G0619 & G0463 RETROFIT KIT

Transcription

1 G0619 & G0463 RETROFIT KIT Midwest Office 444 Lake Cook Road, Suite 22 Deerfield, IL Phone (847) Fax (847) FlashCut CNC, Inc.

2 Table of Contents THANK YOU... 2 PRODUCT SUPPORT... 2 SAFETY AND USAGE GUIDELINES... 3 SHIPMENT DETAILS... 4 INSTALLATION... 6 MOTOR MOUNTING TO BRACKETS... 6 Y AXIS ASSEMBLY... 8 Z AXIS ASSEMBLY X AXIS ASSEMBLY FINISHED! REVISION HISTORY... 20

3 FlashCut CNC 2 G0619 & G0463 Retrofit Kit Installation Guide Thank You Thank you for purchasing the FlashCut CNC G0619 Series Retrofit Kit. It is powered by our own intuitive, powerful CNC control system for Windows 8, Windows 7, Vista, and XP. No system is easier to set up and use than FlashCut CNC. With intuitive controls and real time graphics, it lets you make parts quickly and accurately on your machine tool. We are dedicated to the excellence and ongoing enhancement of all FlashCut CNC products. Feel free to call us with any comments or questions. Product Support We are committed to the full support of FlashCut CNC products. We have many resources devoted to helping you resolve your problems quickly. Please use these resources in the following order: 1. Web Site: Our website has product specifications, documentation, and a dedicated support section containing Troubleshooting Guides and FAQ s. 2. Dealer Support: If you purchased FlashCut CNC from a dealer or other machine tool manufacturer, please contact them as they will have the best knowledge of your complete system support@flashcutcnc.com is the most organized way to convey your issues to our support staff. In your , please state your problem completely. Include your FlashCut version, the processor and speed of your computer, your version of Windows and your signal generator serial number. Attach your setup file (usually found in a folder named c:\flashcut data) and, when appropriate, the G-Code file with which you are having problems. 4. Phone/Fax Support In addition to support, you may call one of our telephone support numbers. We will normally respond to your call within 24 hours. Phone: (847) (9:00 AM-5:00 PM, CST, M-F) Fax: (847)

4 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 3 Safety and Usage Guidelines When running an automated machine tool, safety is of utmost importance. For proper and safe use of the FlashCut CNC program and your CNC machine, the following safety guidelines must be followed: 1. Never let the machine tool run unattended. 2. Require any person in the same room as a running machine tool to wear safety goggles, and to stay a safe distance from the machine. 3. Allow only trained operators to run the machine tool. Any operator must have: Knowledge of machine tool operation. Knowledge of personal computer operation. Knowledge of Microsoft Windows. Good common sense. 4. Place safety guards around the machine to prevent injury from flying objects. It is highly recommended that you build a safety shield around the entire tool envelope. If your machine came with a safety hood, ensure that the hood is closed at all times. The machine or spindle should never be on while the hood is open. 5. Never place any part of your body within the tool envelope while the machine is online, since unexpected machine movement can occur at any time. 6. Always keep the tool envelope tidy and free of any loose objects. Clean the machine regularly and remove chips and dust deposits. 7. Be alert for computer crashes at all times. 8. The machine must not be operated in combustible atmosphere. 9. Ensure sufficient ventilation for dust or gas resulting from cutting your parts. 10. Do not use alcohol as coolant (danger of explosion!). FlashCut CNC, Inc. is not responsible for the safe installation and use of this product. You and only you are responsible for the safety of yourself and others during the operation of your CNC machine tool. FlashCut CNC supplies this product but has no control over how it is installed or used. Always be careful! FlashCut CNC, Inc., or its affiliates are not responsible for damage to any equipment or work piece resulting from use of this product. If you do not understand and agree with all of the above, do not use this product. IF YOU DO NOT UNDERSTAND AND AGREE WITH ALL OF THE ABOVE, DO NOT USE THIS PRODUCT.

5 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 4 Shipment Details Kit Includes: (3) Unibody Aluminum Brackets (X,Y,Z) (1) Z axis Mounting Plate (2) 20XL Pulley (3) 10XL Pulley (1) 40XL Pulley (2) 130XL Timing Belt (1) 150XL Timing Belt X-axis Bracket Hardware o (2) M6 X 120SHCS o (2) 5/8" OD, 1/4"ID, 3-3/4" Steel Spacer o (2) M6 Washer Y-axis Bracket Hardware o (2) M6 X 80SHCS o (2) 5/8" OD, 1/4"ID, 2-3/8" Steel Spacer o (2) M6 Washer Z-axis bracket hardware o (4) 1/4-20 X 2-1/4 Button Head Screw o (4) 1/2" OD, 1/4" ID, 1/8" Steel Spacer o (4) 1/2" OD, 1/4" ID, 1-3/4" Steel Spacer o (3) M5 X 25 Button Head Screw o (3) M5 Washer Motor Mounting Hardware o (12) X 5/8 Button Head Screw o (12) Serrated Lock Nut (3) Belt Covers (X,Y,Z,) (12) #4 X ¼ Self Tapping Belt Cover Screws (6) 1-1/2 X 3 Plastic End Caps Shaft Spacers o (1) Y-axis: ¾ OD, 12mm ID, ½ long Steel Spacer o (1) Z-axis: ¾ OD, 12mm ID, ¼ long Steel Spacer

6 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 5 Compact Stepper Control System (additional items): (1) 3-Axis, 2.5 Amp/axis Stepper Motor Driver box (3) Size 23, 454 oz-in stepper motors (3) 10' stepper motor cables FlashCut CNC Software and Manuals (CD) Stepper Control System (additional items): (1) 3-Axis, 8 Amp/axis Stepper Motor Driver box (3) Size 23, 454 oz-in stepper motors (3) 10' stepper motor cables FlashCut CNC Software and Manuals (CD) Servo Control System (additional items): (1) 3-Axis, 8 Amp continuous, 12 Amp peak Servo Driver box (3) Size 23, 191 oz-in servo motors with (3) 10' Servo motor cables FlashCut CNC Software and Manuals (CD) X, Y and Z mounting hole locations for G0619.

7 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 6 Installation Motor Mounting to Brackets 1) Begin by removing the hand wheels from The X Y and Z axes. You might need a gear puller to remove some of the handles. 2) Attach the 10 toothed flanged pulleys to all of your motors via setscrews using a 5/64 Hex-head wrench. Line up one of the set screws with the flat on the motor shaft and position the pulley so the top flange is 1 from the plateau of the circular boss on the motor flange.

8 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 7 3) Attach the motors to each of the three brackets with the provided X 5/8 button head screws and matching flanged lock nuts using a 1/8 Hex-head wrench and your finger. Do not tighten the screws. The motors will need to slide in the mounting slots when you tighten the belt in a later step. (Note: Take notice of the orientation of the motor cables, install the motors in a way that keeps the cables out of the way during operation See Below) X Y Z

9 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 8 4) Slip the appropriate belt over the pulley on the inside of bracket (Note: the X & Y axis get the 130 XL belts and the Z gets the 150 XL Belt) X Y Z Y Axis Assembly 1) Place the ¾ OD, 12mm ID, ½ long steel spacer and a 20 tooth pulley on the Y Axis Shaft making sure the keyway is still in place. You might need a mallet to get the pulley and spacer over the keyway. You also might need to pull the table towards you and push the pulley in to remove any backlash in the assembly.. Tighten the set screws of the pulley to the end of the lead screw using a 5/64 hex-head wrench.

10 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 9 2) Remove the two screws that attach the Y axis bearing block to the machine (block that supports the end of the shaft) using a 5mm hex-head wrench. 3) Attach the Y axis motor/bracket assembly to the bearing block using the (2) M6 X 55mm Button Head Screws, (2) 5/8" OD, 1/4" ID, 1-1/4" Steel Spacers and (2) M6 Washers as shown below. Tighten assembly using a 4mm hex-head wrench. Make sure the motor is on the left and the motor cable is going downward.

11 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 10 4) Place the belt on larger pulley and make sure that the belt is still on the motor pulley. Tighten the belt by pushing the motor towards the left and tighten the 4 motor screws using a 1/8 hex-head wrench. 5) Spin the motor shaft to make sure the axes move freely with proper alignment and the belt is completely on the pulley. Adjust position of pulley on the motor if not aligned properly. Do not adjust the position of the larger pulley on the lead screw as that will put backlash in your system. 6) Place end caps on the ends of the two brackets and firmly press them in using your palm or a mallet. 7) Install a belt cover plate on the Y Axis motor bracket using the (4) #4 X 1/4 Self Tapping Belt Cover Screws and a Phillips screw driver. Please note that the belt cover is not symmetrical and that the holes are countersunk. The end where the holes are closer to the edge should go towards the right side (towards the end) of the Y axis motor bracket.

12 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 11 8) You have now completed the Y Axis assembly. Z Axis Assembly 1) Before getting started with the Z axis motor assembly, make sure that the Z axis moves as freely as possible on the entire length of travel by adjusting the gib and lubricating the ways. If you have binding in your Z axis, it will greatly affect the top speed of your z axis. 2) Remove the three existing Z axis bearing block screws using a 4mm hex-head wrench.

13 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 12 3) Mount the Z axis mounting plate oriented as shown with (3) M5 X 25 Button Head Screws and (3) M5 Washers using a 3mm hex-head wrench. 4) Mount the Z axis Motor Bracket oriented as shown with (4) 1/4-20 X 2-1/4 Button Head Screws, (4) 1/2" OD, 1/4" ID, 1/8" Steel Spacers (as washers) and (4) 1/2" OD, 1/4" ID, 1-3/4" Steel Spacers using a 5/32 hex-head wrench. 5) Mount the ¾ OD, 12mm ID, ¼ long steel spacer and 40XL motor pulley over the Z axis drive shaft making sure the keyway is lined up. You may need a mallet to make sure the

14 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 13 pulley is in as far as it can go. Place the belt over the pulley. 6) Tighten the set screw on the side of the pulley using a 5/64 hex-head wrench. 7) Place the belt over the pulley and make sure the belt is still on the motor pulley. Tighten the belt by pushing the motor towards the right and tighten the 4 motor screws using a 1/8 hexhead wrench.

15 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 14 8) Spin the motor shaft to make sure the axes move freely with proper alignment and the belt is completely on the pulley. Adjust position of pulley on the motor if not aligned properly. Do not adjust the position of the larger pulley on the lead screw as that will put backlash in your system. 9) Place end caps on the ends of the two brackets and firmly press them in using your palm or a mallet. 10) Install a belt cover plate on the Z Axis motor bracket using the (4) #4 X 1/4 Self Tapping Belt Cover Screws and a Phillips screw driver. Please note that the belt cover is not symmetrical. The end where the holes are closer to the edge is should go towards the left side (towards the end) of the Z axis motor bracket. 11) The Z Axis is now fully installed. X Axis Assembly

16 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 15 1) Place the 20 tooth pulley on the lead screw shaft on the right side of the table. Push the pulley in so that it is snug against the X axis bearing block. Tighten the set screws with a 5/64 hex-head wrench. 2) Remove the screws keeping the X axis bearing block secured to the table

17 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 16 3) Attach the X axis motor/bracket assembly to the bearing block using the (2) M6 X 120 SHCS (2) 5/8" OD, 1/4"ID, 3-3/4" Steel Spacers and (2) M6 Washer as shown below. Tighten assembly using a 4mm hex-head wrench. Make sure the motor is on the left and the motor cable is going downward. 4) Place the belt over the pulley and make sure the belt is still on the motor pulley. Tighten the belt by pushing the motor towards the left and tighten the 4 motor screws using a 1/8 hex-head wrench. 5) Spin the motor shaft to make sure the axes move freely with proper alignment and the belt is completely on the pulley. Adjust position of pulley on the motor if not aligned properly. Do not adjust the position of the larger pulley on the lead screw as that will put backlash in your system.

18 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 17 6) Place end caps on the ends of the two brackets and firmly press them in using your palm or a mallet. 7) Install a belt cover plate on the X Axis motor bracket using the (4) #4 X 1/4 Self Tapping Belt Cover Screws and a Phillips screw driver. Please note that the belt cover is not symmetrical. The end where the holes are closer to the edge is should go towards the right side (towards the end) of the X axis motor bracket. 8) The X Axis is now fully installed.

19 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 18

20 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 19 Finished! Congratulations! You have successfully installed your retrofit kit. Proceed to the Hardware Manuals for the Compact Microstepping, Pro-Series Servo or Pro-Series Microstepping Controllers for instructions on connecting your controller and setting up the software. (These manuals are on a CD and can be accessed through the FlashCut CNC Software on the Help Menu.)

21 FlashCut CNC G0619 & G0463 Retrofit Kit Installation Guide 20 Revision History Revision Date Description of Revision A First Release