Project Number: P15311

Printed Circuit Board Isolation Routing System

Maintenance ManualOriginal Publishing Date: 05/12/2014

Latest Revision Date: 12/10/2015Revision History: 5

Table of ContentsI. Safety Reminders

II. SpindleA. Changing Milling/Drilling BitsB. Unclamp Spindle Mounting Block for Repositioning Spindle

III. Vacuum TableA. Cleaning Vacuum Table BaseB. Replacing the Sacrificial LayerC. Replacing/Adjusting Vacuum HoseD. Servicing Pump

IV. Zen Toolworks CNC MillA. Cleaning and Lubrication

V. Switches Over-TravelA. Replacing Over travel Switches

VI. Vacuum SystemA. Removal and Disposal of Waste(Bag)B. Vacuum Check and Replacement(Filter)C. Cleaning out Tube

I. Safety RemindersAdd in list of PPE and location.

DANGER represents a hazard which may result in death or serious injury.

WARNING represents a hazard which could result in system failure or injury.

CAUTION represents a hazard which could result in minor injury. NOTICE indicates a situation that could result in damage to the system or product.

DANGERElectrical Hazards- System runs on 120 VAC power. Touching exposed electronics or wiring during operation can result in electric shock, causing serious injury or death.

● If exposed electronics or wiring is visually identified, use the emergency stop button to put the PCB Isolation Routing system into emergency state

● Do not touch items or perform maintenance unless system power source (120VAC power cord) is disconnected.

WARNINGRotating parts can contact and entangle fingers/hands, hair, clothing, or accessories.Traumatic amputation or severe laceration can occur.Operate equipment with guards and interlock activated

● Keep fingers/hands away from rotating parts● Tie up long hair and remove jewelry● Do not wear loose fitting clothing, dangling drawstrings, or items that

could become entangled

WARNINGRunning the components of the PCB Isolation Routing System produces heat. Specific components, such as the stepper motors, spindle, electronics enclosures, and vacuum exhaust can become particularly hot.Thermal burns can occur on contact.

● Allow stepper motors, spindle, electronics enclosures and vacuum exhaust to cool before touching

● Remove accumulated debris from vacuum exhaust and milling bed

CAUTIONCopper debris will be generated by drilling and milling operations. Debris can cause irritation and injury to eyes or lungs.

● Always wear safety glasses and face mask during operation, especially when enclosure door is open, or if performing system maintenance

NOTICEDuring operation, the PCB Isolation Routing system produces loud noise.

● Wear hearing protection, though not required, whenever possible, especially if using the PCB Isolation Routing system for extended periods of time.

II. Longdiag LD52GF-300W Air Cooled Spindle Motor

A. Changing Milling/Drilling Bits1. See SOP for instructions.

B. Replacing Spindle Motor1. Loosen screws (2) of spindle mount bracket, no more than a

single turn

2. Disconnect the power wires

3. Rotating back and forth, ease out the motor from the mounting bracket. (May be a tight fit)

4. Insert new spindle motor and ensure that the sticker is facing out5. Reconnect the power wires and ensure that the red wire

connects to the red wire and the black wire to the black wire6. Tighten the screws on the mounting bracket

WARNINGRunning the spindle and collet assembly without a bit securely installed can result in damage to the collet and spindle. Unsecured components can be thrown from the spindle and cause operator injury.

● Ensure collet assembly, with bit installed, is secure before starting spindle

III. Enclosure and Vacuum SystemA. Replacing the Sacrificial Layer on Vacuum Table

1. Home the Spindle.

2. Remove all 12 Philips screws along the perimeter of the vacuum table; this can be done with a Philips wrench.

3. Remove the old sacrificial layer and replace with a new one.4. Place the screws back in their respective holes loosely and then

tighten them in a star patter until they are firmly secure.B. Cleaning the workstation of Debris

1.Open enclosure to access machinery.2.Ensure that spindle is in home position.

3.Turn on the vacuum within the Mach3 program by pressing the “Mist On” button.

4.Use the vacuum hose to remove debris from the enclosure.

II.III.IV.V.

VI.VII.

VIII.IX.X.

XI.XII.

XIII.XIV.XV.

XVI.

XVII.XVIII.

XIX.XX.

XXI.XXII.

XXIII.XXIV.XXV.

XXVI.XXVII.

XXVIII.XXIX.XXX.

XXXI.XXXII.

XXXIII.XXXIV.XXXV.

XXXVI.XXXVII.

XXXVIII.XXXIX.

XL.XLI.

XLII.XLIII.XLIV.XLV.

XLVI.XLVII.

XLVIII.XLIX.

L.LI.

LII.LIII.LIV.LV.

LVI.LVII.

LVIII.LIX.LX.

LXI.LXII.

LXIII.LXIV.LXV.

LXVI.LXVII.

LXVIII.LXIX.LXX.

LXXI.LXXII.

LXXIII.LXXIV.LXXV.

LXXVI.LXXVII.

LXXVIII.

LXXIX.LXXX.

LXXXI.LXXXII.

LXXXIII.LXXXIV.LXXXV.

LXXXVI.LXXXVII.

LXXXVIII.LXXXIX.

XC.XCI.

XCII.XCIII.XCIV.XCV.

XCVI.XCVII.

XCVIII.XCIX.

C. Removal and Disposal of waste from Vacuum SystemI.

1.Open the back bottom door of the enclosure.2.Unplug all hoses connected to the vacuum and remove the

vacuum from the enclosure.3.Unlatch the clips holding the top portion of the vacuum to the

bottom and remove it.

4.Inside the bottom portion of the vacuum, you will see a bag. Remove the old bag and replace it with a new one.

5.Re-attach the top portion of the vacuum and re-latch the clips.6.Place the vacuum back inside the enclosure and reconnect all

hoses.

IV. Zen Toolworks CNC MillA. Cleaning and Lubricating

1.Positioning for Maintenancea) Jog three axes such that the part of the rail and screw to be

cleaned is exposed

b) For the y leadscrew this may involve removing the vacuum table

2.Leadscrewsa) Use a solvent and rag to remove old grease from

leadscrewb) Apply machine grease to a wedge spongec) Lightly pass the sponge over the leadscrew to evenly

distribute the grease

d) Pas the assembly over the screw several timese) Wiped off an extra accumulated greasef)Repeat as needed for other parts of the screw

3.Railsa) Use rag and solvent to clean debris off railsb) Lightly apply one drop of lubricating oilc) Use paper towel to distribute across the raild) Repeat as needed for other parts of the rail

V. Switches- Over-travelA. Replacing Over-Travel Switches

Note: Limit switches should be replaced only if they are faulty. If a limit switch is stuck in the on position refer to troubleshooting manual.

1.Use the appropriate Allen wrench to remove the 4-40 screw from the frame

2.Pull the switch out of its alignment hole3.Insert new switch into the alignment hole. Ensure proper

orientation4.Replace 4-40 screw and tighten with Allen wrench. Do not

overtighten.5.Reconnect the wires.

6.Check that the switch is operational by pressing on it. The appropriate light should light up on the user control panel.

VI. Vacuum SystemA. Removal and Disposal of waste bag

1.Open the back panel of the enclosure. Ensure the system is unplugged.

2.Disconnect the vacuum from the electrical plug and the vacuum tube.

3.Remove the vacuum from the enclosure.

4.Remove the top of the vacuum by pressing on the two side latches.

5.Remove waste bag from the bottom half of the vacuum tube and dispose.

6.Put in new bag. Ensure correct bag size.7.Replace the top of the vacuum, move it into the enclosure and

reconnect power cable and vacuum tube.

B. Clean Filter

1.Open the back panel of the enclosure. Ensure the system is unplugged.

2.Disconnect the vacuum from the electrical plug and the vacuum tube.

3.Remove the vacuum from the enclosure.

4.Remove the top of the vacuum by pressing on the two side latches.

5.Pull off the memory foam filter.

6.With a damp towel wipe down the filter to remove large clumps of dust.

7.In an industrial sink, run the filter under soapy water to remove

finer particulate matter.8.Rinse with water and let dry for 1 hour.9.Place filter back into enclosure.

10. Replace the top of the vacuum, move it into the enclosure and reconnect power cable and vacuum tube.

C. Cleaning out tube1.Using a flat head screw driver loosen the hose clamp that

connect the vacuum tube to the debris inlet tube.

2.Pull off the vacuum tube.3.Remove the vacuum tube and reducer from the shop vac.

4.In an industrial sink, run water through tube.

5.Drain and let dry for 30 minutes.6.Reconnect tube to the vacuum and debris inlet tube.7.Tighten the hose clamp. Do not over tighten.

Rev# Date Reason For Change Author/Title1 9/15/2015 Highlighted Changes Needed from

P14311/ Added New SectionsEmily Roberts-Sovie/ P15311 Documentation Manager

2 9/24/2015 Changed Router to Spindle Emily Roberts-Sovie/ P15311 Documentation Manager

3 10/20/2015 Revised Table of Contents, Added Info on Sacrificial Layer, Changed Safety warnings

Emily Roberts-Sovie/ P15311 Documentation Manager

4 11/5/2015 Added info on Vacuum System, Zen Tool Works, and Over-travel

Emily Roberts-Sovie/ P15311 Documentation Manager

5 12/10/2015 Added pictures. Emily Roberts-Sovie/P15311 Documentation Manager