Burny 1100 CD Installation guide

®
BURNY
REPLICATOR
1100 CCD
Operation and
Maintenance
Manual
CE Compliant
Revision: 7-July-2000
AO-70160-0 (A)

This documentation may not be copied, photocopied, reproduced, translated, or
reduced to any electronic medium or machine-readable format without explicit
written permission fromCLEVELAND MOTION CONTROLS, INC.
Cleveland Motion Controls, Inc.
7550 Hub Parkway
Cleveland, Ohio 44125-5794
Telephone: 216 / 524-8800
Fax: 216 / 642-2199
©Copyright 2000 Cleveland Motion Controls, Inc.
All Rights Reserved

TABLE OF CONTENTS
WARRANTY
PART 1 SYSTEM OVERVIEW............................................................................3
1.1 INTRODUCTION........................................................................................... 3
1.2 SPECIFICATIONS.......................................................................................... 5
1.3 TEMPLATE PREPARATION...................................................................... 16
1.3.1 INTRODUCTION............................................................................... 16
1.3.2 INSTRUCTIONS FOR TEMPLATE PREPARATION..................... 16
PART 2 SYSTEM OPERATIONS...........................................................................19
2.1 INTRODUCTION......................................................................................... 19
2.2 OPERATOR CONTROLS ............................................................................ 20
2.2.1 INTRODUCTION............................................................................... 20
2.2.2 POWER ............................................................................................... 20
2.2.3 TRACER PANEL CONTROLS.......................................................... 21
2.2.4 CUT PROCESS CONTROLS ............................................................. 24
2.3 MANUAL MODE ........................................................................................... 26
2.3.1 DESCRIPTION ................................................................................... 26
2.3.2 DETAILS............................................................................................. 26
2.4 REPLICATOR CCD TRACER OPERATION............................................. 27
2.4.1 INTRODUCTION............................................................................... 27
2.4.2 LOCATING THE TEMPLATE.......................................................... 27
2.4.2 MOVING TO START POSITION...................................................... 27
2.4.3 SETTING THE TRACER PANEL CONTROLS ............................... 27
2.4.4 SETTING THE TRACER FUNCTION KEYS .................................. 28
2.4.5 MAKING THE PIERCE ..................................................................... 31
2.4.5 STARTING LEADIN.......................................................................... 31
2.4.6 STOP THE MOTION.......................................................................... 31
PART 3 INSTALLATION AND MAINTENANCE...............................................33
3.1 INSTALLATION TYPES ............................................................................. 33
3.2 ELECTRICAL INSTALLATION OF THE 1100......................................... 33
3.3 INSTALLATION STEPS.............................................................................. 34
3.4 CHECKING THE INSTALLATION............................................................ 36
3.5 SERVICE AND MAINTENANCE............................................................... 38

3.5.1 INTRODUCTION............................................................................. 38
3.5.2 LAMP REPLACEMENT.................................................................. 39
3.5.3 TOOLS .............................................................................................. 40
3.5.4 PARTS ............................................................................................... 40
PART 4 TRACER CALIBRATION ........................................................................41
4.1 INTRODUCTION......................................................................................... 41
4.2 LOGIC BOARD MO-12199 CALIBRATION AND TESTING.................. 41
4.2.1 POWER SUPPLY CHECKOUT......................................................... 41
4.2.2 LOGIC BOARD ADJUSTMENTS:.................................................... 42
4.2.3 MAXIMUM SPEED SETTING.......................................................... 43
4.2.4 CAMERA ROTATION ADJUSTMENT............................................ 47
4.2.5 SPECIAL KEY FUNCTIONS ............................................................ 50
4.3 120W PWM DRIVE CALIBRATION............................................................. 51
4.3.1 POWER SUPPLY ADJUSTMENTS .................................................. 51
4.3.2 SERVO DRIVE ADJUSTMENTS...................................................... 51
4.3.3 JUMPER SETTINGS (I/O assembly MO-10773 or MO-12565):...... 52
PART 5 INDEX..........................................................................................................55
PART 6 REPLACEMENT ITEMS..........................................................................57
6.1 REPLACEMENT ASSEMBLIES ..................................................................... 57
6.2 REPLACEMENT PARTS ................................................................................. 59
PART 7 DRAWINGS ................................................................................................61

PART 1 –SYSTEM OVERVIEW
PART 1 SYSTEM OVERVIEW
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Figure 1.1 –Operator Control Panel
1.1 INTRODUCTION
The Replicator®1100 CCD is an optical tracing system complete with scanner assembly,
operator control panel, two-axis servo amplifier, and scanner cable. Also available are
motor gearbox assemblies and cables. When integrated with a Burny®CNC, the
Replicator 1100 CCD can be configured for external two-axis and three axis (drive
synchronized) servo amplifier applications.
The optical scanner (tracing head) is normally mounted vertically, allowing it to trace a
horizontal template. The template can be either a line or a silhouette (edge) type.
The tracing head automatically follows the edge of this template and transmits optical
information to the logic card that is located in the enclosure.
The logic card translates this information into speed, axis, and direction signals, which
are then amplified by a second printed circuit card that is also located in the enclosure.

On units with an internal two-axis servo amplifier, the output of this card is then sent
directly to both of the axis servo motors.
The Operator Control Panel contains switches and controls that allow the operator to
utilize all of the features of the tracing head. In addition, manual jog control of each axis
is also provided.
This economical optical tracing system is ideally suited for small and medium size
cutting machines. It can scan and follow either line drawings or contrasting edge patterns.
The Replicator CCD features automatic "lead-in" and "lock-on" in the direction of travel
desired. This canbe either clockwise or counter clockwise around the template. This is
possible with either a line or silhouette template.
In either the tracing mode or the jog mode the operator can change the speed of the
machine using a continuously adjustable potentiometer that is conveniently located at the
Operator Control Panel.

PART 1 –SYSTEM OVERVIEW
1.2 SPECIFICATIONS
1.2.1 ENVIRONMENTAL SPECIFICATIONS
ENVIRONMENT: Operating Temperature
0-50°C (32°-120°F)
Relative Humidity 5%-95%
Non-condensing
1.2.2 FEATURE SPECIFICATIONS
KERF COMPENSATION: Kerf compensation is applied electronically
and is available for tool diameter up to 12 mm.
Kerf Compensation values range:
–1 mm (-0.039 in) to +6 mm (0.236 in)
+ is away from the template
TRACING SPEED: 101.6 mmPM -3048 mmPM (4-120 IPM)
Based on drives selected, machine weight and
stability.
LEADIN SPEED Cannot exceed one third of maximum machine
speed. Can be adjused lower with Speed Pot.
PATTERN (TEMPLATE, EDGE MODE) White background with black line width of 1.0
mm (0.040 in.) recommended.
Minimum of 0.7 mm (0.028 in.) or black and
white silhouette (edge mode only).
PATTERN (TEMPLATE, CENTERLINE) White background with black solid line of
width 0.7 mm to 1.7 mm (0.028 to 0.067 in).
1.0 mm (0.040 in.) line width recommended
FORWARD OFFSET (LEAD) Automatic in software
PATTERN ILLUMINATION: Long life (3500 Hour) lamp
TRACER HEIGHT: 53mm ± 12.5 mm (2.09 ± 0.50 in.) from
template to bottom of tracing-head housing.

1.2.3 ELECTRICAL SPECIFICATIONS
MYX-12383 REPLICATOR 1100 (for AC lifters)
“PWR”connector I/O ratings
PIN # DESCRIPTION RATINGS
1Line HOT input for Replicator power supply. 115 or 230 V max AC, 50/60 Hz, 1.6 A max,
protected by FU1 on rear panel.
CAUTION:Set internal
jumper according to
voltage to be used.
5Line NEUTRAL input Neutral connection for pin 1 ac power.
6Chassis Ground (18 AWG wire)

PART 1 –SYSTEM OVERVIEW
MYX-12383 REPLICATOR 1100 (for AC lifters)
“SOL”connector I/O ratings
Note: All solenoids are served by the same fuse, FU2, 6.3 A, on the
rear panel. Maximum total current of the solenoids is limited by this
fuse.
PIN # DESCRIPTION RATINGS
9Input -Solenoid Hot 24 V max AC, 50/60 Hz, or 24 V max DC, 6.3 A max
33 Input -Solenoid Neutral Neutral or common for pin 9
2, 6,
11, 17,
21, 24,
35, 30
Output -Solenoid Neutral Neutral or common for pins 1, 5, 10, 16, 20, 23, 34,
and 29
3, 7,
12, 18,
22, 25,
36, 31
Chassis ground 18 AWG wire
1Oxygen Vent Solenoid Output 24 V max AC, 50/60 Hz, or 24 V max DC.
2 A max, but on same 6.3 A fuse, FU2 with 7 other
solenoid outputs.
5Second Stage Cut O2 Solenoid Output 24 V max AC, 50/60 Hz, or 24 V max DC.
2A max, but on same 6.3 A fuse, FU2 with 7 other
solenoid outputs.
10 Lo Preheat Solenoid Output 24 V max AC, 50/60 Hz, or 24 V max DC.
2 A max, but on same 6.3 A fuse, FU2 with 7 other
solenoid outputs.
16 Ignite Solenoid Output 24 V max AC, 50/60 Hz, or 24 V max DC.
2 A max, but on same 6.3 A fuse, FU2 with 7 other
solenoid outputs.
20 First Stage Cut Oxygen Solenoid Output 24 V max AC, 50/60 Hz, or 24 V max DC.
2 A max, but on same 6.3 A fuse, FU2 with 7 other
solenoid outputs.
23 Water Solenoid Output 24 V max AC, 50/60 Hz, or 24 V max DC.
2 A max, but on same 6.3 A fuse, FU2 with 7 other
solenoid outputs.
34 Hi Preheat Solenoid Output 24 V max AC, 50/60 Hz, or 24 V max DC.
2 A max, but on same 6.3 A fuse, FU2 with 7 other
solenoid outputs.
29 Auxilliary Solenoid Output 24 V max AC, 50/60 Hz, or 24 V max DC.
2 A max, but on same 6.3 A fuse, FU2 with 7 other
solenoid outputs.

MYX-12383 REPLICATOR 1100 (for AC lifters)“LIFT”
connector I/O ratings Note: All lifters are served by the same fuse,
FU3, 6.3 A maximum, on the rear panel. Maximum total current of
the lifters is limited by this fuse.
PIN # DESCRIPTION RATINGS
10 Lifter 1 up switched output Switched 24 V max AC, 50/60 Hz, 2 A max.
See note above.
5Lifter 1 down switched output Switched 24 V max AC, 50/60 Hz, 2 A max.
See note above.
11 Lifter 1 Hot un-switched output Un-switched 24 V max AC Line, 50/60 Hz, max 2 A
See note above.
6Lifter 1 Neutral un-switched output Un-switched 24 V max AC Neutral, 50/60 Hz, max 2 A.
See FU3 note above.
1Chassis Ground 18 AWG wire
2Lifter 2 up switched output Switched 24 V max AC, 50/60 Hz, 2 A max.
See note above.
3Lifter 2 down switched output Switched 24 V max AC, 50/60 Hz, 2 A max.
See note above.
7Lifter 2 Hot un-switched output Un-switched 24 V max AC Line, 50/60 Hz, max 2 A
See note above.
8Lifter 2 Neutral un-switched outputUn-switched 24 V max AC Neutral, 50/60 Hz, max 2 A
See note above.
4Chassis Ground 18 AWG wire
9Lifter 3 up switched output Switched 24 V max AC, 50/60 Hz, 2 A max. See note above.
15 Lifter 3 down switched output Switched 24 V max AC, 50/60 Hz, 2 A max.
See note above.
14 Lifter 3 Hot un-switched output Un-switched 24 V max AC Line, 50/60 Hz, max 2 A
See note above.
21 Lifter 3 Neutral un-switched output Un-switched 24 V max AC Neutral, 50/60 Hz, max 2 A
See note above.
22 Chassis Ground 18 AWG wire
28 Lifter 4 up switched output Switched 24 V max AC, 50/60 Hz, 2 A max.
See note above.
33 Lifter 4 down switched output Switched 24 V max AC, 50/60 Hz, 2 A max.
See note above.