Charmilles 813078 E / 852029 PLC PCB Circuit Board for Robocut 2 CNC EDM

The Charmilles 813078 E (also identified as 852029) is a PLC printed circuit board designed for the Robocut 2 series of CNC wire electrical discharge machining (EDM) equipment. This PCB is a critical control component responsible for signal processing, I/O management, and communication between the CNC controller and the machine’s power supply, servo drives, and auxiliary systems. Charmilles (now part of GF Machining Solutions) is renowned for precision EDM equipment used in tool and die making, aerospace, and medical manufacturing. This board is typically installed in the main control cabinet and is essential for maintaining the operational integrity of legacy Robocut 2 machines.

Technical Specifications

Board type: multi-layer FR4 PCB with conformal coating for environmental protection. Dimensions: approximately 250 mm × 200 mm × 20 mm. Edge connector: 96-pin DIN 41612 for backplane connection. Operating voltage: +5 V DC, ±12 V DC, +24 V DC (derived from the machine’s power supply). Current consumption: 1.5 A at 5 V. The board contains custom ASICs, logic gate arrays, optocouplers for galvanic isolation, and memory devices (SRAM/Flash). It includes interface circuits for servo drives, position encoders, I/O modules, and the CNC communication bus. Diagnostic LEDs indicate power, communication, and fault status. Operating temperature: 0°C to 55°C. Storage: -20°C to 70°C. Humidity: 10-90% non-condensing. The board is designed for installation in a clean, vibration-controlled environment.

Key Features

• OEM PLC PCB for Charmilles Robocut 2 CNC EDM machines

• Multi-layer FR4 substrate with conformal coating

• 96-pin DIN backplane connector

• Custom Charmilles ASICs for EDM-specific control

• Optically isolated I/O for interference immunity

• Status LEDs for power and fault diagnosis

• Compatible with Robocut 2 series (2A, 2B, etc.)

• Replacement part for original Charmilles equipment

Function in Robocut 2 System

The 813078 E board acts as the PLC (programmable logic controller) within the Robocut 2 CNC EDM system. It interfaces with the main CNC computer (typically a PC‑based controller) and handles real‑time I/O tasks such as: monitoring limit switches, controlling solenoids for dielectric fluid and wire threading, managing safety interlocks, and sending status signals to the CNC. The board also processes encoder feedback from the X, Y, U, V axes and communicates with the servo drives via analog or digital signals. Without this board, the machine cannot execute automatic wire threading, tank filling, or axis homing sequences.

Applications

This PCB is used exclusively in Charmilles Robocut 2 series CNC EDM wire cutting machines. It is not compatible with other EDM brands or newer Robocut models (e.g., Robocut 3). Typical applications for the Robocut 2 machine include precision die manufacturing, punch and mold making, aerospace component fabrication, and medical device prototyping. The board is sought by service companies and machine rebuilders to maintain legacy equipment.

Installation and Replacement

Power down the EDM machine and disconnect the mains supply. Open the electrical cabinet. Locate the existing 813078 board (usually in a card rack). Remove all ribbon cables and wiring connectors, noting their positions. Remove the board by unclipping the retaining latches and pulling it straight out. Insert the replacement board, ensuring the edge connector aligns with the backplane. Reconnect all cables, matching the original orientation. Power up the machine and verify that the board’s LEDs indicate normal operation (green power LED). Run a diagnostic test through the CNC to confirm I/O functionality.

Maintenance and Troubleshooting

If the machine fails to start or I/O functions are erratic, inspect the board for visible damage (burnt components, cracked solder joints). Check the LED status: a red LED indicates a fault. Common issues: power supply failure, loose connectors, or damaged optocouplers. The board is not field‑repairable; replacement is recommended. Keep the board in an anti‑static bag when not installed. Clean the board with compressed air periodically.

Environmental and Compliance

The Charmilles 813078 E board is compliant with CE and RoHS standards (as originally manufactured). Operating temperature: 0-55°C. Humidity: 10-90% non-condensing. It is designed for use in industrial environments with appropriate ESD precautions.

Conclusion

The Charmilles 813078 E / 852029 PLC PCB is a direct replacement part for Robocut 2 CNC EDM machines. It is essential for maintaining the control and I/O functions of these precision wire cutting systems, ensuring continued operation of legacy equipment.