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CNC Router Manual v1 2
INTRODUCTION
IMPORTANT
Read and understand these instructions for use
before you operate this automated equipment.
Viewing Options
Attributes
Declarations
Use of Machine
Disclaimer
AXYZ International Inc. makes every effort to provide
accurate information about the CNC Router. However,
since each machine configuration varies considerably,
AXYZ International Inc. cannot guarantee the accuracy
or completeness of this manual or accept responsibility
Purpose of this publication
for any errors or omissions.
To help you safely and effectively
operate the machine
A training support tool Copyright
This manual contains proprietary information that is protected by
copyright. All rights are reserved. No part of this manual may be
About its use
repurposed by any means without prior consent
It takes about an hour to read through this entire publication. from AXYZ International Inc.
Doing so will help ensure your understanding
of the machine operations.
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Viewing Options
Notebook or Desktop
Use the arrow keys or mouse
to step through the pages.
No scrolling required.
Scan the page thumbnails.
Click the ICON to display them.
Navigate via the bookmarks.
Shown in the example
Tablets
Optimized for the iPad Air
These examples show the manual
being displayed with the Acrobat Reader.
Other viewers may offer different options.
Attributes
Graphics
The drawings and illustrations in this documentation help to expand and enhance the text. They are representations only and are not
drawn to scale. For accurate drawings, refer to the mechanical and electrical drawings provided by AXYZ International.
Style Conventions
Specific text styles indicate various types of information.
Bullets indicate listed items where the specific order is not significant.
Numbered items indicate a systematic procedure, process, or an ordered list.
Bolded text emphasizes important information.
OEM Literature
AXYZ International provides copies of OEM (Original Equipment Manufacturer) literature as received from suppliers.
Select information about OEM devices may be incorporated. For more detailed information, refer to the OEM literature.
If the OEM literature for a specific device is not included, please contact that manufacturer directly for the information.
Suppliers often revise and update their publications. Contact the manufacturer directly for the most current information.
Extended Content
The onscreen version of this publication offers links to web-based content.
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Declarations
Conformity Noise Emissions
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Use of Machine
Environmental Considerations
Climate Control
DO NOT expose the machine to extreme variations in temperature
and humidity as this could decrease both performance and longevity.
Operate and/or store the machine at room temperature
and in a dry, contaminant free environment.
Lighting
Ensure the entire working area of the machine is well lit.
Ventilation
Consider the ventilation system requirements
according to the type and amount of material being processed.
Consult the SDS and MSDS to determine any special requirements.
Corrosion
Some of the machine components are subject to corrosion in an unfavorable environment.
DO NOT expose the machine to free flowing water-based fluids or lubricants.
DO NOT expose the machine to acidic or alkaline substances.
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Intended Use
Machines are designed to machine or cut:
wood, engineered wood, plastics, aluminum and non-ferrous metals,
metal composite materials, steel using a plasma cutting head, vinyl,
paper, cardboard, foam, fabric, rubber, and similar materials.
Foreseeable Misuse
These machines are NOT designed to cut or machine:
stone or similar products, glass, phenolic, and related materials.
Disposal
The majority of the machine components can be recycled.
Only qualified persons should disassemble the machine.
Recycle or dispose of the components according to your municipal guidelines.
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Do not use the machine to cut extremely hard material, such as carbides.
Doing so could damage the machine and/or injure you.
Plastics All plastics, including the hard plastics such as polycarbonate, cast or extruded acrylics, corrugated, and UHMW
Wood Most natural types of wood, other wood-based materials, including MDF, plywood, and other composite boards
ACM - Most types of ACM, including those with stainless steel or titanium
SAFETY
IMPORTANT
Read and understand this entire section
before you operate this automated equipment.
Operator Qualifications
Processing Materials
Protective Features
Hazard Placards
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Rules of Operation
Follow these rules to help ensure your safety when operating the machine.
Failure to comply with these Rules of Operation could result in death or serious injury.
DO NOT operate the machine after the consumption of alcohol or the use of narcotics.
DO NOT attempt to brake or slow down the machine with your hands or any foreign device.
DO NOT use pressurized air, washers, or free flowing liquids to clean the machine.
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Guidelines
These guidelines will help you to operate the machine safely.
Ensure that all operators have access to and understand these instructions.
Read, understand, and comply with the warning labels on the machine
and the mandatory signs posted in the work area.
Ensure that anyone near the machine knows how to perform an emergency stop.
Only authorized persons should enter the working area while the machine is in operation.
Look for and remove any loose parts, work pieces, or tools left in the operating area,
before starting the machine.
Keep the working area clean and free of obstructions, such as waste material.
When machining combustible material, keep the correct type of fire extinguisher accessible.
Keep chemicals and flammable material away from electrical equipment and moving components.
Verify that the emergency stop pushbuttons, machine guarding, and all other safety devices
are functioning correctly.
Ensure that the cutters, knives, and/or engraving tools are in good working condition.
Operator Qualifications
It is your responsibility to ensure that only qualified persons operate this CNC router.
Complete a course of training that is acceptable to and approved by AXYZ International and your company.
Be knowledgeable about the basic design, operation, cleaning, and maintenance of the CNC router.
Be knowledgeable about the types of material that are processed with the CNC router.
Be knowledgeable about the control devices, such as the warning lights, visible and audible signals, and safety systems.
Be able to operate the CNC router in a safe manner, according to the safety rules and guidelines,
and to maintain the required operational logs and records.
You must:
Processing Material
Its important to understand the potential hazards associated with processing certain materials.
Read and understand the following information concerning the varied conditions.
Combustibles
When processing materials such as cardboard, MDF, or other wood products,
the risk of a fire exists. Ensure access to a suitable fire extinguisher.
Refer to the SDS or MSDS to determine the specific requirements.
Dust Explosion
Processing materials such as MDF or other wood products creates dust.
The risk of a dust explosion exists. Use a suitable dust collection system.
Material Hold-down
When processing porous or irregular-surface materials,
alternate methods of hold-down are required.
Use clamps or fixtures to secure the material.
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Protective Features
Emergency Stop Pushbuttons
The machine is equipped with Emergency Stop pushbuttons that, when pressed, halt all motion.
Familiarize yourself with the location of these pushbuttons.
The CONTROLS and INDICATORS section provides more information.
A tool is required for their removal. Without the guards, you may come into contact with
components that could seriously injure or even death.
Carriage
This plate covers the drive and electrical components.
Devices
These covers are unique to each type of device.
Refer to the OEM literature for more information.
Gantry Legs
These covers restrict access to the X-axis drive components.
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Pressure Foot
The pressure foot and bellows are attached to the spindle. Spindle
They help prevent accidental contact with the cutter.
Retraction of the pressure foot and/or bellows may be required
during cutter inspection or manual tool replacement. Bellows
Hearing Protection
Wear hearing protection when machining noise is excessive.
Examples: When cutting some metals, plastics, or hard materials.
Mask or Respirator
Processing some materials may create airborne toxins.
Wear an appropriate mask or respirator.
Refer to the SDS or MSDS for specific information.
Suitable Gloves
Wear suitable gloves when handling sharp edged or hot materials.
Cutters are sharp and may also be hot during changeover procedures.
Clothing
Wear protective clothing when working with sharp edged or hot materials.
You may also come into contact with contaminants, such as dust, debris, or lubricants.
Footwear
Wear safety rated footwear when working with material over 20 kg. or 40 lbs.
or where a cut hazard exists.
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Hazard Labels
Ensure that all of the hazard labels are displayed according
to the direction provided in this segment of the manual
and that they are in legible condition. All operators must be aware of the implications of these labels.
Failure to do so could lead to serious injury or even death.
Electrical Enclosure
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On the Table
Located on both front sides of the table.
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On the Carriage(s)
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Specific Devices
On the Router
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On the Knife
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MACHINE OVERVIEW
Important
Learn about the major components
before operating the machine.
Machine Identification
Device Options
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Machine Identification
What model of machine are you working with
and where is the serial number
Serial Number
Also located on a label on the electrical enclosure.
Identifies the specific machine
Model Number
A combination of the table series and length of the table
The first digit denotes the nominal table width in feet.
The last two digits signify the table length in feet.
E.g. this 5010 table is 5-feet wide and 10-feet long.
Carriage
Your machine is equipped with either single or dual carriages.
Devices are mounted to the carriage.
Devices
Router spindles, pressure feet and options, knives, drills, engravers,
misters, vision system, braille, print head, and more.
Gantry
The beam, support by two legs, spans the width of the table.
Your machine may be configured with the dual gantry option.
Table
The rigid steel frame is fitted with an aluminum deck.
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Table Overview
Popup Pins
These optional pins help you to quickly
and accurately align the material for processing.
They are usually located across the front
and along the left side of the tabletop. (Not shown)
Vacuum Source
The tables vacuum system is connected to either a pump or blower.
Refer to the OEM literature for information about your equipment.
Spoil Board
Use either a standard MDF or precision board.
Fasteners secure the board to the tabletop.
T Slot Deck
Used for securing clamps or fixtures to the tabletop.
Zone Diagram
Identifies the tables vacuum zone configuration.
Corresponds with the numbers on each valve or switch.
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Gantry
The gantry beam is supported above the tabletop by two legs that
move along linear bearing rails attached to either side of the table.
Drive System
The gantry legs contain the X-axis drive system.
There are two drive motor options:
Stepper motor with a drive belt and pulley system
Servo drive system with a planetary gearbox
There are two gear rack options:
Spur gear (usually for stepper drive)
Helical (angled) gear (usually for servo drive)
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Router Spindle
Equipped with a quick tool release feature, the HSD spindle
releases the tool onto the raised tool cup.
Automatic Cover
Opens to allow the actuator to raise the tool cup.
Closes after the tool change to help prevent contamination.
Tool Carousel
Machine controlled to receive and deliver
the appropriate tool for the process.
Actuator
Raises the cups to either receive a tool from the spindle
or insert the selected tool from the carousel into the spindle.
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Carriage(s)
The machine is either equipped with one or two carriages.
On dual carriage machines, Carriage #1 is on the right side
and Carriage #2 is on left.
Device Connectors
There are up to four positions and the corresponding connectors
for cutting devices such as routers, knives, and drills.
Each position is numbered sequentially from right to left.
Options
Such as the AVS, misters, and printers
are mounted directly to the carriage and
are not assigned a numbered position.
Z-Plate
Ball screw driven assemblies are fitted to positions
where routers or knives are mounted. They allow
the cutting device to be raised and lowered.
Device Options
Various devices cut and shape the material.
Other devices assist in that process.
Pressure Feet Help reduce the risk of contact with cutting tools,
may help in material hold-down, and dust and debris collection
Dust and Chip Collection Removes dust and debris from the cutting area
Routers
There are two basic types of cutting tool attachment,
as shown and described below.
Routers are equipped with sharp cutting bits
Learn more about changing the cutter bit that may not stop spinning immediately.
in the OPERATING PROCEDURES chapter
Cutting Tool Change section. Always ensure the router spindle has completely stopped
and use approved gloves to handle the cutter.
Routers vary in horsepower and operating speed.
Coming into contact with the sharp cutting tools
Refer to the OEM literature for more information could seriously injure you.
about your specific the router(s).
Cone
Spindle
Collet
Covernut
Covernut
Collet
Cutter
Cutter
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Pressure Feet
The assembly is fitted to bottom of the spindle and helps There are two types of pressure feet and
to prevent operator contact with the router bit. they can be equipped with various options.
Both types of pressure feet are part of an effective dust and debris
collection system and may assist in material hold-down.
High Capacity
This assembly rides on the surface of the material being cut.
The cutter depth is determined by the spindles Z-plate position.
Universal 5Y
This assembly rides on or just above the surface
of the material being cut. It does not compensate
for variances in material thickness.
Manually set the fixed height.
High Capacity
This assembly rides on the material during processing.
Video Overview
Bellows
Helps to prevent accidental contact with the cutting tool
and assists in effective dust and debris extraction.
Extraction hose
Connected to the dust and debris collection system.
Interface
Various options such as a donut or brush are attached to the base.
Raised position
Provides cutter access for inspection and replacement.
Lowered position
Uses the weight of the spindle and foot to assist in material hold-down.
Processing position
The interface rides on the surface of the material while processing
to ensure a consistent cut depth despite variations in thickness.
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Universal 5Y
Rides at a fixed height either on or just above the material
Video Overview
Fixed stop
Raises and lowers the pressure foot with Z-plate/spindle motion.
Bellows
Helps to prevent accidental contact with the cutter.
Contains the dust and chips and enhances extraction.
Extraction hose
Connected to the dust and debris collection system.
Interface
Various options, such as a donut or brush, are attached to the base.
Clearance position
With a raised Z-plate/spindle, obstacles can be cleared.
Processing position
The spindle/cutter can independently raise and lower while processing.
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Options
The following parts enhance the performance
and capabilities of the pressure foot.
Bellows Seal
Helps prevent accidental exposure to the cutting tool
and significantly assists in dust and debris extraction.
Knives
There are two basic types of precision knives,
as shown and described below.
Knives are equipped with sharp cutting blades.
Learn more about installing cartridges and knives
Use extreme caution when handling the blades.
in the OPERATING PROCEDURES section
Knife Blades segment. Coming into contact with the sharp edges
of the blades could seriously injure you.
Tangential Oscillating
The blade or wheel follows The blade moves up and down
a determined cut path. while following a path to cut through
materials such as foam or cardboard.
Various types of cartridges hold
the knife blade, cutting wheel,
or creasing wheel. Blades are manually installed.
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Drills
There are two basic types of drills,
as shown and described below.
Drills are equipped with sharp cutting bits.
Use caution when handling them.
The edges could cut you.
Engraver
Mounted to the carriage, this assembly
engraves a pattern into the material.
Pressurized air keeps the tip cool.
Mister
Pneumatically dispenses
a microfine lubricant.
Lubricant is added
to the reservoir.
Used to lubricate and cool the
router bit when processing
non-ferrous metals.
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Print Head
(Not shown)
This inkjet unit prints a single colour image on parts.
It is typically raised and lowered by a pneumatic cylinder.
Braille System
(Not shown)
Uses the spindle, with a specific tool, to create a hole in the material.
A dispensing unit then inserts a ball into the hole.
Special fonts are required for this process.
Contact AXYZ International for more information.
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Canister
Collects and contains the dust and debris.
It is connected to a vacuum blower or pump.
Blower
Generates the vacuum used for extraction.
Refer to the OEM literature to learn more about your device.
Important
Read and understand this entire section
before you operate this automated equipment.
Electrical Enclosure
SmartConsole
Hold-down System
Carriage Indicators
Popup Pins
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Electrical Enclosure
Usually located at the back of the machine under the tabletop,
the enclosure is either equipped with a single or double door. Avoid coming into contact with the live electrical components
in this enclosure. Keep the door(s) closed and locked.
Failure to comply with this warning
could result in serious injury or even death.
Main Power Disconnect switch
Enable or disable the main electrical power
supplied to the machine.
Data Connectors
Both a network and a USB port
Smart Console
This device allows you to control and monitor machine operations.
It rests in a holder mounted to the gantry.
Soft keys
The relative function is shown
in the tab above each key.
Control keys
Use them to initiate functions,
Refer to the Operational Overview control devices and processing,
to learn more about using the console. and display pertinent information.
View/Download
Hold-down System
Your table is either equipped with automatic or manual vacuum zone control.
Carriage Indicators
Left - ON during a drill cycle.
Middle - Flashes during Z-axis homing.
Right - Flashes during knife homing.
Popup Pins
Toggle the switches up or down
to raise or lower the popup pins.
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OPERATING PROCEDURES
Important
Read and understand this entire section
before you operate this automated equipment.
Operational Overview
Functions
Processing Considerations
Pre-start Inspection
Operational Overview
A NC Numeric Control file, for each job, is transferred to the machine.
Operators control and monitor the machines production.
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Press the black Stop pushbutton 4. Press the white Power ON pushbutton
on the electrical enclosure on the electrical enclosure
5. Initialize the Machine
The material hold-down system remains ON Electrical power to the devices remains ON
The dust and debris collection systems remain ON The pressurized air supply remains ON
The Smart Console displays the message: The material hold-down system remains ON
continue or abort
The dust and debris collection systems remain ON
Connected Equipment:
Turn OFF/DISABLE the electrical power The machine:
to the vacuum hold-down system * Ensure the machine and all of the connected
Turn OFF/DISABLE the electrical power equipment are ready for operation
to the dust and debris collection system * Perform the Pre-start Inspection
Turn OFF/DISABLE any other sources Turn the machines Main Power Disconnect switch
of energy supplied to the system * to the ON position
Connect the machines pressurized air supply
Press the white Start pushbutton
As required by your company, perform a hazardous on the machines electrical enclosure
energy lockout/tagout on the specified control devices. Initialize the Machine
View and edit the NC code, run a simulation in 2D or 3D, Provides a visual representation of each origin.
and provide information about the job file.
HSD Spindle
ELTE Spindles
To remove the bit assembly from the router spindle: Wear protective gloves or avoid coming into contact
with the cutting edges of the bit.
1. Ensure the spindle has completely stopped rotation
and that it is in the raised position. Coming into contact with these sharp-edge blades
2. Remove or raise the pressure foot. could injure you.
3. Rotate the spindle while pressing the lock button
until the pin engages and locks the shaft.
Continue to press and hold the button.
4. Use the wrench to loosen the cover nut.
5. Remove the cover nut, collet, and cutter.
6. Inspect/clean the collet and cover nut.
Refer to Servicing the Tools
Knife Blades
Removing and replacing cartridges and knife blades
Sharp-edge knife blades.
Wear protective gloves or avoid coming into contact
with the cutting edges of the blades.
Coming into contact with these sharp-edge blades
Tangential could injure you.
To remove the cartridge from the shank:
1. Ensure the knife unit has completely stopped.
2. If applicable, remove the pressure foot/guard.
3. Carefully hold the cartridge.
4. Loosen the lock knob.
5. Remove the cartridge.
Oscillating
Functions
Use them to configure the machine parameters
Consider posting the following two pages in the work area.
F1 Displays information about the A2MC (controller) F26 Automatically measures all valid tools in the ATC
F7 Use to reset the servo motors F27 Set the user Z origin
F9 Abort an existing job or delete the current job F28 Set a new, or plane an existing, spoil board
F10 Set the user X and Y origin and the G55 origin F31 Change the active tool
F11 Select between six user origins F32 Use to load or unload the ATC
F25 Set the height of a specific tool F46 Program a traverse/cut move
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Processing Considerations
Operator Qualification
Ensure that the machine operators are trained and that they have access to the AXYZ support services.
Type of Tool
Select and properly install the optimal bit or blade for the type of material you intend to process.
For production, do not use adaptor bushings to reduce the collet size.
Excessive Heat
Heat can destroy the router bit.
The denser the material, the faster the feed rate to help minimize heat.
If the feed rate is too slow, the friction causes bit burning.
To help prevent excessive heat, do not allow the bit to dwell in the cut.
Use a mister or cold air gun when possible.
Pre-Start Inspection
Perform the following safety checks before starting and operating the machine:
The cutters, drills, and other tooling are ready for operation.
Machine Configurations
FAULT RECOVERY
Overview
Select Messages
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Overview
Message Display
When a machine fault occurs, a message is presented on the SmartConsole screen.
The fault message, with the associated error code, appears in the Information Display field.
Onscreen Help
When available, select to view the instructions
Perform
If the same fault Contact AXYZ
corrective Initiate the machine
reoccurs ... customer service
action
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Select Messages
Below are select fault messages, the error code, and a brief description of the condition.
For more detailed information visit the AXYZ website.
TROUBLESHOOTING
Conditions
Machine will not start
2 Possible cause: The Main Power Disconnect switch is in the OFF position.
Solution: Turn the switch to the ON position and press the ON pushbutton.
If you have verified that none of the conditions listed above are causing the problem,
please contact an AXYZ authorized service technician.
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Responsibilities
Select a link or scan this segment to learn more about:
Welcome Message
Maintenance Overview
Operating Hours
Record the value daily.
Use Function 1 to display the hours.
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General Cleaning
Daily or if the dust and debris are interfering with production
DO NOT use compressed air
Disable and lockout/tagout the electrical power, to clean-off yourself or the machine.
pressured air supply, and any other sources
of hazardous energy, before cleaning Coming into physical contact with pressurized air or
airborne debris could seriously injure or even kill you.
Follow your companys procedures
Use vacuums, brushes, cloths, and cleaners to remove
dust, debris, and other contaminants from the machine.
Carriage, Gantry, and Table
What to do:
1. Use a vacuum or soft brush to remove the debris
from the carriage and gantry.
2. Wipe the components with a damp cloth.
Use a 50/50 mix of Isopropyl alcohol and water to dampen a soft cloth.
3. Manually move the carriage and gantry to gain access for cleaning.
4. Then use a vacuum or soft brush to remove the dust and debris
from the tabletop, side rails, and frame.
5. Wipe the structural components with a damp cloth,
dampened with the 50/50 mix.
This affects both the cut quality and reduces tool life.
Premature spindle failure may also occur.
Covernut
Inspect the inside taper and threads to ensure it is clean
and free of burrs and that there is no wear or damage.
Vacuum Pump
Weekly, check the oil level through the sight glass.
Blower
Yearly, lubricate and replace specific bearings
according to the manufacturers recommendations.
More often in harsh environments
Raised Z-plate
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1. Use your machine to cut (and drill if required) the replacement spoil board.
2. Disable the machine.
3. Turn OFF the power to the vacuum hold-down system.
4. For a Precision Grid,
remove the screws that fasten the existing board to the tabletop.
5. Remove the existing spoil board.
6. Vacuum and wipe the tabletop to ensure it is clean.
7. Inspect and replace the vacuum zone gaskets, as required.
8. Position the new spoil board onto the tabletop.
9. For a Precision Grid,
install the fastening screws.
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SUPPORT
TABLE OF CONTENTS
This Table of Contents is included for the printed version of the manual.
For online viewing, open the Bookmarks pane in the PDF viewer.
For more information, refer to your PDF viewers help files.
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