UNIVERSAL RETROFIT KIT

Transcription

1 UNIVERSAL 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... 7 MOTOR MOUNTING TO BRACKETS - ALL KITS:... 7 Z AXIS- ALL KITS:... 9 ACME KIT X & Y AXES: BALL SCREW KIT X & Y: CLEANING / MAINTENANCE REVISION HISTORY... 28

3 FlashCut CNC Universal Retrofit Kit 2 Thank You Thank you for purchasing the FlashCut CNC Universal Series Retrofit Kit. It is powered by our own intuitive, powerful CNC control system for 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 Universal Retrofit Kit 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 Universal Retrofit Kit 4 Shipment Details ACME Kits Include: X, Y, & Z axis Unibody aluminum brackets (1) 20 tooth pulley (0.595 bore) (3) Belts, (2) 170 XL. (1) 120 XL (4) Steel Shim Washer 0.125" Thick, 11/32" Id, 13/16" OD (3) 20 tooth flanged pulleys ½ bore (6) 2x4 end caps (1 with a special cutout for top of z axis) (12) Round plugs (12) Black Oxide socket head cap screw thread, 1-1/4 L (12) Serrated-Flange Hex Locknut (2) M5 x 25mm or x 1 Socket Head Cap Screw (2) #10 steel washers (4) M8 x 35mm or, 5/16-18 x 1-1/2" thread Black Oxide Socket Head Cap Screw (2) 40 tooth large bore pulley Motors only shown for clarity. They are sold separately as part of the stepper or servo control kit.

6 FlashCut CNC Universal Retrofit Kit 5 Ball Screw Kits Include: X, Y, & Z axis Unibody aluminum brackets (1) 20 tooth pulley (0.595 bore) (3) Belts, (2) 170 XL. (1) 120 XL (4) Steel Shim Washer 0.125" Thick, 11/32" Id, 13/16" OD (3) 20 tooth flanged pulleys ½ bore (6) 2x4 end caps (1 with a special cutout for top of z axis) (12) Round plugs (12) Black Oxide socket head cap screw thread, 1-1/4 L (12) Serrated-Flange Hex Locknut (2) M5 x 25mm or x 1 Socket Head Cap Screw (2) #10 steel washers (4) M8 x 50mm or, 5/16-18 x 2-1/2" thread Black Oxide SHCS (4) Aluminum standoffs (2) 1/2 bore hand wheels (2) 1/2 bore 40 tooth pulley (2) Ball screws with ball-nuts attached (DO NOT REMOVE BALL-NUTS!) (2) Ball-nut Adapters (1 right hand thread (the longer one) & 1 left hand thread) (2) Ball screw shaft extension (2) 5/8 Flexloc nut (4) Zinc-Plated Steel Flat Washer 30mm OD, 17mm ID, 2.7mm-3.3mm Thick Motors only shown for clarity. They are sold separately as part of the stepper or servo control kit.

7 FlashCut CNC Universal Retrofit Kit 6 Stepper Control System (additional items): (1) 3-Axis, 3.5 Amp/axis Stepper Motor Driver box (3) Size 34, 424 oz-in stepper motors (3) 10' stepper 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 34, 550 oz-in servo motors with (3) 10' Servo cables FlashCut CNC Software and Manuals (CD)

8 FlashCut CNC Universal Retrofit Kit 7 Installation Motor Mounting to Brackets - All Kits: 1) Begin by removing the hand wheels from all three axes 2) Attach the 20 toothed flanged pulleys to all of your motors via setscrews using a 3/32 Allen wrench. Typically, it is best to start with the end of the pulley flush with the end of the shaft. (Warning: Do not tighten the setscrew into the keyway; the adjustment or removal of the pulley might become impossible or extremely difficult) 3) Attach the motors to the brackets with the provided by 1-1/4 Socket head cap screws and matching flange nuts using a 5/32 Allen wrench and a 7/16 socket wrench. Do not tighten the motors, they will need to slide in the mounting slots when you tighten the belt in a later step. (Note: Take notice of the motor cables, install the motors in a way that keeps the cables out of the way See Below)

9 FlashCut CNC Universal Retrofit Kit 8 4) Slip the appropriate belt over the pulley on the inside of bracket (Note: the X & Y axis get the 170 XL belts and the Z gets the 120 XL Belt) 5) Place the top plastic end cap with the corners notched (or the shorter of the 6 end caps) on the Z axis bracket leaving the bottom open. Do not install the end caps on the X and Y axes at this time. Install the 4 plastic plugs on the X, Y and Z brackets.

10 FlashCut CNC Universal Retrofit Kit 9 Z axis- All Kits: 1) Remove the top right screw from the Z axis indicator bezel. 2) Remove the graduated dial from the Z axis located right behind the hand wheel. 3) Remove the two screws from the metalized cap but leave the cap in place 4) Take the Z axis bracket, with motor attached, and slip the bracket onto the shaft. Make sure the belt goes around the shaft as seen in the picture below. Proceed by attaching the bracket to the axis via the (2) provided x 1" socket head cap screw and utilizing the (2) #10 steel washers provided. (Warning: If the screw does not thread in easily or seems to slip, you may need metric screws; the provided Z axis bracket screws were selected for Grizzly machines. Typically, M5 screws will fit metric machines) For some models, you may have to push the

11 FlashCut CNC Universal Retrofit Kit 10 entire Z axis motor bracket assembly up against the spindle housing to get the best alignment of the two screws. 5) Slip the bore 20 tooth pulley onto the z axis shaft and tighten the set screw of the pulley onto the shaft via the bottom of the bracket (Note: make sure the belt is straight and aligned between both pulleys before tightening.) 6) Make sure the motor can slide up and down and push the motor up to tighten the belt. Tighten the 4 screws holding the motor to the bracket. You should only need to use an Allen wrench due to the self locking flange nuts.

12 FlashCut CNC Universal Retrofit Kit 11 7) Check belt tension and repeat steps 11 & 12 if not tight (Note: there should be no slack in the belt, it should be firm with a slight spring) 8) Replace hand wheel and install on the shaft by tightening the set screw. 9) Spin the shaft to make sure the quill moves freely up and down with proper alignment so the belt is completely on the pulley. Adjust position of pulley if not aligned properly. 10) Place an end cap on the bottom of bracket.

13 FlashCut CNC Universal Retrofit Kit 12 Acme Kit X & Y Axes: 1) Hammer out the spring-pins using a punch on both the X & Y axes making sure to hammer from the small tapered end out (The spring pin is in the black hand wheel coupling and has a graduated dial attached. Note the orientation of spring-pin hole on the shaft to the coupling) 2) Remove the hand wheel coupling from the shaft and remove the graduated dial. 3) Attach the provided large bore 40 tooth pulleys to the hand wheel coupling via the provided set screws. This pulley replaces the graduated dial that was removed in step 3 (Note: Make sure that the pulley is pushed against the hand wheel coupling as far as possible.)

14 FlashCut CNC Universal Retrofit Kit 13 4) Remove the two screws that attach the bearing blocks to the machine (blocks that support the end of the shaft) 5) Attach the bracket with the provided M8 x 35mm or 5/16-18 x 1-1/2 screws and steel shim washers, placing a washer on the front side of the aluminum bracket. These screws will replace the screws removed in the previous step. Additionally, note how the brackets are oriented in the picture below (The oval holes on the front of the bracket on the Y axis point down - pictured on the left, and on the X axis point up pictured on he right). Make sure the belt is around the lead screw shaft before installing the screws. Holes

15 FlashCut CNC Universal Retrofit Kit 14 6) Slip the 40 tooth pulley assembly and belt onto the lead screw going through the large hole in the front of the bracket. a. Make sure the belt is not pinched between any surfaces before proceeding. b. Locate the large spring-pin hole on the coupling and align it with the shaft to point vertically (Warning: Make sure orientation is correct. Incorrect orientation may make removing the coupling difficult or impossible) c. Look through the spring pin hole to ensure alignment (Note: you may need to spin the lead screw shaft in order to align the holes and to ensure that it is all the way out of the bearing block) d. Hammer the spring pin back into place (Warning: the spring pin should go in with relative ease. If you discover that it is taking more effort to hammer the pin in than hammering it out, your holes are probably not aligned. Stop immediately and assess the problem)

16 FlashCut CNC Universal Retrofit Kit 15 7) Tighten the belt and tighten the 4 motor screws. 8) Replace the hand wheels that originally came with the machine. Spin the shaft to make sure the axes move freely with proper alignment so the belt is completely on the pulley as shown below. Adjust position of pulley if not aligned properly. 9) Place end caps on the ends of the two brackets. 10) Congratulations! You have successfully installed your retrofit kit. Proceed to the Hardware Manuals for the Pro-Series Servo or Stepper 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.)

17 FlashCut CNC Universal Retrofit Kit 16 Ball Screw Kit X & Y: 1) Hammer out the spring-pins using a punch on both the X & Y axes making sure to hammer from the small tapered end out (The spring pin is in the black hand wheel coupling and has a graduated dial attached. Note the orientation of spring-pin hole on the shaft to the coupling) 2) Remove the hand wheel coupling and graduated dial from the shaft. 3) Remove the two screws that attach the X and Y bearing blocks to the machine (blocks that support the end of the shaft) Remove both bearing blocks 4) Remove X axis gib.

18 FlashCut CNC Universal Retrofit Kit 17 5) Slide the X axis table off or over to gain access to the acme nut. Warning: The table is very heavy and it may take two people to move it. 6) Remove the X axis lead screw by unscrewing it from the brass nut. 7) Thread the X axis ball nut adapter (The longer one with the right handed thread) on the bronze Acme nut. Tighten using a wrench. 8) Tighten the set screw on the acme nut to lock in the ball nut adapter.

19 FlashCut CNC Universal Retrofit Kit 18 9) Thread the X axis ball screw assembly onto the left side of the X axis ball nut adapter and firmly tighten using a wrench. (Warning: When handling the ball screw be careful not to unscrew the ball nut all the way off of the ball screw, or you will have a lot of ball bearings rolling around your shop!) 10) Slide the table saddle assembly to the front edge of the machine (away from spindle column). 11) Remove the rubber chip guard from the rear of the saddle by removing the two screws. 12) Remove the Y axis ACME screw.

20 FlashCut CNC Universal Retrofit Kit 19 13) Remove the Y axis ACME nut by removing the screw from the top of the saddle. 14) Tightly connect the Y axis Ball Nut, Ball nut adapter and Acme nut to each other using two wrenches as you did with the X axis assembly. Tighten the set screw also. Carefully place the assembly through the base and out of the front hole of the machine. Orient the screw-nut assembly so that the Ball Nut is towards the front of the machine and the Acme Nut is towards the column of the machine as shown.

21 FlashCut CNC Universal Retrofit Kit 20 15) Using the screw from the top of the saddle, Screw the bronze ball nut adapter back into place. Make sure the lead screw is pretty well centered in the front hole. Firmly tighten. 16) Slide the X axis Table back on and move both the X & Y axis to a location where the ends of the ball screws are accessible and sticking out at least 2. The table is very heavy. You may need two people to move it. 17) Replace and adjust the Gib so the table slides freely with no play

22 FlashCut CNC Universal Retrofit Kit 21 18) Using two wrenches, assemble the X and Y axes bearing block assembles using the ball screw extension shaft (The X and Y are identical), (2) Zinc Plated Steel Flat Washers (30mm OD, 17mm ID, 2.7mm-3.3mm Thick) and the 5/8 flex-lock nut. This is a bearing assembly, so make sure it is snug with no play, but the shaft is free to rotate. Do not over-tighten. 19) Screw in the two set screws so that they protrude into the ID of the ball screw extension shaft by about 1/16.

23 FlashCut CNC Universal Retrofit Kit 22 20) Using the set screws as temporary threads, carefully screw the ball screw into the ball screw extension shaft until the ball screw bottoms out. Next, tighten the set screws extra firm and inspect to make sure there is no play in the joint. (Note: the assembly should be snug without linear play in the bearing block. If the assembly is too tight it will be very difficult to spin the shaft and may result in bearing damage. A little resistance is ok, however; if it is too loose there will be backlash or play in the block, resulting in poor cutting performance). Thread lock may be used to ensure a positive connection. 21) While holding the bearing block in the correct orientation, carefully turn the ball screw extension shaft until the bearing block is in contact with the casting or table. Temporarily secure using the original screws that came with the machine. If the bearing block does not line up with the screw, loosen the bronze nut via screw on the top of the saddel, adjust the position of the bearing block and tighten the screw again.

24 FlashCut CNC Universal Retrofit Kit 23 22) Attach the bracket with the provided M8 x 50mm or 5/16-18 x 2-1/2 screws which will replace the original screws in the bearing block. Start by placing a steel shim washer on a screw and feeding the screw through the bracket mounting hole. Then, slide the aluminum standoff onto the screw on the other side of the bracket. Next, loosely tighten the screw through the bearing block into the machine. Repeat for the other mounting screw. Finally, tighten the entire assembly into place. Note how the bracket is oriented. (The motor is on the left of the front Y bracket and on the right of the X table bracket.)

25 FlashCut CNC Universal Retrofit Kit 24 23) Slip the 40 tooth pulley and belt onto the lead screw through the large hole in the front of the bracket. Make sure the belt is not pinched between any surfaces before proceeding. The belt should be completely on the toothed pulley as shown below. Tighten the set screw against the flat on the ball screw extension shaft. 24) Tighten the belt and tighten the 4 motor screws.

26 FlashCut CNC Universal Retrofit Kit 25 25) Place one of the axis handles with the ½ bore on the ball screw extension shaft and tighten the set screw to the flat of the shaft. Rotate the shaft to make sure the axis moves freely with proper alignment so the belt is completely on the pulley as shown above. Adjust position of 40 tooth pulley or motor pulley if not aligned properly. 26) Install end caps on both ends of the bracket. 27) Replace the rubber chip guard on the back of the saddle.

27 FlashCut CNC Universal Retrofit Kit 26 28) Install the X axis bearing block assembly and motor housing by repeating the steps for installing the Y axis assembly. 29) Congratulations! You have successfully installed your retrofit kit. Proceed to the Hardware Manuals for the Pro-Series Servo or Stepper 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.)

28 FlashCut CNC Universal Retrofit Kit 27 Cleaning / Maintenance Switch off the main power before any cleaning and any maintenance. Also, pull the power plug in order to prevent inadvertent starting. Clean the machine regularly of all chips with a brush or vacuum cleaner (Do not use compressed air) to protect the mechanics against early wear. Lubricate the ways when needed, and the ball-screws every hrs using machine oil.

29 FlashCut CNC Universal Retrofit Kit 28 Revision History Revision Date Draft Description of Revision A Manual Released B Manual Revised C Complete rewrite for new retro-kit D Manual Revised E Manual Revised for updated components F Manual Revised for updated components. Seperated out Limit Switch Instructions G Edits on Packing List H Orientation of Y axis ball nut reversed I Changed 100XL pulley to 120XL Pulley