Vertical router CNC Machine User`s Manual
Contents
1. esses 9 2 Safety Features Emergency Stop Button sss 10 2 Safety Features Interlock Guard Switch sssssssss 11 2 Safety Features Interlock Guard Switch cont sss 12 Installation 3 Lifting and moving your CNC machine sss 13 3 Choosing a site for your machine cea ederet idet ot bre a hot 16 3 Removing Protective Coatings and Packaging sess 17 3 Connecting to the machine sese i duties itae t re he o o t PD Udo tuia 18 3 Microrouter Electrical Pannel cccccssssssssscsssssssssssssssersssserseeserseeseesaesensansanes 18 3 Dust Extraction amp General Wood Precautions sess 19 Machine Control 4 Operators Panel Axis limit overide eee 20 4 Front Machine Operators Panel eene 21 Tool Change operation 9 Pertoiming a TooHODarges aas a utra Dd e Rp an REM 22 Maintainance 6 Planning Procedure for Maintenance Work eee 24 6 MaiitenanmceScheglle cda secte dede altae baeo drt ds dee subi a 25 7 Maintenance of the Router Motor sse 26 9 Maintenance LOO ecoute tear ets detonate belt tate e oe eto n uda 2 Technical Support and Troubleshooting G JECAMIGCAL oup DOPDssssassctia b t obi R 29 10 Troubleshooting Cutt2. Correct method Incorrect method of fitting pairs of collar eyebolts of fitting pairs of collar eyebolts eyebolts with link and Swivel eyebolts with link and Swivel Hoist Rings Hoist Rings Fitting pairs of collar eyebolts The plane of the eye of each of a pair of collar eyebolts should ideally be within 5 of the plane containing the axes of the two eyebolts This may be achieved by the insertion of shims which should not exceed in thickness half the pitch of the relevant screw thread or by machining the contacting surface but not the underside of the eyebolt collar Under no circumstances should the eyebolt be over tightened in an attempt to achieve correct alignment Care should also be taken to avoid an alignment whereby the application of the angular load tends to unscrew the eyebolt from its seating Denford Vertical Router User manual Page 13 3 Lifting and moving your CNC Machine All 4 lifting points must be used and slings adjusted to ensure equal loading on all 4 lifting points The included angle between any pair of chains must not exceed 60 requiring sling lengths of 2100mm each Safe working load for each sling to be no less than 0 26 tonnes A ALL EYEBOLTS AND SHACKLES REMAIN THE PROPERTY OF DENFORD LTD AND SHOULD BE RETURNED WITH SHIPPER Denford Vertical Router User manual Page 14 3 Lifting and moving your CNC Machine When your Vertical router has been delivered you must make sure the stabil
3. ENSDENFORD Vertical router CNC Machine f User s Manual approved t SE C Lus d Videb Co 1 U d fe f a k ts FduCathion Su gehmiczl suppor L P http www denford com 1 Contact Information Address Telephone Fax e mail Technical Support 1 Notes Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK General Enquiries 01484 728000 01484 728100 for sales enquiries contact sales denford co uk for machine servicing enquiries contact service denford co uk for customer services contact customerservices denford co uk Support Forum at www denford co uk e mail customerservices denford co uk Telephone Denford Customer Services 01484 728000 For international dialling 44 and remove first 0 in city code Monday to Friday 8 30am 4 30pm GMT Denford Vertical Router User manual Page2 1 Notes Denford Vertical Router User manual Page 3 1 Contents Preface Page TOON FACT IMOR MN ANON tieggetisestc ste testis otan desertus bits ie natal ata 2 puer er eee E 2 EC ONON sefesbetodus died dads deten a temet idu eaten tide uim 4 DWV AIAN NOU G GS sa cate tac E eg cdi wheel a eames Renae oncaeid 5 T ADOUCIDIS MINGA iaieineea E aes 6 1 Introducing your Vertical ROUGE eerie ep ten ird od 7 1 Before BEGINNING t Setup wssiatas t dott Sues ne Prot n E i 8 Safety 2 Safety Features Overview and Precautions
4. tool number may be listed at the beginning of your CNC program Close the safety guard door and clear the software message window to resume your machining Page 23 6 Planning Procedure for Maintenance Work SA Warning Caution Wear safety glasses and a suitable respiratory mask when cleaning the machine Warning PX Never open the safety guard door and enter the working area when the spindle or machine axes are moving Warning al X Caution If the cutting tool has been recently used it may still be HOT Denford Vertical Router User manual When carrying out any maintenance pay special attention to the following items ensuring safe and correct working procedures in accordance with Health and Safety Regulations in your establishment Before starting any maintenance work define the task and obtain the information relevant to carry out the maintenance Also define the time period needed to complete the task to obtain the correct tools and order any spare parts if required During the maintenance work period display a suitable notice stating that the machine is under maintenance and should not be used until the notice is removed Safety must be a priority when carrying out any maintenance work Covers and safety guards that are removed during the maintenance work must be replaced after the task is completed All work must be carried out by suitably qualified personnel Never attempt to acc
5. The correct tool profile appropriate to the finish required is being used Check that the cutting edges are sharp and undamaged 4 Any machine drive belts are correctly tensioned and not slipping 5 The tool profile is held securely in the tool holder or collet which in turn is held securely in the machine spindle When using double sided tape the billet keeps lifting from the sub table sheet of MDF Check the surface of the sub table is clean and smooth before attempting to add the billet Routinely clean tape adhesive residue from the sub table Check tape adequately covers all parts of the billet Check the sequence in which the various parts of your design are machined For example machine any small or etched surfaces before cutting pieces completely out from the billet If you keep the largest solid area of the billet attached to the sub table for as long as possible you reduce the likelihood of the billet moving during machining Denford Vertical Router User manual Page 30 10 Troubleshooting VR CNC Milling Software Your screen may display the message Error 50 Mint 3 28 Disconnect or similar depending on the hardware fitted The password used to access the Machine Properties window can be changed by the user Remember that the default password listed here will not be recognised if you have changed it If you change any passwords we recommend you make a note of them in the Notes section in eithe
6. Y rails should be examined for signs of compacted dust build up along the line of contact If dust build up is apparent the end wipers on the X axis carriages and the top wiper on the Y axis carriage should be removed and any dust vacuumed out of the bearing housings In extreme cases to ensure effective removal of the dust it may be necessary to cycle the machine back and forth several times along the full length of the axes Any residual dust in the bearings will be transferred on to the rails from where it can be removed using a clean dry cloth after ensuring that the machine is stationary The wiper assemblies should then be replaced before the machine is put back into service At 12 monthly intervals the full procedure for cleaning the X and Y bearing housings should be carried out irrespective of any apparent build up of dust on the rails Note Compressed air must never be used for any purpose on your Vertical Router and no lubricant of any type should be used on the X and Y axes bearings and rails Denford Vertical Router User manual Page 25 Warning Hy X Caution Wear safety glasses and a suitable respiratory mask when cleaning the machine NA Warning Never open the safety guard door and enter the working area when the spindle or machine axes are moving Warning i7 3 X Caution If the cutting tool has been recently used it may still be HOT Denford Vertical Router User manual 7 Maint
7. alter any specifications and documentation without prior notice No part of this manual or its accompanying documents may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of Denford Limited All brands and products are trademarks or registered trademarks of their respective companies Copyright Denford Limited Version 1 04 03 All rights reserved a a s ia B k z i L we a E l E E a i PpO m Videp Co EIS i Language This manual is written using European English Questions and Comments Any questions and comments regarding this guide should be referred to the following e mail address customerservices denford co uk Alternatively telephone Denford Customer Services on 01484 728000 and ask to speak to a member of our Technical Authoring Team Fducaheon Su gehniczl Sapp http www denford com
8. denford co uk Denford Vertical Router User manual Page 6 1 Introducing your Vertical Router Congratulations on your purchase of a Vertical Router series CNC machine In this manual you will learn how to setup and use your Machine correctly and safely M FOIT DEN VERTICAL F Your Vertical Router is a full three axes CNC router with a large work area allowing machining of materials approaching 1380x1040mm in size Suitable for all levels of education and training it is manufactured to meet industrial standards Together with rapid traverse rates of up to 20m min your Vertical Router is the ideal partner for intensive 3D applications such as the F1 Team in Schools CAD CAM Design Challenge www f1inschools co uk Land Rover4x4 challenge Your Vertical Router is designed with you in mind making the processes involved both safe and easy to use Main Features Designed specifically for Education and Training Manufactured to industrial standards Programming via International Standards Organisation format incorporating controls such as FANUC CE approved for safety Capable of cutting common resistant and prototyping materials including Wood MDF Wax Plastics and Acrylics Links to various CAD CAM software packages Totally enclosed high visibility interlocked guard Feedrate override control Dust extraction Denford Vertical Router User manual Page 1 Before Beginning to Setup Be
9. software limits which can only function after the machine axes have been homed referenced Hardwired limits are set outside the software limits to protect the machine from overtravel prior to homing or failure of the home switch In the event that ee always be the machine travels onto the hardwired limit switch on any axis it will be iac when necessary to re home the machine axes initiating the home commands and particularly The axes can be homed by using either the pre programmed Home All the Home All Command or by individually homing each axis sequentially Command where there may be large components in the path of the machine when homing X and Z Axis followed by simultaneous homing of X and Y Y simultaneously In these instances the axes should be The Home All command homes the axes in the following sequence The following is an emergency procedure only to be used if the machine homed individually has travelled onto a hardwired limit It is not intended for routine homing in order to avoid potential collisions As a general rule Z To home the axes depress the Limit Switch Override Button on the Control should always be Panel while initiating the relevant home command on the P C homed first Denford Vertical Router User manual Page 20 4 Front Machine Operators Panel The spindle speed must be overridden using the CNC machine control software please refer to your separate CNC Machine Control Software
10. to clear the error With the button still depressed home the machine then release the axis overide button See page 18 Denford Vertical Router User manual Page 33 11 Specification of Vertical Router Safety Features Manual operation totally enclosed interlocked safety guard door Emergency stop button Toolpath graphics to verify part programs prior to machining Mechanical Details Table size 1380mm x 1040mm 54 x 507 Travel X axis 1200mm 47 Travel Y axis 800mm 32 Travel Z axis 150mm 6 Dimensions Machine width 2200mm 87 Machine height 1920mm 767 Machine depth door open 1780mm 70 Machine depth door closed 800mm 32 Weights Machine weight 458 KG 1007 Ib Electrical Details Mains supply required 220 240Volts 50Hz 13Amps 110 120Volts 60Hz 15Amps Spindle motor 1 68 kW 2 25HP Spindle Speeds 0 21 000RPM Axis servo motors Performance Rapid traverse rate up to 20 m min 780 in min Denford Vertical Router User manual Page 34 11 EC Declaration of Conformity The responsible person Mr P T Harkness Business Name nacen Denford Limited LO Birds Royd Brighouse West Yorkshire HD6 1NB United Kingdom Declares that the machinery described Manufacturer aeienesdeatei titt ten iue Denford Limited Model Name eeeeeeeee Vertical Router Series CNC
11. workstation may allow easier access to the various vents connectors and switches on the machine cabinet when required Do not place the machine in a position which allows any of the cabinet vents to be covered Ensure all cables pipes and flexes are routed to avoid the possibility of users tripping over them Dimensional Data x Machine Width A 2795mm 110 electrical cabinet open i Machine Width B 2280mm 89 Machine Height 1920mm 76 Machine Depth D 750mm 30 without door handles TE E 800mm 32 with door handles F 1750mm 69 cabinet door open Denford Vertical Router User manual Page 16 3 Removing Protective Coatings and Packaging Once your Vertical Router has been sited and connected electrically the protective coatings and transit packaging must be removed to prepare the machine for running 1 The protective plastic sheeting on the guard windows must be removed and the glass and perspex cleaned with an antistatic cleaner 2 Tie wraps may be used in the working area of the machine to prevent movement of components during transit Additional items from your order may also be supplied packaged inside the working area 3 To gain entry to the working area of the machine power must be supplied to the machine in order to release the switch unit that locks the safety guard door Note that the switch unit will also remain locked when the emergency sto
12. 11 Glossary TOOL OFFSET tns When machining allowances must be made for the size of tools being used since they all differ in length The tool offset is the amount the Z value must be moved or offset so that all the different cutting tool tips used line up with each other so they can all be used by one CNC file See OFFSET TRAVERSE usstuussesidusi Movement of the cutting tool through the 3 machine axes between cutting settings ge Standard Windows text only file extension txt WORK WORKPIECE The actual material being machined The work is sometimes referred to as the billet or stock WORKPIECE DATUM Used as a zero reference point on the real billet All machining co ordinates originate from this point when offset files are used WORKPIECE OFFSET A file containing X Y and Z values that can shift the entire three dimensional co ordinate based grid system used by the CNC machine See OFFSET WORDE arcando A combination of a letter address and digits used in a CNC program ie G42 M04 etc VIRTUAL REALITY A fully interactive three dimensional computer based simulation of a real world object or event Z TOOL OFFSET 455i see Tool Offset Denford Vertical Router User manual Page 39 12 Notes Use this page to make a note of any parts of the software you have changed or configured for example common tooling set ups machine parameters changes to installation paths or password
13. Denford Limited cannot accept responsibility for any damage and or loss that may occur through incorrect maintenance of your Microrouter Compact 4 Foreseen Use of Machine Your Vertical Router is designed for routing hard and soft woods certain ceramics and plastics In each case the appropriate tooling speeds and feeds should be used as recommended by the material supplier Your Vertical Router is not intended for use with any ferrous or metallic materials Facility is provided for dust extraction Always use the machine coupled to a vacuum system Do not attempt to use your Vertical Router for manual operations Do not remove the router head and attempt to use it independently of the machine If you have any doubts and or questions regarding the specification servicing or features of your machine please contact Denford Customer Services Denford Limited reserves the right to change the specification and or operating features regarding this CNC machine without notice or documentation Denford Vertical Router User manual Page 5 1 About this Manual Using this manual Disclaimer Screenshots Language Contact This manual provides information describing how to transport site setup and operate the basic functions of your Denford Vertical Router CNC machine including any operational features of hardware specific to the Vertical Router series This manual does not provide any information regarding the software packages
14. Machine Serial Number please refer to warranty card and or machine casing conforms to the following directives The Machinery directive 98 37 EC The LVD Directive 73 23 EEC The EMC directive 89 336 EEC ANGIE TONOWINGStANGAlOS suec oeesitut isum Remind OR where applicable usscseenetuiutt e USE udine SEM ER cubil etenim Ubo ub cea tastes Ue EIER RUEE and complies with the relevant eseeeeeennnnnnnnnnnnnnnnnnnnnn nnne health and safety requirements c cccscsssssecssssesssseessesssessesseseessesssessesseseseseasees SIG AU e xsedelecun iet ntn leo dnd Position within company oenior Design Engineer SS Rss RENT DU Denford Limited Birds Royd Brighouse West Yorkshire Document DC RC 1 01 HD6 1NB Denford Vertical Router User manual Page 35 11 Vertical Router Series Noise Level Test Results Test Report No NL VR1 01 Machinery Manufacturer Denford Limited Machinery Type Model Vertical Router Series The Vertical Router can be supplied with dust extraction The test was carried out with and without this option using a P amp J Dust Extraction Equipment Meter ref Realistic 42 3019 1 off Denford Vertical Router CNC machine 1 off P amp J Dust Extraction 1 off EX Ei Diagram Key A B C and D are measurement D positions 1 metre from the machine Ex dust extraction Test Conditions opindl
15. Microrouter Electrical Panel Warning A Never attempt to access the electronic hardware systems of the machine with the mains power switched ON Note that hazardous voltages can still exist immediately after switching off the power If the machine has previously been switched on wait at least 5 minutes before attempting to open the electrical panel cover plate NX Denford Vertical Router User manual Your Vertical Router electronics are located at the left hand side of the machine Should you need to access the electrical panel turn the isolator to O off and wait at least 5 minutes before opening the cabinet door using the key provided Page 18 3 Dust Extraction amp General Wood Precautions Your Vertical Router is designed to run with a dust extraction system used to remove any potentially harmful airborne wood dust particles from within the working volume of the machine The dust extraction system used should be independently tested to ensure that airborne dust around the machine is kept well below the maximum exposure limits set by law Denford can supply dust extraction systems for your machine or you may wish to connect your own system When emptying the dust extraction system base unit or removing dust from the working area of the machine or components always wear suitable respiratory protective equipment that is CE marked Other personal protective equipment such as eye protection overalls and gl
16. User s Manual for details regarding this feature The spindle speed can be overridden between 50 and 120 spindle Speed and or Feedrate override changes will only be registered when an actual spindle speed or feedrate is being applied by the CNC control software Activating an emergency stop will also trigger the interlock guard switch This will prevent a closed safety guard door from being opened Feedrate Spindle speed Override Control The feedrate of the Vertical Router can be manually overridden during a machining operation using the potentiometer control dial fitted to the right end of the machine The feedrate can be overridden between 0 and 150 The Spindle speed can be overridden between 0 and 150 To increase rotate the control dial clockwise To decrease rotate the contro dial counter clockwise The degree of adjustment applied is displayed in the CNC machine control software Mains Power Switch To supply power to the CNC machine Turn the red switch on the electrial panel to 1 To cut power to the CNC machine turn the switch to the 0 position off Do not cut the mains power when machining or processing of any operational instructions is taking place Note that cutting the machine power will trigger the closing of the interlock guard switch This will lock a closed safety guard door in position preventing access to the machine working area The interlock guard switch will automatically
17. ce completed Denford Vertical Router User manual Page 28 9 Technical Support Denford Limited provides unlimited telephone and e mail Technical Support on this CNC machine to registered users On site visits by our engineers may be chargeable Please refer to the information held in your separate Warranty pack for specific details Before contacting Denford for support please read your hardware and software manuals and check the Denford websites for support Internet access technical support and Forum sections Denford UK htto www denford co uk Denford USA htto www denford com When you request support please be at your CNC machine with your hardware and software documentation to hand To minimise delay please be prepared to provide the following information e CNC Machine Serial Number from the machine ID panel Registered user s name company name The CNC machine control software name and version number from the Help About menu option The wording of any error messages that appear on your computer screen if applicable Alist of the steps that were taken to lead up to the problem Alist of any maintenance work that has been carried out on the CNC machine Contact Details Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK Telephone 01484 728000 Fax 01484 728100 E mail customerservices denford co uk Technical Support Monday to Friday 8 30am 4 30pm GMT For i
18. ch allowing temporary removal of the guard lock feature For manual interlock release the power supply must be switched off This work should only be carried out by authorised personnel If the machine is left unattended before this procedure has been completed a prominent warning must be posted on the machine informing users that the safety guard door lock is not operating and that the machine must not be used Page 11 2 Safety Features Interlock Guard Switch cont 1 Locate 2 cap head screws in the Tee slot in the bottom section of the L H door frame 2 Remove cap screws This will allow the door to open leaving the switch actuator engaged in the interlock switch 3 To release actuator from switch turn lever on top of switch clockwise to the unlocked position position a 4 To reset switch turn lever anti clockwise to reset position and insert release tool Position B Turn lever anti clockwise to locked position 5 Ensure that 24v supply is restored and that switch is in the locked position before checking functioning of interlock switch 6 With machine powered up and E Stop button depressed engage actuator in switch The actuator should be retained in the switch Releasing the E Stop button should release the actuator T Refit actuator to door and close door before returning machine to users Denford Vertical Router User manual Page 12 3 Lifting and moving your CNC Machine SAFE LIFTING
19. d To release a closed emergency stop button push in and turn the button clockwise until it springs back out After releasing an emergency stop you may need to reset any CNC control software messages and home the CNC machines axes Denford Vertical Router User manual Page 10 2 Safety Features Interlock Guard Switch A closed safety guard door cannot be opened when The machine is switched off ie not in use Torelease the interlock guard switch supply power to the machine The emergency stop button is fully pressed in To release the lock push in and turn the emergency stop button counter clockwise until it springs back out to its ready position Machining is taking place The interlock guard switch will release when the machining operations have been completed and the machine controlling software is operating in Jog Mode Warning X A Danger of serious injury Do not let unauthorised personnel use the machine when the guard lock feature is disabled Ensure the guard lock feature is switched back on as soon as possible Denford Vertical Router User manual An interlock guard actuator is fitted to the front machine door The switch unit itself is attached to the bottom of the door frame The lock must be manually released to enter the working area when the 24 volt circuit has failed and the door is clamped electrically An override facility is provided on the interlock guard swit
20. e 37 11 Glossary JOG CONTROL Manual movement mode for the machine axes using very small pre defined movements called jog steps One stepped movement is applied per movement key button press MC ODE aussen A miscellaneous code function in a CNC program used to indicate an auxiliary function ie coolant on tool change etc MACHINE DATUM A fixed zero reference point set by the machine manufacturer The machine datum is used to define the co ordinate based grid system of the CNC machine All machining co ordinates originate from this point However this point can be temporarily moved MACHINE OFFSET The workpiece offset file used with VR and real CNC machines MOT e Manual Data Input A method used for manually inserting data into the control system ie Desktop Tutor qwerty keyboard etc MODAL sariden Modal codes entered into the controller by a CNC program are retained until changed by a code from the same modal group or cancelled ING t Numerical control ORFOE T coan tagen Combination of two types of file the workpiece offset and the tool offset Used to describe the workpiece datum a zero reference used on the CNC machine to ensure machining occurs in the correct place on the billet Offsets are used to shift parts of the three dimensional co ordinate based grid system used by the CNC machine PART DATUM insane Used as a zero reference point in a CNC file All machini
21. e other around the shaft Denford Vertical Router User manual Page 22 Warning Never open the safety guard door and enter the working area when the spindle or machine axes are moving When two of more tools are used in the same CNC file Your new tool MUST be refitted to router motor and machine head in exactly the same position used when originally configuring its Z tool offset value Denford Vertical Router User manual NA 9 Performing a Tool Change Performing a Manually Requested Tool Change Before beginning a manual tool change operation we recommend you home the Y and Z machine axes and drive the X axis to roughly the mid point on its axis When the axes are in this position the maximum amount of free space will be available in the working area allowing easier access to the tooling Performing an Automatically Requested Tool Change during the running of a CNC program On reading a tool change operation line in your CNC program all three machine axes will move to their home positions via an intermediate point if programmed At this point the software will pause the CNC program and a message window will be displayed prompting you to manually change tools Always wait for the spindle and machine axes to stop moving before attempting to open the safety guard door Replace the current tool number with the tool number specified in the software message window the tool profiles allocated to each
22. e speed 21000 RPM Axis speed 8000 mm min Ambient background noise 60 dB A Test Results Sound Levels dB A Position Condition 21 000 RPM Vacuum ON 21 000 RPM NO Vacuum Vacuum ONLY Denford Vertical Router User manual Page 36 11 Glossary BIELE dederis ere ere Asmall usually rectangular bar of wood or metal in an intermediate stage of manufacture CAD a atahstututeditu mb Computer Aided Design the use of a wide range of computer based tools that assist engineesrs architects and other design professionals in their design of real world objects Qn M Computer Aided Manufacture software that is capable of creating tool cutter paths in a number of different axes for different CNC systems Usually taking the design input from CAD system CIN o Computer Numerical Control a computerised system of hardware and software which controls the movement of a machine tool DRIVE eaa The controller unit for a disk system DRY RUN uibensc nis An operation used to test how a CNC program will function without driving the machine itself DWELL ussnsntwaduimin A programmed time delay B i Gee eect rire cet The mode used for altering the content of a CNC program via the Desktop Tutor or qwerty keyboard END OF BLOCK SIGNAL The symbol or indicator that defines the end of a block of data The equivalent of the pc return key ERROR aie iid The deviation of an attained value
23. enance of the Router Motor Failure to Start should the motor fail to start check that the prongs on the mains power cord plug are making good contact inside the machine back panel socket Check the on off switch on the router motor Is set to the on position Check for any blown fuses referring to the electrical diagrams delivered separately with your machine replace them and rectify the cause Lubrication The router motor has been lubricated with a sufficient amount of high grade lubricant for the life of the unit under normal operating conditions No further lubrication is necessary Brush Inspection At approximately 100 hours of use Denford recommends you take or send your motor to your nearest authorised router motor service station or Denford agent to be thoroughly cleaned and inspected worn parts replaced where necessary recharged with fresh lubricant if required reassembled with new brushes and performance tested Any loss of power before the above maintenance check may indicate the need for immediate servicing of your router motor Do not continue to operate the motor under these conditions Page 26 8 Maintenance Log Date of Name of personnel Details of maintenance carrying out the maintenance work work maintenance completed Denford Vertical Router User manual Page 2 8 Maintenance Log Date of Name of personnel Details of maintenance carrying out the maintenance work work maintenan
24. enford Machine Link cable If the cable is bad communication will not occur Try using a different computer to connect to the Vertical Router Check for help on the technical support FAQ and download sections of the Denford websites and or contact Denford Customer Services for further assistance Any optional equipment fitted to your Microrouter Denford Vertical Router User manual Page 32 10 Troubleshooting Mechanical Problems The safety guard door cannot be opened In most cases this is because the interlock guard switch has locked the door in the closed position The interlock guard switch is mounted behind the front lower machine panel accessible from beneath the front of the machine Check the following 1 Mains power is reaching the CNC machine Check the mains plug is fitted to an available power socket and the socket is switched on Check the Router on off keyswitch mounted on the right end panel of the machine cabinet has been turned to the on I position 2 The emergency stop button is not pressed in To release push and turn the button clockwise until it springs back out to its ready position 3 No CNC program is running Wait for all machining operations to finish then switch the software to operate in jog mode 4 If there is an emergency stop error in the control panel box in VR CNC milling and the emergency stop button has been released If your machine has an Axis limit overide switch press and hold
25. ess the electronic hardware systems of the machine with the mains power switched ON Hazardous voltages can still exist immediately after switching off the power If the machine has previously been switched on wait at least 5 minutes before attempting to open the electrical panel access plate When replacing electrical components ensure the new parts are of Suitable replacement specification All work completed on the machine whether progressive or preventative should be logged to ensure a complete service record is available for future referral We recommend the following two pages are used to log any maintenance tasks undertaken When maintenance work has been completed check that the replaced or serviced parts work correctly before allowing general operation of the machine Page 24 6 Maintenance Schedule At one weekly intervals the bellows covers on the bottom Z axis rail should be withdrawn to allow any dust which has ingressed to be removed by vacuum cleaner Any dust which has settled around the top Z axis rail should be similarly removed At one monthly intervals grease should be applied to the nipples on both the top and bottom Z axis bearings until grease is seen to exude from the bearings and the Z axis ball nut A further 3 shots of grease should then be applied to purge the bearings of any dust which may have ingressed Remove any excess grease and dust with a clean cloth At 3 monthly intervals the X and
26. fore beginning to set up your Vertical Router please check your separate order documentation making sure that all items have been delivered to your establishment Any missing or damaged items should be reported to Denford Customer Services as soon as possible The following equipment is supplied as standard with your Vertical Router CNC machine see note left Vertical Router CNC machine Note that the precise specification of your CNC machine will depend on any options selected at the time of ordering see below 1x Set of Workholding Clamps 1 4 Collet and 1 2 Collet e 1 xAllen hex keys pack e 2x Router head spanners External USB Cable 1 4 Dia Ball Nose Cutter e 1x Vertical Router warranty pack UK Machines only 1x CD ROM containing Denford VR CNC Machine Control Software and manuals and Machine user s manual 1x VR CNC Machine Control Software Security Key dongle or Flash screen software supplied on removeable media The following optional equipment may also be supplied with or ordered for your Vertical Router CNC machine Additional Software CAD CAM Offline CNC Machine Control e CNC Machine Control software security keys dongles or licence disks PC workstation Dust extraction unit 4th Axis Programmable Rotary Fixture inc QuickCAM 4D Site Licence F1 in Schools Car Manufacturing Fixture for both D and R Type Cars 4th Axis F1 in Schools Car Manufacturing Conversion K
27. from a desired value O CODE srinanca linai The programming language understood by the machine controller FEEDRATE oreen The rate in mm min or in min at which the cutting tool is advanced into the workpiece For milling and drilling the feedrate applies to the reference point on the end of the axis of the tool gh An arrangement of instructions or information usually referring to work or control settings FORMAT mionnan The pattern or way that data is organised ENG ones tanien iidri th FANUC Miller file extension fnc Contains G and M codes describing the machine and cutting operations OCODE Spngn Enana A preparatory code function in a CNC program that determines the control mode HARDWARE Equipment such as the machine tool the controller or the computer HOME s susnsniwdini dn Operation to send the axes of the CNC machine to their extreme limits of movement Defines the co ordinate based grid system of the CNC machine Commonly referred to as homing the machine or sending the machine to its home position INCREMENTAL Incremental programming uses co ordinate movements that are related from the previous programmed position Signs are used to indicate the direction of movement INPUT nocca The transfer of external information data into a control system INTERFACE nutus The medium through which the control computer directs the machine tool Denford Vertical Router User manual Pag
28. ing Problems enn 30 10 Troubleshooting VR CNC Milling Software esses 31 10 Troubleshooting VR CNC Milling Tool Offsets esses 33 10 Troubleshooting Mechanical Problems ssssss 34 Appendix 11 EC Declaration of Conformity scntecscescverndasnstachven sd etu Fut utor tette EE Rburade 35 11 Vertical Router Series Noise Level Test Results 36 M GOS SIN oraaa a 37 NOE E E 40 Denford Vertical Router User manual Page 4 1 Warning Notices A Warranty Disclaimer The Warranty on your Vertical Router will be invalidated if any modifications additional ancillary equipment is fitted or any adjustments are made to the controlling devices without prior notification from Denford Limited Please refer to the information held in your separate Warranty pack for specific details Do not carry out any portable appliance testing PAT on any of the supplied equipment 4 Maintenance Disclaimer Always obtain permission from the person responsible for machinery in your establishment before accessing the electrical control panel or Vertical Router machine casings to carry out any maintenance work All work must be carried out by personnel suitably qualified for each maintenance task to avoid damage to both the machine systems and the maintenance personnel
29. ising feet are in the raised postion prior to moving Your Vertical Router weighs 458 KG 1007 Ibs Take suitable precautions when moving the router see text below Denford recommends that four or more persons should be used to move the Vertical Router one at each corner of the machine as illustrated in the diagram below Always use sensible lifting precautions in accordance with Health and Safety Regulations in your establishment Do not tip the CNC machine whilst lifting Points to Note Do not use a forklift to move this machine To transport your Vertical Router over long distances a lorry fitted with a tail lift must be used Denford Vertical Router User manual Page 15 3 Choosing a Site for your CNC Machine site your machine in a well ventilated room The Vertical Router is a floor mounted machine so it should be sited on flooring suitable to with stand the weight of the machine plus operator and computer equipment Ideally the user will operate the machine when standing at its front with a clear view of both the machine working area through the transparent guard window and the personal computer being used as the controller unit which should be angled towards the user oufficient room should also be provided for effective maintenance to be carried out around the machine itself In particular leave enough space for opening the electrical panel door at the L H side of the cabinet Positioning the PC on a movable
30. it Various tooling packages Courseware project books and project material packages Video conferencing system Additional and or on site training courses On site CNC machine commissioning Denford Vertical Router User manual Page 8 2 Safety Features Overview and Precautions Safety Features Overview The following safety features are standard on your Vertical Router Emergency stop button e Manually operated totally enclosed guard door with interlock switch Option on control software to check CNC programs using toolpath graphics prior to machining Automatic tool retraction and spindle stop for tool changing Safety Precautions Safety is very important when working with all forms of machinery but particularly when working with CNC equipment due to the hazardous voltages speeds and forces that exist in the hardware Follow the rules below at all times when using your Vertical Router General Safety Precautions Wear clothing suitable for machine operation and follow the safe working procedures in place at your establishment Do not place any objects so that they interfere with the guards or the operation of the machine Never try to clean the machine if any part of it is rotating or in motion Always secure the work on the table or in a fixture or vice Ensure that the correct cable for the power source is used Ensure the mains power is switched off and preferably unpl
31. ng co ordinates originate from this point PART PROGRAM A list of coded instructions which describes how the designed part or component will be manufactured The part program is also referred to as the CNC file program or G and M code program du EM Personal computer POST PROCESSOR A file or setting that contains instructions for a CAM system detailing how to create CNC code that can be understood by a particular CNC system e g VR CNC Milling PROGRAM on A systematic arrangements of instructions or information to suit a piece of equipment RAPID TRAVERSE hes movement of the cutting tool through the 3 machine axes between cutting settings REFERENCE POINTS The machine has 3 reference points used in setting the limits of movement for its slides axes REMOVEABLE MEDIA A computerised storage medium that is not permanently attached to the system e g Floppy Disk Flash Memory Card USB Memory Key CD DVD disc ROUTER MOTOR The removable cutting head motor Also referred to as the machine head REM Serer eee a errr eee er Revolutions per minute rev min a measure of spindle speed SIDES T The 3 machine axes see axis SPINDLE SPEED The rate of rotation velocity of the machine head cutting tool measured in RPM SOFTWARE iicet Programs tool lists sequence of instructions etc Denford Vertical Router User manual Page 38
32. nternational dialling 44 and remove first 0 in each city code Denford Vertical Router User manual Page 29 10 Troubleshooting Cutting Problems The part is being cut at an incorrect depth Check the validity of the following 1 The Z value entered in the tool length offset 2 The Z value entered in the workpiece offset file 3 The number size used for defining the depth of cut used in your CNC program 4 The sign or used for defining the depth of cut used in your CNC program If your workpiece datum is aligned with the upper surface of your billet any Z values cutting into this billet will have a minus sign The machine begins cutting the part at the wrong location Check the following 1 The workpiece and tool offset files have been configured and applied successfully If no offsets have been configured the CNC machine will use the machine datum as the starting point for any machining co ordinates read 2 The X and Y values entered in the workpiece offset file are correct Poor surface finishes are obtained Check the following 1 The correct feedrates and spindle speeds are being used appropriate for the cutting tool profile and type of material being machined Recommended feed and speed values should be available from your tool and material supplier Note that running incorrect feeds and speeds can severely shorten the life expectancy of your tools 2 The billet being machined is securely clamped 3
33. oves should also be considered 4 General Wood Dust Safety Precautions Obtain material safety data sheets from your material suppliers and enforce the recommended precautions Be aware that certain hardwood and man made material dust particles such as oak and MDF could contain known carcinogens Please consult your materials supplier for further details Wood dust particles that remain inside the working area of the Vertical Router after a part has been machined should be removed using a vacuum NEVER USE A PRESSURISED AIRLINE for this purpose When emptying the dust extraction system base unit wear suitable respiratory protective equipment that is CE marked Other personal protective equipment such as eye protection overalls and gloves should also be considered continued Denford Vertical Router User manual Page 19 3 Dust Extraction amp General Wood Precautions Wood dust particles on the floor can cause slipping This should be monitored by the operator and removed before it becomes a hazard Launder overalls regularly provide good washing facilities with hot and cold water soap and towels and encourage a high standard of personal hygiene The following health problems are among the effects associated with exposure to wood dust particles Skin disorders Obstruction to the nose e Rhinitis Asthma Nasal cancer 4 Operators Panel Axis limit overide The machine traverses are limited by
34. p button is fully pressed in Warning Aerosol based or flammable products must not be used to clean your CNC machine To avoid the potential risk of ignition explosion ensure that any trapped solvent vapours can exit fully from any enclosed areas on the CNC machine Wait at least 1 hour before attempting to operate the CNC machine Denford Vertical Router User manual Warning Potential risk of ignition explosion Do not use any aerosol based or flammable products to clean your CNC machine Carefully read and follow any instructions or notices included with cleaning products Page 17 3 Connecting to the machine Warning A Do not connect cables between any electrical hardware with the mains power switched on Since this could cause serious damage to components inside your CNC machine and or service personnel Balls Mains Supply Your Vertical Router is delivered with 3 core mains cable 1 5mm per core and a standard 13 Amp plug Mains supply required 220 240 Volts 50 Hz 13 Amps Note Machine must NOT be connected through an RCD The supply should be fitted with a 16Amp motor circuit breaker Type D opindle motor 1 68 kW 2 25 HP 21000 RPM Communications For guidance and diagrams on connecting the communication cables to you computer using a USB or RS232 please install VR milling software and refer to the How to connect to the machine located in the help section 3
35. perties window will open You can configure the type name of CNC machine attached to your pc and any COM port settings from this window 4 The Machine Properties window will open with the name of the current active machine highlighted and its listing expanded The name of the active machine in the software must match the name and version of your real CNC machine this information is printed on the CE identification panel usually applied to one of the machine cabinet end panels If the correct machine name is NOT listed as the active machine right click over the required machine name title to display a pop up menu Click Make Active then click OK and restart the VR CNC Milling software Reopen the Machine Properties window to check that the changes have been applied Denford Vertical Router User manual Page 31 10 Troubleshooting VR CNC Milling 9 In the Machine Properties window click the Communications property title Change the COM Port setting to match the number of the COM port being used by your pc Note that Compact d Be the hardware resources IRQ etc are those specified in the configured using the Windows Control Panel Set the Baudrate to the highest options available in the value possible according to the specifications outlined in your Machine Properties computer or motherboard manual Baudrate is the speed at window which data can be transferred through your COM ports Se
36. r this or your CNC Control Software manual 1 Your computer communicates with your Vertical Router using the Denford Machine Link cable Check the Denford Machine Link cable RS232 or USB is securely plugged into a valid COM USB port on the computer Note that COM ports are sometimes labelled as serial ports Identify whether the COM port being used is labelled as COM1 or COM2 The opposite end of this cable is securely plugged into the RS232 port located on the right end panel of the machine cabinet 2 Check all mains power connections are correctly fitted and secure Power up the Vertical Router using the red on off switch If no power is present switch off the mains supply then wait at least 5 minutes before attempting to access the Microrouter Compact electronics The Vertical Router electrical panel is mounted on the left side of the machine cabinet Check the condition of the on off switch and any fuses For more information X 3 Start the VR CNC Milling software from the default installation click Start Programs Denford VR Milling The name of CNC machine that can be directly controlled by the VR CNC Milling software is displayed on the main program titlebar From the main menubar at the top of the VR CNC Milling software screen click Setup Setup Machine Parameters You may be required to enter a password The default password Is denny Type the password and click OK The Machine Pro
37. reopen when power is next supplied to your Microrouter Compact Emergency Stop Button The emergency stop button is a circular red push button Pressing the emergency stop button has the effect of stopping all axes and spindle movements immediately To active an emergency stop press the button in fully until it clicks The emergency stop button will remain closed continuing to cut all power to the machine drives until the release sequence is performed To release a closed emergency stop button push and turn the button counter clockwise until it sorings back out then wait 6 seconds for the machine systems to reset unlocking the safety guard door Denford Vertical Router User manual Page 21 9 Performing a Tool Change otandard Tool Change System The tool change system supplied as standard with your Vertical router comprises four elements i The router motor with attached threaded shaft bored to allow fitment of the cutting tool and collet assembly ii The collet and nut assembly a tapered tubular split metal collet held inside the locking nut which threads directly onto the router motor threaded shaft Different sized collets and collet adaptors are available to allow use of cutting tools with varying shank sizes Use a 4mm allen key to release the bracket used to secure the router motor on the machine head plate Use the two C spanners to tighten the locking nut onto the threaded shaft one around the nut th
38. s etc Denford Vertical Router User manual Page 40 Contact Details UK Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK For General Enquiries UK Telephone 01484 728000 Fax 01484 728100 E mail info denford co uk For Sales Enquiries UK Telephone 01484 728000 Fax 01484 728100 E mail sales denford co uk For Customer Services and Technical Support UK Telephone 01484 728000 Fax 01484 728100 E mail customerservices denford co uk Technical Support Monday to Friday 8 30am 4 30pm GMT For international dialling from outside the UK Add 44 to the number and remove the first 0 from each city code Contact Details USA Denford Inc 815 West Liberty Street Medina Ohio 44256 USA For Customer Services and Technical Support USA Telephone 330 7253497 Fax 330 7253297 E mail service denford com Technical Support Monday to Friday 8 30am 4 30pm Eastern y f Disclaimer Please note that due to nature of hardware and software developments the specifications and features of this product can change without notice The information contained in this guide is correct at the date of printing only Nov 2005 If in doubt please refer to your order and delivery invoices No liability can be accepted by Denford Limited for loss damage or injury caused by any errors in or omissions from the information supplied in this manual Denford Limited reserves the right to
39. t the Stop Bits to read 2 Stop Bits are the data signals sent after each data character has been transferred Click the OK button to save and apply any changes made to the property listings 6 Check the LED display status on the NextStep Motion Control Board referring to the descriptive list to determine the condition of the board A problem with this card can cause problems with communications The board is located in the top left corner of the electrical panel Call Denford Customer Services for assistance Warning Risk of electric shock Note that in order to check the readout the CNC machine must be powered up with the electrical panel exposed Exercise extreme caution do not touch any live electrical components since damage may occur to the hardware or technician inspecting the equipment Remember to shutdown the CNC machine then replace the electrical panel cover plate on completion of this step 7 Check the COM port on your computer is functioning correctly Consult your IT person or Computer Support Centre for help with these issues Check the COM port settings in Windows by accessing the Device Manager Check the com ports enabled and labelled properly in the computer BIOS Check the physical COM port itself functional For example Windows and the BIOS may show that the COM ports are fine but the port is not seen by any external devices 8 When all else fails Thoroughly check the condition of the D
40. ugged before starting any maintenance work on the machine Post a notice informing others not to use the machine since it is undergoing maintenance Hazardous voltages can still exist immediately after switching the machine off Always wait at least 5 minutes before accessing the CNC machine electronics f power fails turn off the mains power switch immediately and unplug the machine from the mains power socket Service the required areas at the intervals specified in this manual see the Maintenance section for further details Observe caution when adding or removing machine tooling When an emergency stop is required press the circular red emergency stop button located on the right side of the CNC machine front panel Denford Vertical Router User manual Page 9 2 Safety Features Emergency Stop Button A circular red emergency stop button is located on the right hand side of your Vertical Router located below the feed and speed overide buttons When pressed it has the effect of stopping all axes and spindle movements immediately The guard interlock switch will also close When the safety guard door is in its closed position this will prevent access to the working area of the CNC machine To active an emergency stop press the button in until it clicks The emergency stop button will continue to cut all power to the machine drives and continue to keep the interlock switch closed until the release sequence is performe
41. used to control your Vertical Router please refer to the help section in the machine control software Please note that the Electrical Diagrams for your Vertical Router are not included in this manual they are delivered separately in the standard equipment box supplied with your CNC machine If you have any doubts and or questions regarding the specification servicing or features of your Vertical Router please contact Denford Customer Services Denford Limited reserves the right to change the specification and or operating features regarding this CNC machine without notice or documentation Please note that due to the nature of hardware and software developments the specifications and features of this product can change without notice The information contained in this manual is correct at the date of printing only September 2006 No liability can be accepted by Denford Limited for loss damage or injury caused by any errors in or omissions from the information supplied in this manual Please note that any screenshots are used for explanation purposes only Any numbers wording window or button positions may be different for the configuration of the CNC machine control software being used to control your Vertical Router This manual is written using European English Any comments regarding this manual should be marked for the attention of our technical authoring team and referred to the following e mail address customerservices
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