NOTE: These assembly instructions are for the latest version of the CrossFire CNC. If you have CrossFire Machine Serial #15647 or before (located on your gantry tube), please follow the Legacy CrossFire Assembly Instructions.
NOTE: These assembly instructions are for the latest version of the CrossFire CNC. If you have CrossFire Machine Serial #15647 or before (located on your gantry tube), please follow the Legacy CrossFire Assembly Instructions.
When used correctly, the Langmuir Systems CrossFire CNC Plasma Table will offer you years of safe operation. However, like all other automated and industrial-type machinery, there are important safety considerations and precautions that must be followed in order to avoid injury. Study these safety warnings carefully before assembling and using your machine.
ELECTRIC SHOCK
Electric shock can cause serious injury or death. This machine requires the use of high voltage electricity to operate. To avoid injury, always adhere to the following precautions:
FIRE AND EXPLOSION
Fire and explosion can be caused by the airborne sparks and slag igniting a nearby flammable material. Electrical fires can be caused if the machine is assembled or used incorrectly. To avoid injury, always adhere to the following precautions:
AUTOMATIC OPERATION
The machine may operate at any time, automatically, and without warning. To avoid injury, always adhere to the following precautions:
HAZARDOUS FUMES
Gases and fumes produced during the plasma cutting process can be hazardous to your health. To avoid injury, always adhere to the following precautions:
ULTRAVIOLET AND INFRARED RADIATION
The plasma cutter produces high intensity ultraviolet and infrared light that can damage your eyes and skin. To avoid injury, always adhere to the following precautions:
SPARKS AND AIRBORNE DEBRIS
Plasma cutting creates airborne sparks and debris that can cause eye injuries. To avoid injury, always adhere to the following precautions:
PINCH AND CRUSH POINTS
This machine can create pinch points while in motion during normal operations. To avoid injury, always adhere to the following precautions:
HOT MATERIALS
The plasma cutting process uses extremely high temperatures to cut metal. As a result, the material can be very hot after cutting which can cause burns. To avoid injury, always adhere to the following precautions:
WARNING: This product can expose you to chemicals which are known to the State of California to cause cancer, birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.
Use the following CrossFire Assembly Guide to put together your machine.
View the Software Workflow and follow along our Fusion 360 CAD and CAM guide to start designing parts!
Use the FireControl Guide to Download and install the software used to control your CrossFire.
Download the CrossFire (FireControl) Break-in program from our Downloads page and run it using FireControl.
Start cutting out parts with your CrossFire!
The Langmuir Systems CrossFire CNC ships partially assembled. Therefore, this section serves to provide all of the pertinent information and instructions needed to fully assemble your new machine.
The assembly drawings and pictures included in this guide can be expanded to full-screen and zoomed to provide more detail on a given step.
The CrossFire is delivered via standard (non-freight) delivery in one (1) box. The contents of the box are outlined below. All add ons and upgrades ship via their own packages.
This manual depicts and references black powdercoated frame tubes but you may have received grey powdercoated frame tubes. These parts are otherwise identical and will not affect the assembly or performance of the machine.
If you have the CrossFire XL Kit, please assemble using XL Lower Rail. Please take particular note of the hole locations you will be using for the XL lower rail in Step 1 of the XL Kit instructions.
Gather frame tubes on a large work surface and assemble the frame of the CrossFire CNC.
If you have a CrossFire Water Table, please proceed with installation of the water table at this point in assembly. If you have not received your water table, you can also easily install this at a later time.
If you have the CrossFire XL Kit, please assemble using XL Y-Axis Rail. Please see Step 3 of the XL Kit instructions.
If you have the CrossFire XL Kit, please assemble using XL Y-Axis Lead Screw. See step Step 3 of the XL Kit instructions.
It is critical that you pull back on the white compression collar while screwing into the lead nut. If this is not done, the lead nut can break.
It is critical that you pull back on the white compression collar while screwing into the lead nut. If this is not done, the lead nut can break.
First, install the Y-Axis motor.
Next, install the X-Axis motor.
The next sections cover installation and assembly the CrossFire CNC Add-ons. If you do not have these add-ons or do not want to install them now, please continue to the Connecting Electronics.
The following instructions describe the installation of the CrossFire XL kit on a base CrossFire CNC Machine.
Your CrossFire XL Kit package will include the following items:
If you are installing the XL on a new machine, you can skip steps A1 and A2 below.
Use of the water table is highly encouraged with the XL kit since the larger cutting envelope increases the risk of warpage. However, if you do not have a water table, use the provided self-drilling and tapping sheet metal screws to secure the center sheet metal bracket to the XL Lower Rail.
In this section, we will finalize assembly of the CrossFire by plugging in the electronics components, routing cables, and tightening lead nuts.
Locate the DSUB connector for the X-axis stepper motor and insert into the corresponding socket on the Electronics Enclosure. Do the same for the Y stepper motor as shown in the image below. Be certain to fully tighten the two screw clamps on each DSUB connector into the Electronics Enclosure.
In the following steps, we will need to jog the machine to the front right corner. To do this, we will need to use FireControl software to jog the machine. Please make sure that you have followed all of the steps in the FireControl User Guide section Connecting to a CrossFire Machine before proceeding to power on the machine for the first time.
Next plug in the USB Cable and Power Cord to the corresponding ports on the Electronics Enclosure. Plug the USB cable into your computer and switch on the power to the Electronics Enclosure.
If you are running a Z-Axis kit with your CrossFire, be sure to allow enough slack in your plasma cutter torch lead to not put any lifting force onto the floating Z-Axis and IHS system. Failure to do so will cause errors generated by the IHS system.
Install your plasma cutter's torch into the torch mount and tighten the two stainless fasteners (4 stainless fasteners if using the Machine Torch Mount) to secure your torch. Be careful not to overtighten on the torch body or constrict the movement of internal components as this may lead to lost arc and misfires. The fit should be snug so that the torch doesnt spin in the mount.
Using the provided velcro straps, route your torch lead along the cable routing pole with enough slack to move around the entirety of the cutting surface.
WARNING: The CrossFire water table is designed for use with cutters up to 45 Amps. For use with cutters over 45 Amps, we recommend using additional insulating material to prevent damage to the tray.
Use these installation instructions to assemble and install your water table.
Installation Steps:
Use these installation instructions to assemble and install your laptop stand.
Installation Steps:
If you purchased a CNC - CrossFire Compatible Razorweld Plasma cutter (Razorcut 45 CNC or Vipercut 30 CNC) from Langmuir Systems, your plasma cutter is plug and play with your CrossFire CNC system. Use the provided Torch Firing Cable to plug directly into the CNC Port on your Razorweld Cutter.
The CrossFire was designed to be compatible with plasma cutters that are equipped with a hand torch or machine torch. A hand torch enables the operator to start and stop the cutting action by squeezing and releasing the torch trigger. This section contains the instructions for a hand torch.
When installed on the CrossFire, the electronics system must have control over when the torch turns on and off. Providing this control requires splicing into the wires that connect to the trigger so that the CrossFire’s onboard relay can fire the torch when commanded to do so by the CPU.
The purpose of this section to provide the general procedure required to make the wire splices inside of your plasma cutter to facilitate mechanized cutting on the CrossFire. The procedure was designed to be as easy and minimally invasive as possible while preserving your plasma cutter’s ability to be used for hand cutting when not used on the CrossFire. Since there are dozens of plasma cutters on the market, the procedure is intentionally general so that it may be applied to any compatible plasma cutter you select.
Splicing into the torch trigger wires may or may not violate your plasma cutter’s warranty. It is your responsibility to check with your plasma cutter manufacturer regarding the terms of the warranty and whether or not executing the splicing procedure violates those terms. Langmuir Systems will not be held responsible for warranty violations.
Completing the procedure requires opening up the cabinet of your plasma cutter power supply which will expose you to high voltage and high amperage electrical components. It is your responsibility to make sure that all work is done safely and with the power disconnected. If you have any doubts regarding your ability to safely perform this work, we strongly urge you to solicit the services of a professional electrician. Langmuir Systems will not be held responsible for any injury or death resulting from the incorrect or unsafe execution of this procedure.
After the wire splices are made, it is critical to never leave the torch firing cable connected to the CrossFire electronic enclosure when the torch is not installed in the torch mount and ready to cut. If the torch is required for hand cutting duty, it is imperative to first disconnect the torch firing cable before removing the torch. Failure to do so creates the opportunity for the CrossFire electronic system to turn the torch on when the torch is physically in an unsafe location; such as in the presence of volatile or explosive substances. Failure to disconnect the torch firing cable from the electronic enclosure when the torch is not installed can cause serious injury or death. Langmuir Systems will not be held responsible for any injury or death resulting from the lack of adherence to this critical safety requirement.
A test light or a multi-meter with continuity measuring capability is required to complete this procedure. Your plasma cutter may be different than the one shown so you may find that the procedure for your specific plasma cutter may need to differ somewhat.
Find Torch wiring hardware (Bag #14) and your plasma cutter. We'll be using the Razorweld Vipercut 30 in this example.
Unplug your plasma cutter and wait for at least 10 minutes before proceeding in order to provide sufficient time for the internal capacitors to discharge.
Disconnect the torch hose from the plasma cutter power supply.
With the trigger not depressed, use your multimeter to check if there is continuity between any sets of pins. If there is continuity between a set of pins, make note of them.
Use a piece of tape to temporarily depress the torch trigger.
Again check for continuity between sets of pins with your multimeter.
The set of pins that did not have continuity when the trigger was not depressed, but do now, are the trigger wire pins. Make note of their location in the connector.
Make note of the location of the trigger wire pin receivers in the female connector on the plasma cutter.
Remove the cover of your plasma cutter cabinet. Some plasma cutters will require tools to accomplish this. The objective is to gain access to the wires that connect to the torch hose connector mounted to the exterior of your plasma cutter.
Once open, identify the wires inside of the plasma cutter cabinet that correspond to the trigger wire pin receivers in the female connector.
Attach the T-tap connectors to the trigger wires. You may need to use a set of pliers to clamp them onto the wires to ensure that the clasps fully lock.
Langmuir Systems provides 3 different sizes of T-taps for different gauge wires. Please use the appropriately sized tap for your wire: Not too wide of a slot so it doesn't cut the wire insulation and not too tight where you can't snap it on.
Once snapped into place, work the connector back and forth a few times (half turns) to ensure the insulation is cut and the metal is exposed to the connector.
Locate the torch firing cable that was provided with your machine and connect the blade connectors to the T-Tap connectors.
It does not matter which blade connector gets plugged into which T-tap connector. The polarity and wire coloring is not important.
Plug the torch hose back into the plasma cutter.
With the torch trigger depressed, check the continuity between the two bare ends of the torch fire cable. If you spliced into the correct wires, there should be continuity. If not, go back and verify that the correct wires were identified in Step 3.
Release the trigger. Verify that there is no longer continuity between the two bare ends of the torch fire cable.
Reinstall the cover on the plasma cutter cabinet with the torch fire cable exiting the cabinet in a convenient location. Make sure that there are no sharp edges that could damage the torch fire wire insulation. Add additional abrasion protection as needed.
Plug the male end of the torch fire cable into the 'Torch On/Off' jack in the electronics enclosure.
As instructed in our cutting tutorials, plug in the plasma cutter with torch installed only when the torch is installed into the Torch Mount for firing safety.
View the Software Workflow and follow along our Fusion 360 CAD and CAM guide to start designing parts!
Use the FireControl Guide to Download and install the software used to control your CrossFire.
Download the CrossFire Gen2 Break-in program from our Downloads page and run it using FireControl.
Start cutting out parts with your CrossFire!
All Langmuir Systems products are covered by a 12 month limited warranty on hardware and 6 month limited warranty on electronics. The terms of the warranty are listed below:
All products sold directly by Langmuir Systems are eligible for return and refund. The terms of the return and refund policy are listed below: