G0704 RETROFIT KIT - FlashCut · PDF fileFlashCut CNC G0704 Retrofit Kit Installation Guide 2...

G0704 RETROFIT KIT

Midwest Office 444 Lake Cook Road, Suite 22

Deerfield, IL 60015

Phone (847) 940-9305 Fax (847) 940-9315

www.FlashCutcnc.com

© 1998-2013 FlashCut CNC, Inc.

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 X AXIS ASSEMBLY ................................................................................................................................................... 12 Z AXIS ASSEMBLY .................................................................................................................................................... 15 FINISHED! ............................................................................................................................................................... 18 REVISION HISTORY .................................................................................................................................................. 19

FlashCut CNC G0704 Retrofit Kit Installation Guide 2

Thank You

Thank you for purchasing the FlashCut™

CNC G0704 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: www.FlashCutCNC.com

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.

3. E-mail: [email protected]

E-mail is the most organized way to convey your issues to our support

staff. In your e-mail, 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 e-mail support, you may call one of our telephone support

numbers. We will normally respond to your call within 24 hours.

Phone: (847) 940-9305 (9:00 AM-5:00 PM, CST, M-F)

Fax: (847) 940-9315


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.


Shipment Details

Kit Includes:

(3) Unibody Aluminum Brackets (X,Y,Z)

(2) 20XL Pulley

(3) 10 XL Pulley

(1) 40XL Pulley

(2) 130XL Timing Belt

(1) 150XL Timing Belt

X-axis Bracket Hardware

o (2) M6 X 40 Button Head

Screw

o (2) 1/2" OD, 1/4" ID, 9/16"

Steel Spacer

o (2) M6 Washer

Y-axis Bracket Hardware

o (2) M6 X 55 Button Head

Screw

o (2) 5/8" OD, 1/4" ID, 1-1/4"

Steel Spacer

o (2) M6 Washer

Z-axis Bracket Hardware

o (4) M5 X 16 Button Head Screw

o (4) 1/2" OD, 0.192" ID, 3/16" Steel Spacer

o (4) M5 Washer

Motor Mounting Hardware

o (12) 10-32 X 5/8 Button Head Screw

o (12) 10-32 Serrated Lock Nut

(3) Belt Covers (X,Y,Z)

(12) #4 X 1/4 Self Tapping Belt Cover Screws

(6) 1-1/2 X 3 Plastic End Caps

(1) Y-axis Shaft Spacer, 3/4 OD, 10mm ID, 3/8 L Steel Spacer

(1) Z-axis Pulley Set screw, M16 X 16mm 1.5mm Pitch

Motors only shown for clarity. They are sold separately as part of the stepper or servo control kit.


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)

Pro-Series 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


Pro-Series 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 encoder feeback

(3) 10' Servo motor cables


X, Y and Z mounting hole locations for G0704.


Installation

Motor Mounting to Brackets

1) Begin by removing the hand wheels from The X and Y 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.


3) Attach the motors to each of the three brackets with the provided 10-32 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


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)

Y Axis Assembly 1) 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.

X Y Z


2) Place the 3/8” spacer and a 20 tooth pulley on the Y Axis Shaft making sure the keyway is

still in place.

3) Pull the table towards you so the Y axis lead screw is exposed and simultaneously push

the pulley towards the bearing block taking any slop out of the pulley/bearing block

assembly. Tighten the set screws of the pulley to the end of the lead screw using a 5/64”

hex-head wrench.


4) 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.

5) 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.

6) 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.


7) Place end caps on the ends of the two brackets and firmly press them in using your palm or

a mallet.

8) 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.

9) You have now completed the Y Axis assembly.


X Axis Assembly

1) Remove the screws keeping the Y axis bearing block secured to the table

2) Rotate the handle on the left side of the table clockwise to take up any backlash in the

table.

3) Place the 20 tooth pulley on the lead screw shaft on the right side of the table so that it

aligns with the keyway.

4) 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.


5) Attach the X axis motor/bracket assembly to the bearing block using the (2) M6 X 40

Button Head Screws, (2) 1/2" OD, 1/4" ID, 9/16" 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.

6) 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.

7) 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.


8) Place end caps on the ends of the two brackets and firmly press them in using your palm or

a mallet.

9) 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.

10) The X Axis is now fully installed.


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) Unscrew the black cap using a 3mm hex-head wrench to expose the top end of the Z

axis lead screw.

3) Mount the Z axis bracket oriented as shown with the motor cable towards the back of

the machine. Install the assembly with (4) M5 X 16 Button Head Screws, (4) 1/2" OD,

0.192" ID, 3/16" Steel Spacers and (4) M5 Washers using a 3mm hex-head wrench.

(Note that if you have a limit switch kit, it would be easiest to install the Z axis switch

at this point to avoid disassembly.)


4) Screw in the 40XL motor pulley onto the top end of the lead screw and place the belt over the

pulley. The pulley should bottom out on the locking nut of the leadscrew.

5) Install the M16 set screw over the pulley and tighten with an 8mm hex-head wrench.

6) 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.


7) 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.

8) Place end caps on the ends of the two brackets and firmly press them in using your palm or a

mallet.

9) 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 right side (towards the

end) of the Z axis motor bracket.


10) The Z Axis is now fully installed.

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.)


Revision History

Revision Date Description of Revision

A 12-31-12 First Release

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