Bilby3D 6040 Router Manual

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1 Bilby3D 6040 Router Manual Contents: 1. Router Assembly 2 2. Connection to a Computer 4 3. Installing and configuring Mach Testing Your Machine Watercooled Spindle Operation Installing a Smooth Stepper USB Installing an Smooth Stepper Ethernet Installing a USB Wireless Handwheel Troubleshooting and Common Issues 15 This manual applies to the 6040 series of routers. Variants are 800W or 1500W watercooled spindle with 3 axis or added 4 th axis and tailstock. For the latest information go to or phone 1800-three-D ( , internationally) Bilby3D.com.au Page 1 29/10/2014 1

2 1. Router Assembly 1. Assemble Gantry Slide the gantry over the gantry carriage. This is much easier with two people as the fit is so tight the gantry needs to be kept square while sliding it over the brackets. If doing by yourself, lie the gantry on the bed (put a piece of packing foam down first to avoid scratches), slide it squarely onto the brackets, then rotate the gantry to the upright position. Loosely add screws to each side, we suggest doing the ones underneath first. Do final tightening. 2. Add Stepper Motors Mount stepper motors with spacers and tighten. The Z (vertical) axis motor will be a little shorter and have an aluminium angle mounting bracket use the countersunk Philips head screw to attach the black plastic cable chain to this bracket. The other motors are identical and interchangeable. Tighten the set screws in the couplers. Test each axis moves easily by turning the knobs on the outside of the stepper motors 3. Mount Spindle Mount the spindle and it s mounting block with the four large Allen bolts Connect the harness wires to the spindle On Air cooled models, these will be two push on crimped terminals (shown right) On water cooled this will be an aviation style screw connecter align the plug with the notch, push on and tighten the screw ring to fix in place. Bilby3D.com.au Page 2 29/10/2014 2

3 4. Connect the main cable chain Move the leads to one side within the cable chain so you can access the fixing screw through the cable chain with a Philips head screwdriver. Tighten. 5. Connect leads to the controller box For each axis and the spindle, check the notch in the plug aligns with the socket, push in and tighten the screw ring. If you have the 4 th axis option, it will be marked A Axis on the box and be separate to the X, Y and Z sockets Connect the Parallel Cable and plug in the power chord 6. Water cooled models only attach the water cooling system Slip the hoses over the spigots on the top of the spindle and tighten the locking nuts Push the end of one of the tubes over the spigots on the water pump Place the end of the other tube (the return) in the bucket. Hold it to the inside of the bucket with waterproof tape (Duct Tape) or clothes peg, plastic peg or clamp. Partially fill a bucket with water and submerge the pump in the bucket Attach power to the pump use a high level of caution with water and electricity: make sure that the power connector is well away and higher than the water. It is also a good idea to have a loop in the power cord so any water running along the cord will drip off at that point it would have to run uphill to reach the power socket. Bilby3D.com.au Page 3 29/10/2014 3

4 2. Connection to a Computer Once you have screwed all the aviation style connectors on the router wiring harness in to the control box and plugged in the power chord, you are ready to connect the controller box to the computer or smooth stepper The diagram below shows the basic setup. If your computer has a parallel port, you can connect directly to the router control box. The Parralel Port should be set to EPP mode, the setup of the EPP mode can be done through the main board/motherboard BIOS. It is best to use a PC to run the software. An old Windows XP machine should be sufficient, given that a minimum of other software is installed. Some programs run constantly in the background and cause the signal rate of the parallel port to fluctuate. Similar problems can occur with the use of notebooks and their power regulation functions. With notebooks, an external controller is recommended. Users with Windows 64-bit versions will also have problems with their parallel port drivers. In these cases, an external Smooth Stepper breakout box, USB or Ethernet available from Bilby3D, is recommended. These boxes also help to eliminate electrical noise and interference More information is available in the Mach3Mill user manual Bilby3D.com.au Page 4 29/10/2014 4

5 3. Installing and Configuring Mach3 We strongly recommend Mach3 CNC software. This fully featured software is designed to run anything from small to enourmous machine and so has many options and features we will not attempt to cover them here, you can download a full 157 page manual here: You can download a demo here: The demo version of the software is the same as the full version except it has a limitation of 500 lines of G-Code, but it is sufficient to get your machine to jog around and check that everything is installed and operational prior to buying a license. Bilby3D offers Mach3 licenses at a discount price of $195 at the time of writing at Follow the prompts to install your software. When completed, restart your computer. Warnings: Be sure to configure your software correctly. If you do not, it could damage the machine or become dangerous. 1. After restarting the PC a. You can download a profile for your machine from simply save the.xml file to your Mach3 folder, usually c:\mach3\ and it will appear on the list when you click the Mach3 Loader Icon on your desktop. This then means you do not have to configure the software as detailed in this section b. Alternatively, choose the MACH 3 MILL icon on the desktop to start Mach If you have already installed the Smooth Stepper Driver (See Sections 4 and 5), you will be presented with a screen asking you to select Normal Printer Port Operation, or one of your installed Smooth Stepper Drivers. 3. Now let s get on with configuring the software: a. Go to Menu > Config > Select Native Units b. Choose MM s and click OK Bilby3D.com.au Page 5 29/10/2014 5

6 4. Go to Menu > Config > Ports and Pins. Select the Port Setup and Axis Selection Tab and check the configuration is the same as the ones highlighted in red. Click Apply if you make any changes. 5. Select the Motor Outputs tab and make the configuration match the ticks, crosses and pin numbers show in the applicable pictures below. a. Enabled: This column turns the entire row of setting on or off b. Step Pin # - This is the number of the wire that tells the motor to make a step c. Dir Pin # - This tells the controller box which wire tells it which direction to travel d. Dir Low Active Tells the controller whether high or low signifies that direction. If you think an axis is moving in the wrong direction, toggle this setting to change it. e. Step Low Active Tells the motor whether to make a step when the voltage in the wire goes high or low. f. A motor not moving may be because the step pin number is incorrectly set, or because the Step Low Active needs to be toggled. g. Click Apply if you make any changes. Bilby3D.com.au Page 6 29/10/2014 6

7 For a 3 axis Router, use the following settings: For a 4 axis router, use these settings: Bilby3D.com.au Page 7 29/10/2014 7

8 6. Select the Input Signals tab and make the settings match those below: Click Apply and OK if you make any changes. Note: - If the machine fails to run and the software constantly gives an Emergency Mode message, even when you ve clicked Reset, toggle the Active Low column by clicking on it so that it shows a green arrow. - Sometimes the setting wants to be Pin Number Make sure this works, not just for OH&S, but also because it demonstrates a basic level of communication between the software, the controller box, and back again Bilby3D.com.au Page 8 29/10/2014 8

9 7. Go to Menu > Config > Motor Tuning Change the numbers above for Steps per mm, Velocity, Acceleration, Step Pulse Width and Direction Pulse Width. Then click SAVE AXIS SETTINGS Then select the Y and Z axis and save the settings so the parameters match above. Please note: If you find that the machine is producing output at the wrong scale, change the Steps per mm setting accordingly. 8. Go to Menu > Config > General Config Set the debounce interval to 2500 This setting helps to filter out electrical noise and interference You can change the value as high or low as you like if you need to Bilby3D.com.au Page 9 29/10/2014 9

10 4. Testing Your Machine 1. Power off your machine and the control box 2. Connect the control box to the computer, screwing in the retaining screws 3. Check that the Motor Spindle knob is fully rotated clockwise 4. Power up the computer and controller box 5. Open Mach3Loader 6. Test the reset button Check that the Emergency Stop button on the controller box is not pressed. The button is of the self locking type, so once pressed it stays in until released. You release by turning the know in the direction of the arrow The software usually starts with the Reset button in the bottom left of the screen flashing red/green Click the reset button. It will continue flashing, but the message to the right of the button should disappear Once the system is happy, deliberately press the Emergency Stop button on the controller box The software should then show that the E-Stop button has been pressed. Release the button on the controller box, then press the Reset button in the software 7. With the switch Drive turned on on the controller box, try to turn the black wheels on the back of each axis motor. The X, Y and Z motor should only move if really pushed, indicating that the motor has power and is holding 8. Now you re finally to see the machine move! Let s check the movement of each axis. Press tab on your keyword to display / hide the Mach3 jog controls Use the jog buttons (or the equivalent on your keyboard) to move each of the axis. Check that the positive and negative movement matches the directions shown If one movement is incorrect, repeat the instructions in Software Configuration part 4, through the Motor Outputs Tab, toggle the Dir LowActive box Bilby3D.com.au Page 10 29/10/

11 5. Water Cooled Spindle Controller (VFD) Operation The controller the box has been set up by the factory, and you should just need to press the green run button. The 400 number displayed (395 in the picture) is Hz, referring to the frequency sent by the VFD to the spindle. Hz RPM , , , , ,000 Use the arrow pad until you have the Hz LED light up, turn the knob clockwise until the readout reaches 400, then press RUN, the spindle will start up. It will accelerate from standstill to the set frequency. Press the red button to have the drive stop, the motor will freewheel and come gradually come to a stop. If the display shows RES, then the emergency stop switch is depressed and should be reset by turning the mushroom shaped button clockwise. The FOR/REV (sometimes labelled DIR) button will reverse the direction of the spindle. Only do this when the spindle is not rotating! The other buttons and functions are for setting and recalling programs. You can crate a program which runs at a one speed for a length of time, then changes to another speed for another length of time. We do not find these functions very useful, but if you experiment and find a use for this, we d love to know. Bilby3D.com.au Page 11 29/10/

12 6. Installing a USB Smooth Stepper 1. Open a web browser and go to 2. Scroll down the page until you see the heading USB Driver for the USB SmoothStepper Select the driver that matches your computer. Currently you can choose from SmoothStepperUSBDriver _Win8_Only.zip OR Smooth StepperUSBDriver zip 3. Unzip this file to somewhere on your computer (like the desktop) 4. Open the computer control panel and navigate to the Device Manager. On some computers you will need to go through Control Panel > System > Hardware Tab to get in there 5. Find the Smooth Stepper on the list of devices and right-click and select Update Driver 6. Point this to the zip file you downloaded. Now your PC should be able to recognise the Smooth Stepper every time it is plugged in 7. Now to install the plugin for Mach3 to see the Smooth Stepper. 8. Further down the warp9td webpage you will see the heading PlugIns 9. There are instructions here you should read if you have problems. We will skip ahead but please go back to this website if you have difficulty 10. Select a plugin, we suggest starting at the top, currently SmoothStepper_v17fe.zip 11. Unzip the file and click the.m3p file inside. The file will run itself, install a.dll file to the Mach3/plugins directory and delete the install file. 12. Now when you start Mach3 it should come up with a dialog headed Motion Control Hardware PlugIn sensed!! asking you to select between Normal Printer Port Operation or the plugin you just selected. 13. If you have problems with the plugin you just installed, download another one. You do not need to delete the previous one, the new one will just be added to the list. Notes: - If you start the Mach3 software without the Smooth Stepper connected (or the windows driver installed) it will crash - If you disconnect the Smooth Stepper while Mach3 is running, it will crash - If you change between Smooth Steppers, the software will detect a different serial number and complain, just proceed and choose any default settings offered. - The Top Green LED signifies the USB is connected - The Middle Red LED will be constantly on, until it handshakes with the Mach3 software when it will start to flash as data is transmitted - The Bottom Blue LED shows the power is on Bilby3D.com.au Page 12 29/10/

13 7. Installing an Ethernet Smooth Stepper 1. Open a web browser and go to 2. Under the heading Ethernet SmoothStepper you will see the latest plugin for Mach3 3. Unzip this file to your Mach3 plugins folder, c:\mach3\plugins by default 4. Connect an Ethernet cable between your computer and the Smooth Stepper (ESS) 5. Plug the USB cable from the ESS box to your computer 6. Now when you start Mach3 it should come up with a dialog headed Motion Control Hardware PlugIn sensed!! asking you to select between Normal Printer Port Operation or the plugin you just selected. 7. If you have problems with the plugin you just installed, download another one. You do not need to delete the previous one, the new one will just be added to the list. Notes: - If you start the Mach3 software without the ESS connected (or the windows driver installed) it will crash - If you disconnect the ESS while Mach3 is running, it will crash - If you change between ESS, the software will detect a different serial number and complain, just proceed and choose any default settings offered. - Now the top and bottom light on the ESS should light up when connected to your computer Bilby3D.com.au Page 13 29/10/

14 8. Installing a USB Wireless Handwheel When you first get the handwheel, find the zip-lock bag containing an aluminium tube and screw and attach to the large dial on the handwheel, do up tightly. Installing the handwheel is very straight forward. 1. Download the plugin for Mach3 2. Copy this file to your Mach3 plugins folder, c:\mach3\plugins by default 3. Plug in the USB wireless adapter for your handwheel 4. Start Mach3 and press Tab to reveal the Jog Controls 5. Select the axis you wish to move on the handwheel and turn the large knob on the handwheel. 6. The numbers in the Mach3 software for the selected axis should then change accordingly. 7. Select and different axis and repeat. Note: The handwheel really only controls the Mach3 software, not the router itself. If the numbers in the software display change, but the machine does not move, there is a problem between the software and the router, not a problem with the handwheel. Bilby3D.com.au Page 14 29/10/

15 9. Troubleshooting and Common Issues For the latest FAQ and Troubleshooting tips, please visit our support website: support.bilby3d.com.au How do I Jog My Router? - To get your router to move around manually, when in the Mach3 software, click Tab on your keyboard to display the Jog Controls - Make sure the box above the word cont. is lit up yellow. Click the button marked Jog Mode to change this. If you do not want to move the router continuously but in steps, select Step, but change the number above to something noticeable or the machine might appear not to move. My router moves perfectly when jogging but behaves erratically once the spindle is running. - This is caused by the inevitable electrical noise created by the running spindle - Change the debounce interval in Config>General Settings. This filters out much of the noise. - One cause is insufficient grounding of the machine and controller box. Use a multimeter to try to measure any voltage difference between the router body and ground. - Are you running a Smooth Stepper? The Smooth Stepper USB is more rugged in these situations than a Parallel port connection, and the Smooth Stepper Ethernet is better again. - Changing the cable, whether USB or Parallel, for a different one changes the natural harmonic frequency of the cable and so often solves the problem. Bilby3D.com.au Page 15 29/10/

16 Copyright 2014 Bilby 3D Pty. Ltd. Website: Support: support.bilby3d.com.au Australian Freecall: 1800-three-D ( ) International: Head Office: PO Box 62, Bega, NSW 2550, Australia Sydney Showroom: 25/566 Gardeners Rd, Alexandria, NSW, 2015 Bilby3D.com.au Page 16 29/10/

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