Section 03, Installation, 10 LCD Plus

Section 3:
Installation
This information is subject to the controls of the Export Administration Regulations [EAR].
This information shall not be provided to non-U.S. persons or transferred by any means to
any location outside the United States contrary to the requirements of the EAR.
Section 3: Installation BK8053-000006 Rev A
Revision History
Rev ECO Author Date Description of Change
A -- CAD 01/15/2014 Released
Table of Contents
3.0 Installation .................................................................................. 3-4
3.1 Overview ....................................................................................................... 3-4
3.2 Initial Inspection ............................................................................................ 3-4
3.3 Bench Test .................................................................................................... 3-4
3.4 Placement ..................................................................................................... 3-5
3.5 Mounting ....................................................................................................... 3-6
3.5.1 10 LCD Plus ........................................................................................ 3-6
3.5.2 10 LCD Plus Open Frame ................................................................... 3-7
3.6 Grounding ..................................................................................................... 3-8
3.6.1 Cable Shields ...................................................................................... 3-8
3.6.2 Communication Cables ..................................................................... 3-10
3.6.3 AC Power Cables .............................................................................. 3-10
3.6.4 Isolation from Plasma Noise .............................................................. 3-10
3.6.5 Grounding the CNC Cabinet ............................................................. 3-11
3.6.6 Ground Rod ....................................................................................... 3-11
3.6.7 Star Ground (Ground Bus) ................................................................ 3-12
3.6.8 Typical Grounding Scheme ............................................................... 3-13
3.6.9 Ferrite Beads ..................................................................................... 3-14
3.7 General Interfacing Requirements .............................................................. 3-15
3.7.1 Cabling............................................................................................... 3-15
3.7.2 Tracers............................................................................................... 3-15
3.7.3 Power Supplies .................................................................................. 3-15
3.8 Machine Interface........................................................................................ 3-16
3.8.1 Optional Drive Interface Cards .......................................................... 3-16
3.9 Input Power ................................................................................................. 3-17
3.10 Plasma Interfacing .................................................................................... 3-18
3.11 Oxy Fuel Interfacing .................................................................................. 3-19
3.12 Waterjet Interfacing ................................................................................... 3-20
3.13 Encoder Interfacing ................................................................................... 3-21
3.14 Drive Interfacing ........................................................................................ 3-22
3.15 E-Stop Interfacing ..................................................................................... 3-23
3.15.1 With OKToRun Type 1 .................................................................... 3-23
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
Page 3-2
BK8053-000006 Rev A Section 3: Installation
3.15.2 With OKToRun Type 0 .................................................................... 3-24

3.16 Serial Communications ............................................................................. 3-25
3.16.1 RS-232............................................................................................. 3-25
3.16.2 RS-422 / RS-485 ............................................................................. 3-25
3.16.3 Internal Modem ................................................................................ 3-25
3.17 Check the Installation ................................................................................ 3-26
3.18 Initial Power Up Sequence ........................................................................ 3-27
Appendix A : Electrical Specifications ......................................... 3-28
30 RECP ........................................................................................................... 3-28
31 RECP ........................................................................................................... 3-40
32 RECP ........................................................................................................... 3-41
33 RECP 34 RECP ........................................................................................... 3-42
35 RECP ........................................................................................................... 3-43
36 RECP ........................................................................................................... 3-44
41 RECP 42 RECP ........................................................................................... 3-45
Page 3-3
3.0 Installation
3.1 Overview
The CNC must be installed in accordance with the National Electrical Code in the United
States, and with IEC 364-4-41 in European Community countries. Additionally, the system
must always be installed in accordance with local statutes.
The CNC must be installed, adjusted, tested and serviced by qualified personnel familiar
with electrical equipment and with the contents of this manual. The CNC is intended to be
used only as described herein.
These instructions have been prepared to ensure compliance with the European
Community Electromagnetic Compatibility Directive, and Low Voltage Directive.
Before beginning installing the CNC, read this manual completely and keep it available for
reference. Get familiar with the overall installation process by studying the order of the step
outlined in this manual. Finally, gather all necessary materials.
3.2 Initial Inspection

1) Upon receipt, unpack and retain all shipping and packaging materials until the CNC is
installed and operational.
2) Record the model number and serial number for future reference.
3) Carefully inspect all pieces for shipping damage, loose parts, and exposed un-
insulated electrical parts. Contact Technical Support to resolve any problems.
3.3 Bench Test

1) Connect an appropriate power cable to 32 RECP (see Appendix A in this section) on
the back panel of the CNC; connect the other end of the power cable to wall power.
2) Turn ON the power switch located on the back of the CNC.
3) Make sure the CNC boots successfully. See the Burny Software Operator’s Guide to
verify basic functionality. Contact Technical Support to resolve any problems.
4) Press the Shutdown icon [ ] on the Main Menu (Main01); Press OK when
prompted with "Are you sure you want to shutdown?"
5) Once the Burny Software is shutdown (touchscreen turns off), turn OFF the power
switch located on the back of the CNC and disconnect the power cable.
Page 3-4
3.4 Placement
Determine the location where the CNC will be installed taking into consideration the
following cautionary points. Make sure the CNC is:
• Located within its Environmental Operating Specifications.
• Free from sources of moisture and splashing water.
• Free from undue sources of dust and other particles if possible.
• Out of high travel (traffic) areas.
• Not in areas subject to objects accidentally falling, rolling, or sliding.
• Away from sources of heat.
• Away from combustible vapors or gases.
• Located so that cables can be routed safely.
• Located so that cables can exit the cabinet, if necessary.
• Located with access to the back panel for connection or disconnection of cables and
the reading of labels and safety warnings.
• Located where the operator has a clear field of view and an acceptable physical
environment.
• Not inside another box that prevents heat from radiating away from cabinet.
Page 3-5
3.5 Mounting
3.5.1 10 LCD Plus
Mount on a flat surface, using appropriate hardware at all provided mounting locations.
The cabinet bottom includes threaded inserts that accept M8 bolts, however, ¼-20 or M6
bolts will fit through the threaded inserts, if necessary.
The cabinet also includes a plugged hole through the bottom. Do not remove the plug.
This hole is only used when the 10 LCD Plus is mounted to the Burny Operators Console.
12.00 18.30
(305) (465)
14.50
(368)
Keep
6.00 Away
(152) Zone 5.25
(133)
1.00
(25)
2.80
(71)
(121)
1.50∅ 4.75
(∅38)
3.25
(83)
12.70
6.00 Away
Keep
(152) Zone
(323)
Page 3-6
3.5.2 10 LCD Plus Open Frame

Mount on a flat surface, using appropriate hardware at all provided mounting locations.
M4 hardware is required (14 places).
11.84 0.09 19.80

(301) (2) (503)
14.40
(366)
15.98
(406)
Keep
6.00 Away
(152) Zone
0.20∅
(14 Places)
(∅5)
0.09
(2)
19.90 Clearance Required
(505) on Panel Surface
18.50 Panel Cut Out

(195)
7.69
(470)
16.10 Clearance Required
2.56
(65)
(409) on Panel Surface
14.70 Panel Cut Out
11.84
(301)
2.56
(65)
15.00
(373)
(381)
(195)
7.69
6.00 Away
Keep
(152) Zone
4.85 4.85
(123) (123)
9.60 9.60
(244) (244)
Page 3-7
3.6 Grounding
All conductors and connectors must be installed in accordance with the National Electrical
Code (NEC) in the United States, the IEC for CE installations, and must be in accordance
with all local codes and statutes.
Although earth ground and noise ground are often used interchangeably, they do in fact
describe two different and important grounding schemes. The earth (power) ground uses
the earth as the conductive current return path to the lowest potential point of a power
generation system, while the noise ground channels radio frequency (RF) electrical noise to
the earth. Both schemes should be considered prior to installing a CNC.
CNC controls require an adequate ground as specified in this section for proper operation.
Operating problems caused by a faulty ground may not qualify for warranty coverage.
Further information on grounding can be found in the National Electrical Code, Section 250.
Also, power companies usually have experience with local grounding conditions and can
provide some advice. However, the grounding requirements for power companies are not
necessarily rigid enough to insure proper performance of sensitive electronic equipment.
3.6.1 Cable Shields

We recommend double shielding on all cables. This is critical when the CNC is used near
plasma cutting equipment because electrical noise from the plasma torch can be picked up
by unshielded power cables, lifter cables, and motor leads. Electrical noise is then carried
back into the CNC where it couples to sensitive circuitry and problems or damage may
occur.
The first shield in proper cable construction is the internal cable shield, which protects the
low level signals carried by the cables. The second shield is the external braided shield.
This blocks RF noise that would otherwise reach the internal shield and conducts it to
chassis ground via 360° ground clamps. More information on shielding follows.
Internal Shields
The proper connection for a cable’s internal shield depends on what is carried in the cable.
The internal shield of a cable carrying 115VAC power should be tied to the 115VAC power
ground, normally chassis ground on the cabinet.
The shield in a cable that carries low level analog signals should connect to the analog
circuit common at the receiving end. For the cable in which a CNC sends analog drive
reference voltages to a Servo Drive, the internal shield should connect to the analog
ground at the Servo Drive (receiving end).
Note that internal cable shields are connected at one end only.
External Shields
The external shield consists of a braided tinned copper wrap over the outside of the cable.
This may be applied by the wire manufacturer or fabricated by sliding a hollow braid over
internally shielded cable.
Page 3-8
Electrically, this external braid acts like steel conduit. It does not create a common mode
shield for signals like the internal shield. Instead, it shunts outside RF interference to the
chassis before it gets to the internal shields and signals; that is, if connected correctly.
The outside braid should never be connected to any signal or pin on any connector at
either end of the cable.
Never permit the noise picked up by this braid to get into any cabinet. Even connecting it to
a separate grounding pin on a connector is likely to cause trouble because the wire length
inside the cabinet would act as an antenna, re-radiating the noise.
Properly terminate the external braid by connecting it to chassis ground. Never use any
kind of wire pigtail to make the ground connection. The impedance of a six inch piece of
wire at 300 MHz is several hundred Ohms; hardly a good ground. A proper connection is
made with metal clamps that wrap around the braid and bolt to the metal chassis with short
tabs, no longer than one inch.
If signal cabling has two or more sections joined by a connector, a connector shield should
be used to give continuity to the external braided shielding. An example is shown in
Drawing AO-72107, found in the Drawing section of this manual.
Clamps must ground the external braid of all cables coming into the back of the CNC and
also the other end, usually a motor, encoder, or other electronics cabinet. Additional clamps
can be added anywhere along the braid to provide connections to chassis ground.
Grounding Clamp must fit tight on external braid. Crimp the clamp onto braid if necessary
to insure a tight fit.
Braid stops before

entering cabinet
Grounding
Clamp
Cable With
External Braid
Figure 1: Typical Braid Clamp on CNC Back Panel
Page 3-9
3.6.2 Communication Cables

As stated previously, all cables must have an external braided shield connected with
clamps to the chassis. This applies especially to RS-232 or Modem cables. Even if our
internal modem is used, the cable can still introduce plasma noise problems if it does not
have the clamped external braid.
Fortunately, the external braid is not required over the entire length of the cable. It is only
needed where the cable is in the vicinity of the plasma leads. This usually means using
braid from the CNC, across the machine, through the power track, and for at least ten feet
after the cable leaves the power track. Make sure it is routed well away from any plasma
cables.
It is also very important that this external braid be grounded with several 360 degree metal
clamps to the machine chassis; one at the CNC and several along the length of the
machine. The last one should be at the start of the power track.
3.6.3 AC Power Cables

Power to the CNC should be separate from any plasma supplies, grinders or any other
devices that generate electrical noise.
Do not run any plasma power cable close to control cables. This includes motor/tach,
tracing eye, servo drive, and encoder cables. The minimum allowable distance between
plasma and control cables is two feet (0.6 meters).
Any 115VAC control cables which carry high voltages for AC power and solenoid control do
not normally require the internal shield. They must, however, have an external braid which
is grounded to the CNC cabinet and to the machine frame with the 360° metal clamps.
Separate Power and Signal Cables

Low level signal voltages and high level power voltages should not be routed in the same
shielded cable. Noise will couple from the power to the signal lines in such an arrangement.
These different levels may be routed through the same connector but they must arrive in
separate shielded cables. (These voltage levels are described in NEC article 725.)
3.6.4 Isolation from Plasma Noise

High frequency electrical noise generated by a plasma torch system can be very harmful to
the operation of a CNC. If this noise reaches the internal circuits, it acts as false signals
that can cause malfunctions. Great care should be taken to block this noise.
Since plasma cutting generates significant amounts of RF noise it is critical that

all conductors and connections in the system (encoders, motors, height controls,
plasma power supplies and similar devices) are properly shielded and grounded.
Electrical isolation of the plasma torch assembly from the cutting machine will improve the
quality of the machine frame as a ground. Some torches have non-conductive tubes, while
others do not. If the torch has a metal tube, consult with the manufacturer of the plasma
system about isolating it somehow from the machine.
Page 3-10
For plasma systems, the resistance to earth of the ground post must be 0.75 Ohms or less.
Please note that AC neutral must be connected to chassis common ground at the power
distribution box according to electrical code.
3.6.5 Grounding the CNC Cabinet

The CNC cabinet must be connected to the frame of the cutting machine so as to provide a
good RF ground path. Normally the CNC is mounted to the machine with a metal bracket
that has several screws making direct contact with the chassis of the CNC. The paint
should be sanded away from both ends of these screws (under the head and under the nut
and washer). The attachment of the bracket to the machine frame should also be checked
for good electrical contact. These multiple bolted connections through a large surface make
a good ground.
In addition, an external ground strap must be used. This must be a wide, flat, metal strap,
not a small round wire. Round wires have higher RF impedance than wide, flat conductors
and do not work as well as ground straps.
The best ground is either a wide (0.50” to 1”) solid metal strap or a piece of flat braided
ground strap material that is at least 0.50” wide. The strap should connect between one of
the grounding screws on the back of the CNC to the chassis ground point on the machine
carriage. This connection should be as short as possible.
3.6.6 Ground Rod

Proper earth grounding must be provided to ensure personnel safety and to suppress high
frequency noise. The foundation of good grounding is an effective earth ground rod. A star
ground point usually connects to the rod with a short, heavy conductor. Lines radiate out
from this ground point to each component of the system, establishing a central grounding
point. In turn, grounding lines radiate out again to sub-assemblies.
While a simple copper clad steel rod can be driven into the ground, the performance of this
type of ground is highly dependent on soil conditions and moisture levels. Also, simple
driven ground rods can corrode due to soil acidity. We recommend the installation of an XIT
type ground rod.
This type of rod is protected from soil acidity and has a self-moisturizing effect that provides
reliable long term grounding. A site survey or, minimally, a soil test from the drilled hole is
recommended to determine optimum ground rod length.
The connection from the water/cutting table to the earth ground should be made with a
piece of 4/0 welding cable no more than 10 feet (3 Meters) in length. Connect to the rod
with a large clamp that has a socket into which the cable end can be silver soldered.
Page 3-11
3.6.7 Star Ground (Ground Bus)

At the water table, provide a star ground (ground bus) similar to the figure below.
Ground Bus
Mounting To
Water Table
Ground Bus
To Ground Rod Tapped Hole
To Equipment
Figure 2: Ground Bus
The ground bus itself should be solid copper. It should be free of paint, grease, or other
contamination. The bus is mounted to a clean area on the frame of the water table with at
least two bolts. Tap as many holes as needed for the incoming ground lines. Check for
clearance behind the bus for the screws holding the ground lines so that the bus is not
levered away from the water table. Use star washers under all nuts and screw heads.
Page 3-12
3.6.8 Typical Grounding Scheme

A typical cutting machine with an effective grounding system is shown below. The earth
ground lies close to the Water/Cutting table. There the central grounding point connects
lines to all major assemblies, where subassemblies are ‘star-connected’ to the line. No
grounds should be connected in a series or ‘daisy chain’ configuration.
AC POWER 3 O AC POWER 115, 230, 460

EARTH PLASMA POWER EARTH N H
GND O1 O2 O3 DISTRIBUTION GND EARTH GROUND
BOX FROM POWER DISTR.
ENCLOSURE
CHASSIS MACHINE POWER
GROUND DISTRIBUTION
POINT BOX WITH STEP-
DOWN ISOLATION
TRANSFORMER
AC POWER TO CNC
AND DRIVE SYSTEM
PLASMA INPUT POWER
GROUND POST Secondary of Isolation trans-
former must be connected to X
XX earth ground. RAIL
RAIL
MACHINE FRAME STAR

PLASMA 1 PLASMA 2 GROUND POINT
PLASMA Y AXIS CARRIAGE

4/0 * 4/0 *
POSITIVE SERVO
RETURN DRIVE
LEAD 4/0
STAR GROUND BUS

4 GA.
CUTTING TABLE BURNY
HI FREQ CONSOLE
4/0
MIN. 1/2"
GROUND
STRAP
WATER CUTTING
TABLE
* Size to match plasma

supplies, minimum 4/0.
** Locate within 10 feet of

cutting table star ground. EARTH GROUND
ROD **
Figure 3: Correct Ground Cable Wiring For Cutting Machine
Notes:
1) Recommended sizing and arrangement of wiring are to meet local and national code.
2) All ground wires are to be run individually to the star ground (ground bus) and never
run in series. Then one cable attaches the star ground to the earth ground rod.
3) The plasma system should be grounded with 4/0 insulated copper welding cable or
cable sized for the plasma system. Connect rails with at least 10 Gauge cable.
Page 3-13
3.6.9 Ferrite Beads

If these guidelines are followed there will be few problems with plasma noise. However, if a
problem does exist or additional suppression is desired, ferrite beads can be installed to
further suppress high frequency noise on cables.
Ferrite beads come in two varieties: solid and two-piece. See the figure below. The two-
piece version can be clamped over existing wiring. Solid beads require the wire to be
looped through them before connections are made.
For best results, the ferrite bead should be located as close to the CNC connector as
possible.
Bead Location
CNC
Cable Connector
Ferrite Bead Located

Near Cable Connection
to CNC
Two-Piece Type
Tape Together
Tightly
One-Piece Type
Loop Small
Cables
Through Twice
Figure 4: Ferrite Beads
Page 3-14
3.7 General Interfacing Requirements

3.7.1 Cabling
• Cables must be obtained from, designed by, or approved by the factory.
• Cables and leads shall be insulated. The insulation must be rated for the maximum
voltage of insulated or uninsulated conductors that the cable does or could contact. If,
after installation, there are unused connectors on the rear panel of the unit, they must
be covered with a plastic protective cap.
• Metal ground clamps are used at each end of every cable to connect the cable shield to
equipment cabinets. Where the shield is not snug within a clamp, the clamp should be
gently crimped. Over-crimping can cause internal damage to the cable. The clamp
must make snug contact with the shield around the full circumference of the cable.
• Cable ends connected to the CNC should have shield clamps connected directly to the
CNC cabinet. Refer to the cable ground to back of cabinet drawing, AO-72105, in the
Drawings section of this manual.
• Cables ends connected to rack mounted encoders (H20 or H25 type) must have the
shield clamp connected to the housing of the encoder. See customer instruction
drawing AO-72103 in the Drawings section of this manual for the rack mounted encoder
ground clamp instructions.
• When motor mounted encoders are used, the factory-supplied shielding kit must be
installed over the junction of the plastic connectors, between the cable and the short
lead coming from the encoder. The shielding kit and the instructions are shipped with
the cables for the motor-mounted encoders. The connector shield is shown on
customer instruction drawing, AO-72107 in the Drawings section of this manual.
Be aware that if, for example, a cable was connected to an extension cable, a shielding
kit must be installed over the junction to ensure compliance with CE regulations.
• Motor cables are handled as shown on the drawing for motor cable ground clamp
installation, AO-72106 in the Drawings section of this manual.
• For plasma cutting applications, keep all CNC cables routed and separate from the
plasma cables by a minimum of two feet. This practice minimizes the possible damage
caused by high frequency spikes produced by a plasma system.
• Use figure 8 shape for excess signal cables. Do not coil.
3.7.2 Tracers
Tracer unit cables are handled as shown on the customer instruction drawing, AO-72108 in
the Drawings section of this manual.
3.7.3 Power Supplies

Compliance with the AC line Conducted Emission portion of the EMC Directive of the EC is
only possible if the CNC is equipped with a supplied line transformer power supply. If the
CNC is powered with the DC supply of the cutting machine drive or tracing system,
compliance with the Line Conducted Emission portion of the EC directive is the
responsibility of the drive or tracing system manufacturer.
Page 3-15
3.8 Machine Interface

The CNC requires connections to certain signals on the cutting machine to allow it to
control the various cutting and servo drive functions. The following is a block diagram
showing the CNC drive and cutting circuitry interface connections.
SPEED REF FROM OPERATOR PANEL

SPEED DIAL
X REF OUT TO CUTTING MACHINE
DRIVE RAIL AXIS SERVO
INTERFACE
XX REF OUT TO CUTTING MACHINE
CARD
RAIL SLAVE AXIS SERVO
Y REF OUT TO CUTTING MACHINE
CROSS AXIS SERVO
ROT C OUT TO CUTTING MACHINE
ROTARY HEAD SERVO
FROM CUTTING MACHINE
OXY CUT SWITCH CIRCUIT
PCI I/O
CARD FROM CUTTING MACHINE
OPTICAL INHIBIT CIRCUITRY
ISOLATION
CIRCUITRY FROM CUTTING MACHINE
PLASMA SELECT SIGNAL
FROM CUTTING MACHINE

PLASMA " ARC ON " SIGNAL
OXY STOP CONTACT

OXY START CONTACT
PREHEAT CONTACT
RELAY
PLATE MARKER CONTACT
CONTACT
OUTPUTS PLASMA STOP CONTACT
PLASMA START CONTACT
PLASMA HEIGHT SENSOR DISABLE CONTACT

PLATE MARKER #2 CONTACT
3.8.1 Optional Drive Interface Cards

A drive interface card is required for Burny 3 and Burny 5 controllers to interface to various
servo drive systems. However, the 10 LCD Plus does not require a drive interface card.
The only exception is when the 10 LCD Plus is used with a Burny OPCON. In this case,
MO-12795 is the required card.
If a 10 LCD Plus is replacing a Burny 3 or Burny 5 controller, the existing drive interface
card can be installed into the 10 LCD Plus and the existing servo drive and drive interface
cables can be re-used. Be aware that the pin-out of 30 RECP changes based on which
drive interface card is installed. Refer to Appendix A: Electrical Specifications at the end of
this section for details about various interface cards.
IMPORTANT! If a drive interface card is ever removed from the 10 LCD Plus, the short
ribbon cable (A44-32204) must be re-installed on the back panel printed circuit board
between 27RECP and RECP2.
Page 3-16
3.9 Input Power
10 LCD Plus
Back Panel
32 RECP
Line 1 Hot
Neutral 34 Neutral AC Supply

115/230
Ground 18 Ground
Page 3-17
3.10 Plasma Interfacing

This is typical plasma interfacing. Refer to the System Diagram and Appendix A at the end
of this section for additional I/O information.
A torch crash switch can be connected through either the optional Aux I/O Card or through
the Inhibit Input with a Special Configuration (see Section 4, Appendix A). Use one or the
other, not both.
10 LCD Plus
Back Panel
Optional 2 COM ports required if THC and Power Supply are non-Kaliburn
COM
Port
Optional
COM INOVA
Port or
Serial
THC In
31 RECP
21 Serial
Plasma Start
Out
Start 22 In
36
Height Height
Disable
Disable 37 In
16
Arc On
Not used if Non-Kaliburn Plasma Supply

Motion
Input 29 Out
Power
Supply
24-115V AC or DC Start Motion
Out In
5 V V
Plasma Plasma Return
Select 18 Select
Optional 8
Aux I/O
Card 9
32 RECP
11 Start
Input Motion
Inhibit Out
Input 24
(See Special Config)
Torch
Crash Serial
Switch In
Plasma
Line 1 Hot Supply

115/230
Ground 18 Ground
Page 3-18
3.11 Oxy Fuel Interfacing

This is typical oxy fuel interfacing. Refer to the System Diagram and Appendix A at the end
of this section for additional I/O information.
V
Power
10 LCD Plus Supply
Back Panel V 24-115V AC or DC
Return
Manifold Gases
Off On Solenoids
32 RECP
4 Gas On
Fuel
On
Oxy Stop)
Oxy
8
32 Manifold Oxy Cut

Solenoid
On
Cut Oxy
Oxy Start Off
Auto
37
Manifold Oxy
Vent Solenoid
10 (normally open)
Cut Switch
Sense
23
21
High On
High Preheat
Preheat Off Fuel
22 Auto
Oxy
Manifold High
Preheat Solenoids
Line 1 Hot

115/230
Ground 18 Ground
Page 3-19
3.12 Waterjet Interfacing

See Appendix C in this manual for important waterjet information.
Page 3-20
3.13 Encoder Interfacing

The drawing below is provided if non-factory cables are to be used.
10 LCD Plus
Back Panel
8 B
3 /B
33 RECP 9 A X
(X Encoder Input) 5 /A Servo
6 I
2 /I
1 Gnd
Internal Shields from Internal shield
all 3 pairs twisted from one pair
together and crimped only
in one common pin
8 B
3 /B
34 RECP 9 A Y
(Y Encoder Input) 5 /A Servo
6 I
2 /I
1 Gnd
in one common pin
8 B
3 /B
41 RECP 9 A XX
(XX Encoder Input) 5 /A Servo
6 I
2 /I
1 Gnd
in one common pin
Page 3-21
3.14 Drive Interfacing

The drawing below is provided if a non-factory drive cable is to be used.
Outer shield bolted to CNC Outer shield bolted to

10 LCD Plus cabinet using 360° clamps.
Back Panel outer drive cabinet using Outer Drive Cabinet
Reference drawings 360° clamps. Reference
AO-72102 and AO-72105 drawing AO-72104
Inner Drive Cabinet
30 RECP X Drive
X Reference 7 REF +
REF –
Signal Com
Y Drive
Y Reference 6 REF +
REF –
Signal Com
Analog Ground 9
XX Drive
XX Reference 5 REF +
REF –
Signal Common 15 Signal Com
Internal
Chassis
Jumper from Drive Signal Ground
Common to Internal Drive
Chassis Ground
**One Place Only
Page 3-22
3.15 E-Stop Interfacing

3.15.1 With OKToRun Type 1
CNC Back Panel E-Stop Drives OK Stop Start Drive Power

32RECP No Faults Relay (PR)
25 30
X Y XX
PR
X Y XX 24-120V
Drive Enabled Drive Enabled Drive Enabled
AC or DC
Power Supply
CNC Back Panel
32 RECP
31
Run/ E-Stop Input
Method A
Signal Common
35
Use Method A or Method B to satisfy the Run / E-Stop Input. Use only one, not
both.
X Y XX
Drive Enabled Drive Enabled Drive Enabled
CNC Back Panel

30 RECP
20
Run/ E-Stop Input
Method B
Signal Common
15
The above diagrams show the recommended way to interface the E-Stop I/O. This
configuration will only work properly if the IO Configuration⇒OKToRun Type parameter is
set to 1. Two important functions are achieved when interfaced this way:
1) The servo drives cannot be enabled until the CNC is ready. This prevents the
drives from being on, enabled, and moving if the CNC is not booted up and ready to
control position. The External Contactor contact at 32 RECP-25 & 30 will only be
closed after the CNC is reset and out of E-Stop. The contact will also open if the CNC
develops a problem and is no longer able to control position.
Page 3-23
2) The CNC will be alerted and stop all machine functions if a machine problem
occurs. If a drive fault occurs or an E-Stop button is pressed, all the drives will be
disabled and the CNC Run / E-Stop input will no longer be satisfied. When this
happens, the servo commands go to zero and all cutting or marking functions are
stopped.
The above recommended E-Stop interfacing is not always possible due to the limitations of
the servo drives used. In this case, the interfacing can be modified as required, but it is
important to achieve the two points listed above whenever possible.
NOTES:
When the OKToRun Type parameter is set to 1, the CNC can be reset as soon as the
boot-up process is complete. This is accomplished by holding the membrane STOP button
for at least 2 seconds. At this time the External Contactor contact at 32 RECP-25 & 30 will
close. The Run/E-Stop input must still be satisfied for normal operation, but it is not
required to reset the CNC. If the Run/E-Stop input is removed, the CNC will go to an E-
Stop state, but the External Contactor contact will remain closed.
When the OKToRun Type parameter is set to 0, the Run/E-Stop input must be satisfied
before the CNC can be reset by holding the STOP button for at least 2 seconds. Once
reset, the External Contactor contact will close and the CNC is ready for normal operation.
If the Run/E-Stop input is removed, the CNC will go to an E-Stop state, and the External
Contactor contact will open immediately. Once the Run/E-Stop issue is resolved, the 2
second E-Stop reset must be done again to continue.
3.15.2 With OKToRun Type 0

OKToRun Type 1 is the recommended setting when interfacing the E-Stop logic. However,
OKToRun Type 0 was developed to use with servo systems that have limited fault and I/O
features. Block diagrams of the OKToRun Type 0 configurations are not provided due to
the virtually endless number of possible configurations.
Page 3-24
3.16 Serial Communications

For complete serial communication information, refer to Appendix A in this manual.
3.16.1 RS-232
35 RECP Signal Name Description
PIN 1 SHIELD PROTECTIVE GROUND (SHIELD)
PIN 2 RIN RECEIVED DATA INPUT TO CNC
PIN 3 XOUT TRANSMITTED DATA OUTPUT FROM CNC
PINS 5, 6 5V PULLUP TO +5 V. MAY BE USED FOR ANY SIGNAL
REQUIRING HIGH LEVEL
PIN 7 GND SIGNAL GND
PIN 8 CTRL-OUT CONTROL STATUS LINE OUTPUT FROM CNC (RTS)
PIN 9 STAT-IN INPUT STATUS LINE INPUT TO CNC (CTS)
3.16.2 RS-422 / RS-485

35 RECP Description
PIN 2 RX- RECEIVED DATA INPUT INTO CNC
PIN 3 TX- TRANSMITTED DATA OUTPUT FROM CNC
PIN 5 +5V FOR PULLUP
PIN 6 +5V FOR PULLUP
PIN 7 SIGNAL GROUND (DO NOT CONNECT TO SHIELD)
PIN 8 TX+ TRANSMITTED DATA OUTPUT FROM CNC
PIN 9 RX+ RECEIVED DATA INPUT INTO CNC
3.16.3 Internal Modem

36 RECP Signal Name Description
PIN 1 SHIELD NO CONNECTION
PIN 2 RX+ MODEM RX+
PIN 3 TX+ MODEM TX+
PIN 4 ** SENSE INPUT #1 (FOR MULTIPLEXER)
PIN 5 ** SENSE INPUT #2 (FOR MULTIPLEXER)
PIN 6 ** CONTACT OUTPUT #1 (FOR MULTIPLEXER)
PIN 7 ** CONTACT OUTPUT #2 (FOR MULTIPLEXER)
PIN 8 TX- MODEM TX-
PIN 9 RX- MODEM RX-
Page 3-25
3.17 Check the Installation

Complete the following checklist to ensure safety and performance before continuing with
the installation:
All holes in CNC cabinet have been sealed against dust and intrusive objects.
Unused wires have been protected and insulated according to local standards.
Electrically live parts are protected by enclosures or barriers from external access.
There are no loose parts, including screws, especially CNC front panel screws.
Burny Kaliburn has been informed of any problems with the hardware.
The operating environment is within operation specifications.
The CNC is away from sources of moisture.
The equipment is away from combustible vapors and gasses.
The equipment is not too close to source of high heat.
Area dust and particulate level is satisfactory.
The operator and equipment are away from areas where objects fall, slide, roll etc.
The operator's view of work and equipment is satisfactory.
The operator and equipment are located out of a heavy traffic pattern.
Cables routed so as to avoid damage after the installation.
Cables not unduly cramped or stretched.
The rear panel of unit is accessible enough to see and to change cables.
The operator is not subjected to unsafe or unnecessarily stressful conditions.
The wire size for AC and DC mains is AWG 18 or larger.
All connected cables are supplied by, designed by, or approved by Burny Kaliburn.
The CNC and all other electrical devices have been properly grounded.
Both ends of every cable have a ground clamp attached snugly to the cable shield.
Every ground clamp is attached to the component in the proper manner.
The system programs and files are backed up properly.
For CE installations, following specific tests must be performed on the completed
installation:
Non-accessibility
Performance
Insulation Resistance (greater than 0.5 MOhm measured from AC input to chassis.)
Page 3-26
3.18 Initial Power Up Sequence

Once all machine components are installed and interfaced, the system is ready to be
powered up and commissioned. Follow the steps below to prepare the system before
continuing on to the Motion Setup and Drive Tuning Procedure detailed in Section 4.
1) Disengage the pinions from the rack or do what is required to ensure that the motors
can turn without causing machine motion.
2) Apply power to CNC and confirm that the Burny Software starts up and that no errors
are displayed.
3) Verify that all purchased software options are licensed and enabled. From the Main
Menu, select Utilities > Miscellaneous Setup > OCX Options. Make sure that the
Slave Axis option is enabled if it is to be controlled by the CNC.
4) If any software options had to be enabled, perform a normal shutdown by pressing the
Shutdown icon on the main menu. Cycle the power switch to re-boot the control.
5) Complete the Motion Setup and Drive Tuning procedure detailed in Section 4.
Page 3-27
Appendix A : Electrical Specifications
30 RECP - DRIVE INTERFACE

Specifications when CNC configured for: Standard Interface – No Interface card installed.
Pins not listed in this table are not used – do not make any connection to these pins.
PIN(s) DESCRIPTION RATINGS
Active low by pull-down to signal common on pin 15.
Internally pulled high to 24 VDC with 1.5 kΩ resistor.
Diode protected to only sink current.
1 General Purpose Input
HIGH = Open circuit at 24 VDC, and 50 μA maximum allowed
leakage.
LOW = 1 VDC maximum, 16 mA.
2 General Purpose Input
HIGH = Open circuit at 24 VDC @ 50 μA maximum allowed
leakage.
LOW = 1 VDC maximum @ 16 mA.
4 C Axis Speed Reference output +/- 10 VDC @ 2mA maximum
5 XX Axis Speed Reference output +/- 10 VDC @ 2mA maximum
6 Y Axis Speed Reference output +/- 10 VDC @ 2mA maximum
7 X Axis Speed Reference output +/- 10 VDC @ 2mA maximum
Active low open-collector driver output for relay control.
8 General Purpose Output Maximum current sink is 100 mA.
Voltage source for relay is 24 VDC on pin 14.
9 Analog Ground 0V
+10 VDC @ 10 mA maximum
10 +10 VDC output
Can be used to source power to an external speed potentiometer.
Active low open-collector driver output for relay control.
11 General Purpose Output Maximum current sink is 100 mA.
Voltage source for relay is 24 VDC on pin 14.
12 Chassis Ground 0V
Feature Not Yet Implemented Active low open-collector driver output for relay control.
13 Output Reserved For Maximum current sink is 100 mA.
X Drive Enable Voltage source for relay is 24 VDC on pin 14.
+24 VDC @ 100 mA maximum
14 +24 VDC output Protected by “TR1” fuse on back panel power board, an automatic
resetting fuse. Fuse is reset by removal of power.
15 Signal Common 0V
Y Drive Enable Voltage source for relay is 24 VDC on pin 14.
Axis Speed Reference input from
17 0-10 VDC @ 100 mA maximum
external speed potentiometer.
XX Drive Enable Voltage source for relay is 24 VDC on pin 14.
C Drive Enable Voltage source for relay is 24 VDC on pin 14.
Page 3-28

Specifications when CNC configured for: Standard Interface – No Interface card installed.
Active low for RUN by pull-down to signal common on pin 15.
Internally pulled high to 24 VDC with 1.5 kΩ resistor for external
STOP.
20 External Stop/Run Monitor Input Diode protected to only sink current.
leakage.
21 X Axis Home Switch input
leakage.
22 Y Axis Home Switch input
leakage.
23 XX Axis Home Switch input
leakage.
24 C Axis Home Switch input
leakage.
Page 3-29

Specifications when the CNC is equipped with: MO-12795 OPCON Interface card.
1, 2, 3 Tied together 30 VDC @ 500 mA, maximum carrying capacity.
C Axis Speed
4 +/- 10 VDC @ 2mA maximum
Reference output
XX Axis Speed
Reference output
Y Axis Speed
Reference output
X Axis Speed
Reference output
8 Analog Ground 0V
9 Analog Ground 0V
Pin 10 is +24 VDC supply out from OPCON when OPCON is not in E-Stop.
Pin 11 is Ready Signal input requiring +24 VDC @ 5 mA from pin 10.
Drives Ready A relay or switch contact closure signaling that drive is ready is required between
10, 11
contacts these two pins.
Open circuit signals a drive not ready condition.
Jumper these pins together if not used.
13 Signal Common 0V
Pin 14 is +24 VDC supply out from OPCON.
Pin 16 is External E-Stop input requiring +24 VDC @ 150 mA from pin 14.
External E-Stop A relay or switch contact closure signaling that no external E-Stops are active is
14, 16
contacts required between these two pins.
Open circuit signals an external E-Stop condition.
15 Signal Common 0V
Pin 17 is +24 VDC looped over from pin 16.
Pin 18 is Drive Fault input requiring +24 VDC @ 150 mA from pin 17.
Drive Fault A relay or switch contact closure signaling that no drive faults are active is
17, 18
contacts required between these two pins.
Open circuit signals a drive fault condition.
Pin 20 is Drive Out-of-Sync Fault input requiring +24 VDC @ 150 mA from pin 19.
Drive Out-of-Sync A relay or switch contact closure signaling that no drive out-of-sync faults are
19, 20
contacts active is required between these two pins.
Open circuit signals a drive out-of-sync fault condition.
X Axis Home
21 Diode protected to only sink current.
Switch input
HIGH = Open circuit at 24 VDC, and 50 μA maximum allowed leakage.
Y Axis Home
Switch input
Page 3-30

Specifications when the CNC is equipped with: MO-12795 OPCON Interface card.
XX Axis Home
Switch input
C Axis Home
Switch input

Specifications when the CNC is equipped with: MO-12426 or MO-12703 Replicator™ Interface card.
Drive enable common
1 connection for pin 2 25 VDC @ 250 mA, maximum carrying capacity.
and pin 3.
Open-Collector active-low pull-down to pin 1.
Transistor sinks current to pin 1 to enable X-Axis of external drive.
2 X Axis Drive Enable
Sink current is 125 mA maximum.
Maximum of 25 VDC, measured from pin 1, is allowed when transistor is off.
Open-Collector active-low pull-down to pin 1.
Transistor sinks current to pin 1 to enable Y-Axis of external drive.
3 Y Axis Drive Enable
Sink current is 125 mA maximum.
Maximum of 25 VDC, measured from pin 1, is allowed when transistor is off.
C Axis Speed
Reference output
XX Axis Speed
Reference output
Y Axis Speed
Reference output
X Axis Speed
Reference output
8 Analog Ground 0V
9 Analog Ground 0V
Pin 10 is +24 VDC supply out from OPCON when OPCON is not in E-Stop.
Pin 11 is Ready Signal input requiring +24 VDC @ 5 mA from pin 10.
A relay or switch contact closure signaling that drive is ready is required
10, 11 Drives Ready contacts
between these two pins.
Open circuit signals a drive not ready condition.
13 Signal Common 0V
Page 3-31

Specifications when the CNC is equipped with: MO-12426 or MO-12703 Replicator™ Interface card.
Pin 14 is +24 VDC supply out from OPCON.
Pin 16 is External E-Stop input requiring +24 VDC @ 150 mA from pin 14.
External E-Stop A relay or switch contact closure signaling that no external E-Stops are active
14, 16
contacts is required between these two pins.
Open circuit signals an external E-Stop condition.
15 Signal Common 0V
Pin 18 is Drive Fault input requiring +24 VDC @ 150 mA from pin 17.
A relay or switch contact closure signaling that no drive faults are active is
17, 18 Drive Fault contacts
required between these two pins.
Open circuit signals a drive fault condition.
Pin 20 is Drive Out-of-Sync Fault input requiring +24 VDC @ 150 mA from
pin 19.
Drive Out-of-Sync
19, 20 A relay or switch contact closure signaling that no drive out-of-sync faults are
contacts
active is required between these two pins.
Open circuit signals a drive out-of-sync fault condition.
X Axis Home Switch
input
Y Axis Home Switch
input
XX Axis Home Switch
input
C Axis Home Switch
input
Page 3-32

Specifications when the CNC is equipped with: MO-03204-x C&G MST-40,150 (-0) and MST-250 (-1) Tracing
system Interface card. Pins not listed in this table are not used – do not make any connection to these pins.
CNC Enable—connect 30RECP-5 to
30RECP-9 to enable the drive outputs from the CNC.
+VDC when Open
Open connection to
5 0V @ 1mA when connected to Signal
30RECP-5 to pass external Rail and Cross reference
Common
signals from 30RECP-11 and 16 to through the
interface card to the servo drives
Cross Axis Speed Reference output—connects to +/- 5 VDC @ 2mA maximum for MO-03204-0
6
MST Cross Axis servo drive +/- 10 VDC @ 2mA maximum for MO-03204-1
Rail Axis Speed Reference output—connects to MST +/- 5 VDC @ 2mA maximum for MO-03204-0
7
Rail Axis servo drive +/- 10 VDC @ 2mA maximum for MO-03204-1
9 Signal Ground 0V
Rail Axis Speed Reference input from MST Tracer—
when 30RECP-5 is Open, voltage on this pin is
11 switched to the rail axis speed reference output at 0-+/-10 VDC @ 1 mA maximum
30RECP-7 Also acts as Speed reference input for
CNC cutting speed control
15 Signal Ground 0V
Cross Axis Speed Reference input from MST
Tracer—when 30RECP-5 is Open, voltage on this
16 pin is switched to the cross axis speed reference 0-+/-10 VDC @ 1 mA maximum
output at 30RECP-6

Specifications when the CNC is equipped with: MO-03205-x Stewart Warner ECT 150 (-0) and ECT-250 (-1)
Tracing system Interface Card. Pins not listed in this table are not used – do not make any connection to these
pins.
Cross Axis Speed reference output to ECT Tracer

6 +/-10 VDC @ 2ma maximum
Cross axis Servo drive
Rail Axis Speed reference output to ECT Tracer Rail
axis Servo drive
-15VDC output to ECT-250 “Catch” signal used to -15VDC @ 20ma maximum – MO-03205-1
8
enable servo drives on ECT-250 systems only Only
9 Signal Common 0V
Rail axis speed reference from ECT Tracer. When
11 CNC is not in control, voltage at this pin is switched +/-10 VDC @ 0.1 mA Max
to the Rail axis reference output at 30RECP-7
15 Signal Common 0V
Cross axis speed reference from ECT Tracer. When
16 CNC is not in control, voltage at this pin is switched +/-10 VDC @ 0.1 mA Max
to the Cross axis reference output at 30RECP-6
Cutting speed reference input from ECT Tracer
17 0 to –10VDC @ 0.1 mA Max
Speed dial circuit
Page 3-33

Specifications when the CNC is equipped with: MO-03206 Stewart Warner HST-1000 Tracing system Interface
card. Pins not listed in this table are not used – do not make any connection to these pins.
Square Wave Speed Reference Sync signal from HST-
1 20V P-P @ 0.1 mA Maximum
1000 Tracer
Isolated contact connects to HST-1000 tracer to disable
3, 4 Maximum 30V AC/DC @ 0.1 A
the tracer jog functions when CNC is in control
6 Cross axis Speed Signal Output to HST-1000 Tracer— 0 to 20V P-P @ 2 mA Max -- Square wave
7 Rail axis Speed Signal Output to HST-1000 Tracer— 0 to 20V P-P @ 2 mA Max -- Square wave
9 Signal Ground 0V
Common for Drive enable outputs at 30RECP-11 and
10 0V
16
Sink Output Connects to HST-1000 to enable Rail axis
11 Sinks +24VDC @ 0.1A max
drive when CNC is in control—Common is 30RECP-10
15 Signal Ground 0V
Sink Output Connects to HST-1000 to enable Cross
16 axis drive when CNC is in control —Common is Sinks +24VDC @ 0.1A max
30RECP-10
17 Cutting speed Reference input 0 to 20 V P-P @ 0.1 mA max

Specifications when CNC equipped with: MO-03209 Stewart Warner M33 Type Tracing system Interface card.
Sine Wave Speed Reference Sync signal from M33
1 33VAC @ 1 mA Maximum
Type Tracer
CNC Enable—connect 30RECP-5 to 30RECP-9 to
+VDC when Open
enable the drive outputs from the CNC. Open
5 connection to 30RECP-5 to pass external Rail and
0V @ 1mA when connected to Signal
Cross reference signals from 30RECP-11 and 16 to
Common
through the interface card to the servo drives
Isolated contact connects to M33 type tracer to disable
3, 4 Maximum 30VDC, 42VAC @ 0.1 A
the tracer jog functions when CNC is in control
6 Cross axis Speed Signal Output to M33 Type Tracer-- 8VAC @ 5 mA Max -- Sine wave
7 Rail axis Speed Signal Output to M33 Type Tracer-- 8VAC @ 5 mA Max -- Sine wave
9 Analog Ground 0V
17 Cutting speed Reference input 0 to 8VAC @ 0.2 mA max
Page 3-34

Specifications when CNC equipped with: MO-03210 Hancock Tracker Tracing system Interface card.
Cross Axis Speed reference output to Hancock Tracker
6 +/-10VDC @ 2mA max
Tracing system/drive
Rail Axis Speed reference output to Hancock Tracker
7 +/-10VDC @ 2mA max
Tracing system/drive
Speed reference input from Hancock Tracker control
8 0 to +15 VDC @ 0.1 mA max
panel
9 Signal Common 0V
Rail axis speed reference from Hancock Tracker. When
11 CNC is not in control, voltage at this pin is switched to +/-10 VDC @ 0.1 mA Max
the Rail axis reference output at 30RECP-7
15 Signal Common 0V
Cross axis speed reference from Hancock Tracker.
When CNC is not in control, voltage at this pin is
16 +/-10 VDC @ 0.1 mA Max
switched to the Cross axis reference output at 30RECP-
6

Specifications when CNC equipped with: MO-03387 PCT Tracing system Interface card.
Cross Axis Speed reference output to PCT Tracer Cross

6 +/-6.5 VDC @ 2ma maximum
axis Servo drive
Rail Axis Speed reference output to PCT Tracer Rail
7 +/-6.5 VDC @ 2ma maximum
axis Servo drive
9 Signal Common 0V
Rail axis speed reference from PCT Tracer. When CNC
11 is not in control, voltage at this pin is switched to the Rail +/-10 VDC @ 1.5 mA Max
axis reference output at 30RECP-7
15 Signal Common 0V
Cross axis speed reference from PCT Tracer. When
16 CNC is not in control, voltage at this pin is switched to +/-10 VDC @ 1.5 mA Max
the Cross axis reference output at 30RECP-6
Cutting speed reference input from PCT Tracer Speed
17 0 to +7.8VDC @ 0.02 mA Max
dial circuit
Page 3-35

Specifications when CNC equipped with MO-03469 Tanaka Tracing system Interface card.
(Pins not listed in this table are not used – do not make any connection to these pins).
Isolated Relay contact will be OPEN when
3, 4 30VDC @ 0.1 A Max
CNC is in control
Isolated Relay contact will be closed when
5, 10 CNC is in control. Used to Enable the Cross 30VDC @ 0.1 A Max
Axis Servo Drive.
Cross Axis Speed reference output to TANAKA

Tracer Cross axis Servo drive
Rail Axis Speed reference output to TANAKA
Tracer Rail axis Servo drive
Isolated Relay contact will be closed when
8, 13 CNC is in control. Used to Enable the Rail Axis 30VDC @ 0.1 A Max
Servo Drive.
9 Signal Common 0V
Rail axis speed reference from TANAKA
Tracer. When CNC is not in control, voltage at
11 +/-10 VDC @ 0.05 mA Max
this pin is switched to the Rail axis reference
output at 30RECP-7
15 Signal Common 0V
Cross axis speed reference from TANAKA
Tracer. When CNC is not in control, voltage at
16 +/-10 VDC @ 0.05 mA Max
this pin is switched to the Cross axis reference
output at 30RECP-6
Cutting speed reference input from TANAKA
17 0 to +7.5VDC @ 0.02 mA Max
Tracer Speed dial circuit
Page 3-36

Specifications when CNC equipped with MO-04028 Multi-Drive Interface card.
Relay contact and 7.2 Volt reference output used to
connect to tracer or supply voltage to tracer or cutting 7.2V reference supplied
machine speed pot. 7.2 VDC @ 50 mA maximum
If CNC in control:
Pin 1 is Open (no connection)
1, 2
Pin 2 supplies 7.2 VDC reference
If CNC not in control:
Relay contact closed between Closed relay contact:
Pin 1 and Pin 2. No voltage 30VDC or 42VAC @ .1 A max
supplied to either pin
3 interconnected relay contacts used to connect to
tracer or servo drive as required. Relay operation is
as follows:
3, If CNC in control:
4, Contacts Closed:
30VDC or 42VAC @ .1 A max
5, Pin 4 to Pin 10
10 Pin 5 to Pin 10
Contacts Closed:
Pin 3 to Pin 4
Cross Axis Speed reference output to Tracer Cross

6 +/-10 VDC @ 2 ma maximum
axis Servo drive
Rail Axis Speed reference output to Tracer Rail axis
Servo drive
Isolated Relay contact is CLOSED when CNC is in
8, 13 30VDC or 42VAC @ .1 A max
Control
9 Signal Common 0V
Rail axis speed reference from Tracer. When CNC is
11 not in control, voltage at this pin is switched to the Rail +/-10 VDC @ 1.5 mA Max
15 Signal Common 0V
Cross axis speed reference from Tracer. When CNC
16 is not in control, voltage at this pin is switched to the +/-10 VDC @ 1.5 mA Max
Cross axis reference output at 30RECP-6
Cutting speed reference input from Tracer Speed dial
17 0 to +10VDC @ 0.02 mA Max
circuit
External Jog input. Pin 19 is grounded (connected to
Pin 9 signal common) when the external tracer or jog Open circuit voltage -- +5 VDC
controls are being used to move the machine. While
19
grounded, the external speed reference inputs at pin When input connected to signal common -
11 and 16 are switched to the speed reference sink current = 25 mA max
outputs at pins 6 and 7.
Page 3-37

Specifications when the CNC is equipped with MO-06213 Westinghouse HL series Interface card.
Relay contact and 7.2 Volt reference output used to
connect to tracer or supply voltage to tracer or cutting 7.2V reference supplied
machine speed pot. 7.2 VDC @ 50 mA maximum
If CNC in control :
1, 2
If CNC not in control: Closed relay contact:
Relay contact closed between 30VDC or 42VAC @ .1 A max
Pin 1 and Pin 2. No voltage
supplied to either pin
3 interconnected relay contacts used to connect to
tracer or servo drive as required. Relay operation is
as follows.
3, If CNC in control: 30VDC or 42VAC @ .1 A max
4, Contacts Closed:
5, Pin 4 to Pin 10 Jumper J1 can be installed on the card to
10 Pin 5 to Pin 10 connect Pin 10 to Signal Common if desired
Contacts Closed:
Pin 3 to Pin 4
Cross Axis Speed reference output to Tracer Cross

axis Servo drive
Rail Axis Speed reference output to Tracer Rail axis
Servo drive
Isolated Relay contact is CLOSED when CNC is in
8, 13 30VDC or 42VAC @ .1 A max
Control
9 Signal Common 0V
Rail axis speed reference from Tracer. When CNC is
11 not in control, voltage at this pin is switched to the Rail +/-10 VDC @ 1.5 mA Max
15 Signal Common 0V
Cross axis speed reference from Tracer. When CNC
16 is not in control, voltage at this pin is switched to the +/-10 VDC @ 1.5 mA Max
Cross axis reference output at 30RECP-6
0 to +10VDC @ 0.02 mA Max
Cutting speed reference input from Tracer Speed dial
17
circuit
0 to 7.2VDC when CNC is in control
External E-STOP Monitor input. An isolated relay
contact from the cutting machine should be used to Open Circuit voltage -- 7 VDC
drive this input--- Pin 20 should be connected to
20
signal Common (pin 9) when machine is ready to run. Sink current required when input connected
Pin 20 should be OPEN (no connection) when to signal common: 1 mA maximum
machine is in an E-STOP condition
Page 3-38

Specifications when CNC equipped with MO-06214 ServoPak / Multi-drive Interface card.
Rail Axis External Jog input-- Pin 1 is open for normal operation
Open Circuit voltage +5 VDC
where CNC is in Control of the machine.
1 Sink current required when
Pin 1 is grounded (Signal Common – Pin 9) to indicate that the
input is connected to signal
external machine or tracer jog control is moving the Rail axis of
common: 1.5 mA maximum
the machine.
Cross Axis External Jog input-- Pin 2 is open for normal operation
Open Circuit voltage +5 VDC
where CNC is in Control of the machine.
Sink current required when
2 Pin 2 is grounded (Signal Common – Pin 9) to indicate that the
input is connected to signal
external machine or tracer jog control is moving the Cross axis of
common: 1.5 mA maximum
the machine.
Relay contact and 7.2 Volt reference output used to connect to
tracer or supply voltage to tracer or cutting machine speed pot.
If CNC in control :
7.2V reference supplied
7.2 VDC @ 50 mA maximum
3, Pin 5 supplies 7.2 VDC reference
4, Pin 10 supplies 7.2 VDC reference
5,
10 If CNC not in control:
Relay contact closed between
Pin 3 and Pin 4. No voltage
Closed relay contact:
supplied to either pin.
30VDC or 42VAC @ .1 A max
Pin 5 is Open—no voltage applied
Cross Axis Speed reference output to Tracer Cross axis Servo

drive
7 Rail Axis Speed reference output to Rail axis Servo drive +/-10 VDC @ 2 ma maximum
8, 13 Isolated Relay contact is CLOSED when CNC is in Control 30VDC or 42VAC @ .1 A max
9 Signal Common 0V
Rail axis speed reference from Tracer. When CNC is not in
11 control, voltage at this pin is switched to the Rail axis reference +/-10 VDC @ 1.5 mA Max
output at 30RECP-7
15 Signal Common 0V
Cross axis speed reference from Tracer. When CNC is not in
16 control, voltage at this pin is switched to the Cross axis reference +/-10 VDC @ 1.5 mA Max
output at 30RECP-6
0 to +10VDC @ 0.02 mA Max
17 Cutting speed reference input from Tracer Speed dial circuit
0 to 7.2VDC when CNC is in
control
External E-STOP Monitor input. An isolated relay contact from the Open Circuit voltage -- 7 VDC
cutting machine should be used to drive this input--- Pin 20 should
20 be connected to signal Common (pin 9) when machine is ready to Sink current required when
run. Pin 20 should be OPEN (no connection) when machine is in input connected to signal
an E-STOP condition common: 1 mA maximum
Page 3-39
31 RECP - PLASMA FUNCTION INTERFACE

Pin(s) Description Ratings:
2, 3, 4 Plasma Stop (Enable) Output 115 VAC, 5A maximum or
(Isolated Form-C dry-contact relay) 24 VDC, 5A maximum.
Pin 4 – Normally Open contact
Pin 3 – Common contact
Pin 2 – Normally Closed contact
5, 18 Plasma Select Sense Input 24-115 VAC/DC 5-25mA
(Isolated)
Pin 5 – source
Pin 18 – return
6, 11 General Purpose Output #3 (Isolated Form-A dry- 115 VAC, 5A maximum or 24 VDC, 5A
contact relay) maximum. (optional)
7, 12 General Purpose Output #6 115 VAC, 5A maximum or 24 VDC, 5A
(Isolated Form-A dry-contact relay) maximum. (optional)
8, 9 General Purpose Input #3 24-115 VAC/DC 5-25mA (optional)
(Isolated)
Pin 8 – source
Pin 9 – return
10, 17 General Purpose Output #4 115 VAC, 5A maximum or
(Isolated Form-A dry-contact relay) 24 VDC, 5A maximum. (optional)
13, 20, 26 Plate Marker #2 Output 115 VAC, 5A maximum or
15, 21, 22 Plasma Start Output 115 VAC, 5A maximum or
(Isolated Form-C dry-contact relay) 24 VDC, 5A maximum
16, 29 Plasma Go (Arc On) Input 24-115 VAC/DC 5-25mA
(Isolated)
Pin 16 – source
Pin 29 – return
27, 28 General Purpose Input #4 24-115 VAC/DC 5-25mA (optional)
(Isolated)
Pin 27 – source
Pin 28 – return
35, 36, 37 Plasma Height Sensor Disable Output 115 VAC, 5A maximum or
Page 3-40
32 RECP - OXYGEN CUTTING INTERFACE AND AC POWER INPUT

115 or 230 VAC, 50/60 Hz, 4 A maximum.
1 Line HOT Input Protected by “FU1” fuse on back panel
power board, a 4 A time-delay fuse.
General Purpose Input #1 24-115 VAC/DC 5-25mA (optional)
(Isolated)
2, 7
Pin 2 – source
Pin 7 – return
Oxy Stop Output 115 VAC, 5A maximum or
3, 4, 8 Pin 8 – Normally Open contact
General Purpose Output #1 115 VAC, 5A maximum or
6, 12
Plate Marker #1 Output 115 VAC, 5A maximum or
(Isolated Form-C dry-contact relay) 24 VDC, 5A maximum
9, 14, 15 Pin 9 – Normally Open contact
Oxy Cut Switch Sense Input 24-115 VAC/DC 5-25mA
(Isolated)
10, 23
Pin 10 – source
Pin 23 – return
Program Inhibit Input 24-115 VAC/DC 5-25mA
(Isolated)
11, 24
Pin 11 – source
Pin 24 – return
General Purpose Output #2 115 VAC, 5A maximum or
16, 17
18, 19 Chassis Ground Input
General Purpose Input #2 24-115 VAC/DC 5-25mA (optional)
(Isolated)
20, 27
Pin 20 – source
Pin 27 – return
Preheat Start Output 115 VAC, 5A maximum or
21, 22,
28
External Contactor Output 115 VAC, 5A maximum or
25, 30
(Isolated Form-A dry-contact relay) 24 VDC, 5A maximum.
External E-Stop Monitor Input 24-115 VAC/DC 5-25mA
(Isolated)
31, 35
Pin 31 – source
Pin 35 – return
Oxy Start Output 115 VAC, 5A maximum or
32, 36,
37
34 Line NEUTRAL Input
Page 3-41
33 RECP – X Encoder Input

34 RECP – Y Encoder Input
RATINGS
Single-ended encoders Differential encoders
PIN(s) DESCRIPTION
“SW1” on back panel ISO “SW1” on back panel ISO
Board all open Board all closed
Supply Common
1 0V 0V
(to power encoder)
Differential driver input paired with pin 6.
Not used, do not connect 150 Ω internal resistor to ground.
2 /I channel input
anything to this pin. Minimum differential: 500 mV.
Maximum differential: 5 V.
3 /B channel input
anything to this pin, Minimum differential: 500 mV.
5 /A channel input
anything to this pin, Minimum differential: 500 mV.
Designed for open-collector type
input.
HIGH = Pulled to +5 VDC supply
150 Ω internal resistor to ground.
6 I channel input with 1.5 kΩ internal resistor. 3
Minimum differential: 500 mV.
VDC minimum.
LOW = Pull down to Supply
Common. 1 VDC maximum.
+5 VDC supply output
7 +5 VDC @ 500 mA +5 VDC @ 500 mA
(to power encoder )
input.
8 B channel input with 1.5 kΩ internal resistor. 3
VDC minimum.
input.
9 A channel input with 1.5 kΩ internal resistor. 3
VDC minimum.
Page 3-42
35 RECP – Serial I/O-RS-232/422

This communication port is isolated (100 V minimum) from the rest of the system.
Configuration Jumper Designators:
“J3”—10 LCD Plus (Reference numbers 1436 or above)
RS-232 RS-422
Configuration jumper on back panel board set Configuration jumper on back panel board set to “A”
to “A” and Burny Software set to RS-232 and Burny Software set to RS-422 communication
PIN(s) (IO Configuration⇒UseRS422=False) or (IO Configuration⇒UseRS422=True) or
Configuration jumper on back panel board set Configuration jumper on back panel board removed.
to “B”.
DESCRIPTION RATINGS DESCRIPTION RATINGS
Logic LOW = 0.8 V
Differential input paired with pin
maximum.
9.
Logic HIGH = 2.4 V
Minimum differential voltage is
minimum.
200 mV.
5 kΩ input resistance.
24 kΩ input resistance.
Maximum voltage to pin is Receive Data
Receive Data Maximum voltage to pin is
2 ±20 VDC reference to pin inverted input
input (RX) ±20 VDC reference to pin 7.
7. (RX-)
Pulled to isolated +5 V with 5.1
Pulled to isolated +5 V with
kΩ internal resistor.
5.1 kΩ internal resistor.
Logic HIGH on this pin diverts
Logic HIGH on this pin
communications over to “36
diverts communications
RECP”.
over to “36 RECP”.
Minimum output swing is Differential output paired with
±5 V into a 3 kΩ load. Transmit Date pin 8.
Transmit Data
3 inverted output 2 V minimum to 6 V maximum
output (TX)
Maximum no-load output is (TX-) output with 50 Ω load.
±18 V. Short circuit protected.
+5 VDC pull-up +5 VDC pull-up
Pulled to isolated +5 VDC Pulled to isolated +5 V with
with 5.1 kΩ internal 5.1 kΩ internal resistor.
May be used for May be used for
5, 6 resistor.
any signal any signal
0.4 mA maximum to insure 0.4 mA maximum to insure high
requiring high requiring high
high level. level.
level level
7 Signal common 0V Signal common 0V
Differential output paired with
Minimum output swing is
Control Status Transmit Date pin 8.
±5 V into a 3 kΩ load. 2 V minimum to 6 V maximum
8 Line output non-inverted
Maximum no-load output is
(RTS) output (TX+) output with 50 Ω load.
±18 V.
Short circuit protected.
Logic LOW = 0.8 V
Differential input paired with pin
maximum.
2.
Logic HIGH = 2.4 V
Receive Data Minimum differential voltage is
Control Line minimum.
9 non-inverted input 200 mV.
input (CTS) 5 kΩ input resistance.
(RX+) 24 kΩ input resistance.
Maximum voltage to pin is
Maximum voltage to pin is
±20 VDC reference to pin
±20 VDC reference to pin 7.
7.
Page 3-43
36 RECP - SERIAL I/O-B MODEM

For communications to LDM-70 Modem by DATAFORTH©.
This pin is paired with pin 9 to create a current loop
sensitive input. Current into pin 2 is a mark and current out
of pin 2 is a space.
2 Receive Data high input (RX+)
1000V isolation.
33 Ω input impedance.
©
Exact specifications are proprietary to DATAFORTH .
This pin is paired with pin 8 to create a current loop output.
Current out of pin 3 is a mark and current into pin 2 is a
space.
3 Transmit Date high output (TX+)
1000V isolation.
Maximum output it ±18 VDC.
©.
Exact specifications are proprietary to DATAFORTH
Intended for use with our Modem Switching Box.
4, 5 Sense Input from multiplexer Logic LOW = 1 V maximum
Logic HIGH = 8 V minimum
Contact Output #1 to multiplexer Intended for use with our Modem Switching Box.
6, 7
(Isolated Form-A dry-contact relay) 25 VDC, 100 mA
8 Transmit Date low output (TX-) See pin 3 ratings.
9 Receive Data low input (RX-) See pin 2 ratings.
Page 3-44
41 RECP - XX encoder input

42 RECP - C encoder input
RATINGS
Single-ended encoders Differential encoders
PIN(s) DESCRIPTION
“SW2” on back panel ISO “SW2” on back panel ISO
Board all open Board all closed
Supply Common
1 0V 0V
(to power encoder)
Differential driver input paired with pin
Not used, do not connect anything to 6. 150 Ω internal resistor to ground.
2 /I channel input
this pin. Minimum differential: 500 mV.
3 /B channel input
this pin, Minimum differential: 500 mV.
5 /A channel input
this pin, Minimum differential: 500 mV.
input.
HIGH = Pulled to +5 VDC supply with
2. 150 Ω internal resistor to ground.
6 I channel input 1.5 kΩ internal resistor. 3 VDC
minimum.
LOW = Pull down to Supply Common.
1 VDC maximum.
+5 VDC supply
7 output +5 VDC @ 500 mA +5 VDC @ 500 mA
(to power encoder )
input.
8 B channel input 1.5 kΩ internal resistor. 3 VDC
minimum.
1 VDC maximum.
input.
9 A channel input 1.5 kΩ internal resistor. 3 VDC
minimum.
1 VDC maximum.
Page 3-45
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Page 3-46

Section 03, Installation, 10 LCD Plus

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Section 03, Installation, 10 LCD Plus

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Section 3:

3.15.2 With OKToRun Type 0 .................................................................... 3-24

3.2 Initial Inspection

3.3 Bench Test

3.5.2 10 LCD Plus Open Frame

11.84 0.09 19.80

18.50 Panel Cut Out

14.70 Panel Cut Out

3.6.1 Cable Shields

Braid stops before

Figure 1: Typical Braid Clamp on CNC Back Panel

3.6.2 Communication Cables

3.6.3 AC Power Cables

Separate Power and Signal Cables

3.6.4 Isolation from Plasma Noise

Since plasma cutting generates significant amounts of RF noise it is critical that

3.6.5 Grounding the CNC Cabinet

3.6.6 Ground Rod

3.6.7 Star Ground (Ground Bus)

To Ground Rod Tapped Hole

Figure 2: Ground Bus

3.6.8 Typical Grounding Scheme

AC POWER 3 O AC POWER 115, 230, 460

MACHINE FRAME STAR

PLASMA Y AXIS CARRIAGE

STAR GROUND BUS

* Size to match plasma

** Locate within 10 feet of

Figure 3: Correct Ground Cable Wiring For Cutting Machine

3.6.9 Ferrite Beads

Ferrite Bead Located

Figure 4: Ferrite Beads

3.7 General Interfacing Requirements

3.7.3 Power Supplies

3.8 Machine Interface

SPEED REF FROM OPERATOR PANEL

FROM CUTTING MACHINE

OXY STOP CONTACT

PLASMA HEIGHT SENSOR DISABLE CONTACT

3.8.1 Optional Drive Interface Cards

3.9 Input Power

Neutral 34 Neutral AC Supply

3.10 Plasma Interfacing

Not used if Non-Kaliburn Plasma Supply

Neutral 34 Neutral AC Supply

3.11 Oxy Fuel Interfacing

32 Manifold Oxy Cut

Neutral 34 Neutral AC Supply

3.12 Waterjet Interfacing

3.13 Encoder Interfacing

3.14 Drive Interfacing

Outer shield bolted to CNC Outer shield bolted to

Inner Drive Cabinet

3.15 E-Stop Interfacing

CNC Back Panel E-Stop Drives OK Stop Start Drive Power

CNC Back Panel

3.15.2 With OKToRun Type 0

3.16 Serial Communications

3.16.2 RS-422 / RS-485

3.16.3 Internal Modem

3.17 Check the Installation

3.18 Initial Power Up Sequence

Appendix A : Electrical Specifications

30 RECP - DRIVE INTERFACE