Avid CNC Plug and Play User manual

Plug and Play CNC Controller
Technical Manual
v2022Q1.2, 17.4 Model Revision

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
All Rights Reserved
System Overview
Major Components

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
All Rights Reserved

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
All Rights Reserved
Emergency Stop
The emergency stop system is a normally closed circuit and must be plugged in for the CNC controller to operate. It is
recommended to keep it within easy reach during machine operation so it is quickly accessible if the machine needs to be
emergency stopped.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
All Rights Reserved
To activate the emergency stop, press down on the red button. The machine will come to an immediate stop and all
outputs connected to the CNC controller will be turned off.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
All Rights Reserved
In order to clear the emergency stop, twist the red button clockwise until it releases.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
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Motor Disable Switch
The motor disable switch can be found on the side of the box below the fan. Using the motor disable switch will disconnect
power to the motor drives and motors. This works as a safety measure and allows you to perform maintenance, manually
move the machine, or disconnect and reconnect motors without any danger to the motors or drives.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
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System Requirements
Size Requirements
CRP800-00E Control Box
18in (450mm)
19in (480mm)
8in (205mm)
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
PART REV:
SCALE:
CRP800-00E
DO NOT SCALE DRAWING
AVID CNC
DWG REV:
P/N:
1:5
00001
SHEET 1 OF 1

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
All Rights Reserved
Power Requirements
NEMA 23 CNC Controller:
Input power: 100-120VAC or 200-240VAC, 50/60Hz
Voltage range must be set on main power supplies. They will be pre-congured for 100-120VAC, unless the system
was specically ordered for 200-240VAC power.
Current draw (approx.): 6A @ 120VAC, 3A @ 240VAC
NEMA 34 CNC Controller:
Input power: 100-120VAC or 200-240VAC, 50/60Hz
Voltage range must be set on main power supplies. They will be pre-congured for 100-120VAC, unless the system
was specically ordered for 200-240VAC power.
Current draw (approx.): 12A† @ 120VAC, 6A @ 240VAC
† The C13 type input power socket is rated for 15A in North America and 10A in most international regions. In those
regions the Plug & Play Controller should be powered with 200+ VAC.
Plug and Play Spindle / VFD Systems:
Please see the Power Requirements section in our Plug and Play Spindle / VFD Manual.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
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Initial Setup
Avid CNC Plug and Play Spindle Connections
Refer to the appropriate setup instructions for your Spindle/VFD package:
Plug and Play Spindle / VFD System: CRP800 VFD Setup Guide
Avid PRO CNC Plasma System Connections
Refer to the PRO CNC Plasma setup instructions: PRO CNC Plasma Instructions
Relay 1 Output Connections
Relay 1 is rated for 250VAC and 15A† AC. The relay requires external AC power to be plugged in to "Relay 1 In" on the CNC
controller. This output is commonly used in two ways:
Control a router: When Avid CNC's version of Mach4 is congured with a router cutting tool, the router should be
plugged into "Relay 1 Out". By default it is controlled by either the Router toggle button in Mach4 or by G-code with M03
(spindle ON) and M05 (spindle OFF) commands.
Control a dust collector, coolant system, or general AC load: When Avid CNC's version of Mach4 is congured with a
spindle or plasma cutting tool, relay 1 can be controlled either manually or using G-code. To manually operate the relay,
use the relay 1 toggle button. Using G-code, M08 will turn relay 1 on and M09 will turn BOTH relay 1 and relay 2 off.
† The C13 type relay power plugs/sockets are rated for 15A in North America and 10A in most international regions.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
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Relay 2 Output Connections
Relay 2 is rated for 250VAC and 15A† AC. The relay requires external AC power to be plugged in to "Relay 2 In" on the CNC
controller.
This output is commonly used for dust collection or coolant systems, but can be used for many general AC loads. Relay 2
can be controlled manually in Mach4 with the relay 2 toggle button. The use of G-code to operate relay 2 will depend on
your Mach4 conguration.
Router cutting tool: Use M08 to turn relay 2 on and M09 to turn relay 2 off.
Spindle or plasma cutting tool: Use M07 to turn relay 2 on and M09 to turn BOTH relay 1 and relay 2 off.
† The C13 type relay power plugs/sockets are rated for 15A in North America and 10A in most international regions.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
All Rights Reserved
3rd Party Spindle/VFD or non-Hypertherm Plasma Torch Connections
Use the information below to adapt external equipment to the 14-pin control cable supplied with the Avid CNC Plug and
Play controller. The 14-pin female connector is pre-wired into the Plug and Play controller with these functions. Note:
"Plasma" wires are only connected in plasma-enabled Plug and Play systems.
14-Pin Control Cable Pinout
Plasma pins are populated but not connected by default on routing controllers, and Spindle pins are populated but not
connected on plasma controllers.
ConnectorPin # Use In / Out Description Color ESS Port/Pin
1 Spindle Digital In Fault Ground Blue
2 Spindle Digital In Fault Signal White 2/13
3 Plasma Digital Out Torch ON Orange/Black 3/17
4 Plasma Digital Out Torch ON Green/Black
5 Plasma Analog In Voltage Divider - Red/Black
6 Plasma Analog In Voltage Divider + Red/White
7 Spindle Digital Out FWD Orange 2/14
8 Spindle Digital Out DCM Green
9 Spindle Analog Out AVI Red 2/1
10 Spindle Analog Out ACM Black
11 Spindle (optional) Analog 10V Ref Blue/White
12 Plasma Digital In Arc OK White/Black 3/10
13 Plasma GND Ground Blue/Black
14 Plasma Signal GND Arc OK Ground Green/White
Pin 1/2, Fault Signal/Fault Ground: This input is used to read a fault from an external VFD, typically from thermal overload
or a disconnected spindle power cable.
Pin 3/4, Torch ON: This output is from a small dry contact relay on the TMC3in1 used to trigger a CNC controllable plasma
torch ON/OFF.
Pin 5/6, Voltage Divider: This input is the Tip Voltage used for Torch Height Control (THC). It is critical that the (+)(-)
polarity of this signal is correct, as well as the voltage divider ratio. The ratio must be 50:1 (used by Hypertherm and preset
in the Avid CNC Mach4 prole), 40:1, 30:1, 20:1, 16.67:1, or 15:1. Note: Do not connect raw tip voltage, this will damage the
TMC3in1.
Pin 7/8, Spindle Relay: This output is from a small dry contact relay on the CRP850 breakout board and is used for sending
an on/off signal to an external VFD, typically for a forward/stop command.
Pin 8/9, Spindle Analog Signal: This output is a 0-10V analog signal used to control VFD frequency/spindle RPM.
Pin 11, 10V Reference: Unused in most systems, this pin can provide a 10V reference if required by the VFD.
Application

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
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Pin 12/14, Arc Okay: This input signals to the CNC controller that the plasma arc has successfully transferred to the
material and the cut program can continue motion. Typically the plasma power supply will close a dry contact relay to
control this signal.
Custom M12 Inputs Connections
For custom machine applications, the M12 sensor inputs on the CRP860-00E breakout board can be used for purposes
other than limits and probes. The inputs are Normally Open, rated for 12V, and follow a standard M12 A-coded pinout. See
the section for more details on pin assignments in Mach4.
This picture is looking at a Female connector body - pin assignments will be mirrored for Male.
Not all pins are populated for connectors on the CRP860-00E IO breakout board.
Sensor and Aux inputs: Pin 2 (Normally Closed) is not populated
E Stop input: Pin 4 (Normally Open) is not populated
Note

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
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System Settings
Power Settings
For NEMA 34 systems, the switch to change input voltages can be found on the power supply towards the top of the CNC
controller enclosure.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
All Rights Reserved
The switch can be moved up or down and will display the input voltage setting of the power supply.
The second power supply in a NEMA 23 5-axis system will be smaller than those shown above. The switch to change input
voltages on that power supply will be located on the top of the power supply.
NEMA 23 5-Axis Systems

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
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DIP Switch Settings
DIP switch settings on the motor drives will vary depending on your application. The DIP switch positions are shown below.
CRP8070 for 7.0A 1/2" NEMA 34 motors
CRP5056 for 4.2A 3/8" Nema 23 motors
If you are using an Avid CNC rotary axis on a NEMA 23 system, be sure the rotary axis motor is hooked up to the 5th drive
with that drive's DIP switch positions are set as shown below.
CRP5056 for 5.0A motors

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
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ESS Jumper Settings
The jumper pins shown here can provide 5V to pin 26 of their adjacent header, port 1 or port 2. The ESS comes pre-
congured in the CNC controller with these jumpers connected on port 1 and port 2.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
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Peripherals
5th Drive Upgrade for NEMA 23 Plug and Play Systems
If your system has an existing 5th motor drive and you only need to install the capacitor, skip to the Capacitor Installation
section.
Ensure your plug and play control box is powered off with the power cable disconnected from the box. It is also
recommended to remove the control box from the machine for easier installation of the motor drive.
Capacitor Installation
Warning

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
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1. Disconnect Components
1.1
The st step in upgrading your NEMA 23 system with a 5th drive will be to remove the gland plate and disconnect the
breakout board. Unplug the four motor drivers and the ethernet cable connected to the breakout board.

CNC Controller
Technical Manual
17.4 Model Revision
Version 2022Q1.2
© 2022 Avid CNC
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1.2
Remove the gland plate fasteners, disconnect the ribbon cable attached to the relay board, and pull the gland plate away
from the box.