR who must be fully informed and trained as to
eventual residual hazards relative to the machine, the correct operating procedures and safety
garments to wear while working; the operator must also review this manual.

• This machine can only be used for the purpose for which it was built, as specified in the user’s
manual.

• Perform all maintenance procedures in the manner and at the times set forth in this manual.

• Before doing any maintenance work or making any adjustments, make sure that the machine
is in the safety mode. Follow the instructions contained in this manual to be sure that you do
the procedures correctly.

>>Assembly and installation procedures as well as dismantling and re-assembly must be


performed by technicians who are duly authorized by the builder.

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1.1. Warnings

• DO NOT perform any maintenance procedures on any part or parts of the machine while it is
live.

• DO NOT remove the protective devices from the machine while it is in operation; DO NOT
tamper with the protective devices. Removing and/or tampering with the protective devices can
endanger the safety of persons and things.

• DO NOT clean, lubricate or grease any moving parts of the machine by hand, unless
specifically required for technical reasons. In this case, use suitable means to avoid hazards.
All staff must be clearly informed of the contents of this article; they must be affixed in a
readily visible location (Art. 48 ex D.P.R. 547/55 - Section III - Par. 1)

• DO NOT perform any repairs or adjustments on any moving parts of the machine. Follow
the instructions. Before doing any work, wait and make sure that none of the machine
parts are moving.
______________________________________________________________
• No part of this manual may be reproduced by any means.

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2. Description of the Machine and General Principles of Running.

2.1. Identification Data of the Machine, and Scheduled Use.


2.1.1. Technical Particulars of the Machine:

The width and depth, then the dimensions of the working field of the ADVANCED PLASMA
machine, change according to the different models.
The basic models are:

MODEL LENGTH x WIDTH WORKING FIELD No. OF WINDOWS OF THE


EXTENTION GRID WHEN LENGHT
(mm x mm) (mm x mm) CHANGES
HD-3-15 4600x2500 3000x1500 6
HD-4-20 5800x3000 4000x1500 7
HD-6-20 7600x3000 6000x2000 10
HD-8-20 9600x3000 8000x2000 13
HD-12-20 12600x3000 12000x2000 20
HD-6-25 7600x3500 6000x2500 10
HD-8-25 9600x3500 8000x2500 13
HD-12-25 12600x3500 12000x2500 20

WORKING FIELD WIDTH (mm) MAXIMUM WEIGHT for a m2 UNIT


OF A GRID WINDOW (Kg/m2)
1500 274
2000 275
2500 275

Standard Height of the Machine 1400 mm


Cutting Speed Da 0.10 a 12 m/min

2.1.2. Electrical Input of the Machine

The Electrical Input of the ADVANCED PLASMA machine during the realization of the working
schedule is given by the amount of the following inputs:

- plasma generator (see the manual about this unit);

- exhauster (see the manual about this unit);

- electric board/console (4 kW).

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NOTE: The customer needs to fit out a power supply system complying with the standards in force, so that it can
support the interlocking uses.

2.1.2.1. Required outlets

• Personal Computer and Accessories

PC Power Supply Siemens 220 V outlet

Printer Power Supply Siemens 220 V outlet

• Electric Board/Console

Electric Board/Console Power Supply 400 V

• Plasma Generator

Power Supply of each Plasma Generator see the relative manual

• Exhaust System

Exhaust System Power Supply see the relative manual

2.1.3. Scheduled Use of the Machine

ADVANCED PLASMA is a numerical control machine for the plasma cutting of metallic
sheets, that has been realized by CR Electronic with the objective to use, in a correct way,
the technology of cutting, so defined as High Definition.

The principle of running of the machine consists basically of two periods: Project and
Machining
The Project is completely developed on board of the Personal Computer by using the
available CAD/CAM software.
On the contrary, the Machining Phase is carried out by means of the Numerical
Control.
These two aspects (project and machining) are linked together by a Data Transmission
Phase, during which the work produced by the Personal Computer is entirely sent to the
Numerical Control through serial communication line (network).
The system structured in this way, allows to place the Personal Computer in an office, and
so at a certain distance from the place where the mechanical and control parts of the
machine are going to be put.

The machine has been designed for the metallic sheet machining.

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The maximum and minimum machinable thicknesses, change according to the model of
plasma generator used.

KIND of PLASMA GENERATOR MINIMUM MACHINABLE MAXIMUM MACHINABLE


USED THICKNESS (mm) THICKNESS (mm)

Hypertherm HD 3070 0.6 12.7


Hypertherm MAX 100 2 16
Hypertherm HT 2000 2 35
Hypertherm MAX 200 2 32

It is generally scheduled the use of a generator once a time1).

WARNING!!! A correct choice of parameters of plasma will have influence on the quality of the
result, for them consult the manual about the plasma source used.

2.1.4. Operator Workstation

To make the machine work it is necessary the intervention of one only operator.

When the machine is running, the workstations due to the operator are: the console, that’s a
control station during the execution of the operation schedule; the loading, to carry out each
loading operation of a sheet (for a correct use of it see the chapter about: Instructions for Use); the
unloading, to carry out the loading of pieces and sheet scraps (for a correct use see the chapter
about: Instructions for Use).

WARNING!!! During the correct carrying out of the operation schedule ( see the chapter
about: Instructions for Use) the operator for no reason has to intervene on the operative
area of the machine and, moreover, in case of failures or because of maintenance, before
intervining on the machine, see the correct procedures of intervention written out in the
chapters about “Failures” and “ Maintenance”.

1
Also considering that the standard equipment of the machine provides only one torch.

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2.2. Technical Description of the Constituting Parts of the Machine

The system is provided with: a Personal Computer and its accessories, a Electric Board/Console, a
Cutting Plotter, a "High Definition" Cutting Plotter (Hypertherm HD 3070) and a “Traditional” one;
and on customer’s eventual request (Hypertherm MAX 100, MAX 200, HT 2000), a Cutting Dust
Exhauster, eventual Optionals or Accessories ( for them see the relative chapter , appendix or
manual).

2.2.1. Cutting Plotter

The Cutting Plotter is equipped with (see the following picture):


- The Bench,
- The Truck,
- The Torch Group,
- The Grid Bench,
- The Exhaust Hood.

The main cable carrier chain (see “Layout with Dimensions”, reported in the chapter
Attachments: Design Section) of the mchine, that contains all cables and pipes needed for

the machine power supply, has been arranged along the Cutting Plotter side ( X-axis ).

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• The bench

It is made up of an electric-welded structure, provided with two load-bearing


longitudinal sides connected together by four cross members (two on the front side: the
upper one and the lower one; two on the back side: the upper one and the lower one).
Two linear guides, (one for each logitudinal side), have been secured, by screws, along
the two logitudinal sides of the bench, where the four linear sets, that are the support
where the truck is secured, slide.
Along the two longitudinal sides, in correspondence with the front and back sides of the
machine, there are the mechanical beats for the truck in their movement along the X-
axis.
On the cross members, in correspondence with the front and back sides of the machine,
there are the mechanical beats for the exhaust hood in their motion of translation along
the X-axis.
On one of the two linear guides, towards the front side of the machine, it has been
assembled a reference cam for the X-axis end of strocks, assembled on the truck. The
other reference cam is directly assembled on the longitudinal side member(back side of
the machine).
The Grid Bench is assembled on the bench (see further on the relative description).

The surface for the sliding of the exhaust hood floating pins is welded along the two
lateral sides, on the internal part.
At the ends of the left longitudinal side (if you put yourself as reference in
correspondence with the front side of the machine), on the internal part there are the
end of the strokes for the dust axhaust hood: at the end towards the front side there are
a zero end of stroke and an emergency end of stroke; towards the back side there is an
emergency end of stroke.

• Truck

The truck is made up of a rigid electric-welded structure, that contains and moves all
main translation members.
The truck is secured, by a detachable connection, on four “linear set” supports, sliding
on the two linear guides, that are assembled on the longitudinal sides.
The truck moves along the main axis of the machine, the X-Axis in the picture, by
means of a brushless motor and a precision rack. The kinematic chain along the X-axis
is realized as shown in the following schematic diagram and it is contained in the truck.

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In the internal part, the truck also has the members for transmitting the motion to the
Torch Group along the Y-axis (see the above schematic diagram). The kinematic chian
of the Y-axis is shown in the following picture.

Two rails, on which the torch group slides, are assembled on the truck.
The Y-axis end of strokes are assembled internally to the truck at its ends, if you put
yourself in front of the machine in correspondence with the front side: at the right end of
the truck there is a zero end of stroke and one for emergencies; at the left end there is
an end of stroke for emergencies. (For them refer to the “Electric Circuit Arrangment”
reported in the Attachment chapter).
The cam for the end of stroke along the X-axis is assembled on a plate, secured nut.

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The X-axis end of strokes are assembled on the truck plate, as support on the linear
sets: on the front side of the truck there are a zero end of stroke and one for the
emergencies; on the back side of the truck there is an emergency end of stroke. (For
them refer to the “Electric Circuit Arrangment” reported in the Attachment chapter).

Brushless Motor – X axis 4 Nm, 3000 revolutions/min

Epicycloidal Reduction Gear Gear Ratio = 1 : 3


Brushless Motor - Yaxis 2.2 Nm, 3000 revolutions/min
Rolled Screw 25x25 (for a truck dimension of: 1500
and 2000 mm)
32x32 (for a truck dimension of: 2500
mm)
Preloaded Nut

• The Torch Group

It is assembled on an Aluminium Vertical Plate with a screw and two ball bearing sliding
blocks, that are preloaded and slide along cylindrical guides in order to realize a vertical
movement, called Z-axis, of approaching/moving away to/from the sheet that has to be
cutted.
The movement of the cutting head, that takes place along the Z-axis, realizes a correct
positioning of the torch as regards the materials that have to be cutted.
The motorization is carried out by a direct current motor.
The cutting torch is a tool for the realization of machining.

The torch group moveses on the truck (axis of Y). The movement of the Plate carrying
the cutting head, defined as Y-axis, takes place on the truck itself by means of a
brushless motor and a precision ball bearing screw; such movement develops on the
rails.

The plasma torch is assembled on a support (see the following picture) and slides on a proper
guide along the Z-axis of the machine. The motion of the torch is made sure by a motor-
epicycloidal reduction gear group. The support of the torch is floating thanks to the action of
springs, that, in case of crash, reduce eventual damages to the torch.

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DC Electric Motor of the torch 0.1 kW

Epicycloidal Reduction Gear Gear Ratio = 1 : 4


Screw 16x5

• Grid Bench

The Grid allows to lay on the cutting plane sheets of any dimension, but always
smaller than the maximum size; it changes according to the different models of the
machine and it is made up of components that can be considered as rectangular
(being a very sheet metal) and jointed (see as an example the following picture) that
together make a grid.
The Grid is built in the bench, made up of an electric-welded frame, where the grid is
welded.
The grid is divided in windows with the dimensions: X= 680 mm; Y= working field
width (in the following picture is shown an example of the grid components).

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The number of windows changes as a function of the machine length (see the above
item: “Technical Particulars of the Machine”).

The grid is assembled windows after windows.


WARNING!!! The second window (front side) is always detachable in order to favour
eventual maintenance operations.

• The Exhaust System and the Off-Cuts Collection

The Exhaust System and the Off-Cuts Collection scheduled on the ADVANCED
PLASMA is: “the exhaust hood” or “the disjoint bench”.
The exhaust hood (see the following picture) is assembled under the support bench of
the sheet.
That is movable with the truck and the units assembled on it.
Cutting Dusts are conveied towards the back of the machine by special metallic
channels ( suction pipes), placed along the X-axis.
During the cutting phases of pieces, the exhaust hood is always found in correspondece
with the active cutting area.
The translation motion of the hood, K-Axis, is realized by means of a brushless motor
and a reduction gear and the transmission of motion is obtained by pinion gears and
chain.
The motor – reduction gear group is secured on an electric-welded frame in the lower
part of the machine back side. At the ends of this frame there are two motor pinions, on
the opposite side (front side of the machine) there are the two floating pinions. The

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chain is secured to the hood and slides within a proper tubolar pipe, assembled along
the long side of the machine ( in the direction of X).
The hood is sliding, through 8 SKF floating pins on a special plane surface, as already
said, welded on the two longitudinal sides.
There are 4 eccentric and 4 center floating pins.
The hood has a lower trapdoor, for the manual collection of the machinig off-cuts,
equipped with a proper handle for opening.

The exhaust system changes in case of assembling the so called “Disjoint Bench”, see
“Appendix C”.

WARNING!!! In any case, the System for the Cutting Dust Exhaust has to be
connected at customer’s expense to the Fumes Exhauster (see further on) by
special pipelines in compliance with the standards in force (for setting up see the
chapter about “Assembly”).

Brushless Motor - K axis 4 Nm, 3000 revolutions/min

Worm Reduction Unit Gear Ratio = 1 : 30

2.2.2. The Electric Board/Console

The electric board/console has to be placed, as shown in the “Diagram for the positioning of the
Machine Units” and in the “Layout of the machine” (see the chapter: Attachments – Design
Section), externally to the areas limited by protections, so that the operator may easily have
access to it without getting in potentially dangerous areas.

The electric board/console consists of a lower part: the electric board and an upper part: the
console.
The cut-out switch of the machine is placed in the lower part, on the electric board door (see the
following picture).

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The electric system of the machine provides some protections against overcurrents, against direct
and undirect contacts, against overtemperatures of the board and against electric arcs (in
compliance with CEI EN 60204-1); it also provides an unipotential protection circuit (grounded)
(terminal PE).

All information about the electric board/console is reported in the Attachment chapter.

The electric particulars of the electric board are:

Supply Voltage 400 V


Frequency 50 Hz
Power In 4 kW
Maximum Input 8.5 A
Degree of general protection IP 54

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Section of supply conductors Minimum 4 mm2
Dimensions 810x545 mm
Electric Board/Console weight 215 Kg

The console is equipped with: a keyboard, a graphic interface, three pilot lights for the presence
of supply, an emergency mushroom-head push button, a reset button.

Above the Consol, there are the control lights, that indicate the state of the machine: for the
lights meaning see further on the item: “Protections and Safety Devices”.

2.2.3. Equipments for Preparing the Cutting “Planes”

The machine needs to be equipped with a Personal Computer and all its accessories, a printer.

The least technical particulars of the Personal Computer, printer etc. are:

- Personal Computer

Kind of CPU Pentium 133


Frequency 133 MHz
Cache Memory 256 kB
RAM Memory 8 MB
Hardware Architecture ISA
Hard Disk Interface IDE
Monitor color
14"
low radiation
resolution 1024x760
Supply Voltage 220-230 Volts a.c. With ground outlet

- Printer

Kind of Print Laser


Emulations HP LaserJet IIP, Epson FX-850, IBM
Proprinter
Ram Memory 0.5 Mbyte
Resolution 300x300 i.p.d. (individual protection
device)

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Supply Voltage 220-230 Volts a.c. With ground outlet

2.2.4. Plasma Generator

Generally, the plasma generator, as equipment of the machine, is:


a) Hypertherm HD 3070;
in presence of the disjoint bench (see Appendix C: Exhaust Bench (disjoint bench)), and that
is a customer’s choise, it is also possible to supply it with:
b) Hypertherm HT 2000
c) Hypertherm MAX 200
d) Hypertherm MAX 100
e) Or any other kind of generator compatibile with such a use.

Each generator is equipped with its own instruction manual, where the operator may find all specific
technical data, concerning the kind of use.

2.2.5. The Exhauster

The machine needs to be provided with a dust exhaust system adequate to the machine emissions.
On the back side of the machine there are small opening for eliminating dusts, the exhaust
system will need to be connected to them by special pipelines.

In order to carry out a correct suction it is necessary to have pressure out, in an equivalent
amount to that given by the ventilator of the exhauster.

Dusts that are going out the suction system of the machine contain: particulate material dependent
on the kind of metal or alloy cutted; Nitric Oxids (NOx), Carbon Monoxides (expressed as COX),
Oxygen (expressed as OX), Volatile Organic Substances; for that reason the exhauster needs to
contain a filter adquate for elimination, at the way out of the suction system, for dusts produced
during the plasma cutting.

Solid residuals from the plasma cutting (off-cuts), that are convoid in the proper collection
drawer of the machine, need to be collected in special containers for stocking and eliminated
through a specific authorized Company in compliance with the rules in force on the matter.

The cutting dust, filtered by a filter adequate for the kind of emission and collection in proper
sacks, will have to be eliminated trough an authorized Company, in compliance with the
indications of the rules in force on the matter.

The filter cardtridge ( or handles) needs to be maintained, on the ground of all indications
reported on the relative instruction manual.

>> It is an expense of the customer, to provide for the connection of the exhauster to the
machine and to the chimney, able to blow off the filtered area outside according to the
environmental rules that are in force in the country where the setting up is carried out.

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The European Directives concerning rules about the air quality, in relation to specific pollutant
agents and pollution caused by industrial plants are: 80/779, 82/884, 84/360, 85/203.

In Italy, the accomplishment with such Directives took place by DPR ( Deccree of the
Republic President ) no. 203 of May 14, 1988; the provisions of the above D.P.R. have to be
integrated with the regional laws and regulations, expressed on the matter, which regulate dust
and smoke emissions in the atmosphere.
For exhausts in the atmosphere, considering the D.P.R. no. 203/88, it is necessary that the User-
Company, (at least fifteen days) before the setting at work of the plant, therefore before
realizing the setting up of the plnat, forwards the application for the authorization to the
competent self-governing Region or Province. The application needs to be accompanied by: the
project of the plant, showing the indication of the production run, technologies adopted to
prevent from pollution, quantity and quality of emissions, the term for the setting at work of the
plant.
Consulting the above mentioned D.P.R. or reference Directives, and the regional provisions is
advisable before carrying out the setting up of the exhaust system.

ATTENTION!!!! The most adequated exhauster to use, is established by CR Electronic


according to the model of the machine chosen by the customer.

WARNING!!!!!!! If the customer decides to purchase this unit separately, we advise you to
consult with CR Electronic, for a correct choise.

>>>> The technical particulars and specific data about the exhauster used are contained in the
relative instruction manual.

2.2.6. Protections and Safety Devices


The main protection and safety devices of the machine are:

- Protection Cases, fixed, in correspondence with: the power supply sources and members in
motion.

Cases are placed and assembled in order to avoid the access to potentially dangerous areas;
they are realized in compliance with: the essential requirements of the Machine Directive; the
indications of the UNI EN 292 rule.

- Cable Carrier Chains, assembled to protect cables and feed pipes of the machine, in order to
avoid the pipe and cable entanglement and their eventual consequent damages, in order to reduce
potential dangers.

- Control Lights, placed on the electric board/console, is equipped with the following lights to
indicate what kind of function of the machine is working:
- the red light lights up when the machine is in emergency stop.
- the green light lights up when the machine is working.
- thr yellow light lights up when the reset of the machine takes place.

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The choice of the light colours was decided in compliance with the following points of the CEI
EN 60204 – 1 rule and in compliance with the essential requirements of the Machine Directive.
- Photoelectric Cells (see chapter Attachment: Diagram for the positioning of the
machine units), that have the task to operate the emergency system of the machine if the
operator is working in their range; the cells are always active during the auto operation of the
machine.
- The Bumpers (that are part of the equipment only when there are no phoelectric
cells, for further information see Appendix B) allows the machine to stop immediately in case of
crush against any obstacle during the auto operation.
- The Emergency Stop Devices ( see chapter Attachments: Diagram for the positioning of the
machne units), have the function to avoid or reduce dangers to people, machines, machinings, for
human intervention; in compliance with: the essential requirements of the Machine Directive and
the indications of the UNI EN 418 rule.
- The Emergency End of Stroke, has the function to makee the emergency system work as soon
as the cam reaches the emergency end of stroke, then as soon as the units go out of the pre-
established field.
- Push Buttons, the buttons disposition was thought as a function of the intervention due by the
operator on the supplied machine. The reset button is timed: it is necessary to keep pushing it for
some seconds, before the reset takes place.
Buttons were thought and realized in compliance with the essential requirements of the Machine
Directive and with the indications of the UNI EN 292 rule. The colour for the push buttons has
been chosen in compliance with the indications reported in the CEI EN 60204 – 1 rule.

- Electric cutout switch for controlling the machine, it has two positions:
a) OFF position: on such position the electric equipment of the machine is complitely
isolated; on this position the switch can be locked with a padlock;
b) ON position: when the switch is on this position the board is under tension (hot).

- The Electric Protections are for a non restart of the machine in case of current
drops; in compliance with the essential requirements of the Machine Directive.

- for the other electric protections, see “Electric Circuit Arrangment of the Machine” (chapter:
Attachments).

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2.3. General Running Principles of the Machine
Remember that the insertion of data concerning those pices that have to be realized, is carried out
sending directly the information from the Personal Computer (PC), where , with the CAM Program,
all designs concerning pieces to realize are prepared, at the Numerical Control of the machine.

The running of the machine provides for some preparation phases of the machine and the
following realization of the operation schedule.
The preparation phases of the machine consist of:
- Power supply of the machine, by turning the cutout switch placed on the electric
board/console.

NOTE: When starting, if the machine is in emergency conditions, see the “Instructions for
Use” chapter to come out from this situation

- Operation of the Exhasut System, intervining on the proper switch.

- Operations for preparing the Machine (see the chapter about: “Instructions for Use”)

- Start of the plasma generator and operations connected to its use (see the manual of this
unit); the starting of the plasma generator will be necessary every time that the machine is
put in emergency. The generator has to be placed as shown in the “Diagram for the
positioning of the machine units” (see chapter: Attachments: Design Section) in order to
favour the gas adjustment and any eventual restarting needed.
- Operations concerning the execution of cutting (see chapter: “Instructions for Use”)
- To unload machined products/sheet scraps you need to stop the machine pushing the proper
emergency button and after it will be possible to remove those pices by using the overhead
traveling crane and magnet or any other kind of system able to make easier this operation. As
far as the load handling, remember that it is important to operate complying with the rules in
force on the matter and using adequate I.P.D. considering what has been reported in the
Analysis of Risks” .

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2.4. Remote Controls (emergency stop button)

Remote controls that equipe the machine are the following:

• Emergency Stop Buttons: these push buttons operate to stop the machine in emergency and
have to be used any time that a dangerous situation advises to stop immediately the machining,
or any time that it is necessary to get in some areas around the machine for inspections and/or
maintenance. More than one emergency button has been placed on the machine in the following
areas: on the truck, on the console.

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3. Handling and Moving the Machine and its Components

The machine was designed so that it can be handled and moved easily and in accordance with the
basic requisites of the Machinery Directive.

3.1. Handling and moving the main units


The main units comprising the machine are: the work station, the control console, the plotter, the
plasma generator and the dust extractor.

These units are packed, loaded onto a truck with crane, positioned and fastened to avoid damage,
transported to their destination and unloaded from the tuck.

You must use suitable equipment to move these parts inside the plant such as fork lifts (for lighter
parts, compatibly with the lifts’ nominal payload) bridge cranes, make sure that you only use
approved-type accessories (belts or chains and hooks, with the maximum load clearly indicated, or
boards on the forks).

During handling:
- wear a hard hat, protective gloves and safety shoes;
- mark off the working area and access paths;
- whwn moving parts wirh cranes or bridge cranes , move tha device slowly and carefully
avoiding abrupt movements that would cause the part to swing; stay out of way of the hanging
loads;
- work very carefully;
- abide by the regulations for moving loads.

3.1.1. Moving the work station

The parts comprising the work station (personal computer and accessories) are packed in cardboard
boxes. They can be handled and moved by hand over short distances (abiding by the regulations for
moving loads); use dollies for longer distances.

3.1.2. Electric Board/Console Handling.


Before slinging the Electricl Board/Console the operator needs:

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1) To remove the lights ( see the chapter about “Disassembly”) and, once the operator has
packed them with shock-resistant materials, secure it on the console in horizontal position.

2) To take the wheels away from the electricl board/console, put it on a wood platform and
secure the console on it.

3) To pack the electric board/console with shock-resistant materials.

4) Hoist the electric board with a lift truck

WEIGHT = 215 Kg

WARNING!!! The Electric Board/Console need to be handled in standing position, it must


NOT be laid on its sides or turned over.

3.1.3. Cut Plotter Handling


The equipments may change according to the different models of the Advanced Plasma, when handling
the Cut Plotter.

• Models: HD-3-15 and HD-4-20

These models (that have been completely set up mechanically and clearly disconnected from
the interlocking unit (see the chapter concerning the “Disassembly”)) have to be slinged with
approved belts and hook as shown in the picture. The plotter is made up of four eyelets
suitables for assuring an easier sling.

As far as the weight of these models see the following table.

MODEL of PLOTTER PLOTTER WEIGHT (Kg)


HD-3-15 1560
HD-4-20 2480

WARNING!! For a correct positioning on the lorry, pay attention to the dimentions of the
machine according to the model. These features are shown in the chapter about the:
“Description of the Machine”.

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• Models: HD-6-20, HD-8-20, HD-6-25, HD-8-25

These models, before being slinged (see the following picture) and after handled, have to be
partially disassembled (as far as the operations concerning disassembly see the chapter about
“Disassebly”).
For these models, once disconnected the Cutting Plotter from the interlocking units (see the
chapter about “Disassembly”), you must mechanically remove the truck from the bench and
place it on a wood platform ( handling it with a lift truck ), the lateral cases of the plotter, and
carry out the sling by using approved belts as pointed out in the following picture; remember
that, for these models, the bench and the grid are kept installed on the plotter.
The plotter, partially disassembled as above said, can be placed on the lorry laying on its
longitudinal side and the belts have to be secured to the winches of the lorry body in order to
wind up the member side.

WARNING!! For a correct positioning on the lorry, pay attention to the dimentions of
the machine according to the model. These features are shown in the chapter about the:
“Description of the Machine”.
To carry out the sling of the cases, wind up them, aproximately at their ends, with approved
belts and hoist them with a crane.

COMPONENT COMPONENT COMPONENT COMPONE


NAME of the WEIGHT WEIGHT WEIGHT NT
COMPONENT MOD. HD-6- MOD. HD-8- MOD. HD-6-25 WEIGHT
20 20 MOD. HD-8-
25
TRUCK (with 245 245 275 275
cables)
LATERAL CASES 10 Kg each 10 Kg each 10 Kg each 10 Kg each
PLOTTER 2800 3390 3020 4240

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• Models: HD-12-20, HD-12-25

These models, before being slinged and after handled, have to be partially disassembled (as
far as the operations concerning the disassembly see the chapter about: Disassembly).
As far as these models, once disconnected the Cutting Plotter from the interlocking units ( see
the chapter about “Disassembly”), you mechanically need: to remove the truck from the
bench and place it on a wood platform (and hoist it with a lift truck), the lateral cases of the
plotter, to disassemble the grid by the windows (each component of the grid windows are
welded together to make easier their handling and the following reassembly), to place them on
a wood platform, to disassemble partially the cap group, to disassemble the plotter in two
parts, the longitudinal side and the tubolar pipe, where the chain of the cap runs, divide in two
parts; sling each half plotter with approved belts and the other components as shown in the
following pictures.

WARNING!! TO SLING THE SUPPORTING BENCH OF THE GRID, ADOPT THE


SAME METHOD USED FOR THE PLOTTER SLING.

To carry out the sling of cases, wind up them aproximately at their ends, with approved belts
and hoist them by using a crane.
The weights concerning each component that has to be removed from these models HD-12-
20, HD-12-25, are shown in the following table.

COMPONENT
3.1.1.1. NAM WEIGHT for MOD: HD- COMPONENT WEIGHT
E of the
COMPON
12-20 (Kg) for
ENT
MOD: HD-12-25 (Kg)
TRUCK 215 240
GRID 1400 (70 Kg x 20 1700 (85 Kg x 20 windows)
windows)
LATERAL CASES About 10 Kg each About 10 Kg each
PLOTTER (HALF with CAP) 1660 2030
PLOTTER (HALF without CAP) 1600 1880

The plotter, partially disassembled, can be placed on the lorry laying on its longitudinal side
and the belts have to be secured to the winches of the lorry body, in order to wind up the side
member.
The truck and the grid windows placed on some wood platforms may be handled with a lift
truck.

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3.1.2. Plasma Generator Handling
For the lifting of the Plasma Source it is necessary to use approved belts; the sling has to be realized as
shown in the relative instruction manual of each component.

3.1.3. Exhauster Handling


For the lifting of the Exhauster refer to its respective manual.

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3.2. Assembly, Installation, Adjustements, Commisioning and dismantling

>You must first study the layout of the machine to find the most appropriate place for it in
the shop so that the various phases of the production cycle can be carried out in the
simplest and most ergonomic manner.

>> Assembly and installation as well as dismantling and re-assembly must be done by
technicians authorized by the manufacturer, that is, personnel who can perform all the
procedures correctly.

>>> Before the machine is delivered, prepare the electric power, gas and pneumatic supply
lines needed to operate the machine as specified in the section entitled “Machine
Description.”

>>>>Make sure that the systems required for machine installation are suitably rated and
that they meet local requirements.

>>>>>Personnel assembling and dismantling the machine must wear: hard hat, protective
gloves and safety shoes.

>>>>>>The assembly instructions below refer to the main structure of the machine which
is preassembled by the manufacturer.

>>>>>>>Use torque wrenches and strong locktite to tighten all the screws.

>>>>>>>>Air for the pneumatic systems must be filtered and dry before it is let into the
circuit.

IMPORTANT!!! It is the user’s responsibility to prepare an electric power supply system that
is capable of powering the systems and that meets local regulations.

Once the parts of the machine have been moved to the area where the setting up will take place
and the Personal Computer and its accessories have been moved to the office, it will be possible
to provide for collecting the several manulas about the machine together and keep them in the
most suitable places.

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3.3. Placing and installing the system’s office equipment.

3.3.1. Placing

The personal computer (PC), printer must be placed on a desk. The monitor may be placed on
top of the PC base module.
The keyboard must be in front of the PC base module, leaving enough space to access the disk
drive.
If possible, install the PC far from dust sources.
To protect the PC from temperature and humidity changes that exceed the mean, make sure it is
installed far from windows and heat sources.
The area around the PC should have good air circulation.

Two outlets are needed in the office: one 220 V stabilized Siemens outlet to power the PC; one
220 V Siemens outlet to power the printer.

It is advisable to install a voltage stabilizer on the PC power supply circuit (Power = 700 W for
the PC) to protect the computer from power surges that could damage the memory with serious
consequences for machine operation.

3.3.2. Installation.

The following connections must be made:

Connect the PC power cable to the stabilized 220 Siemens mains outlet and the back of the base
module using the serial connectors.

Connect the keyboard cable to the rear of the PC base module with the biggest connector.

Connector the monitor power supply cable (the cable with the serial connector exiting the monitor)
to the corresponding port on the left side on the back of the base module.

Connect the monitor video signal cable (it has a coaxial plug and is attached to the monitor) to the
corresponding port on the right side on the back of the base module.

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Connect the mouse wire to the port on the back of the base module.

Connect the printer to the PC using the parallel interface cable fitted with two serial connectors.
Plug the bigger connector into the port on the rear of the printer and the smaller one into the port on
the right side of the back of the base module.
Connect the printer power cable to the 220 V mains outlet.

Connect the network PC-C.N.C.

Do not leave the network cable on the floor unprotected it can create a hazard and it can be
damaged if pressed or cut.

>> Do not install any other programs in the personal computer without prior authorization
from CR Electronic since they may interfere with the machine programs and cause them to
malfunction.

>> IMPORTANT WARNING! DO NOT switch off the stabilizer before you switch off the
personal computer as this may severely damage the computer’s hard drive.

For further information about installing the personal computer and printer, see the respective
manuals that are packed with the PC based module.

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4. Placing and setting the machine up in the workshop

4.1. Placing the machine

The floor where the machine will be placed on, must not present neither holes or juts, that may
compromise the stability, duration and noise caused by vibrations because of a wrong
positioning; the floor needs to respect some proper constructive characteristics.

The machine needs to be positioned so that it is possible to respect the dimensions reported in the
“Diagram for the Positioning of the Machine Units” and “Layout with Dimensions” (see chapter
Attachments: Design Section).

The above minimun distances allow an easy realization of the operation schedule and an easy
accessibility to the parts of the machine to carry out the needed checks, inspections and
maintenace operations with safety in order to reduce the risk (in compliance with: the essential
requirements of the Machine Directives, with the indications of the UNI EN 292 rule).

4.1.1. Positioning the units constituting the machine


The several units will be assembled on the basis of what has been indicated in the “Diagram for
the Positioning of the Machine Units” and the “Layout with Dimentions” (see chapter:
Attachments: Design Section)

WARNING!!!! The Electric Board/Console, the Plasma Generator and the Exhauster
need to be placed out of the photoelectric cells range, as shown in the “Diagram for the
Positioning of the Machine Units” and “Layout with Dimensions” ( see chapter Attachments:
Design Section).

Note: Pipes and cables for power supply, that will be arranged and connected to the
several units, are pre-assembled on the cutting plotter

4.1.1.1. Cutting Plotter Positioning

For a correct positioning of the cutting plotter, in order to avoid any kind of mistake during
machining, the so called “rigging” needs to be carried out.

Rigging Procedure of the Plotter

Remember to wear protection gloves, safety shoes, overalls.

WARNING!!! DURING THESE OPERATIONS, BE VERY CAREFUL. THESE


ACTIONS ARE POTENTIALLY DANGEROUS.

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Lift, aproximately 30 cm, the plotter up using a lift truck (or two if the model of the machine has
central legs and consequently a quite long side) placing forks in correspondence with the side where
the leg is;

Screw a specific bolt under the leg concerned (see the following picture) and, before lowering the
plotter gradually, place the washer under the leg in correspondence with the bolt head, that will act
as base; remember that the washer has a proper counter-sink for placing the bolt;

Once the leg has its own bolt and washer, and the machine lays on the floor, start like this: put a
(0.02 mm/m precision) level on the linear guides of the X-axis and on the Y-axis rails; screw or
screw out the bolts under the legs up to lay the machine flat; at this point, when the machine is
rigging, screw each nut on its respective plotter leg.

Grid assembling as far as those models of machine that needed to be disassembled for
handling

In this case, the grid asssembling consists in placing the several screened windows in the places
of the support bench of the plotter.

On the contary, in case of replacement of the grid for maintenance, consult with CR
Electronic as far as the specif model of the machine.

Truck Assembling as far as those Models of Machine that needed to be Disassembled for
Handling

In order to carry out a correct assembling:

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1) Wear: protection gloves, safety shoes, overalls.
2) Operate observing the rules about the load handling.
3) Check that the “linear sets”, which are the support of the truck and where the truck is
secured, are at the ends of the machine where the truck is before disassembling: this end side
can be well-individuated because the previous position, before disassembling, was pointed
out on the rack (X-axis) with a marker.
4) Handle the truck and lay on the “linear sets”. This operation needs at least two operators, one
of them will handle the truck, with the help of a lift truck, the second one will direct the first
one towards the correct handling. !!! It is necessary to operate slowly in order to avoid
damages to people or materials!!! And in compliance with therules about load handling.
5) Once the truck lays on the linear sets, secure it with screws.

4.1.1.2. Cable and Pipe Positioning

Lay cables and pipes to connect the several units of the machine together and to the power supply.

WARNING!!!! Cables and pipes laying on the floor, need to be properly protected in order
to avoid dangers of stumbling and falling.

4.1.1.3. Electric Board/Console Positioning

The electric board/console will be placed as shown in the “Diagram for the Positioning of the
Several Machine Units” and “Layout with Dimensions” ( see the chapter about Attachments:
Design Section).
The necessary connections for making the machine work, need to be realized as follows:

4.2.3.1. Positioning of protections and protection devices: photelectric cells


Protections and protecions devices will be placed on the machine finally:

- photoelectric cells need to be placed along the machine as shown in the “Diagram for the
Positioning of the Several Machine Units” and “Layout with Dimensions” (see the chapter
about Attachments: Design Section).

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4.2. Setting the Machine up

4.2.1. Connecting and Setting the Plasma Generator Up

In order to realize correctly the operations about the connection, the setting up and the
adjustment of the plasma generator, refer to the relative instruction manual.

4.2.2. Connecting and Setting the Machine Exhaust System Up


The machine is provided with an exhaust hood for sucking dusts; the outlet openings of the hood
have to be connected (“Diagram for the positionig of the sevral machine units” and “Layout with
Dimensions” (see the chapter about: Attachments: Design Section)) to an Exhauster proper for
this use (see the chapter about “Description of the Machine”).
Connection pipes need to be rigid and no longer than 12 m: a bigger length determins excessive
load losses and for this reason further shrewdness are needed, in such a case consult with the
producer company.

The electric connection of the system will have to be realized observing the specific
requirements reported in the instruction manual about this equipment.

4.2.3. Connecting Transmission Cables and Pipes to the Several Machine Units

Once the operator has placed the several units in the workshop, it will be possible to proceed
with the several connections; see the chapter Attachments: Design Section – “Diagram for the
Positioning of the Several Machine Units” and “Layout with Dimensions”:

- electric board/console and cutting plotter, electric board/console and plasma generator
(see the chapter: Attachments- Electric Documentation Section, “Diagram for the
Positioning of the Several Machine Units” and “Layout with Dimensions” ( see the
chapter Attachments: Design Section));
- Cutting plotter and plasma generator (WARNING!!! The opening of the gas cock
need to take place only when the machine is ready to cut, but not during the
setting up). The necessary electric cables and gas pipes, are contained in the cable
carrier chain, which is placed along the longitudinal side of the machine (see the
chapter Attachments: Design Section: “Layout with Dimensions”);
- Plasma generator with gas bottles;
- Exhauster and cutting plotter (see the chapter Attachments: Design Section: “Layout
with Dimensions”);
- Personal Computer and Numerical Control (C.N.C.);
- finally!! Connect the several units to the electric current.

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4.2.4. Electrical connections and installation

WARNING!!! The electric connection of the machine units needs to be realized at the end,
when at last the machine is ready for testing!!

ATTENTION!! The customer company has to prearrange a proper feeder line for the
machine.
For the necessary protection due to the plasma generator, see the relative manual.
Moreover, the electric connection needs to be carry out by skilled technical staff.

For the electric connection of the several parts see the electric circuit arrangement (chapter:
Attachments – Electric Documentation Section).

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4.3. Main settings
4.3.1. Settings to make during assembly or re-assembly and before commisioning the
machine

4.3.1.1. Squaring the plotter

Squaring the plotter consists of rendering carriage axes X and Y orthogonal.

First evaluate the entity of the out-of-square by cutting a very large plate rectangle, for example 1.4
x 2.5 meters.

You do not have to do the entire cut. Rather, cut small sections at the corners and do the rest in the simulation mode.

The shape you cut may not be a rectangle, but a trapezoid which is shown in exaggerated form in
the following Figures.

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Evaluate the correction “a” or “b” to make on the carriage position using the following formula:

error (a or b) = (D/2) . ((C/X)2 + (C/Y)2)1/2

Where:

D/2 = half difference between diagonals d1 and d2

X= long side of the cut rectangle in meters

Y= short side of the cut rectangle in meters

c= 1.9 m for Y dimension = 1500 mm


2.4 m for Y dimension = 2000 mm
2.9 m for Y dimension = 2500 mm

Example for Model HD-3-15

The rectangle's dimensions are the following

x= 1.5 meters

y= 2 meters

d1 = 2,502 meters

d2 = 2,498 meters

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We have:

error (a or b) = error (a or b) = (D/2) . ((C/X)2 + (C/Y)2)1/2 = 3.1 mm.

So, according to this result, we have to correct the carriage position 3 mm in the direction “a” as
“d1” is greater then “d2”.

To align the carriage, release joint that fastens the cogged pulley of the motor shaft so that one side
of the carriage can be moved forward or back while keeping the other side fixed, see figures.
After you have corrected the carriage position, tighten joint and repeat the test, perhaps by cutting a
slightly smaller rectangle out of the same plate. If the correction has not completely solved the
problem repeat the procedure.

4.3.1.2. Setting the Plasma cutting unit

See the plasma generator instruction manual for these settings.

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4.4. Starting the machine

Start the machine by turning the main switch on the electrical cabinet. Open the air and gas cocks.
Carry out the procedures needed to clear the clamps and set the axes as described in the chapter
entitled “Operating Instructions”.

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4.5. Disassembly and Packing of the main groups of the machine

Before carrying out any operation of disassembly: cut out the power supply of the
machine and all the other interlocking units; make sure that the gas cocks are turned
off; disconnect the plasma torch supply; disconnect the connection pipes to the
exhauster.

In order to realize these operations see the: “Diagram for the Positioning of the Several
Machine Units” (see the chapter Attachments: Design Section) and the electric circuit
arrangment of the machine; consult the indications about disassembly reported in the
other manuals provided with the equipments of the machine units.

For the machine disassembly operations, use the required individual protection devices,
follow the instructions reported as far as the component handling; use only tools in
good conservation state and adequate for use; check tools before use.

For disassembly realize then the following operations:

• Disconnect the connections of the Electric Board/Console from the machine and the
other interlocked units

• Disconnect the connection from the PC to the C.N.C.

• Disassemble the machine protections: photoelectric cells and bumpers.

• Disassembling the truck from the bench


This activity may be usefull for handling some models of the Advanced Plasma.
Remember that when realizing the truck disassembly, cables contained in the X-axis cable
carrier chain are in advance collected and fixed on it.

To disassemble it:
- Remove the protection cases for the linear guides of the X-axis and the brush holder
support ( also brushes are a protection for guides and rack ), connected in the upper
part to these cases and in the lower part to the bench frame;
- Before removing the truck, to assure a following correct geometric positioning, mark
the mesh points on the rack and gear;
- Disasemble the back end of strokes – X axis;
- Screw out the 8 screws of connection between the truck and the linear sets, sliding on
the X-axis linear guides;
- Handling as described in the chapter: “Handling and Transport” and place the
materials on a wood platform.

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• Case Disassembly

This operation may be usefull:


- for handling some of the Advanced Plasma models;
- for the ordinary maintenance (see the chapter about: “Maintenace” as far as the
specific actions to disassemble the cases).

When realizing the handling of some of the Advanced Plasma models (see the chapter about this
subject) it is necessary to disassemble each specif screw by screwing:
- All lateral cases on the lower part of the plotter;
- The cases as protection for the x-axis linear guides and the racks.

• Grid Plane Disassembly


When realizing the handling of some Advanced Plasma models ( see the chapter about this subject )
it is necessary to strat removing the grid. Disassembly takes place windows after windows: each
window consists of biult-in “rectangular” components, that made up the grid.

Plasma Generator Disassembly


The Plasma Unit disassembly needs to be carried out observing the operations shown in the
manual of the very component. Remember to disconnect, before carrying out any operation,
the line cord of the machine and to turn off the gas cocks.

Once disconnected all cables collect them in tidy skeins; cables allocated within the pipe
guide chain need to be wound up and positioned at the entry of it.

Exhauster Disassembly

For the exhauster disassembly, refer to the relative instruction manual.

Workstation Disassembly
The workstation disassembly provides for disconnecting all connectors of the personal
computer, printer.
Such an operation needs to be realized with all devices off. After, all the components that
made up the workstation, need to be replaced in their proper packings. Once carried out this
operation of packing, each box may easily be handled manually.

• Exhaust Hood Group Disassembly

This procedure may be usefull in case of extraordinary maintenance operations (for example:
piece replacement) on the exhaust hood and the partial disassembly may be usefull for
handling some machine models.

CR Electronic – Advanced - Page 43


To disassemble the hood for maintenance operate like this:
- Before cutting out the machine supply, place the hood in correspondence with the
second window of the grid (front side of the machine);
- Hoist, slinging with approved belts, the second window of the grid (front side of the
machine);
- Screw out the support components (along Y) of the grid window of the bench frame
(only the support components of the second window, front side, are screwed; in the
case of the other windows this components are welded);
- Screw out the hood from the two plates, that are connected to each other by a tube
and slide on rails: at this point the hood is extractable.

For a “partial” disassembly of the hood in order to handle some of the machine models act in the
following way:
- Before disassembling the hood, place it at the back end of the machine and anchor it
to the upper cross member;
- Extract the chain, that slides within a tubolar pipe collect it and tie it to the hood;
- Remove the the gum screwed on the dusts suction pipes (channels);
- Disjoin the tube where the chain slides in the middle along the x side of the machine;
- Disjoin the crop ends of the suction channel, placed along the X-axis.
At this point the plotter consists of two divided parts.

• Electric Board/Console Disassembly

This procedure may be usefull when the electric board/console need to be handled: in this case the
disassemly to realize, refers to the control lights, that are secured on to the console by four screws.

• Sequence of Operations for a Partial Plotter Disassembly, Usefull for Handling Some
Machine Models

The sequence of operations for a partial plotter disassembly is:

- disassembly of the X-axis cable carrier chain and collection of cables over the truck, being
careful to tie cables together properly and to sucure them on the truck; during the cable
collection pay attention don’t to create too narrow bends that could damage the gaiters;
- cable carrier chain collectioni;
- disassembly of the support channel and guide of the cable carrier chain – X axis (that’s a kind
of detachable connection (screws));
- disassembly of the truck (see above) and its handling (for this see the relative chapter);
- disassembly: lateral plotter cases; cases placed for protecting racks and X-axis linear guides
(for disassembly see above);
- disassembly of the grid windows (see above);
- remove a crop end of rack (the central one) from both sides of the X-axis;

CR Electronic – Advanced Page 44


- screw out the screws that connect the two linear guides support of the x-axis to the
longitudinal side;
- screw the bench frame of sheet support from the longitudinal side;
- lift the bench before ,and the bench frame after;
- screw the connection screws of the longitudinal side crop ends from both sides;
- disassemble “partially” the hood group as mentioned above.

CR Electronic – Advanced - Page 45


5. Use
5.1. Orienting the axes and physical home

5.2. Computer Numerical Control: structure, use and commands.

The software related to the Numerical Control C.N.C. (Computer Numerical Control) for CR
Electronic machines was developed in the Windows 95 environment; it has the same graphic
interface and facility of use.

The Numerical Control makes it possible to perform:

Cutting in the manual mode


Automatic cutting of parts designed with the Winplasma CAM program (see
the respective manual on how to use this program).

The keyboard with a limited number of keys facilitates use. The CNC interface guarantees
immediacy, thanks also to the association between the functions of each screen and the
keys.

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5.2.1. Keyboard commands.

The keys on the console keyboard are arranged as shown below:

Parameter setting keys Function

Numerical keys

Zoom
keys

Keys guided by the Manual control keys


graphic interface (Cursor keys)
(Software Keys)

Parameters scrolling keys General keys Zoom reset and plane


scrolling key

Keyboard Layout

CR Electronic – Advanced - Page 47


• The parameter setting keys : +, -

Make it possible to increase (+ key) or decrease (- key) the value of a given parameter shown next,
on the display.

• Cutting procedure function keys

START: controls the start of cutting of the sheet that is loaded and shown
on the display

FIRE: controls torch firing if you want to cut in the manual mode

SIMUL: starts simulation of the cut to be done on the sheet


loaded and shown on the display (see «performing the cut» below).

PAUSE: if pressed, this key will stop cutting, both during real cutting and
simulation.

• Zoom keys: +, -

IMPOST menu, PARAMETERS function:


- These keys make it possible to increase (+ key)/decrease (- key) the value of the
parameter you selected using the cursor keys.

PLANES and MAIN menu:


- Once the operator has loaded the cutting plane these functions show the zoom
(enlargement: + key; reduction: - key).

• Numeric pad

- The numeric keys allow you to input directly the numerical value of a selected parameter
or a given size (see the individual menus for specific instructions).

- BACKSPACE2) ( ← ): cancels the value you keyed-in

IMPORTANT! Instructions for using the BACKSPACE key are provided in the description of the program
menus.

• Software Keys - graphic interface (F1, F2...)

2
Some keyboards may have an ENTER key, which confirms the set value or selects a given size. This key is
located where the BACKSPACE key would be (on these keyboards the BACKSPACE function is performed
by the C key; see further on for the description).

CR Electronic – Advanced Page 48


F1, F2, F3… the functions of these keys change according to the menu in which you are interfacing
with the CNC (for details on these functions, see the summary block diagrams for the individual
menus).

• Cursor keys

- The cursor keys are set by CR Electronic technical staff, according to the arrangement of
the console with respect to the cutting plotter to guarantee easy use. They can perform
various functions (for details see below). They can be used to make selections (horizontal
(→, ←) and vertical arrows (↑, ↓)), to move the cutting torch in the manual mode (3), to
scroll the image of the plane to cut shown on the display (you can use all the arrow keys
in these last two cases). Pressing the cursor keys and the FAST key at the same time, the
operator will be able to move the torch faster in the manual mode.
- The central button of the cursor keys has the function to reset the zoom and the plane
scrolling. It is active in the PLANES and in the MAIN menu.

Zoom reset and


plane scrolling key

FAST

• Parameter Scrolling Keys

If implemented, these keys allow to scroll the list of cutting parameters in the Main menu and to
display them all alternately.

• General Keys

- OK can confirm a value set in each menu and allows you to exit each screen (unless there
is a similar, specific command for a given menu), confirming any modification you may
have made to that menu.
- C or CANCEL can be used: a) like the «BACKSPACE» key on keyboards that do not
have a backspace key; b) as the key (if implemented) to return to the preceding screen.

3
The slanted arrows allow you to move the torch 45° with respect to the cutting plane (after the X
and Y axes are identified).

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- HELP displays a help window relative to the display on the monitor (it is a context-
sensitive help function).

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5.2.2. NUMERICAL CONTROL: structure and use

The Numerical Control is structured with several MENUS as shown in the following schematic
diagram:

Start Up Menu

F2 key (Access to diagnostics function)


F1 key (Clear the Machine)
Diagnostics function
Main Menu

F1 Key
F6 Key

Torch Up/down
F2 Key Exit the
program
Lock/unlock
Height
F3 Key F5 Key
F4 Key

PLANES Menu IMPOST Menu REFER Menu


F1 Key
F4 Key
F2 Key F3 Key
New axis
Diagnostics
defining
function
Cursors Control
Setting Settings
F1 Key

F2 Key F4 Key

Load file from


local memory

Load file from Load file from Remove file from the
remote PC floppy disk local memory

F1 Key F6 Key
F5 Key

Move the torch to a F2 Key


F4 Key
Y-Axis cut
reference point F3 Key

Define reference Physical


Always
point Home Empty hood
motor

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5.2.2.1. Switching on the machine and START-UP MENU

In order to be able to perform any procedure, you must first switch-on the
machine. Set the main switch, which is located on the door of the electrical board
(see the chapter entitled Machine Description) to ON.
The control program will automatically start once you have started the machine.
When the Numerical Control initialization is completed, the START MENU will appear on the
screen as shown in the following FIGURE. It will show the settings used in the last working
session.

START Menu

The commands and functions available in this phase are: consent for PHYSICAL HOME, which
you activate with the F1 key, located right below the words PHYSICAL HOME; DIAG, key F2, to
access the machine diagnostic screen (see the «IMPOST Menu: DIAG function» below).
The clear or reset procedure will move the torch back to the origin of the machine axes (see above
the home position); the point of arrival will be the reference point for calculating distances
(absolute home point).

None of the values that appear on the screen can be changed during this phase.

When you have completed the clear procedure, the MAIN MENU will appear on the screen.

5.2.2.2. MAIN MENU

Once you have entered the main menu, the following will appear on the screen:

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The MESSAGES box shows the information relative to the procedure under way.
See the IMPOST Menu/DIAG function (diagnostics) for all possible messages the
machine can send.

You can carry out the following procedures from the MAIN MENU

1. Raise and lower the torch (TORCH UP/DOWN(4): key F1)

2. Select the operating mode at locked height (LOCK /UNLOCK HEIGHT function: key
F2)

3. Go to the load file menu containing the profiles to cut (PLANES MENU: key F3)

4. Go to the setting menu (IMPOST MENU: key F4)

5. Go to the reference menu (REFER MENU: key F5)

6. Exit the program (EXIT: key F6)


MAIN Menu
You can also:

4
The wording changes if it is enabled, that is from TORCH UP to TORCH DOWN, after the torch is lowered,
and vice versa.

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7. Modify the cutting parameters by pressing the «set parameter» keys next to each
measurement. Set all parameters from the IMPOST menu (see below). In order to
set the parameters correctly you must work from the manual mode for the plasma
generator you are using. In this screen the cutting parameters are displayed four at
a time using the scrolling parameters keys.

8. Define the current position of the torch as the new LOGIC HOME point. (5) (The
command is FAST^0: Press the FAST and 0 keys at the same time).

9. Move the torch to the last memorized LOGIC HOME by pressing «0».

IMPORTANT: In the Main Menu the following boxes are displayed on the right side of the
screen:
- Arc voltage: the box shows the instantaneous arc voltage
- Plane: the box shows the number of the loaded “plane”. (for the full meaning and
details, please see the section entitled «Cutting planes»)
- Track: the box shows the number related to the cutting outlines (for the full meaning
and details, please see the section entitled «Cutting planes»).
- Position: the box shows the X and Y coordinates of the torch position with respect to the
memorized LOGIC HOME (please see below for the definition of LOGIC HOME)
- Status: the box shows machine status.

5
The logic home point corresponds to the origin of the cutting PLANE, that is the initial cutting point of the
displayed contour.

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5.2.2.3. MAIN MENU: Setting the cutting parameters

The cutting parameters are:

Cutting speed: the speed at which the torch moves during cutting.

Arc voltage: the reference voltage for height control

Z-axis response speed (6): the speed at which the torch moves upwards
(expressed as a percentage of the «maximum speed» set by the CR
Electronic staff. If you are working at a locked height, the word «LOCK» will
appear in the box instead of a numerical value.)

Piercing height: the height at which the plate is pierced.

To set the cutting parameters ( then to change values) from the main menu, use the «Set cutting
parameters keys», described above.
The cutting parameter values are displayed in the main menu, on the left side of the screen. Next
to each cutting parameter on the keyboard, there is a pair of parameter setting keys («+» to increase
it, and «-» to decrease it)

IMPORTANT! In order to set the parameters correctly you must work from the manual for
the plasma generator you are using.

6
The predefined setting of 10% is almost always correct. The value can be decreased if working with a
particularly smooth plate; it must be increased if there are any corrugations inclined surfaces.

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5.2.2.4. MAIN MENU: Moving the torch with manual controls and the TORCH UP or
TORCH DOWN functions

• Moving the torch manually along the Z-axis

The TORCH UP or TORCH DOWN commands are displayed alternatively according to


the torch position. They are used to raise or lower the torch along the Z-axis in
relation to the preset highest and lowest distances.

For example, if the display shows TORCH UP function, by pressing F1, the CNC will
automatically move the torch to the highest reference point and TORCH DOWN will
appear on the display instead of TORCH DOWN, and vice versa.

IMPORTANT!! This command is only active if the plasma generator is switched OFF.

This function is also useful for moving the torch to the safety height at the end of
the cutting procedures.

• Moving the torch along the X- and Y-axes with manual controls (as when the torch moves
along the X-axis, it is one unit with the carriage),

Use the cursor keys to move the torch along the X and Y-axes in the manual mode.

The cursor keys allow you to move the torch manually in the direction of the arrow
you press. In this case, the speed is fixed and independent of the cutting speed. You
can move the torch faster by pressing the desired direction key and the FAST key at
the same time.

IMPORTANT!!! For your convenience, the direction of the arrows changes according to the
arrangement of the electrical board/console with respect to the cutting plotter.
CR Electronic personnel set the direction once you have established the arrangement of the
machine units, and at this time the operator will be apprised of the current setting.

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5.2.2.5. MAIN MENU: LOCK HEIGHT or UNLOCK HEIGHT (block or release torch
height)

LOCK HEIGHT or UNLOCK HEIGHT, which are alternately displayed according to the
torch position, have the function to lock or unlock the torch working height set
(see the IMPOST Menu below on how to set the working height)
For example, if the display shows LOCK HEIGHT, by pressing F2 the CNC will
automatically lock the preset working height and UNLOCK will appear on the
display instead of LOCK HEIGHT, and vice versa.

The locked height status is also confirmed by the word LOCK in the Z-axis speed box on the main
menu.

IMPORTANT!!! Do not cut corrugated or very thin plates with the LOCK HEIGHT
function.

IMPORTANT!!! This function is also active when the plasma generator is on, so you can use
it during cutting.

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5.2.2.6. MAIN MENU: PLANES MENU

You can perform the following procedures from the load cutting plane menu:

1. Load the file to use from the local memory (LOAD FILE function: key F1)

2. Load a file from a personal computer into the local memory (RECEIVE PLANES
function: key F2).

3. FLOPPY function: key F3; DO NOT USE THIS FUNCTION KEY!! ONLY AUTHORIZED CR
ELECTRONIC technicians can use it.

4. Delete a file from the local memory (DELETE function: key F4)

5. Confirm the file to use (OK)

PLANES Menu
PLANES MENU: LOAD FILE function (Loads a file from the local memory)

The LOAD FILE function allows the operator to load the file to perform into the
control program. With this function you can only load these files that are already
in the CNC local memory.
When the function is activated, a window will appear on the display (see figure
below). The window contains the names of each file in the local memory. To load
the file you want to run, scroll through the list using the cursor keys, and then
press OK after you have selected the file. To cancel your selection press F6
(CANCEL).

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Once you have pressed OK, «Display cutting plane» will appear on the screen.
The first cutting plane from the file that you just loaded will be in the middle of
the screen. The starting track is red; the numbers relative to the selected plane
and track will appear on the right (see “Doing the cut”, below).

PLANES MENU: RECEIVE PLANES (from a Personal Computer connected to the CNC)

The RECEIVE PLANES function allows you to load a file from a personal computer
into the local memory, for either immediate or future use. The monitor will
display a file selection window that is similar to the one for the LOAD FILE
function. You select, load and confirm the files using the cursor, OK and F6 keys as
described above.
After you have pressed OK, «display cutting plane» will appear on the screen
(see LOAD FILE function above).

PLANES MENU: FLOPPY function (load a file from a floppy disk)

The FLOPPY function CANNOT BE USED BY THE OPERATOR!!!

THIS FUNCTION CAN ONLY BE USED BY AUTHORIZED CR ELECTRONIC


PERSONNEL
CR Electronic – Advanced - Page 59
PLANES MENU: DELETE function (Remove file from the local memory)

The DELETE function allows you to remove a file from the local memory. Although the memory
is large enough to store a considerable number of files, it is advisable to leave only the most
frequently used files and to remove those that you do not plan on using soon. The display that
appears on the screen is identical to the one shown for the load file functions. There are two
functions, OK and CANCEL, (OK and F6) to confirm or cancel the procedure.

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5.2.2.7. MAIN MENU: IMPOST MENU

You can perform the following procedures from the impost menu:

1. Access the machine diagnostics program (DIAG function, key F1)

2. Redefine the directions associated with the arrow keys (CURSORS function,
key F1).

3. Load the initial set of parameters (PARAMETERS function, key F3).

4. Define the axis of the metal sheet (ALIGN FUNCTION, key F4).

5. Confirm the displayed settings (OK).

IMPOST Menu

To change a given parameter, first select it using the cursor keys. The selected
parameter will have a red border.

You can enter the new value using the keys on the keypad, or it can be obtained
by changing the current one with the two «+» and «-»zoom keys located on the
right of the keyboard to increase or decrease the values.

CR Electronic – Advanced - Page 61


When you key in the new parameter, an Edit box will appear on the screen
showing the limits of validity and the value you set (you can confirm by pressing
OK or correct it using the BACKSPACE Key).

IMPORTANT –The Slowing down function, if selected, makes it possible to enable the
slowdown function in certain situations. To select this function, move the cursor
to the box and press OK. This can be useful when the profile to cut has circles
with asmall radius of curvature. For further details, contact the CR Electronic
technical service department.

Cutting Parameters Window

IMPOST MENU: DIAG (Diagnostics) function

When you press F1 in the impost menu the status of the motors and plasma torch
will appear on the screen. There are several inputs and outputs.

CR Electronic – Advanced Page 62


INPUTS:

Endpoint (X)
Endpoint (Y)
Endpoint (K)
Torch contact

Inclined Torch
Arc Transfer
Emergency
Encoder (0) (X-Axis)
Encoder (1) (Y-axis)
Encoder (2) (K-axis)
Encoder (3) (Z-axis)

OUTPUTS:

Motor On (X)
Motor On (Y)
Motor On (K)
Plasma On/Off
Motor (X) (DAC 0)
Motor (Y) (DAC 1)
Motor (K) (DAC 2)
Motor (Z) (PWM)

To return to the IMPOST menu press F6 (EXIT).


You can monitor the machine inputs and outputs at any time as long as you are
not doing a cut and the machine is not in the emergency mode.
In the illustration the Endpoint K alarm is active. It is identified by «•», and it
means that the hood has reached the home endpoint of the K-axis, the same is
for the other inputs.
IMPORTANT: The endpoints listed among the inputs are the home endpoints of the
machine axes.
Selecting the outputs the operator must activate them. That determines:
- motor on: the corresponding motor is ON
- plasma on/off: the plasma is on
If outputs are activated, but no expected effect takes place, it shows that there is
some problem or failure.

CR Electronic – Advanced - Page 63


You can verify only the outputs, which are contained in the box entitled Output, by
going to the output using the cursor keys and using:

OK to select and deselect


the keypad to set the voltages to send to the motors
BACKSPACE to cancel.

You can perform the following diagnostic procedures:

• Motor diagnostics

To perform this diagnostic procedure

1. Switch on the motor you want to test by using the cursor keys to go to
the Motor On box for the selected (X-, Y- or K-) axis and pressing OK. The
motor will switch on. Remember that the «✓» symbol inside the box
means that the motor is on.
2. Set desired motor movement in either of the two following modes: a) by
setting the voltage value using the keypad; use the cursor keys to go to
the box to text, press OK to confirm the value that is keyed-in or press
BACKSPACE to cancel it. When you press OK, on the basis of the set
value, the motor will move if it is functioning properly. You can see the result
on the corresponding input encoder; b) by setting movement by varying
the value of the encoder assigned to the motor; use the set parameter
keys («+» to move away from the machine physical home, or «-» to
approach it). To stop motor movement release the «+» or «-» key.

CR Electronic – Advanced Page 64


3. To stop the motor, press F1 (RESET), or go to the MOTOR ON box for that
motor and press OK.

IMPORTANT: You can start more than one motor and perform the diagnostic
procedures at the same time.

• Plasma diagnostics

To perform this diagnostic procedure:

1. Make sure that the plasma generator is off. If it is on, switch it OFF.
2. Use the cursor keys to select the Plasma On/Off box and press OK.
Remember that the «✓» symbol inside the box means that torch trigger
signal is being sent to the RHF console of the plasma generator. The
selected box corresponds to the Plasma On function (send trigger active
command).
3. To verify that the CNC has sent the signal, skilled personnel can check
electrical continuity on the plasma connector as follows: a) unplug the
connector of the plasma cable that goes to the console; b) take a tester
and set it on «Ωx1» on feet 1 and 2 of the connector on the console (see
Attachments - Wiring diagrams) and check for electrical continuity.
4. Press F1 (RESET function) to disactivate the function or go to the Plasma
ON/OFF box and press OK.

WARNING!! Keep clear of the output status, which rationally could damage the machine.

IMPOST MENU: CURSOR Function (Cursors setting)

When you press F2 in the impost menu a window will appear on the screen
showing the directions of movement currently associated with the cursor keys.
Use this function to reset the directions associated with each arrow key.

Use the cursor keys to make changes related to the assignment. Press OK to
confirm or F6 to cancel the new assignment.

It is important to remember that the directions of the X- and Y-axes can ONLY be
associated with the horizontal (←, →) and vertical (↓, ↑) cursor keys. The
optimum selections for use and operator convenience can be made in relation to
the arrangement of the console and cutting plotter.

To clarify matters, here is an example of a setting. If the units are arranged like
those shown in the figure below, the ideal cursor setting could be:

CR Electronic – Advanced - Page 65


Cutting X-Axis
Plotter

Y-Axis

Console

In this case, on the basis of the figure, the ideal setting for cursors could be as
follows:

• Assign the horizontal keys (shown parallel to the X-axis of the machine) to the
X-axis. As far as the arrows direction, the operator can establish right and left
in relation to his own right and left with respect to the machine.

• Assign the vertical keys (shown parallel to the Y-axis of the machine) to the
direction of the Y-axis. As far as the arrows direction, the operator can
establish forward and back according to whether the torch unit moves away
from the console (cursor forward ↑) or towards the console (cursor back ↓).

Cursor setting display

CR Electronic – Advanced Page 66


IMPOST MENU: PARAMETERS function (Control Settings)

When you press F3 in the IMPOST menu the program will request the password for
modifying the parameters that were sent to the control system during start-up.

Only authorized CR Electronic personnel can do this procedure.


To exit this phase press OK twice.

Request for passward to set the C.N.C. parameters

IMPOST MENU: ALIGN Function (new cursor axis definition)

The ALIGN function allows you to define a new X-axis for the machine. This is
useful when the plate is not positioned on the bench so that its lateral edges are
not parallel to the machine’s axes. In this case the control system calculates the
angle between the edge of the plate and the X-axis of the machine, and then uses
it to cut correctly.

Y-Axis
y’ alfa
1 Point2 Point
• • x’
X-Axis

Inclined plate of an alfa angle with respect to the machine bench


CR Electronic – Advanced - Page 67
When you press F4 in the impost menu a window will appear on the screen
showing the two areas, Point 1 and Point 2, each of which shall contain the X and Y
coordinates of a point on the plate (see figure below).

Window for defining the axis of the plate

The x’ axis of the plate is defined as a straight line passing through two points
(Point 1 and Point 2 in the figure). The operator can select the two points at will.

It is IMPORTANT to remember that the x’ and y’ axes become the reference axes for cutting
the plate. Therefore, when selecting the points make sure that you do not go beyond the
outlines of the plate during cutting.

To define the x’ axis, proceed as follows:


1. Use the cursor keys to move the torch to the point on the plate that will be the
starting point for the x’ axis (Point 1) (the variation in the coordinates as the
torch is moving is shown in boxes X and Y of the Current Position (7)).
2. Assign the value that you see in Current Position for X and Y to Point 1 by
activating the POINT 1 function (key F1).
3. Use the cursor keys to move the torch to another point on the plate that will
become Point 2 (the variation in the coordinates as the torch is moving is
shown in boxes X and Y of the Current Position).
4. Assign the value that you see in the Current Position for X and Y to Point 2 by
activating the POINT 2 function (key F2).

7
These are absolute coordinates (they refer to the physical home).

CR Electronic – Advanced Page 68


5. Confirm the data you entered by pressing OK.
6. If you want to return to the preceding values for Point 1 and Point 2, press F3
(RESET).

MAIN MENU: REFER MENU

You can perform the following procedures from the reference menu

1. Move the torch and position it at a previously defined reference point (GO
function, key F1).

2. Define a new reference point (DEFINE function, key F2).

3. Turn the switch of the motors to ON (switched ON) or OFF (switched OFF)
position (ALWAYS MOTOR ON/MOTOR OFF function: key F3).

4. Clear the machine axes (PHYSICAL HOME function, key F4).

5. Automatic cleaning exhaust (EMPTY HOOD, key F5)

6. Exit the menu (OK).

7. Cut the plate in two along the Y-axis (Y-AXIS CUT function: key F6).

Reference setting menu

CR Electronic – Advanced - Page 69


REFER MENU: GO Function (moves the torch to the reference point)

After you have selected one of the references using the cursor keys, the GO
function (key F1) will position the torch on the desired reference point. Only when
this point is reached, it will become the current LOGIC HOME.

IMPORTANT: To define a given «Reference» point see the DEFINE function further on this
menu.

REFER MENU: DEFINE Function (Define reference point)

The DEFINE function allows the operator to define the coordinates for up to a
maximum of nine reference points in the absolute coordinates system. Having
several reference points can be useful for memorizing several logic home positions.
To assign a value to a «reference» proceed as follows:

1. Using the manual function on the sheet move the torch to the position you want
to assign to the new reference, with the cursor keys. The coordinates will be
displayed in the Current Position box.
2. Select the reference you want to «define» by keying-in the number next to the
word «Reference» (see the diagram of the REFER menu); use the keypad. The
selected point will be marked as shown in the figure in the REFER menu.
3. To assign the value you selected for the reference press F2 (DEFINE function).

IMPORTANT - The set references will be saved in the local memory, therefore, they
will not be lost when you switch off the machine and can be reused during the
next working session.

REFER MENU: ALWAYS MOTOR ON/MOTOR OFF Functions

The words ALWAYS MOTOR ON/MOTOR OFF (key F3) are alternatively viewed. These
functions show the motors operation status and must only be used during calibration.

ALWAYS MOTOR ON is generally displayed on the screen. It shows that the machine
will switch OFF in case of prolonged pauses.

a) If during calibration, the operator always wants the machine ON, press the key F3 and the
words MOTOR OFF will be displayed on the screen.

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REFER MENU: PHYSICAL HOME Function

The PHYSICAL HOME function (key F4) allows you to clear the machine axes again. The
program will request a confirmation before it carries out the procedure. To confirm press OK, to
cancel press F6 (CANCEL).

Physical home procedure, request for confirmation.

REFER MENU: TRIM Y-AXIS Function

The TRIM Y-AXIS function (key F6) allows you to cut the plate in two along the y-
axis. Before implementing these operation, the program will ask for confirmation
(press key OK) or cancellation (CANCEL: key F6).

Cutting along the Y-axis, request for confirmation

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EXIT from the MAIN MENU

The EXIT from the MAIN menu function displays the window shown below, with the following
optional functions:

- CLOSE (key F5): is used to exit the program and close the Windows session.
- RESTART (key F2): is used to restart the program
- CANCEL (key F6): is used to cancel the EXIT command.

You must close down the system following this procedure before you switch off the power
supply by turning the main switch located on the electrical control board.

Main menu, request for confirmation to exit the Main Menu

CR Electronic – Advanced Page 72


5.2.3. Cutting in the manual mode

To make a cut by moving the torch in the manual mode (using the cursor keys),
you must:

1. Enter the main menu as described above

2. Press F4 and enter the cutting parameters (working speed, piercing height, etc.)
from the settings, IMPOST menu (see above).

3. Press OK and return to the main menu.

4. Move the torch, using the cursor keys and position it over the point where you
want to start the cut.

5.2.3.1. Manual mode cutting procedure

1. Press FIRE

The machine will go through the firing sequence: the torch will lower until it touches the
plate and then will move back up to the piercing height. (8).

IMPORTANT - if you decide NOT to cut, release the FIRE key.

2. Press the cursor key that corresponds to the desired cutting direction BEFORE
you release the FIRE key.

You must press the cursor key before you release the FIRE key; otherwise the torch
will switch off. You can also press the cursor key immediately after you
have pressed FIRE; once you have pressed the cursor key you can release
the FIRE key because the manual cutting mode is now in effect. You can
stop the cutting by releasing the cursor key.

To change cutting direction, press the new cursor key BEFORE you release
the key related to the former direction.

3. If you want to terminate the cut, release the key or keys (cursor or FIRE) that
you pressed during the manual cut.

8
After piercing, the torch will move down to the set working height.

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5.3. Initializing/preparing the machine and the working cycle

5.3.1. Initializing/preparing the machine

The machine initialization procedures are the following:

• Starting the personal computer

The CNC is connected to a personal computer that carries the WINPLASMA CAM program
that the operator use to prepare the parts to cut (see the Winplasma program manual).

If you have to transfer data from the PC to the CNC, make sure that you switched on the personal computer
that is connected to the cutting plotter console BEFORE you turn the main switch that starts up the machine
(this switch is situated on the door of the electrical board, see the chapter entitled «Machine
Description»).

Switch on the CNC after the personal computer has been booted up, so that the network connection can
be properly established.

• Starting the machine.

Start the machine by turning the main switch, which is located on the door of the electrical
board, to ON (see the chapter entitled «Machine Description»).

When the machine is switched on it is automatically in the emergency mode (red light on). Before
you can do any cutting-related procedure you must exit the emergency mode.

• Exiting the emergency mode

To exit the emergency mode, press the reset button on the console (see the chapter entitled
«Machine Description») and keep the button depressed until the green light goes on.

• Clearing the axes

In the START menu (see the description of this menu, above), press F1 (PHYSICAL HOME
function). Before the program carries out the procedure, it will ask for confirmation. To
confirm press OK, to cancel press F6 (CANCEL).

The machine will clear itself, and move the carriage to the home position. If you want to
increase carriage speed, keep the FAST key depressed.

• Loading the plate

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With the carriage at the physical home (or at either end), put the machine in the emergency
mode by pressing the emergency key; put the plate on the grid.

Use only suitable equipment to hoist the plate, and follow safety instructions for handling
loads. Be sure to wear personal protection equipment: appropriate work clothes, protective
gloves, safety shoes and helmet.

IMPORTANT!!! When the green light is on, the machine is live and, therefore, potentially
hazardous. In this mode the operator should not and MUST NOT approach the machine for
any reason. The machine is protected with photoelectric cells that form a safety barrier, that
will trip and put the machine in the emergency mode if anything enters their field of action.

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5.3.2. Cutting PLANES

Let us suppose you want to perform a cut using the taglio.pm1 file, it is a WINPLASMA file in the
personal computer.

The taglio.pm1 file contains 2 planes, the first consists of 3 profiles: a triangle, a square and a
circle; the second consists of three circles.

Cut the first plane starting with contour number 2 on one plate, and the second plane starting from
the first contour on a second plate.

Follow the procedure described below:

Initialize/prepare the machine

After the clearing procedure, the MAIN menu will appear on the screen. Load the
cutting file, access the PLANES menu (key F3) (see above for details). Since the file is
in the personal computer use the RECEIVE PLANES function (key F2) to display the
list of files in the personal computer.

Use the cursor keys to select file taglio.pm1 and confirm the selection by pressing OK. The
screen will display:

Example of the loaded file

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IMPORTANT!! When you load a cutting file, the program performs a loading session and
automatically returns to the MAIN MENU and the first plane and profile to be cut will be
selected, unless you make another selection. In this case enter the PLANES MENU and select
the outlines desired.
Since you want to do plane 1 starting with contour 2, you must change the selection to contour
2. To do this: a) use the parameter setting keys + and - that are located next to the SELECT
TRACK function. Press + once, and track 2 will be selected (the triangle will become red); b)
or, key-in a number on the keypad and a window will appear on the screen where you can enter
the number of the contour you want to cut; press OK to go to the contour selected.
IMPORTANT: To get a better view of the loaded plane, you can enlarge the image by
pressing the “zoom keys”, and run along it with the “cursor keys”.

To launch the cut, return to the main menu by pressing OK.

Before you actually launch the cut, make sure that the cutting parameters are set correctly
(see the plasma generator manual). When a file is loaded, the cutting parameters are either
those set in WINPLASMA or those memorized on the CNC (according to the machine setting
selected by the user); make sure the settings are correct and make any necessary changes.
To configure parameters from the MAIN menu press F4 (IMPOST menu, see above).

Before proceeding you must establish the logic home position (see above for details).
Let us suppose that you want to define position B as the logic home (see the figure
below). In order to evaluate the exact position of the torch with respect to the plate,
lower the torch until it touches the plate. To do this, press the FIRE key and the torch
will keep on lowering as long as the key is depressed, and will go up when you release
it.

IMPORTANT: if the plasma generator is on, the torch will try to trigger and will damage
the plate. Therefore, you must work quickly and release the FIRE key as soon as the
torch touches the plate. Remember that if the torch does trigger, you can interrupt the
cut by releasing the FIRE key. To avoid undesired torch triggering, make sure the
plasma is off when doing this procedure.

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Now you are ready to start the cut. If you prefer, you can do a simulation with the plasma off,
and see how the carriage moves along the axes. Press the SIMUL key, the interface will display
the next menu and the CNC will start the simulation.

To stop the simulation at any time press the STOP button. The machine will go into the pause
mode. (WARNING!! In this mode the machine is live and the signal light is GREEN!
Therefore, you cannot approach the machine.) In this mode you can move the carriage with
the cursor keys. The CANCEL function,(key F6) is active during the pause and you can use it to
cancel the simulation.

Press START to begin the cut: the torch will move to the initial point and will cut contour 2 in
sequence, and then contour 3 on the first plate. The END OF CUT message on the display and
the return to the main menu means that the cut is completed.

IMPORTANT: If you only want to do one of the displayed cuts (e.g. only contour 2) you must press
STOP after that cut is completed. The machine will automatically go into the pause mode; to exit
this mode press: F6 (CANCEL) to terminate the cut, START to resume cutting.

To cut the second plane you must return to the planes menu by pressing F3 (PLANES), select
plane 2 using the + and - keys located next to the SELECT PLANES function. After you press +
plane 2 will be selected, and its contents will appear on the display. Contour 1 is automatically
selected when you load the plane.

Press OK to return to the main menu.

Define the logic home on the second plate, (position C: on the above diagram).

Perform the procedures for the cut as described above in sequence.

• SCREEN: «CUTTING PLANE DISPLAY»

This screen is similar to main menu except for the functions at the bottom, here there are only two:
LOCK/UNLOCK HEIGHT (key F2) (see the Main Menu for the description) and OK TO
MOVE/F. SIMUL OFF (key F4).
This last function can be useful when cutting is interrupted abruptly. If you wish to resume cutting
(START key, see above) because the plate may already be pierced at the point of interruption and
the torch will not find the material needed for triggering, you can use the OK TO MOVE/F.
SIMUL OFF function. It simulates the Plasma On mode on the CNC, which permits the axes to
move along the current cutting contour, and thus moves the torch to find the material.

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IMPORTANT!! When cut is completed, the “TORCH UP” function is entered and the torch
goes up to the upper reference point.

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5.3.3. Unloading cutting scrap manually

1. Move the hood to the front end of the machine: remember that the hood moves together with the
cutting torch.
Press the mushroom head emergency stop button to put the machine in the emergency mode.

2. Wear protection gloves, safety shoes and working clothes.


3. Remove the cover on the front end of the machine (physical home side) by loosening the screws.
4. For manual emptying: a) place a suitable scrap container under the hood; b) turn the release
handle on the bottom of the hood (see the chapter entitled Machine Description); c) use
appropriate equipment to move the container, and follow the safety regulations on material
handling.

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5.3.4. Unloading cutting scrap automatically

The automatic unloading cutting scrap takes place with the EMPTY HOOD function in the REFER
menu (see the related paragraph above).
Using this function (key F5) the operator can automatically start the following procedure: moving
the hood along the positive Xs ( the X value is set during setting up). Once in position, the hood is
opened and scraps are discharged in container proper for use.
During emptying the C.N.C. displays a message for the operator showing the waiting state due to
the operation under way.
At the end of emptying, the C.N.C. dispalys a window with the HOOD BACK function (key F5).
The hood keeps the emptying position until the operator will depress the above-mentioned key.
Scraps must be contained in a proper drawer, stored and disposed of in compliance with
regulations in force.

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5.3.5. Unloading plate scraps and parts manually

Put the machine in the emergency mode by pressing the mushroom head emergency stop button,
and position the carriage to facilitate the procedure. Always remember to operate complying with
the material handling regulations. Wear personal protection equipment: appropriate work clothes,
safety shoes and protective gloves and in case of special machineries (i.e. brige-cranes) use the
helmet.

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5.4. Sequence of steps performed by the CNC to start cutting

The steps the CNC performs to start cutting take place as follows:

1. The torch moves to the point where the cut will start (LOGIC HOME).
2. The torch moves down to touch the plate.
3. The torch contacts the plate and moves back up to the set piercing height.
4. When the torch reaches the piercing height the CNC sends the plasma generator the
PLASMA ON signal: the generator begins the sequence that will activate the electric
arc.
5. The plasma generator returns the PLASMA SIMUL signal signifying that the arc is
activated.

6. When it receives the PLASMA SIMUL signal the CNC will start the piercing delay, at
the end of which the CNC will make the torch descend to the set working height.
7. When it reaches the working height, the torch sends a signal to the CNC, which will then
enable torch movement.

IMPORTANT: It is the tip of the torch that creates the electric contact with the plate.

The following diagram shows the curve for the working height of the torch (Z-axis) as a
function of time:

Where:

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Z is the height of the Z-axis

T is time

Zs is the piercing height of the torch. The torch moves


to this position to pierce the plate (to prevent any molten
metal from damaging it). The torch remains at this height for a
certain time, known as the piercing delay, to prevent
abrupt lowering of the torch to the working height and hitting
against the edges of the «crater» formed by piercing. (9)

Zw is the torch working height. Once the torch has


passed the crater it goes to the working height. As soon as the
speed reaches K times the number set for cutting (K<1)
the distance between the torch and the cutting surface is
regulated by a mechanism that tracks arc voltage. The K value
depends on the type of material being cut.

T0 is the instant the sequence begins


T1 is the instant the torch touches the plate
T2 is the instant the torch reaches the piercing height
and the PLASMA ON signal is sent to the plasma
generator at the same time.
T3 is the instant the generator sends the PLASMA
SIMUL signal
∆T4,3 is the piercing delay.

9
The «track» left by the torch as the start of piercing is called a «crater» because it resembles a volcano
crater.

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T4 is the instant the torch moves to the working
height, when the piercing delay has run out, and the CNC
enables movement
T5 is the instant the arc voltage (Va) varies in relation
to speed:
Va = K vx, y with K<1 and the cutting begins

• Torch-Off sequence

The following is the curve for the torch-off sequence:

Z3

Z2

Working height

T0 T1 T2 t

T3

Where:

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T0 → is the instant the command to turn off the torch is sent

T1 → is the instant the torch is turned off (10)


T2 → is the instant movement (x, y) begins from the endpoint of
the cut.
T3 → is the instant of the endpoint along the z-axis
Z2 is the instant that the upward stroke of the torch
begins to slow down. While upward movement
from the working height Z2 must be fast to
prevent the torch from hitting against any
irregularities on the metal surface as it moves (x,
y), starting as of T2 the upward stroke is
slowed down. When doing close cuts, this permits
considerable timesavings by decreasing the initial
height from which the torch begins its start-up
sequence.
Z3 is the safety height. It is reached at the end of the
cut or if the next cut is to start sufficiently far from the end
of the previous one. (T (x, y)> T3 -T1).

10
Some plasma generators switch off after a set delay (see the plasma generator manual).

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5.5. Resetting the machine after an emergency stop

The machine has to be reset following a deliberate emergency stop or at machine start-up.

To reset the machine, proceed as follows:


- If the machine is in the emergency mode because the mushroom head
emergency stop button was pressed (deliberate emergency stop) turn the
mushroom head button, then press the reset button on the console; keep the reset
button depressed until the green light goes on.
- When the machine is in the emergency mode due to the start-up procedure, press the
rest button and keep it depressed until the green light goes on.

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5.6. Exiting the emergency mode due to units exceeding their stroke

• Exhaust hood exceeding stroke

If the hood exceeds its stroke, proceed as follows:

- Put the machine in the safety mode: no parts of the machine must be live.
- Loosen the screws holding the cover on the back of the machine, the motor-
reduction unit that moves the hood along the x-axis is mounted on the lower
beam of the cutting plotter.
- turn the fast shaft of the reduction using a number 13 hexagonal wrench

• Carriage exceeding stroke

If the carriage exceeds its stroke, put the machine in the safety mode: no parts of
the machine must be live and manually push the carriage back into position.

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6. Safety instructions and safety/warning signs
6.1. Safety instructions
• Do not approach the areas identified as hazardous (see the chapter entitled Risks, safety
and protection), where lowering the risk is not compatible with working needs, while the
machine is operating in the automatic mode.

• Operator intervention for working procedures is shown in machine diagram (see


Attachments: Drawings). If the operator has to intervene for reasons other than the work
cycle, make sure the machine is switched off, for maintenance and adjustments follow the
instructions provided in the respective chapters of this manual.

• The operator must wear the appropriate safety garments and protective devices as
indicated in the “risk analysis table in the chapter entitled Risks, safety and protection”;
safety and warning signs are mounted on the machine.

• Before using them, the operator must check that the safety garments are protective devices
are in good condition.

• Before starting the machine, check the tools, wiring, and the protective devices.

• Keep significant heat sources away from the plasma generator to avoid risk of explosion.

• The user must provide the electric, gas and pneumatic lines needed to operate the machine.
These lines must meet the technical requirements as set forth in the chapter concerning the
technical description of the machine. All systems must conform to current local regulations.

• Do not remove the protections and/or protective devices from the machine. If they have to
be removed for maintenance purposes, bifore

• Restarting the machine, make sure that they have all been properly replaced.

• All electrical outlets must be grounded; the electrical system must meet the technical
requirements as set forth in the chapter concerning the technical description of the machine,
be adequate for the intended use and confirm to current local regulations.

• DO NOT CLEAN, LUBRICATE OR GREASE ANY MOVING PARTS OF THE


MACHINE BY HAND, unless specifically required for technical reasons, in which case you
must use appropriate equipment to avoid risks. All workers must be apprised of this
warning by clearly visible signs and notices.

• DO NOT DO ANY MAINTENANCE WORK ON LIVE PARTS OF THE MACHINE.


Before doing any maintenance work or adjustments make sure that the machine is in the
safety mode. To perform such work correctly carefully follow the instructions in the
manual.

• DO NOT REMOVE the machine’s protective devices while it is operating; DO NOT TAMPER
WITH the machine’s protective devices. REMOVING AND/OR TAMPERING WITH THE
PROTECTIVE DEVICES CAN ENDANGER THE SAFETY OF PERSONS AND THINGS.

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• IMPORTANT WARNING! CHECK THE COLOR OF THE WARNING LIGHTS BEFORE
APPROACHING DANGER ZONES!

6.2. Safety and warning signs

The machine has two types of signs: warning signs (in yellow) and safety signs (in blue).
Sign colors were selected in accordance with the guidelines of Directive 92/58 EC (concerning
minimum requirements for safety and/or health warnings in the workplace) implemented in Italy by
D. Lgs. n.493 dated 14 August 1996.
The purpose of the signs on the machine is to protect the operator from residual hazards and
risks.
During work, the operator must use the protective garments and devices according to the evaluation
of the machine’s hazards.
The safety signs are:

6.2.1. SAFETY SIGNS

Protective Gloves

Safety Shoes

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Earguards

Protective Goggles against Ultraviolet Radiation

Hard Hat

6.2.2. WARNING SIGNS

Danger! Crushed Hands

Danger! Danger of Explosion

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Danger! High Voltage

Danger! Flying sparks

Danger! Noise

Danger! Ultraviolet Radiation

When loading and unloading materials, the following type warning sign should be clearly visible:

Danger! Watch out for Hanging Loads

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7. Risk, safety and protection
7.1. Introduction

The analysis and evaluation of the machine’s risks was conducted in accordance with the basic
requirements of the Machinery Directive and on the basis of the definitions, classifications and
guidelines set forth in the European Standards EN 292/1 and EN 292/2.
For some parts of the machine, as well as machine safety and protective devices, reference was
made to the provisions of specific standards (item 5.3.2 Cylinders of prEN 982 - Safety
requirements for fluid power systems and components - Hydraulics; UNI EN 418; UNI EN 294; EN
60204/1; Decree of the President of the Republic n. 547 dated 27 April 1955 - Standards for
Accident Prevention in the Work Place, as well as the information provided in Appendix A).

7.2. Analysis and evaluation of the system’s hazards

In order to schematize and facilitate reading of the results, we have used a table, entitled Risk
Analysis and Evaluation which is printed in this chapter. The table contains all the hazards and
risks that the system may generate based on the guidelines of UNI EN 292-1 and the Machinery
Directive. The table also contains three main columns:
- the first column is broken down into three columns indicating whether or not there is a hazard in
the system under review, YES or NO, exactly where the hazard is on the machine, Danger zone
and what caused it CAUSE;
- the second column, entitled Risk evaluation contains the evaluation of the risk on the basis of the
indices: P frequency or probability of the risk under consideration; this varies from 1 to 3, with 3
being the highest probability; D the gravity of the risk, also graded from 1 to 3, with 3 as the most
severe; R = PxD the criticality of the risk;
- the third column, Evaluation of the safety measures (to eliminate or reduce the hazard) shows
the evaluation of the safety measures in relation to each hazard on the machine; it is broken down
into safety measures already in on the system “adopted solutions” to reduce the hazard during
machine engineering and construction, and the safety measures to adopt, “planned solutions” to
satisfy better the machine safety requirements of the current European Union standards, and
selected according to the guidelines contained therein, taking production (e.g. limiting costs) and
machining requirements into account.
The risk analysis was based on:
- identification of potential risks and deviations that can trigger hazards;
- identification of the area of influence of the hazards in relation to the operator’s task in the
danger zone;
- evaluation of the risk bearing in mind: probability (index of the frequency with which accidents
may occur); the gravity of any damage that the accident may cause; the number of persons
involved;
- evaluation of the most appropriate safety measures, taking into account costs and available means.
RISK EVALUATION MATRIX R = PxD
P 3 3 6 9 P SCALE OF PROBABILITY
2 1) Improbable 2) Slightly probable 3) Probable
2 4 6

1 1 2 3 D SCALE OF THE ENTITY OF THE DAMAGE

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1) Slight 2) Moderate 3)Severe
1 2 3D

The most unfavorable area of the risk evaluation matrix is the one with the highest risk R index:
If R = 9 (very high risk index) we must identify and plan improvements with protective and
preventive measures to reduce both the probability and the damage.
• If R = 6 (high risk index) we must identify and plan improvements with protective and
preventive measures to reduce both the probability and the damage.
• If R = 2-3-4- (slight risk index) we must verify that the hazards are under control
• R = 1 (negligible risk index) the hazards can be considered under control.
Some hazards remain as Residual risks (see table - Risk analysis, below).
Risks listed without any notes can be considered eliminated or reduced in a satisfactory manner or
with the adopted or planned measured.

7.2.1. Operator intervention on the system

An essential step in risk analysis is the “identification of work tasks and the outline of the danger
zone.”
>> Note that only one operator is required for the machine to function.
In this specific case, we refer to the operator’s tasks during the machine’s various work phases.
The operator’s areas of intervention during the work cycle are shown on the machine diagram (See
Attachments: drawings). To summarize, these are: the plate loading zone for the procedures related
to loading the plate (see the chapter entitled Operating Instructions); the parts unloading zone for
manual unloading of parts (see the chapter entitled Operating Instructions); the console for
monitoring the work.
>> Note that: In order to avoid hazards that could cause intervention in danger zones, it is
important to follow the guidelines set forth in the chapter containing the machine description,
general operating principles - loading plate, unloading parts in the chapter entitled Operating
Instructions and the Table Risk Analysis, below.
NOTE: The protective devices are described in the chapter Machine description and general
operating principles - Technical description of the machine’s components

7.2.2. Warnings for Operator

WARNING!!!! BEFORE detailing the operator to the machine, he needs to be trained


adequately as far as all the machine components, on the basis of the information reported in this
manual.
• The operator needs to read carefully the analysis of risks about the machine and to
operate on the machine according to what indicated in the present manual.
• The operator needs to have and wear the necessary I.P.Ds. ( Intividual Protection Devices ), as
pointed out in the “analysis and risk evaluation table”.

7.2.3. Noise emissions

7.2.3.1. Principal significant noise sources in the system

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The main sources of noise on the machine are:
- the electrical board
- the dust extractor
- the cutting process

7.2.3.2. Notes on the noise emitted by the machine in a closed environment

The ADVANCED PLASMA machine’s noise emissions exceed the limits set forth in the
Machinery Directive (Leq > 85 dB(A)). Due to the fact that, for technological reasons, at the current
state of knowledge, no changes can be made on the main noise sources, it is recommended that
the users employ adequate ear guards and devices to protect their hearing.
It has also bee found that environmental noise is strong affected by the ambient in which the
noise source (the machine) is operating, therefore it is advisable that area surrounding the
machine be fitted with sound insulation.
IMPORTANT: The user shall be responsible for fulfilling the requirements of the current
European standards on this issue. With regard to the machine operator, the employer shall:
- have the operator undergo periodic medical check-ups;
- train and inform the operator as to the risks deriving from exposure to noise, the adopted
measures, and measures the operator has to take;
- provide the operator with personal hearing protection devices, adapted to the operator and
his/her working conditions.

7.2.3.3. Intervention and attempts at intervention at the main noise sources

- Cutting process
The cutting area (torch) is not completely shielded for noise abatement since the current state of
technical knowledge has not favored the attempts made by the manufacturer (in compliance with
the basic requirements of the Machinery Directive).
Adequate noise shielding of the torch would have led to additional risks to persons and things.
NOTE: appropriate warning signs have been affixed to the machine.

7.2.3.4. Fire Prevention

Important: there are specific standards for fire prevention measures to adopt for storing and using
flammable gas (in relation to quantities).
As a basic preventive measure, there must be a dry type fire extinguisher - not water - near the
machine, outside the danger zone.

7.2.3.5. Electromagnetic compatibilità

On the basis of the tests performed on a similar machine, the machine meets the basic requirements
of Directive 89/336/EEC (dated 3 May 1989) concerning the reconciliation of legislation in the
member states regarding electromagnetic compatibility, as modified and transposed by Italian law).
Important: The user must set up an adequate electric transforming booth upstream from the
machine.

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7.2.5. Risk analysis and evaluation.

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8. Troubleshooting

> This chapter is organized as follows: the problem is named, it is followed by a list of causes and then the solutions.
The causes are listed in order of occurrence, starting with the most common cause. For example, if it is not cause 1) it
will be cause 2) or 3) and so forth.

8.1. Problems concerning the plotter machine and cutting


IMPORTANT PRELIMINARY WARNING: If the torch is malfunctioning DO NOT do any work on it while it is still hot. Let
the torch cool for a few minutes through gas flow by setting the plasma generator on TEST; wear heat insulating gloves!

• The plasma arc does not fire

See the plasma generator manual.

• The cut is interrupted

See the plasma generator manual

• Excess burrs on the bottom of the part


See the plasma generator manual

• Burrs on the top of the part


See the plasma generator manual.

• The plasma does not pierce the plate

See the plasma generator manual

• Excessive fumes during cutting

Causes:
1) The exhaust is off.
2) The hood is filled with slag

Solutions:
1) Turn on the exhaust
2) Clean the hood and remove the slag.

>> For any other problems that are not listed here, check with the manufacturer before doing
any work on the machine.

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• If the three net pilot lights on the console do not light up with the same intensity
Cause:
1) A phase is lacking.
Solution:
1) When the machine is not feeded: look for the burnt fuse on the power supply outlet or on the
transformer primary (see the chapter Attachments: Electric Circuit Arrangments).

• The machine is feeded, but the display is not on


Cause:
1) The fuse placed at the output of the transformer (220 V) is burnt (see the “Electric Circuit
Arrangment”, Attachments chapter).
Solution:
1) Replace the fuse.

• The machine does not come out from the emergency state
Cause:
1) the self-deducted mushroom-head button is still pushed.
2) An electric protection intervened: a) photoelectric cells out of alignment.
3) A situation of extra-stroke of one of the X,Y,K-axis occured.
4) The fuse on the emergency circuit is defective or it burnt or a short circuit occurred on the
emergency series.
Solution:
1) In this case come out from the emergency on the basis of what indicated in the Instructions for Use
chapter.
2) If a protection intervened, it occurs to operate like this: a) align the photoelectric cells so that the ray is
not interrupted.
3) Come out from the extra-stroke determined on the basis of what indicated in the “Instructions for Use”
chapter.
4) Replace the defective or burnt fuse or contact CR Electronic to carry out the check on the emergency
series.

• The Personal Computer is not able to communicate to the C.N.C.


Cause:
1) Before the C.N.C. and after the Personal Computer were made work.
2) Problems on the telematic network.
3) The Personal Computer was not correctly configured for network transmission.
Solution:
1) Disconnect both units and the C.N.C. switch before, and then the PC.
2) Check if the C.N.C. is viewed in the network (as to this subject, read the Windows manual).
3) Contact CR Electronic.

• It is impossible to lift up/lower the torch operating on the proper control


Cause:
1) Z-axis motor not feeded: a) fuses on the power supply of the Z-axis card are not working; b) the Z-axis
control is damaged.
Solution:
1) a) replace fuses that are not working (contact CR Electronic); b) replace the control (contact CR
Electronic).

• The torch oscillates few mm on the upper reference point


Cause:
1) Inclined torch.
2) Balancing support of the torch damaged.
Solution:

CR Electronic – Advanced Page 114


1) To verify this condition, have a look to the MENU IMPOST, DIAG control (see the Instructions
for Use chapter); in such a case contact CR Electronic.
2) Verify if there are slags, if so clean; or verify that no electric breakdown occured to the support:
switch it off electrically and if the problem is solved replace the support.

• Pushing the FIRE button, the cutting head presses against the sheet with exessive force
Cause:
1) There is a failure at the torch contact.
2) The torch is inclined.
Solution:
1) To verify this condition consult the MENU IMPOST, DIAG control : “Torch Contact” (see the
Instructions for Use chapter); in such a case contact CR Electronic.
2) To verify this condition consult the MENU IMPOST, DIAG control: “Inclined Torch” (see the
Instructions for Use chapter); in such a case contact CR Electronic.

• The torch lift up before the contact with the sheet or strikes by air
When coming down the cable pushes the torch inclining it, a false signal is recived:
- check that the support springs are not too weak, in this case replace it contacting CR Electronic;
- place better the torch cable in order to avoid pushing the torch.

• The sheet around the cutting outline is burnt


There are problems depending on the plasma generator: consult the relative manual.

• “Torch Contact” and “Inclined Torch” do not answer to their functionalitis11


Cause:
1) the plasma generator mass is not correctly connected.
Solution:
1) Connect properly the mass on the basis of what was pointed out in the plasma generator manual.

• Misures of cutted pieces are not the right ones.


Cause:
1) The sheet moved during the cutting.
2) Scale factors have been accidentaly modified in a wrong way.
Solution:
1) Repeat the cutting, checking that, during it cut, the sheet is not dragged moving it.
2) Contact CR Electronic.

11
) To verify the entry state, it is necessary to access to the “DIAG” menu (see the Instructions for Use
chapter). The correct functionality of the two entries: “torch contact” and “inclined torch” is the following: 1)
active entry (for instance, the torch contact is developing) in this condition the entry has to be selected; 2) not
active entry: not selected needs to appear in the diagnostic window.

CR Electronic – Advanced - Page 115


8.1.1. LEDs on the control cards

In the cards: Z-AXIS (Height Control), PHOENIXII (Axis Control), I/O (Plasma Interface and Motor Drives)
there are some LED diodos that can make easier the identification of some breakdowns under the guide of
the specialized CR Electronic technical staff.

8.1.1.1. Layout of the height control card (Z-AXIS)

JP10

JP3

D36
D29
rosso
D2 rosso
rosso D3
rosso
D15
D6
rosso D16
rosso D5
verde
rosso

COMPONENT SIDE

Ref. Component Normal Running State Associated Signals

D2 red LED OFF Entries currently unused

D3 red LED OFF Entries currently unused

D5 red LED OFF12 Torch Contact


(terminal board JP3, pin 1) that comes from the
filter card
D6 red LED OFF13 Inclined Torch
12
The LED is ON when the “Torch Contact” takes place

CR Electronic – Advanced Page 116


(terminal board JP3, pin 3) that comes from
the filter card

D15 green LED ON +12VA


(Analogue Power Supply at +12V from a
CENNI transformer (transformer entries
from terminal board JP10, pin 1 and 2
connected to the network transformer))14

D16 green LED ON -12VA


(Analogue Power Supply at -12V from a
CENNI transformer (transformer entries
from terminal board JP10, pin 1 and 2
connected to the network transformer))15
D29 red LED OFF Therm
(Thermic Flag of the motor driver / Z-axis
LMD18200 (U13), pin 9)
D36 green LED ON +34V
(Power Supply at +34V for the motor driver
– Z axis for rectification of 12V alternated
(terminal board JP10, pin 1 and 2 connected
to the network transformer))16

13
The LED is ON when there is the “Inclined Torch”
14
Tensions reported at the outlet of the stabilizer
15
Tensions reported at the outlet of the stabilizer
16
Tension reported after rectifier diodes

CR Electronic – Advanced - Page 117


8.1.1.2. Layout of the axis control card (PHOENIX II)

PHOENIX II D4 D3
verde rosso

JP16
JP3

JP1

JP17
D2 D1 JP9
JP8
verde rosso

JP14 JP7

COMPONENT SIDE

Ref. Component Normal Running State Associated Signals

D1 red LED ON A+15V


(Analogue power supply at +15V from the
60 poles connector (pin 59) coming from the
I/O card)
D2 green LED ON A-15V
(Analogue power supply at -15V from the 60
poles connector (pin 59) coming from the I/O
card)

D3 red LED BLINKING (every 2s.) Pin 14 FPGA (U25)


Internal Clock FPGA)

D4 green LED BLINKING (every 1s.) Pin 72 FPGA (U25)


It indicates the correct running of the C.N.C.
interruption routine

CR Electronic – Advanced Page 118


8.1.1.3. Layout of the I/O card (NC-PLASMA INTERFACE )

M3 M4

D1
rosso

M2 M5

M1 M6

Ref. Component Normal Running State Associated Signals

D1 red LED ON +15V (anode), –15V (cathode)


(Power Supply at +15V and -15V from
rectifier bridge with entries connected to the
12 and 11pins of the M3 terminal board
(alternated tension at 18V from the T1
transformer) and directed to the 60 poles
connector (pin 59: +15V; pin 60: -15V)) 17

17
Tensions out from the rectifier bridge and not yet sended to the stabilizer

CR Electronic – Advanced - Page 119


9. Maintenance, cleaning, inspections, checks

WARNING!!! DO NOT INTERVENE ON THE MACHINE when it IS POWERED! Before serving


the machine make sure that it is in safety conditions: that there are not live components
or that gas cocks are turned off.

• Before removing any machine protection or carrying out any kind of maintenance service,
make sure that the machine is in safety conditions.

• The kind of grease to use, in order to realize greasing, needs to be: of F Class (FD5, FD10,
FD12)
PRELIMINARY NOTE: The under mentioned maintenance interventions, refer to an use of
the machine at full speed.
WARNING!!! Complying with maintenance modalities and times helps in the correct
running of the machine.

CR Electronic – Advanced Page 120


OPERATION OPERATING TIME MODALITIES
EMPTYING OF THE At least 2 or 3 NOT AUTOMATIC HOOD EMPTYING

(AUTOMATIC or NOT times/daily. 1) Bring the hood to the zero point position of the machine (see the
chapter: “Instructions for Use”);
AUTOMATIC) NOTE: the frequency
Put the machine in safety conditions.
EXHAUST HOOD of cleaning depends
2) Wear protection gloves, safety shoes, overalls;
on the thickness of
the machined sheet, 3) Take away the case placed on the front side of the machine
(zero side), screwing out screws;
as well as the amount
4) For emptying operations: a) put a proper container for
of work. collecting off-cuts under the hood; b) turn the unlocking handle
of the hood bottom (see the chapter about the “Description of
the Machine”); c) handle the container using proper means and
complying with the load handling standards.
CLEANING the GRID 2-3 times/month With the machine in safety conditions:
For a correct maintenance operation: use a pneumatic
out from OFF-CUTS stonecutter;
wear: protection glasses and gloves, safety shoes, overalls.
GRID REPLACEMENT once/year As far as the needed spare parts (that may change
acording to the model) contact the producing
company.
The procedure for replacement is the following:
1) Wear protection gloves, safety shoes, overalls;
2) move (see the chapter about: Instructions for Use) the truck to
one of the machine ends;
3) put the machine in safety conditions;
4) take the old grid away (see the “disassembly” chapter);
5) fix the new grid windows on the base of those indications
pointed out by the producing company and replace the old ones.
BELT REPLACEMENT No more than 3000 NOTE: the belt state needs however to be checked once a month,
operating with the machine in safety conditions..
hours of work
TRUCK Y-AXIS Once/month With the machine in safety conditions:

MOTION For cleaning, use a gas oil satured rag; for a correct opeartion wear
safety shoes, overalls, protection gloves and operate in rooms
TRANSMISSION sufficiently aerated.
SCREW, X-AXIS X-AXIS GUIDES CLEANING
GUIDES CLEANING 1) Take the aluminium cases away, that are placed over them;
2) Do cleaning.

Y-AXIS MOTION TRANSMISSION SCREW CLEANING


1) Remove cases assembled on the truck;
2) Do cleaning
GREASING of the once/month Wear protection gloves, as well as safety shoes and overalls.
CHAIN for Use a F class grease (FD5, FD 10, FD 12)
TRANSMITTING HOOD CHAIN GREASING
MOTION TO THE
1) In order to grease the chain, the hood needs to be
HOOD
moved to one of the machine ends;
2) Put the machine in emergency, pushing the
emergency button;
3) For the chain greasing, the operator needs to screw
out the protection cases placed along the long sides
of the machine;
4) Greas the chain along the X length of both sides
with a brush;
5) Come out from emergencY (see the chapter about:

CR Electronic – Advanced - Page 121


Instructions for Use);
6) Move the chain to the opposite end, put the machine
again in emergency and repeat operations for
greasing.
7) Reset protections before coming out from the
emergency.

GREASING of the once/month Wear protection gloves, as well as safety shoes and overalls.
TORCH SUPPORT Use F class grease (FD5, FD 10, FD 12)
SLIDING BLOCKS, TORCH SUPPORT SLIDING BLOCKS GREASING
TRUCK SUPPORT AND
1) move the torch to one of the truck ends, in
SCREW NUT, X-AXIS
order to make the sliding block easily accesible;
KINEMATIC
FLOATING SHAFT With the machine in safety conditions:
SUPPORT (see further 2) Do greasing;
on the “lubrication 3) reset protections, before making the machine
points map”) work again.
TRUCK SUPPORT AND SCREW NUT GREASING
1) move the torch to one of the truck ends, in
order to make nut easily accessible;
With the machine in safety conditions:
2) remove cases on the truck and put grease on
the support and the nut lubricators;
3) reset protections, before making the machine work
again.
X-AXIS FLOATING SHAFT SUPPORT GREASING
(See further on the “lubrication points map: X—
AXIS kinematic”)
With the machine in safety conditions:
1) remove the lateral sides on the truck;
2) put grease on the bearing lubricators (for their
position see the following: “lubrication points
map”)

RACK CLEANING once/month With the machine in safety conditions:


Screw out the protection cases and protection brushes.
Cleaning needs to be carried out by using an iron brush in order to
clean out dirt and, after, blowing the produced dust by compressed
air. Wear: protection gloves, glasses and mask.
BALL BEARING once/month In order to service the machine do not operate when it is live
(machine in safety conditions).
SCREW AND GUIDES
This cleaning operation is advisable before the sliding blocks
CLEANING greasing, that slide on the screw supports and guides, using a gas oil
satured rag: when operating, wear protection gloves and act in rooms
sufficiently aerated.
With the machine in safety conditions:
CHECKS ABOUT THE carry out the operations reported in the relative manual.
PLASMA GENERATOR
TORCH Daily Before starting cutting, with the machine in safety conditions:
Check that the main body of the torch and the spare parts are in a
good state.
Check that there are no burnings or colour alterations on the torch
spare parts, in such a case replace them (see the manual about the
plasma generator).
Check that connections are tight.
CHECK THE TORCH once/2 months With the machine in safety conditions:
Check the cable conservation state, verifying that there are no
AND PLASMA damages. In case of wear, replace damaged parts.
GENERATOR CABLES,
AND THE AMOUNT OF

CR Electronic – Advanced Page 122


CABLES PLACED ON
THE MACHINE
PLASMA GENERATOR once/month With the machine in safety conditions:

CLEANING Carry out each operation on the base of what reported in the manual
of the unit in question.
CLEAN THE once/week With the machine in safety conditions:
by compressed air or using a clean light brush.
POTHOELECTRIC
CELL MIRRORS
CLEAN OUT the twice/month With the machine in safety conditions:

COOLING FAN 1) wear protection gloves; protection glasses and mask, as well as
safety shoes and overalls;
FILTERS(18) of the
2) Take the grid away (which pushes the filter against the
ELECTRIC fan);
BOARD/CONSOLE 3) Take filters away;
4) Blowing compressed air in each filter.

18
The degree of electric protection for filters is IP55; the degree of protection to flame: S1 (DIN 55438); it
holds dusts with a granulometry major than 10 µ.

CR Electronic – Advanced - Page 123


9.1. Lubricator Points Map – Belts Position

9.2. How to Replace Belts

• Replacement of the Belt Kind A


To replace it, operate as follows, referring to the above mentioned “lubrication points map – belts
position”.
1) Unloose screws of the tightening pulley in order that the belt is no more tight.

CR Electronic – Advanced Page 124


2) Screw up the aluminium support of the X-axis motor: the shaft is sliding towards the motor,
then free the belt on the pinion.
3) Release the two joints of the floating shaft in order to separate the central part from the lateral
ones.
4) Unloose the security dowels of the two lateral bushes in correspondence with the floating shaft.
5) Screw out the support R1 in order that it can be extractable and take all the block away.
6) Unloose the tollock on the pulley, so that the belt is extractable.
7) Replace the belt A and repeate all operations in the opposite direction.
8) Before releasing the support R1 of the motor, the belt needs to be streatched with the proper
register, until obtaining a 5 mm camber by placing in the center point of the belt A, in its free
section, a dynamometer charged with a 15 Kg force.
After replacing the belt, it is necessary to square the plotter ( see chapter: “Assembly, Disassembly,
Adjustments..….”).

• How to Replace the Belt Kind B


To replace it, operate as follows, referring to the above mentioned “lubrication points map – belts
position”.
1) Release the support R4 trying carefully don’t to move registers that regulate the distance
between the X pinion gear and the rack below. (The support R4 is equipped with two
adjustments: one for streatching and unloosing the belt B and the other one for adjusting the X
pinion gear pressure on the rack below ).
2) Unloose dowels on the bearing in correspondence with the support R3. Release the support
with bearing ( position R3 ); then unloose the pulley tollock with a bigger diameter (block R4),
that locks the pulley on the internal shaft, screw out the block R4 in correspondence with the
external and internal pulley bushes; at this point it is possible to extract the belt.
3) Replace the belt B and repeat the operation in the opposite direction.
4) In order to streatch the belt B, the support R4 needs to be registered with the proper registers up
to the belt, untill obtaining a 5 mm camber by placing a dynamometer with a 14 Kg force, in its
central part of the free section. Be careful don’t to damage the support R4 register, which adjust
the distance of the X pinion of the rack below.
After replacing the belt, it is necessary to square the plotter (see the chapter about: “Assembly,
Disassemly, Adjustments.….”).

WARNING!!! During the parts reassembly, as the last operation, tighten the tollock by
screwing the cross screws and pay attention to do it more times.

• How to Replace the Belt Kind C


To replace it, operate as follows, referring to the picture: “lubrication points map – belts position”.
1) Release the support R5 of the Y motor, in order to make the motor sliding on it, so that it is
possible to extract the belt.
2) Replace the belt C and streatch it with the proper register on the register R5, until obtaining a
5mm camber by placing a dynamometer charged with a 11 Kg force in the central point of its
free section.

After replacing the belt, it is necessary to square the plotter (see the chapter about: “Assembly,
Disassembly, Adjustments….”).

CR Electronic – Advanced - Page 125


10. Taking the machine out of service and dismantling

To take the machine out of service, you must dismantle it and dispose of the various materials in
accordance with current local regulations. To take the machine out of service you must first isolate it
by disconnecting all power supplies to make sure that it is entirely safe.

10.1. Differentiated waste disposal

Ferrous materials must be scrapped.


Plastics must be disposed of by special firms authorized to transport and dispose of these items
according to current local waste disposal regulations.

CR Electronic – Advanced Page 126


11. Spare parts – optionals – Technical Service

11.1. Plasma consumables


Please see the plasma generator instruction manuals for plasma consumables.

11.2. Recommended spares


• X Axis unit

Item Reference Code


X axis motor’s belt 32 AT5 - 600
X axis belt 50 AT5 - 1050

• Y Axis unit

Item Reference Code


Y axis belt 25 AT5 - 545

• Grid
The grid changes as a function of the machine model; for that apply to the producing
Company.

• Exhaust Channel Rubber

Article Name Reference Code


Exhaust Channel UNICALOR - 4
Rubber
For the other spare parts not mentioned here, apply CR Electronic.

11.3. Optionals

• Drier
For further data about it, consult the relative manual of this unit.
Uninterruptible Power Supply
For further data about it, consult the relative manual of this unit.

11.4. Technical Service

CR Electronic s.r.l.
Piazza Vivaldi, 1
50069 Sieci - Pontassieve (FI) - Italy
Tel: 39 055 8309874 - Fax: 39 055 8328384

CR Electronic – Advanced - Page 127


12. Attachments
In this chapter the customer will find schematic diagrams, designs about the machine.
Note: Electric Circuit Arrangements were realized in compliance with the point 19 – CEI EN 60204
Technical Documentation - 1: Machinery Safety – Electric Equipment of the Machines - Part 1,
General Rules.

In the chapter you will find: Design Section, Electric Circuit Documentation

12.1. Design Section

CR Electronic – Advanced Page 128


12.2. Electric Documentation Section

Internal Front View of the Electric Board

CR Electronic – Advanced - Page 129


Electric Board/Console Lateral View

CR Electronic – Advanced Page 130


Console Internal Upper View

CR Electronic – Advanced - Page 131


Detailed Disposition of the Console Internal Components

CR Electronic – Advanced Page 132


Electric Board/Console Outside Front View

CR Electronic – Advanced - Page 133


Number Identification Code Description
1 AZ-EI-IBD506 X-axis drive(19) (506 RM 220VCA-6A)
2 AZ-EI-IBD506 Y-axis drive (506 RM 220VCA-6A)
3 AZ-EI-IBD506 K-axis drive (506 RM 220VCA-6A)
4 MCR 04/97 Plasma Emergency Warning Card
5 M-AB1-VV435U kind -54 terminals for end of stroke
stocks
6 CEV10000M-063 Electrolytic Condenser 10000µF
63V(20)
7
8 MCR-03/96 CNC-PLASMA Interface
9 LEG 058 08 (x 2) FUSE 2 x 1 A am (10,3 x 38)
18 Vac Data-Mem-Az
10 LEG 058 08 (x 2) FUSE 2 x 1 A am
220 Vac Ventil-Cass
11 I-TETR-4x16A (PAL 275113) door interlock switch
12 CAB TE6O terminals for cable electric
shielding
13 LEG 058 08 (x 3) FUSE 3 x 6 A am
380 V/R-S-T
14 LEG 058 08 (x 3) FUSE 3 x 12 A am
220 V/drive
15 LEG 058 08 (x 3) FUSE 3 x 4 A am
24 Vac Control-Card -H
16 LEG 058 08 (x 3) FUSE 3 x 4 A am
22,5 Vac Console- Power Supply
17 T-LC1-D3210B7 PWR-MOTORS
C-AUX-LA1DN40
18 T-LC1-D2510B7 ACC/BRAKE-X
C-AUX-LA1DN04
19 T-LC1-D2510B7 ACC/BRAKE-Y
C-AUX-LA1DN04
20 T-LC1-D2510B7 ACC/BRake-K
C-AUX-LA1DN04
21 LEG 048 84 quadrupole distibution frame

19
Descriptions and codes corresponding to the numbers: 1, 2 and 3 (X, Y, K-axis) refer to the “Elettronica
Industriale (EI)” drives, as alternative it is possible to assemble the following drives: “TDE-MACNO” or “ECS”
(further on see the relative electric circuit documentation and for varying identification codes apply to CR
Electronic).
20
Descriptions and codes corresponding to the numbers: 6 and 7 refer to the “Elettronica Industriale (EI)”
and “ECS” drives; as far as “TDE-MACNO” drives, they are not present (further on see the relative electric
circuit documentation and for varying identification codes apply to CR Electronic).

CR Electronic – Advanced Page 134


22 unipotential conductor
23 TRF-TT-4600/109 4600VA screened (21)three-phase
transformer
24 TM-TC82-857 TC82 24 Vac timer
25 R-R55.34-24VAC emergency relay
26 R-R55.34-24VAC Relay for enabling drive
27 R-R55.34-24VAC drive alarm reset relay
28 FIL-832.010V finmotor filter 832.010v
29 M-AB1-VV435U Console terminal stocks
30 M-AB1-FU10135 FUSE 1 x 6 A (5 x 20 glass)
24 Vac AUX
31 M-AB1-FU10135 FUSE 1 x 2 A (5 x 20 glass)
24 Vac emergency series
32 M-AB1-FU10135 FUSE 1 x 1 A (5 x 20 glass)
24 Vac filter consent
33

34

35

36

37

38

39

40

41
42
43
44
45
46

21
Descriptions and codes corresponding to the number 23 are for “Elettronica industriale (EI)” and “TDE-
MACNO” drives; as far as “ECS” drives, it defers (further on see the relative electric circuit documentation
and for varying identification codes apply to CR Electronic).

CR Electronic – Advanced - Page 135


47
48
49
50 CPC09MPM-P/1 Male Connector AMP 9 Poles
Optic Barrier
51 CPC09MPM-P/1 Male Connector AMP 9 Poles
Optic Barrier
52
53 CONN-40F-AGG Harting Connector 40 poles
CAL-M/PA/H40P X and Y axis motor power
54 CONN-64F-AGG Harting Connector 64 poles
CAL-M/PA/H64P X and Y- axis signals
55 CONN-16F-HAN Harting Connector 16 poles
CAL-M/PA/H16P Filter Consent
56
57
58
59
60 Oerre RC 20 230 0W957 Ventilator 220 Vac
With IP55 filter
61 RTA 84004 metal cable press connector
62 PAL 295 107 door interlock hand grip
100
101 MCR-03/98 torch height control card
102 multislot bus card ISA
103 MCR-07/97 PHOENIX II N.C. card
104 ETHERNET ISA network card
105 CPU Pentium card
106
107
108
109
110 MCR-17/91 plasma signals filter
111 CPC37MPM-P/1 Connetctor AMP 37 Poles
112

CR Electronic – Advanced Page 136


113
114 CPU power supply
115 unipotential conductor
116
117
118
119
120 XVA-C06 gasket. Control lights for the machine state
XVA-C11 base
XVA-C02 bar
XVA-C21 terminals
XVA-C33 green L.
XVA-C34 yellow L.
XVA-C35 red L.
DL1 BA024 lamp
121 P-ZB2-BS54 red mushroom-head push button
C-NC-ZB2BZ102 (emergency)
122 TL-ZB2BV6 bridge and condenser signal lamp OK
TL-ZB2BV04
123 TL-ZB2-BA2 reset button
C-NO-ZB2BZ101
124 TL-ZB2BV6 phase R signal lamp
TL-ZB2BV03
125 TL-ZB2BV6 phase S signal lamp
TL-ZB2BV03
126 TL-ZB2BV6 phase T signal lamp T
TL-ZB2BV03
127 TL-ZB2BJ2 Selector for plasma change
C-NO-ZB2BZ101
128
129
130
140 keyboard
141
142 STAF 20 STI-S Plasma 1 Connector
HAN 16A-AGG-RB
143 STAF 20 STI-S Plasma 2 Connector
HAN 16A-AGG-RB
144
145 CONN-16 Kit-HAN HARTING Connector 16 poles
Height Control

CR Electronic – Advanced - Page 137


146
147
148
149
150 BNC at connection Data transmission connector

CR Electronic – Advanced Page 138


EV. CONNECTOR AND FILTER CONTROL (CF16)
( Inside case/console)
Connector kind: ⊗ Male on drawer’s plate
⊗ Female on case
Pole Numb.: 16 Harting
PI No. wire Sec. & colour To/from Note
N
1 15 Awg 20 black Ev. return wire and exhaust filter
2 0100 Awg 20 black Exhaust Filter Control
3
4
5
6
7
8
9
10
11
12
13
14
15
16

CR Electronic – Advanced - Page 139


X,Y-AXIS POWER CONNECTOR (C40)
(Inside and outside case/console)
⊗ 40 PIN connector ⊗ Male on drawer’s plate
⊗ Female on case

A B C D
1 U-X Awg 20 light 1 U-Y Awg 20 light 1 1
blue blue
2 U-X Awg 20 light 2 U-Y Awg 20 light 2 2
blue blue
3 U-X Awg 20 light 3 U-Y Awg 20 light 3 3
blue blue
4 V-X Awg 20 brown 4 V-Y Awg20 brown 4 4
5 V-X Awg 20 brown 5 V-Y Awg20 brown 5 5
6 V-X Awg 20 brown 6 V-Y Awg20 brown 6 6
7 W-X Awg 20 black 7 W-Y Awg 20 black 7 7
8 W-X Awg 20 black 8 W-Y Awg 20 black 8 8
9 W-X Awg 20 black 9 W-Y Awg 20 black 9 9
1 81 Awg 20 white 10 K25 Awg 20 yellow 1 X axis screen 1 Y axis screen
0 0 power 0 power

CR Electronic – Advanced Page 140


X,Y AXIS SIGNALS CONNECTOR (C64)
(Inside case/console)
⊗64 PIN CONNECTOR ⊗ Male on drawer’s plate
⊗ Female on the board

A B C D
1 brown (Excit+) 1 brown(Excit+) 1 1
Screened 3X Screened 3Y
2 white (Excit-) 2 white (Excit-) 2 2
Screened 3X Screened 3Y
3 Brown (Sin +) 3 brown (Sin +) 3 3
Screened 2X Screened 2Y
4 white (Sin-) 4 white (Sin-) 4 4 60 Awg 20 black
Screened 2X Screened 2Y end of stroke
return wire
5 5 5 5 60 Awg 20 black
end of stroke
return wire
6 6 6 6 Awg 20 orange
FC.X ahead
7 brown (Cos+) 7 brown (Cos+) 7 7 Awg 20 yellow
Screened 1X Screened 1Y FC.X back
8 white (Cos-) 8 brown (Cos-) 8 8 Awg 20 violete
screened 1X Screened 1Y FC.Y ahead
9 screens 9 screens 9 9 Awg 20 green
FC.Y back
10 X25 Awg 20 10 Y25 Awg 20 10 10
green brown
Emergency X Emergency Y
11 X26 Awg 20 11 Y26 Awg 20 11 11
orange gray
Emergency X Emergency Y
12 Awg 20 yellow 12 X26 Awg 20 12 12
Truck emergency yellow
Y push button
13 X25 Awg 20 13 Y25 Awg 20 13 13
white white
Truck emergency Y push button
14 brown 14 brown 14 14
Screened TR-X Screened TR-Y
15 white 15 white 15 15
Screened TR-X Screend TR-Y

CR Electronic – Advanced - Page 141


Photoelectric Cells Connector 1 (C91)
(Inside case/console)
Connector kind: ⊗ Female on drawer’s plate
⊗ Male on case
Pole Numb.: Amp 9

PI No wire Sec. & colour To/From Note


N
1 15 1 black 24 Vac distribution frame photoelectric cells
power supply
2 78 1 black 24 Vac distribution frame
3
4
5 1 yellow/green
6
7
8 78 1 black 24 Vac distribution frame emergency series
9 24 Awg 20 yellow emergency terminal board

CR Electronic – Advanced Page 142


Photoelectric Cells Connector 2 (C92)
(Inside case/console)
Connector kind: ⊗ Female on drawer’s plate
⊗ Male on case
Pole Numb.: Amp 9

PI No wire Sec. & colour To/from Note


N
1 15 1 black 24 Vac distribution frame photoelectric cells power
supply
2 78 1 black 24 Vac distribution frame
3
4
5 1 yellow/green
6
7
8 24 Awg 20 yellow emergency terminal board emergency series
9 25 Awg 20 yellow emergency terminal board

CR Electronic – Advanced - Page 143


37 Poles Amp Case-Console (J37)
(Inside case/console)
Connector kind: ⊗ Male on drawe’s plate ⊗ Female on case
No wire Sec. & colour Note
PIN Destination (to) Origin (from)
1 EN Z red Encoder Z I/O MS2-4
2 black I/O MS2-3
3 white I/O MS2-2
4 green I/O MS2-1
5 screen I/O MS2-5 00
6
7 AWG18-20 red encoder power I/O MS4-3 + 12 Vdc
8 AWG18-20 black supply I/O MS4-4 0 Vdc
9 225 1 mmq black bridge, power Fuses for
10 225 1 mmq black supply, R-S-T console power
11 225 1 mmq black lamps supply
12 00 AWG18-20 grey Return wire for stock
I/O entries
13 3 1 mmq. black 24Vac Power Motor Z-axis power supply
14 3 1 mmq. black transformer
15 3 1 mmq. black
16 AWG18-20 green C16/12 spare terminals stock
17 AWG18-20 green C16/13 spare terminals stock
18 AWG18-20 spare terminals stock
orange
19 79 AWG18-20 black plasma switch distribution
1/2 frame
20 15 AWG18-20 black Return wire distribution 0 Vac
plasma relay frame
1/2
21 15 AWG18-20 black Return wire distribution 0 Vac.
emergency frame
signal lamps
22 85 AWG18-20 black Together with Timer RT1
wire no. 84: 7
starting button
23 84 AWG18-20 black Together with Timer R1
wire no. 81: 9
console
emergency
button
24 81 AWG18-20 Board emerg. card 9 Emergency series
yellow Terminals
25 90 AWG18-20 Emergency R1
yellow relay 11
26 90 AWG18-20 R1
yellow 7
27 188 AWG20 black emergency R1
signal lamp 6

CR Electronic – Advanced Page 144


28 189 RT1
3
29 190 RT1
4
30 PL1 brown FIRE ON I/O MS1-12
31 white I/O MS1-11
32 Screen PL1 I/O MS2-5
33 PL3 white FIRE SIMUL I/O MS1-1
34 Screen PL3 + brown turret
35 15 black 1 mmq. Red lamp distribution 0 Vac
frame
36 1 mmq. yellow- ground Ground bar
green
37 79 black 1 mmq. Red lamp distribution 24 Vac
frame

CR Electronic – Advanced - Page 145


HEIGHT CONTROL CONNECTOR (C16)
(Inside case/console)
Connector kind: ⊗ Male on drawer’s plate
⊗ Female on case
pole numb.: 16 Ilme
PI No wire Sec. & colour To/From Note
N
1 Awg 24 red I/O card MS4-3 + 12 Vdc encoder
power supply
2 Awg 24 black I/O card MS4-4 0 Vdc encoder
power supply
3 black I/O card MS2-3 A phase
4 red I/O card MS2-4 A’ phase
5 white I/O card MS2-1 B Encoder phase
6 green I/O card MS2-2 B’phase
7 ground + screens
8 Awg 24 red Height control card J3-1 + filtro
Torch contact
9 Awg 24 Blue Inclined torch
10 00 Awg 20 black Prearrangment for
Arc Writer
11 501 Awg 20 orange Prearrangment for
Arc Writer
12 Awg 20 green stock
13 Awg 20 green stock
14 1 brown Height Control card J10-11 (M1) Z-axis motor
15
16 1 Blue Height control card J10-12 (M2) Z-axis motor

CR Electronic – Advanced Page 146


HD Plasma Connector (C141 e C142)
(Inside and outside case/console)
Connector kind: ⊗ Male on drawer’s plate
⊗ Female on case
pole numb : 20 Harting
PI No wire Sec.& colour To/From Note Cable Colour
N (est.)
1 white scr.1 plasma source/ Scr. I/O MS1-11 Plasma On red
2 brown scr.1 plasma source/ Scr. I/O MS1-12 Plasma On red/black
3 white scr.3 plasma source/ Scr. I/O MS1-1 Plasma green
simul
4 brown scr.3 plasma source/ Scr. I/O mass Plasma green/black
simul
5 Blue + Blue/black
6 white scr.6 plasma source/ Scr. CA J10-8 + VA orange
7 Brown scr.6 plasma source/ Scr. CA J10-9 - VA orange/black
8 screens braidings +
white-white/red
9 90 White scr.9 plasma source/ R1 or R2 Emergency white
10 90 Brown scr.9 plasma source/ R1 or R2 Emergency white/black
11 brown
12 brown/black
13 yellow
14 yellow/black
15 Cable 8x2x0,15
16 14 poles amp male
17
18
19
20

CR Electronic – Advanced - Page 147


Height Control Connector (C16)
(Outside case/console)
Connector kind: ⊗ Male on drawer’s plate
⊗ Female on case
pole numb.: 16 Ilme
PI No wire Sec. & colour to/from Note
N
1 Awg 24 red Z-axis Encoder + 12 Vdc encoder power
supply
2 Awg 24 red/black 0 Vdc encoder power
supply
3 orange phase A Encoder
4 orange/black phase A’ Encoder
5 green phase B Encoder
6 green/black phase B’ Encoder
7 graound + screens
8 Awg 24 white/red plasma source Torch contact
9 Awg 24 white Grid contact
10 00 Awg 20 Prearrengment for Arc
white/black Writer
11 501 Awg 20 white Prearrengment for Arc
Writer
12 Awg 20 stock
yellow/black
13 Awg 20 yellow stock
14 1 Z-axis motor Z-axis current motor (M1)
brown/brown/blac
k
15
16 1 Z-axis motor Z-axis current motor (M2)
Blue/Blue/black

CR Electronic – Advanced Page 148


EV. CONNECTOR AND FILTER CONTROL (CF16)
(Outside case/console)
Connector kind: ⊗ Male on drawer’s plate
⊗ Female on case
pole numb. : 16 Harting
PIN No wire Sec. & colour To/FROM Note
1 15 Awg 20 brown Ev. return wire and filter from I/O card
2 0100 Awg 20 light blue Exhaust Filter Control from I/O card
3
4
5
6
7
8
9
10
11
12
13
14
15
16

CR Electronic – Advanced - Page 149


POWER CONNECTOR AND K-AXIS SIGNALS (C24)
(Outside case/console)
Connector kind: ⊗ Male on drawer’s plate
⊗ Female on case
pole numb. : 24 Harting
PIN No wire Sec. & colour To/From Note
1 orange Screened 3K Excit +
2 orange/black Excit -
3 white screened 2K Sin +
4 white/black Sin -
5 green Exhaust brake K (FRK) store (not used)
6 green/black store (not used)
7 white Screened 1K Cos +
8 white/red Cos -
9 screens
10 U-K Awg 20 light blue K-axis motor power
11 V-K Awg 20 brown
12 W-K Awg 20 black
13 Y26 Awg 20 Blue Emergency
14 K25 Awg 20 Emergency
Blue/black
15
16 63 Awg 20 end of stroke return wire
brown/black
yellow/black
17 Awg 20 brown FC K ahead store (not used)
18 Awg 20 yellow FC K back
19 red Screened TR-K Thermic motor
20 Red/black Thermic motor
21 Power screen
22 U-K Awg 20 light blue K-axis motor power
23 V-K Awg 20 brown
24 W-K Awg 20 black

CR Electronic – Advanced Page 150


X, Y- AXIS SIGNALS CONNECTOR (C64)
(Outside case/ console)

⊗ 64 PIN Connector ⊗ Male on drawer’s plate


⊗ Female on the board

A B C D
1 orange (Excit+) 1 orange (Excit+) 1 1
screened 3X screened 3Y
2 orange/black 2 orange/black 2 2
Excit-) Excit-)
screened 3X screened 3Y
3 white (Sin +) 3 white (Sin +) 3 3
screened 2X screened 2Y
4 white/black 4 White/black 4 4 60 Awg 20
(Sin-) (Sin-) brown/black
screened 2X screened 2Y yellow/black
return wire of the
end of stroke X
5 5 5 5 63 Awg 20
brown/black
yellow/black
return wire of the
end of stroke Y
6 6 6 6 Awg 20 brown
FC.X A (store)
7 white (Cos+) 7 white (Cos+) 7 7 Awg 20 yellow
screened 1X screened 1Y FC.X back
8 white/red 8 white/red 8 8 Awg 20 brown
(Cos- FC.Y (store)
(Cos-) )
screened 1X screened 1Y
9 screens 9 screens 9 9 Awg 20 yellow
FC.Y back
10 X25 Awg 10 Y25 Awg 20 10 10
20 Blue Blue
FC emergency X FC emergency Y
11 X26 11 Y26 11 11
Awg 20 Awg 20
Blue/black Blue/black
FC emergency X FC emergency Y
12 Awg 20 green 12 X26 Awg 20 12 12
Truck emergency green
Y push button
(not used)

CR Electronic – Advanced - Page 151


13 X25 13 Y25 13 13
Awg20 Awg 20
green/black green/black
Truck emergency Y push button
(not used)
14 red 14 red 14 14
screened TR-X screened TR-Y
15 Red/black 15 Red/black 15 15
screened TR-X screened TR-
Y
16 16 16 16

CR Electronic – Advanced Page 152


CURRENT DISTRIBUTION
(TDE-MACNO DRIVERS)

22.5V CONSOLLE
0225 F 4A 225 J37/9 225
22.5V 0225 F 4A 225 J37/10 225 Phase lamps
0225 F 4A 225 J37/11 225
22.5V
24V AUX TLR1
03 F 4A 003 63 64 3 J37/13 3 NC J37/35 15 024VAC
Height
24V 03 F 4A 003 73 74 3 J37/14 3 Control NC J37/37 79 24VAC
Board
03 F 4A 003 83 84 3 J37/15 3 NC J37/36 GV
24V
76 Ground
24V 76 F 6A 79
79 24VAC
76 F 6A 78 24VAC Emergency
15 024VAC
15 15 15
15
Ground
220V BACKUP DRV. X
17 F 1A 220 T1 BACKUP DRV. Y
Cooler
18 F 1A 220 R1 BACKUP DRV. X Pack
220V BACKUP DRV. Y 220Vac
F 1A 220 T 220 T
GV
F 1A 220 R 220 R
Ground
F 2A 220 T3 PC Power Supp.(CONSOLLE)
F 2A 220 R3 PC Power Supp.(CONSOLLE)

220V
9R F 12A 09R 1 2 9R POWER XY DRV
220V 10S F 12A 010S 2 4 10S POWER XY DRV
T1 10T F 12A 012T 3 6 12T POWER XY DRV
220V TLR1 Power

CR Electronic – Advanced - Page 153


Supp.
S1 18V 13 13
M3-12

R1 0V 16 16 M3-11
16
Ground
18V 14 14 M3-10
Ground
I/O BOARD XY
DOOR-BLOCK MCR 03/96
RELAY 4-poles
Plug
380V 16A
R1 R1 F 6A R 2 1 Phase 1
NETWORK
S1 FILTER S1 F 6A S 4 3 Phase 2
EMI
T1 T1 F 6A T 6 5 Phase 3
8 7 PE
Ground

CR Electronic
Title
EUROPA HD
Size Document Number Rev
A3 CURRENT DISTRIBUTION (MACNO DRIVERS) 2/99
Date: Monday, August 30, 1999 Sheet 1 of 14
TDE-MACNO XY DRIVERS (1/2)
X-Axis DRV
CN1 1 CN1 1 Y-Axis DRV
2 2

3 3

4 4

5 5
C64 CONNECTOR
6 6

7 7

8 brown C64/A1 C64/B1 brown 8

9 3X white C64/A2 C64/B2 white 3Y 9

10 brown C64/A3 C64/B3 brown 10

11 2X white C64/A4 C64/B4 white 2Y 11

12 12
brown C64/A7 C64/B7 brown
13 13
1X white C64/A8 C64/B8 white 1Y
14 14
Ground C64/A9 C64/B9 Ground
15 15

16 brown C64/A14 C64/B14 brown 16

17 TRX white C64/A15 C64/B15 white TRY 17

18 18

19 19

20 20

CN2 CN3 CN2 CN3 GROUND CONNECTED ONLY


AT THE OTHER SIDE
1 1

2 2
1 Excit+ X brown 1 Excit+ Y bro
3 6 3 6
2 Excit- X white 3X 2 Excit- Y whi 3Y
4 7 Cos+ X 4 7 Cos+ Y
3 Sin+ X brown 3 Sin+ Y bro
5 8 Cos- X 5 8 Cos- Y
4 Sin- X white 2X 4 Sin- Y whi 2Y
6 9 6 9
5 brown 5 bro
white 1X whi 1Y

POWER brown POWER bro


POWER XY 9R white TRX POWER XY 9R whi TRY

CR Electronic – Advanced Page 154


POWER XY 10S POWER XY 10S
GROUND CONNECTED ONLY
POWER XY 12T AT THE OTHER SIDE POWER XY 12T
GND GND
51 52 2 1 brown UX 51 52 2 1 brown UY
61 62 4 3 cyan VX 61 62 4 3 cyan VY
71 72 6 5 black WX 71 72 6 5 black WY
AUX TLR2 TLR2 AUX TLR3 TLR3

BACKUP DRV. X 220R1 BACKUP DRV. Y 220R1


BACKUP DRV. X 220T1
BACKUP BACKUP DRV. Y 220T1
BACKUP
C40 CONNECTOR

C40/C10 C40/D10 Ground yellow


Ground white
C40/A1 C40/B1
UX cyan C40/A2 C40/B2 UY cyan
C40/A3 C40/B3
C40/A4 C40/B4
VX brown C40/A5 C40/B5 VY brown
C40/A6 C40/B6
CR Electronic
C40/A7 C40/B7
Title
WX black C40/A8 C40/B8 WY black EUROPA HD

C40/A9 C40/B9 Size Document Number Rev


A3 TDE-MACNO DRIVERS / Axes XY (1/2) 2/99
Date: Monday , August 30, 1999 Sheet 2 of 14
XY-AXIS TDE-MACNO DRIVERS (2/2)
ENX I/O BOARD ENY
MCR 03/96
VRX VRY
MOT X MOT Y

brown
brown MOT Y white Y-Axis DRV
MOT X white brown
CN1 1
X-Axis DRV
brown
CN1 1 EY white 2

EX white 2 3

3 white 4

white 4 RY brown 5

RX brown 5 6

6 brown 7 7

brown 7 7 VRY white 8 8

VRX white 8 8 9 9

9 9 10

10 11

11 12

12 brown 11 7 13
R2
brown 11 7 13 white RESET Y 14
R2
white RESET X 14 15
brown 11 7
15 R3 16
white EMERG Y
brown 11 7 16 17
R3
white EMERG X 17 18

18 19

19 20

20

CN2 CN3
CN2 CN3 red ENC.Y A/ 1 1
red ENC.X A/ 1 1 black ENC.Y A 2 2
1
black ENC.X .A 2 2 white ENC.Y B/ 3 3 6
1 2
white ENC.X B/ 3 3 6 ENY green ENC.Y B 4 4 7
2 3
ENX green ENC.X B 4 4 7 5 8
3 4

CR Electronic – Advanced - Page 155


5 8 6 9
4 5
6 9
5

POWER
POWER

BACKUP
BACKUP

CR Electronic
Title
EUROPA HD
Size Document Number Rev
A3 TDE-MACNO DRIVERS / Axis XY (2/2) 2/99
Date: Monday , August 30, 1999 Sheet 3 of 14
CURRENT DISTRIBUTION
(EI DRIVERS)

22.5V CONSOLLE
0225 F 4A 225 J37/9 225
22.5V 0225 F 4A 225 J37/10 225 Phase lamps
0225 F 4A 225 J37/11 225
22.5V
24V AUX TLR1
03 F 4A 003 63 64 3 J37/13 3 NC J37/35 15 024VAC
Height
24V 03 F 4A 003 73 74 3 J37/14 3 Control NC J37/37 79 24VAC
Board
03 F 4A 003 83 84 3 J37/15 3 NC J37/36 GV
24V
76 Ground
24V 76 F 6A 79
79 24VAC
76 F 6A 78 24VAC Emergency
15 024VAC
15 15 15
15
Ground 1000 uF 63V BACKUP DRV. X
BACKUP DRV. Y
18 red
17 F 1A 170 ~ +
+
18 F 1A 180 ~ -
18 black Cooler
BACKUP DRV. X Pack
BACKUP DRV. Y 220Vac
220V Ground
220 F 1A 220 T 220 T
GV
220 F 1A 220 R 220 R
220V
Ground
F 2A 220 T3 PC Power Supp.(CONSOLLE)
F 2A 220 R3 PC Power Supp.(CONSOLLE)

220V
9R F 12A 09R 1 2 9R POWER XY DRV
220V 10S F 12A 010S 2 4 10S POWER XY DRV

CR Electronic – Advanced Page 156


T1 10T F 12A 012T 3 6 12T POWER XY DRV
220V 24 VAC
Emergency
S1 18V 13 13
M3-12

R1 0V 16 16 M3-11
16
Ground
18V 14 14 M3-10
Ground
I/O BOARD XY
DOOR-BLOCK MCR 03/96
RELAY 4-poles
Plug
380V 16A
R1 R1 F 6A R 2 1 Phase 1
NETWORK
S1 FILTER S1 F 6A S 4 3 Phase 2
EMI
T1 T1 F 6A T 6 5 Phase 3
8 7 PE
Ground

CR Electronic
Title
EUROPA HD
Size Document Number Rev
A3 CURRENT DISTRIBUTION (EI DRV) 2/99
Date: Monday, August 30, 1999 Sheet 4 of 14
EI XY DRIVERS (1/2)
X-Axis DRV Pin 14 white Y-Axis DRV Pin 14 white
Pin 15 brown TRX Pin 15 brown TRY
Pin 16 Shield Pin 16 Shield
CN1 CN1
1 Pin 17 brown 1 Pin 17 brown
9 CN2 3X 9 CN2
Pin 18 white Pin 18 white 3Y
1 1
6
Pin 19 Shield 6
Pin 19 Shield

Pin 20 brown Pin 20 brown


Pin 21 white 2X Pin 21 white 2Y
9 9
5 Pin 22 Shield 5 Pin 22 Shield

15 15
Pin 23 white Pin 23 white
8 8
Pin 24 brown 1X Pin 24 brown 1Y

CN3 CN4 Pin 25 Shield CN3 CN4 Pin 25 Shield

1 1 CN4 Pin M 1 1 CN4 Pin M

CN5 CN5
1 1
C64 CONNECTOR
2 2
brown C64/A1 C64/B1 brown
3 3
3X white C64/A2 C64/B2 white 3Y
4 4
brown C64/A3 C64/B3 brown
5 5
2X white C64/A4 C64/B4 white 2Y
6 6

7 brown C64/A7 C64/B7 brown 7

8
1X white C64/A8 C64/B8 white 1Y 8
Shield C64/A9 C64/B9 Shield
brown
brown C64/A14 C64/B14
TRX white C64/A15 C64/B15 white TRY

R R
9R POWER XY 9R POWER XY
S S
10S POWER XY 10S POWER XY
10T POWER XY 10T POWER XY

CR Electronic – Advanced - Page 157


T T

PE U V W PE U V W

TLR2 AUX TLR2 TLR3 AUX TLR3


WX 5 6 72 71 WY 5 6 72 71
VX 3 4 62 61 VY 3 4 62 61
UX 1 2 52 51 UY 1 2 52 51
Ground Ground
C40 CONNECTOR
Shield white C40/C10 C40/D10 Shield yellow
C40/A1 C40/B1
UX cyan C40/A2 C40/B2 UY cyan
C40/A3 C40/B3
C40/A4 C40/B4
VX brown C40/A5 C40/B5 VY brown
C40/A6 C40/B6 CR Electronic
C40/A7 C40/B7 Title
PLASMA HD
WX black C40/A8 C40/B8 WY black
Size Document Number Rev
C40/A9 C40/B9 A3 EI DRIVERS / Axes XY (1/2) 2/99
Date: Monday , August 30, 1999 Sheet 5 of 14
EI XY DRIVERS (2/2) I/O BOARD
MCR 03/96
ENX ENX (CN1X) (CN1Y) ENY ENY
+5V (CN1X) (CN1Y) +5V
GND (CN1X) (CN1Y) GND

MOT X (CN3X) (CN3Y) MOT Y


VRX (CN3X) (CN3Y) VRY
CN1 Pin F 00 (CN3X) (CN3Y) 00
Pin 1 white
Pin 2 green
CN1 Pin F
Pin 5 red Pin 1 white
Pin 6 black MOT X Pin 2 green

X-Axis DRV Pin 7 orange


Y-Axis DRV Pin 5 red
Pin 6 black
Pin 8
CN1 CN1 Pin 7 orange
1 Pin 9 brown 1
9 CN2 9 CN2 Pin 8
1 1
6 6
CN3 Pin F Pin 9 brown

Pin 17

9
Pin 1 brown MOT X 9
CN3 Pin F
5 5
brown EX
15 15 Pin 17
brown RX
8 8 Pin 1 brown MOT Y
Pin 9 white MOT X brown EY
CN3 CN4 Pin 10
CN3 CN4 brown RY
1 1 Pin 11 white EX VRX 1 1
Pin 9 white MOT Y
CN5 Pin 25 white RX CN5 Pin 10

1 Pin 7 white VRX 1 Pin 11 white EY

2 Pin 20 brown VRX 2 Pin 25 white RY

3 3
Pin 19 Pin 7 white VRY
4 00 4

CR Electronic – Advanced Page 158


Pin 20 brown VRY
5 Pin 21 5

6 black 6 Pin 19
Pin 24 00
7 7
Pin 14 Pin 21
8 8
black
Pin 24
Pin 14
Backup X-DRV
Backup X-DRV

Backup Y-DRV
R R
Backup Y-DRV
7 11 brown
R2
S EMERG X white EX S
7 11 brown
T T R2
7 11 brown EMERG Y white EX
R3
RESET X white RX
7 11 brown
R3
PE U V W PE U V W RESET Y white RX

CR Electronic
Title
PLASMA HD
Size Document Number Rev
A3 EI DRIVERS / Axes XY (2/2) 2/99
Date: Monday , August 30, 1999 Sheet 6 of 14
ELECTRIC BOARD/CONSOLLE ELECTROTECHNICS
(TDE-MACNO/EI DRIVERS)

24Vac Em 78
24Vac 79 79
024Vac 15 79
90 J37/25
R1 R1 11
10 10 R1 Emergency
7
2 6
12 90 J37/26
CONSOLLE
86 R1
Brown
8 54
RT1 RT1 AUX
TLR1 Stop
1 1 53 CPU I/O
85 87 85 9 8 88
4 3 181
R1 RT1
5 6 190 189 188

87
13 13 2 J37/29 J37/28 J37/27
181 181 181
13 Red Yellow Green
14 14 7 A2 A2 A2

14
A1 A1 A1
J37/21

15 15 15 15 15 15 15 15
15
R3 R2 RT1 R1 TLR1 TLR2 TLR3
ResDrv EmDrv Timer Emerg. Power Supp. Halt x Halt y
Restart
button
(side 1)
Restart
button
(side 2) Emergency
Series

CR Electronic – Advanced - Page 159


R3 R2 RT1 R1

12 8 12 8 1 3 1 4 10 6 10 2
11 7 11 7 8 6 12 8
11 7
9 5

R3 R3
DrvY DrvX
12 8 RY 11 7 RX

12 8 EY 11 7 EX
R2 R2

CR Electronic
Title
EUROPA HD

Size Document Number Rev


A3 CONSOLLE ELECTROTECHNICS (MACNO, EI DRV)
2/99

Date: Monday, August 30, 1999 Sheet 7 of 14


EMERGENCIES SERIES
15 Black
Emergency
Series 78 Black 78

Restart MACHINE 25
button 84
(side 2) C64/A12 Yellow 25
Restart Black 15 C91/1 C91/8 78 Black
button 85 C64/A13 White
(side 1) Mach. Emer.

Black 78 C91/2 C91/9 24 Yellow


X25
Photoelectric cells
Black 15 C92/1 C92/8 Yellow

C64/A10 Green

C64/A11 Orange Black 78 C92/2 C92/9 25 Yellow


EPX
OPTICAL
C91/5 BARRIER C92/5 Yellow/Green
X26

Ex Em.Y C64/B12 Yellow


Ground

C64/B13 White

Y25

C64/B10 Brown

C64/B11 Grey
EPY EMERGENCY LED CONNECTOR

Y26 MCR 04/97


Black 78 FUSE
Yellow 25 EXT. PROTECT.
X25 MACHINE BUTTON
X26 EP EMERG.X
Y25 SPARE Y
CONSOLLE
Y26 EP EMERG.Y
Restart NC EP EMERG.K
J37/22 85

CR Electronic – Advanced Page 160


81 POWER CONNECTOR
J37/23 84 Black Black 84 CONSOLLE BUTTON
Black Black 85 Restart
J37/24 81 White
NC N.C
Emergency Butt. Black 15 0 VAC

C40/B10 81 Yellow

C40/A10 Y26 White


MACHINE
Power Conn. XY Motors

CR Electronic
Title
EUROPA HD
Size Document Number Rev
A3 EMERGENCIES SERIES 2/99
Date: Monday , August 30, 1999 Sheet 8 of 14
Brown
Reserved
XY-AXES BRUSHLESS MOTORS CONNECTIONS Brown/Black
MOT. CONN.
Ground Ground GND
X-Emergency Button
MX
1 Green Orange/Black Excit X B
C64/A1 Orange Excit+ X Orange Excit+ X A
C64/A2 Orange/Black Excit X Green/Black
C64/A3 White Sin+ X White Cos+ X D
C64/A4 White/Black Sin X
Blue White/Red Cos X C
ep EmX
C64/A7 White Cos+ X White/Black Sin X E
C64/A8 White/Red Cos X Blue/Black
White Sin+ X F
C64/A9 Ground
C64/A10 Blue ep Emerg X Yellow G
C64/A11 Blue/Black ep Emerg X ep XB
C64/A12 Green Emrg Butt
C64/A13 Green/Black Emrg Butt Yellow/Black
C64/A14 Red ThermMot X 6
C64/A15 Red/Black ThermMot X Red Therm X E
C64/D3 Brown/Black Reserved Red/Black Therm X F
C64/D6 Brown Reserved
C64/D4 Yellow/Black Com epX Cyan UX A
C64/D7 Yellow ep XB
Brown VX C
X-MOTOR SIGNALS CABLE
C64/B1 Orange Excit+ Y Black WX B
C64/B2 Orange/Black Excit Y X-MOTOR POWER CABLE
C64/B3 White Sin+ Y D
C64/B4 White/Black Sin Y
Ground Ground
X-MOTOR
C64/B7 White Cos+ Y
C64/B8 White/Red Cos Y SBC MOTORS
C64/B9 Ground
C64/B10 Blue ep Emerg Y
C64/B11 Blue/Black ep Emerg Y
C64/12B Green Emrg Butt
C64/B13 Green/Black Emrg Butt
C64/B14 Red ThermMot Y Brown
C64/B15 Red/Black ThermMot Y Reserved
Brown/Black
C64/D10 Brown/Black Reserved
C64/D8 Brown Reserved
C64/D5 Yellow/Black Com epY
C64/D9 Yellow ep YB
MOT. CONN.
Ground Ground GND
MY
1 Green Orange/Black Excit Y B
Ex Emergency Y Orange Excit+ Y A
Green/Black
White Cos+ Y D
C40/A1
Blue White/Red Cos Y C
C40/A2 Cyan UX ep EmY
White/Black Sin Y E
C40/A3 Blue/Black

CR Electronic – Advanced - Page 161


White Sin+ Y F
C40/A4
Yellow G
C40/A5 Brown VX ep YB
C40/A6 6 Yellow/Black
C40/A7 Red Therm Y E
C40/A8 Black WX Red/Black Therm Y F
C40/A9 Cyan UY A
C40/C10 X-Motor ground Brown VY C
Y-MOTOR SIGNALS CABLE
C40/B1 Black WY B
Y-MOTOR POWER CABLE
C40/B2 Cyan UY D
C40/B3 Ground Ground
Y-MOTOR
C40/B4
SBC MOTORS
C40/B5 Brown VY
C40/B6
C40/B7
C40/B8 Black WY
C40/B9
C40/D10 Y-Motor ground
CR Electronic
C40/A10 81
Title
C40/B10 Y26 Emerg. EUROPA HD
Size Document Number Rev
A3 XY-AXES BRUSHLESS MOTORS CONNECTORS 2/99
Date: Monday , August 30, 1999 Sheet 9 of 14
I/O BOARD
Yellow

I/O BOARD
MCR 03/96

Transf. T1 13
18 VAC 12 1 +5 Vdc Orange (CN1 MACNO)
Transf. T1 16 (CN1 EI)
16 0 VAC -12 Vdc
Transf. T1 14 18 VAC +12 Vdc (C16/1)
(C16/2)
012 Vdc
Ground
EP zero Y EP zero X
EP zero W M3 M4 EP zero K Brown (CN1 MACNO)
(CN1 EI)
GND GND
White Mot On Y Mot On X White
(CN1Y MACNO) MOTY Brown Mot On Y Mot On X Brown MOT X (CN1X MACNO)
(CN3Y EI) (CN3X EI)
White -Vref Y -Vref X White
(CN1Y MACNO) VRY Brown +Vref Y +Vref X Brown VR X (CN1X MACNO)
(CN3Y EI) (CN3X EI)
Mot On Z Mot On K
1 12

Mot On Z 12 1 Mot On K
-Vref Z -Vref K
+Vref Z +Vref K
Red EncY /A EncX /A Red
Black EncY A EncX A Black
(CN3Y MACNO) ENY Magenta EncY /B M2 M5 EncX /B Magenta EN X (CN3X MACNO)
(CN1Y EI) (CN1X EI)
White EncY B EncX B White
Ground GND GND Ground
Red EncZ /A EncK /A
Black EncZ A EncK A
(C16) ENZ White EncZ /B EncK /B
Magenta EncZ B EncK B
1 12
15 024Vac
(C141/1)
(C141/2) CF16
CF16/1

CR Electronic – Advanced Page 162


00 12 1 78
Fire On Filter
Fire On Filter 100 F 1A 0100 CF16/2

C64/D5 60
C64/D4 63 M1 M6
EP YB EP XB

C64/D7 Yellow
C64/D9 Magenta
Brown Emergency
White
(C141/4) Plasma Sim. Fire Sim. 1 12

(AUX TLR1) 88
Ground

CR Electronic
Title
EUROPA HD
Size Document Number Rev
A3 I/O BOARD 2/99
Date: Monday , August 30, 1999 Sheet 10 of 14
HEIGHT CONTROL (1/2)
Ground
FILTER Rev01 Plasma 1 C141
MCR 17/91 Connector
PE PE
Brown Bro -Varc 12 4 RC1 Bro Bro -Varc C141/7
AMP
Connector White Whi +Varc 11 3 RC1 Whi Whi +Varc C141/6
37 poles
J37 Red 10 2 RC1 (Emergency) White C141/9
Blue 9 1 RC1 (Emergency) Brown C141/10
J37/30 Brown (PlasmaOn) White 12 4 RC2 (PlasmaOn) White C141/1
J37/31 White (PlasmaOn) White 11 3 RC2 (PlasmaOn) Brown C141/2
J37/32 Shield SHLD1 (PlasmaSim) Orange 10 2 RC2 (PlasmaSim) White C141/3
J37/33 White (PlasmaSim) Orange 9 1 RC2 (PlasmaSim) Brown C141/4
J37/34 Brown + 90 Yellow Yellow
Shield SHLD3
90 Yellow Yellow (Emergency) GV C141/8
J37/25 90
Ground
J37/26 90 (Emergency)
Ground
Plasma 2 C142
Connector
J37/35 15 Black Ex 024 Cool 12 8 RC1 Bro Bro -Varc C142/7
J37/36 GV Yellow/Green GND Ex 24 Cool (Arc Voltage) 11 7 RC1 Whi Whi +Varc C142/6
J37/37 79 Black Ex 24 Cool Red (Torch Contact) 10 6 RC1 (Emergency) White C142/9
Blue (Torch Tilted) 9 5 RC1 (Emergency) Brown C142/10
12 8 RC2 (PlasmaOn) White C142/1
J37/19 79 24 Vac 79 77 HEIGHT CONTROL 11 7 RC2 (PlasmaOn) Brown C142/2
BOARD
PLASMA 1/2 10 6 RC2 (PlasmaSim) White C142/3
SELECTOR A1 A1 Rev. 01 MCR 03/98
9 5 RC2 (PlasmaSim) Brown C142/4
J3/1 Red
A2 A2 J3/2
GV C142/8
J37/20 15 024 Vac 15 J3/3 Blue
RC1 RC2
J3/4 Ground

Emergency J3/6
button
J37/24 81 White Red Torch Contact C16/8
J3/8
Restart Blue Torch Tilted C16/9
J37/23 84 Black J3/9
C16 fem
J37/22 85 Black J3/10 ILME
Machine
J37/21 15 Black J3/11

J37/27 188 Black


Green Lamp
J37/28 189 Black J10/1 3

CR Electronic – Advanced - Page 163


Yellow Lamp
J37/29 190 Black J10/2 3
Red Lamp
J10/3 3
J10/4 GND
Phase lamps
24 v
R S T

J37/9 225 J10/7 GND


J37/10 225 J10/8 AGND (+Varc)
J37/11 225 J10/9 Bro (-Varc)

J10/11 (Curr.1 Motor Z) Brown C16/14


J10/12 (Curr.2 Motor Z) Blue C16/16
C16 fem
ILME
Machine
J37/13 3 Black 24Vac
J37/14 3 Black 24Vac
J37/15 3 Black 24Vac
CR Electronic
Title
EUROPA HD
Size Document Number Rev
A3 HEIGHT CONTROL (1/2) 2/99
Date: Monday , August 30, 1999 Sheet 11 of 14
HEIGHT CONTROL (2/2)

AMP
Connector
37 poles ILME fem Connector
J37 C16 (Machine)
J37/1 A\ Red Black A C16/3
J37/2 A Black Red A\ C16/4
J37/3 B White White B C16/5
J37/4 B\ Green Green B\ C16/6
J37/5 Shield Shield C16/7

J37/7 Red (+12Vdc) C16/7

J37/8 White (012Vdc) (Enc.Z Sup.) C16/8

J37/16 Green Reserve C16/12


J37/17 Green Reserve C16/13
YG

I/O BOARD
Ground SHLD3 MCR 03/96

J37/30 Brown Brown M1/12


J37/31 White (PlasmaOn) White M1/11
J37/32 Shield
J37/33 White (PlasmaSim) White M1/1

CR Electronic – Advanced Page 164


J37/34 Brown + Shield
Ground SHLD1

White B M2/1
(Enc.Z) Green B\ M2/2
Black A M2/3
Red A\ M2/4

Red (+12Vdc) M4/3


Black (012Vdc) (Enc.Z Sup.) M4/4

CR Electronic
Title
EUROPA HD
Size Document Number Rev
A3 HEIGHT CONTROL (2/2) 2/99
Date: Monday , August 30, 1999 Sheet 12 of 14
CONSOLLE (UPPER PART)
PLASMA
CONNECTOR

FILTER 220T
Fire SIMUL MCR17/91
Fire ON 220R

PE

MULTIPLE-SLOT POWER SUPPLY


ISA BUS
1
NETWORK BOARD To bus ISA
2

Torch Torch VARC


Tilted Contact

PHOENIX II BOARD
MS1 60-poles Flat Rev. 01 MCR 07/97 16-poles Flat (PLASMA HEAD SENSORS) J3 J10
1 11 12 (PMAC-COMPATIBLE)
+5V 1
-12V 2
14-poles Flat (VARC)
+12V 3
0V 4
34-poles Flat
0V 7 (PLASMA AND HEADS I/O) 10-poles Flat (PWM)
I/O BOARD Z-AXIS BOARD
MS4 MCR 03/96 Rev. 01 MCR 03/98

CPU BOARD
FLOPPY
RG174
Floppy Power Supp.
37-poles Flat
(CN10 MITAC BOARD)

7-poles small din


KEYBOARD BOARD (CN16 MITAC BOARD)
RADIO-COM

CR Electronic – Advanced - Page 165


50-poles Flat
(CON1 MITAC BOARD) 40-poles Flat
(CN7 MITAC BOARD)

LCD-DISPLAY
BOARD PWM CONNECTIONS (10-POLES FLAT)

PHOENIX II BOARD Z-AXIS BOARD


Rev. 01 MCR 07/97 Rev. 01 MCR 03/98

HARD DISK
J16/4 PWM1 (DIR) 10 J9/4
J16/6
J16/4 PWM2 (PWM) 14 J9/6
J9/4
LCD DISPLAY
J16/8
J16/6 PWM3 (BRK) 16 J9/8
J9/6

INVERTER CR Electronic
Title
EUROPA HD
Size Document Number Rev
A3 CNC HARDWARE 2/99
Date: Monday , August 30, 1999 Sheet 13 of 14
NUMERIC CONTROL BOARDS FLAT CABLES
I/O Z-AXIS FLAT
CABLE

AXIS CONTROL BOARD JP3


JP6
Rev. 01 MCR 07/97
JP16 PWM Z-AXIS FLAT
CABLE

JP3 JP9

JP17

JP1

JP18
JP7
JP14

DRIVERS
FLAT CABLE
I/O FLAT
CABLE

CR Electronic – Advanced Page 166


JP10

M4 M5 M6
JP3

60
poles JP4 JP9
34
poles JP7
HEIGHT CONTROL BOARD
Rev. 01 MCR 03/98
I/O BOARD
MCR 03/96

M3 M2 M1

A/D INPUTS Z-AXIS


CR Electronic
FLAT CABLE Title
EUROPA HD
Size Document Number Rev
A3 CNC BOARDS CONNECTORS 2/99
Date: Monday, August 30, 1999 Sheet 14 of 14
Torch Height Control Card

Connector Ref. Type From To

JP3 Terminal Filter Card X


board: Pin 12
JP4 Flat: Pin 16 Axes Control Card X

JP7 Flat: Pin 14 X Axes Control Card


JP9 Flat: Pin 10 X Axes Control Card

JP10 Terminal C16 (Inclined torch and C16 connector (motors


board: Pin 12 torch contact) voltage)

C37 (18 Vac phases)

Axes Control Card

Connector ref. Type From To

JP3 Flat: Pin 16 X Torch height control card

JP8 Flat: Pin 60 X I/O Card

JP9 Flat: Pin 34 X I/O Card

JP16 Flat: Pin 10 Torch height control card X


JP18 Flat: Pin 14 Torch height control card X

I/O Card

Connector ref. Type From To

JP1 Flat: Pin 60 Axes control card X

JP2 Flat: Pin 34 Axes control card X

CR Electronic – Advanced - Page 167


CR Electronic – Advanced Page 168