CNC Router Parts Plasma Upgrade Kit · CNC Router Parts Plasma Upgrade Kit Installation Instructions Version2016Q3.1. PlasmaUpgradeInstructions CONTENTS Contents 1 Mechanical Components3

CNC Router PartsPlasma Upgrade Kit

Installation InstructionsVersion 2016Q3.1

Plasma Upgrade Instructions CONTENTS

Contents

1 Mechanical Components 3

2 Slat Installation 18

3 Material Sensor Installation 27

Plasma Upgrade InstructionsVersion 2016Q3.1

Copyright©2016 CNC Router Parts LLC.All Rights Reserved. 2

Plasma Upgrade Instructions

1

Mechanical Components




M8 Roll-in T-nut

CRP145-06 Torch Base Adapter

M8x16mm Socket Head Cap Screw

• Remove any existing routers, spindles, or other tooling from your Z-Axis.

• Remove any existing spoilboard or table extrusion from your machine.

• Install the torch base adapter as indicated.




100.00 mm

• Position the torch base adapter 100mm from the bottom of the z-axis extrusion.

• Tighten the highlighted fasteners.




CRP145-00 Torch Mount Assembly

• Attach the torch mount assembly to the torch base adapter

Note: The torch mount assembly is magnetically attached to the torch baseadapter. Not fasteners are required.




• Route the cables for your plasma torch and sensor through the cable track asindicated.

Note: Bundle the sensors cables away from the plasma cable.




PowerMax Plasma Torch

Note: Ohmic retaining cap and tip shield must be removed to slide torch intoclamp

• Install the plasma torch into the torch mount assembly.




6.5"

• Locate the tip of the plasma torch about 6.5" from the bottom of the torchmountassembly.





Note: Do not overtighten, just tighten enough to prevent the torch from moving.




CRP511 Water Table

• Place the water table onto the crossmember extrusion as indicated.




CRP511-05 Water Table Mounting Bracket

M8 x 12mm Socket Head Cap Screw

• Attach a mounting bracket to the front of the water table as indicated.








• Repeat the previous steps on the other side of the water table.




• Place two roll-in t-nuts into the t-slots behind each of the two water table mount-ing brackets.




M8 x 12mm Socket Head Cap Screw

• Slide the water table such that the mounting bracket is flush with the crossmem-ber extrusion.

• Attach the bracket to the table as indicated.

Note: The water table should be roughly centered between the table side rails.








2

Slat Installation




M8 Roll-in T-nut

1 5/8" Spacer

M8x35mm Hex Bolt

• Install a spacer into the water table as indicated.




2.25"

5"

2.25"

• Install spacers in each of the three t-slots as indicated.




4"

4"

4"

• Install the remaining standoffs with the indicated spacing.








• Bend a water table slat and install it between the front 3 standoffs, using thestandoffs to maintain tension on the slat.




• Install the remaining slats in the same way.




M4x14mm Socket Head Cap Screw

Material Sensing Reciever

M4 Roll-In T-Nut

• Install the material sensing reciever beneath one of the crossmembers as indi-cated.








3

Material Sensor Installation

• This section will describe the wiring of the Ohmic protection circuit and floatinghead sensor to your plasma torch and CRP800 control unit.




• Hypertherm Ohmic Retaining Cap must be used (pictured above standard Re-taining Cap). Remove the standard retaining cap but do not install Ohmic Re-taining Cap until the torch has been inserted into the torch mount.

Note: The Hypertherm Powermax 45XP, 65 and 85 us a different retaining capthan older powermax 45 models. Be sure you order the correct retaining cap foryour plasma torch, they are not interchangeable.




• Once the Torch has been inserted into the torch mount assembly and fastened,the Ohmic Retaining Cap should be fitted. The indicated female quick discon-nect of the Floating Head Sensor should then be attached to the Ohmic Retain-ing Cap.




• The female quick disconnect should be attached to the Ohmic Retaining Capas shown




• Remove the indicated rubber sheathing from the hypertherm torch clamp




• String the grounding wire from the Ohmic protection box through the rubbersheathing of the hypertherm torch clamp.




• Use the included bolt and nut to attach the ring terminal of the grounding wireto the existing hole in the handle of the hypertherm torch clamp.




• The sheathing for the torch clamp can now be slid back over the clamp handleand grounding wire as indicated.

Note: The clamp should always be fastened to material before cutting.




• The material sensing switch should connect to the Ohmic protection box as indi-cated.




• The opposite port of the Ohmic protection box should be connected to theCRP800 control unit.




• TheOhmicprotectionbox should beconnected to the "Aux 1" input of theCRP800control unit as shown



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CNC Router Parts Plasma Upgrade Kit · CNC Router Parts Plasma Upgrade Kit Installation Instructions Version2016Q3.1. PlasmaUpgradeInstructions CONTENTS Contents 1 Mechanical Components3