Plasma Upgrade Kit Installation Instructions

CNC ROUTER PARTSPlasma Upgrade KitInstallation InstructionsVersion 2019Q2.1

1. Mechanical ComponentsPlasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.1CRP145-06 Torch Base AdapterM8 Roll-in T-nutM8x16mm Socket Head Cap ScrewRemove 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.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.2100.00 mmPosition the torch base adapter 100mm (4") from the bottom of the A-axis extrusion.Tighten the highlighted fasteners.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.3CRP145-00 Torch Mount AssemblyAttach the torch mount assembly to the torch base adapter. Assembly NoteThe torch mount assembly is magnetically attached to the torch base adapter. No fasteners are required.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.4Route the cables for your plasma torch and sensor through the cable track as indicated. Assembly NoteBundle the sensor cables away from the plasma cable.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.5PowerMax Plasma TorchInstall the plasma torch into the torch mount assembly. Assembly NoteOhmic retaining cap and tip shield must be removed to slide torch into clamp.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.66.5"Locate the tip of the plasma torch about 6.5" from the bottom of the torch mount assembly.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.7Tighten the highlighted fasteners. Assembly NoteDo not over-tighten, just tighten enough to prevent the torch from moving.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.8CRP511 Water TablePlace the water table onto the crossmember extrusion as indicated.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.9CRP511-05 Water Table Mounting BracketM8 x 10mm Socket Head Cap ScrewAttach a mounting bracket to the front of the water table as indicated.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.10Tighten the highlighted fasteners.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.11Repeat the previous steps on the other side of the water table.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.12Place two Roll-in T-Nuts into the t-slots behind each of the two water table mounting brackets.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.13M8 x 16mm Socket Head Cap ScrewSlide the water table such that the mounting bracket is flush with the crossmember extrusion.Attach the bracket to the table as indicated. Assembly NoteThe water table should be roughly centered between the table side rails.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

1.14Tighten the highlighted fasteners.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

2. Slat InstallationPlasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

2.1M8x35mm Hex Bolt1 5/8" SpacerM8 Roll-in T-nutInstall a spacer into the water table as indicated.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

2.22.25"5"2.25"Install spacers in each of the three t-slots as indicated.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

2.34"4"4"Install the remaining standoffs with the indicated spacing.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

2.4Tighten the highlighted fasteners.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

2.5Bend a water table slat and install it between the front 3 standoffs, using the standoffs to maintain tension on the slat.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

2.6Install the remaining slats in the same way.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

2.7M4 Roll-In T-NutM4x14mm Socket Head Cap ScrewMaterial Sensing RecieverInstall the material sensing receiver beneath one of the crossmembers as indicated.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

2.8Tighten the highlighted fasteners.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3. Material Sensor InstallationThis section will describe the wiring of the Ohmic protection circuit and floating head sensor to your plasma torch andCRP800 control unit.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.1Hypertherm Ohmic Retaining Cap must be used (pictured above the Standard Retaining Cap). Remove the standardretaining cap but do not install Ohmic Retaining Cap until the torch has been inserted into the torch mount. NoteThe Hypertherm Powermax 45XP, 65, and 85 use a different retaining cap than older Powermax 45 models. Be sure youorder the correct retaining cap for your plasma torch, they are not interchangeable.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.2Once the torch has been inserted into the torch mount assembly and fastened, the Ohmic Retaining Cap should be fitted.The indicated female quick disconnect of the Floating Head Sensor should then be attached to the Ohmic Retaining Cap.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.3The female quick disconnect should be attached to the Ohmic Retaining Cap as shown.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.4Remove the indicated rubber sheathing from the Hypertherm torch clamp.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.5String the grounding wire from the Ohmic protection box through the rubber sheathing of the Hypertherm torch clamp.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.6Use the indicated bolt and nut to attach the ring terminal of the grounding wire to the existing hole in the handle of theHypertherm torch clamp.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.7The sheathing for the torch clamp can now be slid back over the clamp handle and grounding wire as indicated. NoteThe clamp should always be fastened to material before cutting.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.8The material sensing switch should connect to the Ohmic protection box as indicated.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.9The opposite port of the Ohmic protection box should be connected to the CRP800 control unit.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

3.10The Ohmic protection box should now be connected to the "Aux 2" input of the CRP800 control unit as shown.Plasma Upgrade KitInstallation InstructionsVersion 2019Q2.1 2019 CNC Router Parts LLCAll Rights Reserved

Hypertherm Ohmic Retaining Cap must be used (pictured above the Standard Retaining Cap). Remove the standard retaining cap but do not install Ohmic Retaining Cap until the torch has been inserted into the torch mount. Note The Hypertherm Powermax 45XP, 65, and 85 use a different retaining cap than older Powermax 45 models. Be sure you