Denford PCB Engraver User manual
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PCB Engraver Operator Manual 11
PCB Engraver
CNC Machine
User’s Manual
http://www.denford.co.uk
approved
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PCB Engraver Operator Manual
1: Contact Information
1: Notes
Address: Denford Limited,
Birds Royd,
Brighouse,
West Yorkshire,
HD6 1NB,
UK.
Telephone: General Enquiries 01484 728000
Fax: 01484 728100
Technical Support: Visit DenfordTechnical Forum at www.denfordata.com/bb
Telephone Denford Customer Services: 01484 728000
Monday to Friday 8.30am - 4.30pm GMT
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PCB Engraver Operator Manual
Table of Contents
1 : Notes
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PCB Engraver Operator Manual
1: Contents
Contents Page
1: Contact Information............................................................................................ 2
1: Notes.................................................................................................................. 2
1: Contents............................................................................................................. 4
1: Warning Notices................................................................................................. 5
1:About this Manual............................................................................................... 7
1: Introducing your PCB Engraver
..........................................................................
8
1: Before Beginning to Setup.................................................................................. 9
2: Safety Features Overview and Precautions....................................................... 10
2: Safety Features - Emergency Stop Button......................................................... 11
2: Safety Features - Interlock Guard Switch........................................................... 11
2: Dust Extraction & General Wood Precautions.................................................... 12
3: Unpacking and Lifting your CNC Machine...........................................................13
3: Choosing a Site for your CNC Machine.............................................................. 14
3: Removing Protective Coatings and Packaging.................................................. 15
4: Switching the Engraver On................................................................................. 16
4: Switching the Engraver Off................................................................................. 17
4: Homing the MachineAxes (Home Mode)........................................................... 18
4: Manual Control -Axis Definitions (Jog Mode).................................................... 19
4: Front Machine Operators Panel ........................................................................ 20
5: Spindle Motor Features and Controls................................................................. 21
5: Performing a Tooll Change................................................................................. 22
6: Planning Procedure for Maintenance Work........................................................ 26
7: Maintenance Schedule
......................................................................................
27
7: Cleaning the Engraver Motor ............................................................................ 28
7: Cleaning the Microswitches................................................................................ 28
7: Lubrication of the Slideways and Leadscrews.................................................... 29
8: Maintenance Log................................................................................................ 30
9: Technical Support............................................................................................... 32
10: Specification .....................................................................................................33
10: EC Declaration of Conformity for Machines Prior to 29.12.09.......................... 34
10: EC Declaration of Conformity for MachinesAfter 29.12.09.............................. 35
10: PCB Engraver Noise Level Test Results.......................................................... 36
11: Glossary............................................................................................................ 37
12: Notes................................................................................................................ 40
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PCB Engraver Operator Manual
Warranty Disclaimer.
The Warranty on your Engraver will be invalidated if any modifications are made to the
machine or any additional ancillary equipment 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.
Maintenance Disclaimer.
Always obtain permission from the person responsible for machinery in your establishment,
before accessing the electrical control panel or Engraver 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. Denford Limited cannot accept responsibility for any damage and/or loss that may
occur through incorrect maintenance of your Engraver.
Use of Machine.
Your Engraver is designed for cutting common resistant and prototyping materials, including
copper circuit board, plastic and acrylic. In each case, the appropriate tooling, speeds and
feeds should be used as recommended by the material supplier. Information should also
be sought from suppliers regarding the safey specification of the materials to be cut. Facility
is provided for connecting a vacuum system for dust extraction. Always use the machine
coupled to such a system.
Your Engraver is not intended for use with any metals other than copper circuit board.
Do not remove the Engraver head and attempt to use it independently of the machine.
Do not use the machine without the floating head feature in place, and a suitable extraction
system fitted and enabled.
Do not machine any toxic, radio-active or volatile materials.
Use of the machine for any purpose other than those for which it is
designed may result in injury, and may also invalidate the warranty.
The machine should only be used under constant supervision, to help guard against, and
respond to, any unforeseen hazard such as fire or explosion. First aid and firefighting
equipment (CO2 Extinguisher) should be located nearby in a clearly signed and prominent
position.
1: Warning Notices
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PCB Engraver Operator Manual
1: Warning Notices
Sound Level Disclaimer.
The Noise Level test published in this manual is for the machine and any essen-
tial equipment such as dust extraction equipment, and complies with the relevant
standards. It cannot allow for noise resulting from the cutting process, since this is a
variable, depending on such factors as material, cutting data and tooling.
Any ancillary equipment supplied by Denford will also comply with the relevant stand-
ards. It may, however, when used jointly with the machine in a machining environ-
ment, emit combined sound levels requiring the use of Personal Protection Equipment,
such as ear defenders. Other factors, such as high ambient noise levels and nearby
machinery and equipment can also increase the sound levels.
It may be possible to reduce the sound levels by changing the machining process
and/or repositioning the machine and/or its ancillary equipment.
If, under these circumstances, it is felt that the sound level is still unacceptably high,
then independant advice should be sought and complied with.
If you have any doubts and/or questions regarding the use, 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.
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PCB Engraver Operator Manual
Using this manual This manual provides information describing how to transport, site,
setup and operate the basic functions of your Denford Engraver,
including any operational features of hardware specific to the
Denford Engraver series.
This manual does not provide any information regarding the
software packages used please refer to the help section within the
appropiate software.
Please note that the Electrical Diagrams for your Engraver 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 Engraver, 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.
Disclaimer 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 2010. 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.
Screenshots 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 Engraver.
Language This manual is written using European English.
Contact Any comments regarding this manual should be marked for the
attention of our technical authoring team and referred to the
1:About this Manual
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PCB Engraver Operator Manual
Congratulations on your purchase of a PCB Engraver. In this manual you will learn how to
setup and use your Machine correctly and safely.
1: Introducing your PCB Engraver
Your Engraver is a three axis CNC Engraver with a large work area, allowing machining
of materials approaching 330 x 210mm 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 5000 mm/min your Engraver is the ideal partner for the manufacture of Printed Circuit
Boards. Your PCB Engraver 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 copper circuit
board, plastic and acrylic.
• Links to various CAD/CAM software packages.
• Totally enclosed high visibility guarding.
• Feedrate override control.
• Dust extraction ready.
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PCB Engraver Operator Manual
1: Before Beginning to Setup
Before beginning to set up your PCB Engraver, 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 Engraver CNC machine :
• PCB Engraver CNC machine. Note that the precise specification of your CNC
machine will depend on any options selected at the time of ordering (see below).
• Range of Collets from 1mm to 3.2mm.
• Collet Spanner.
• Slot Drill.
• Depth Gauge.
• 1 xAllen (hex) keys pack.
• External USB Cable.
• Mains Cable.
• Spare Fuses.
• Swanslip Lubricant.
• 1 x PCB Engraver warranty pack (UK Machines only)
• 1 x CD-ROM containing Denford VR CNC Machine Control Software and
manuals, and Machine user’s manual.
• 1 x 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
machine:
• Additional Software: CAD/CAM, Offline CNC Machine Control.
• CNC Machine Control software security keys (dongles) or licence disks.
• Machine work bench and PC workstation.
• Vacuum for dust collection.
• Various tooling packages.
• Courseware, project books and project material packages.
• Video conferencing system.
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PCB Engraver Operator Manual
2: Safety Features Overview and Precautions
Safety Features Overview.
The following safety features are standard on your Router Emergency stop button.
• Manuallyoperated,totallyenclosedcabinet,doorwithguardswitch.
• 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 Router.
General Safety Precautions :
• Wear clothing suitable for machine operation and follow the safe working procedures in
place at your establishment. When cleaning down machine, or handling tooling, consider
additional protective clothing such as respitory masks, eye protection, gloves and overalls.
• 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 unplugged) before starting any
maintenance work on the machine. Depending on ancillary equipment supplied with
machine there may be more than one power supply to the machine. When isolating
machine always ensure that all power sources have been disconnected. 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.
• If 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 handling machine tooling or cleaning down machine, particularly
with regard to hot and/or sharp cutters. Consider wearing protective gloves.
• When an emergency stop is required, press the circular red emergency stop button, located
on the right side of the CNC machine front panel.
• If laser scanner fitted do not stare into laser beam. Refer to Scanner instruction manual for
all aspects of safe use of laser.
• Visually check door and window for signs of cracks or chips.Any damage should be
reported immediately to Denford and a suitable replacement obtained without delay.
• Regularly check door hinges for correct tension and adjust or replace if necessary.
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PCB Engraver Operator Manual
2: Safety Features - Emergency Stop Button
Acircular, red emergency stop button is located on the right front panel of your Engraver,
as shown above. When pressed, it has the effect of stopping all axes and spindle
movements immediately.
To activate an emergency stop, press the button in until it clicks. The emergency stop
button will continue to cut all power to the machine drives until the release sequence is
performed.
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.
Check the emergency stop button is released before attempting to power up the Engraver
The emergency stop button is
located on the right front panel of
the CNC machine. To activate an
emergency stop, press the button
fully in until it clicks.
2: Safety Features - Guard Switch
Aguard switch is used on the door of the machine. The switch
itself is fitted to the frame of the cabinet and the sensor is fitted
to the door.
When the door is opened with the machine in cycle, the axes
and spindle will stop. The axes can then be manually jogged,
but the spindle will be inhibited. Closing the door will return
the machine to full functionality, but will not cause the axes or
spindle to restart.
x
Opening the door
when the machine is
in cycle could result in
damage to the machine,
the tooling and the
component.
Warning
-
x
When the door is opened with the machine powered up, but not in cycle, the axes can
be manually jogged, but the spindle will be inhibited. Closing the door will return the
machine to full functionality, but will not cause the axes or spindle to start.
If the machine is powered up with the door open, the axes and spindle will be inhibited
until the door is closed and the machine has been homed.
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PCB Engraver Operator Manual
Launder overalls regularly, provide good washing facilities with hot and cold water, soap
and towels and encourage a high standard of personal hygiene.
Failure to fit and enable a suitable dust extraction system, and
failure to adhere to the material safety data sheets could lead
to the following health problems which are among the effects
associated with exposure to certain dust particles:
• Skin disorders.
• Obstruction to the nose.
• Rhinitis.
• Asthma.
• Nasal cancer.
2: DustExtraction & General DustPrecautions
Your Engraver is designed to run with a dust extraction system, used to clear dust
and swarf from the cutting area, and to remove any potentially harmful airborne dust
particles from within the working area of the machine.
Note the floating head of your Engraver cannot function without a
dust extraction system fitted and enabled.
The dust extraction system used should be independently tested every 14 months to
ensure that dust 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. Connectthepipefromyourdustextractionsystem to the aperture in the
right hand wall of the machine cabinet.
General Dust Safety Precautions.
Obtain "material safety data sheets" from your material suppliers and enforce the
recommended precautions. Be aware that certain hardwood and other material dust
particles, such as oak and MDF, could contain known carcinogens. Please consult
your materials supplier for further details.
Dust particles that remain inside the working area of the Engraver after a part has been
machined, should be removed using a vacuum.
Never used a compressed airline for this purpose.
When emptying the dust extraction system base unit or cleaning down the machine,
wear suitable respiratory protective equipment that is CE marked. Other personal
protective equipment, such as eye protection, overalls and gloves should also be
considered.
Dust particles on the floor can cause slipping. This should be monitored by the
operator and removed before becoming a hazard.
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PCB Engraver Operator Manual
3: Unpacking and Lifting your CNC Machine
13
Caution.
Always use sensible
lifting precautions in
accordance with Health
and Safety Regulations
in your establishment.
Warning -xIf your CNC machine has been supplied inside a delivery box, cut the
top of the box open and remove any packaging carefully. To obtain
better access to the machine, remove all the sides from the delivery
box. Your PCB Engraver weighs 43 kg. for bench mounting: with floor
standing unit it weighs 157 kg.
With the bench mounting unit a suitable method of transportation
must be used as the unit is not fitted with wheels: for example secure
machine on a pallet and transport using a pallet truck.
The machine only can be lifted by 2 people.Account should be taken of
the non-uniform distribution of the weight of the machine. It is generally
heavier at the back than at the front of the machine.The use of suitably
rated lifting bars through the hollow sections under the machine may
assist in lifting the machine.
Always use sensible lifting precautions in accordance with Health and
Safety Regulations in your establishment. Particularly in the case of
manual lifting be aware of the danger of trapping.
Ensure that your CNC machine is both secure and balanced before
lifting. Do not tip the machine whilst lifting.
All lifting equipment must be certified as being suitable for the loads
involved.
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PCB Engraver Operator Manual
3: Choosing a Site for your CNC Machine
Site your machine in a well ventilated room. If the Engraver is supplied for bench mounting
it should be sited on a bench of sturdy construction to take the weight of the machine and of
a height which enables comfortable operating and programming to take place.
If the Engraver is supplied with a Universal Machine Bench, the adjustable corner feet
should be wound down to contact the floor to help minimise noise and vibration.
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), as
shown in the diagram below.
Sufficient room should also be provided for effective maintenance to be carried out around
the machine itself. In particular, leave enough space for removal of the large plate covering
the electronics at the rear side of the cabinet. Positioning the PC on a movable workstation
may allow easier access to the various vents, connectors and switches on the machine
cabinet, when required.
Position any vacuum pumps used with the dust extraction at the rear, or under, the machine
table. The use of a centralised extraction system or, where possible locating the extraction
unit in a seperate room, will help in noise reduction.
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.
Plan View showing Ideal Machine
Layout and Operating Positions.
Dimensional Data.
MachineLength (leftto
right) 570mm (22.5”).
Machineheight(topto
bottom 385mm (15.2”).
Machinedepth(frontto
back) 585mm (23”).
Dust extraction
here.
Computer desk, monitor,
keyboard and mouse angled
towards Operator.
Engraver on suitable
table.
Machine
Operator.
Allow space to remove the electrical
panel cover plate at the rear of the
cabinet.
Ensure
that any
inlet/exhaust
vents are not
covered or
blocked.
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PCB Engraver Operator Manual
3:RemovingProtective Coatings andPackaging
Once your Engraver has been sited, the protective coatings and
transit packaging must be removed to prepare the machine for
running:
1) Theprotective plastic sheeting on the guard door mustberemoved
andthedoorcleanedwithanantistaticcleaner.
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.
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.
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.
Warning -x
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PCB Engraver Operator Manual
4: Switching the Engraver On
Do not connect cables
between any electrical
hardware with the
mains power switched
on, since this could
seriously damage
components inside your
CNC machine.
Warning -x
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.
Many electronic
components are
sensitive to electrostatic
damage - ensure
components and/or
personnel are suitably
earthed to minimise
this risk.
Warning -x
Follow these instructions to switch on your Engraver:
1) Check the Denford machine link cable is fitted securely between the
USB port socket on the machine controller PC and the USB socket,
located on the right-hand panel of the Engraver cabinet.
2) Check that all access panels are in position and securely fastened.
3) Check that all inlet/exhaust vents are clear from obstructions.
4) Check the flexible hose from your separate dust collection vacuum
system is securely fitted to the connection hole, adjacent to the
lifting handle on the right-hand panel of the cabinet.
5) Check that the guard door is fully closed.
6) Plug the Engraver mains supply cable into an available power
socket. Switch the power socket on.
7) The on/off power switch is located on the right-hand panel of the
Engraver cabinet. To switch machine on depress the left-hand side
of switch. The switch will illuminate when power is being supplied to
the machine.
If the Engraver does not begin its power-up routine, switch off the
mains power and check all connections and fuses.
8) Switch on the machine controller PC and start the CNC machine
control software.
Establish a communication link between your machine controller and
PC.
When the ‘found new hardware’box appears install the driver for the
USB connection (VR CNC milling cd must be in the CD Drive - for
help please contact technical support 01484 728000.
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PCB Engraver Operator Manual
4: Switching the Engraver Off
Follow these instructions to switch off your Denford Engraver off:
1) Wait for the Engraver to fully complete any machining or
processing of any operational instructions.
2) Open the safety guard door and remove any finished parts from
the working area.
3) Close the safety guard door.
4) Close down the communication link between the CNC control
software and the Engraver, then exit the CNC control software,
as described in your separate CNC Control Software User’s
Manual.
5) Shut down and switch off the machine controller personal
computer.
6) Power down the Engraver by depressing the right-hand side of
the red on/off mains power switch. The on/off switch is mounted
on the right-hand cabinet panel.
7) Switch off the mains power socket.
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.
Many electronic
components are
sensitive to electrostatic
damage - ensure
components and/or
personnel are suitably
earthed to minimise
this risk.
Warning -x
Depending on ancillary
equipment supplied with
machine there may be
more than one power
supply to the machine.
When isolating machine
always ensure that all
power sources have
been disconnected.
Warning -x
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PCB Engraver Operator Manual
4: Homing the MachineAxes (Home Mode)
The CNC machine
control software Jog
andAuto Modes will not
become available until
the machine has been
configured by homing all
three machine axes.
Note -x
Immediately after establishing a communication link between the CNC
control software and the Engraver, all three axes of the CNC machine
must be homed. The process is commonly referred to as homing the
machine, or datuming each of the three machine axes.
When a communication link is first established between the Engraver
and the CNC machine control software, or when the CNC machine
“loses” position, the software will not know the true position of the
machine head in relation to the three machine axes.
Homing the CNC machine defines:
• The machine datum, by physically driving the machine head to a
fixed zero reference point.
• The constraints of three dimensional co-ordinate grid system used
for plotting any programmed movements, effectively the working
envelope of the CNC machine.
After homing the machine, the zero position of the three dimensional
co-ordinate grid system is referred to as the machine datum. You can
find the position of the machine datum by switching the co-ordinate
display in your CNC control software to read Machine Co-ordinates.
The position of the machine datum is achieved when the X, Yand Z
panels of the co-ordinate display all read zero.
In addition to homing the CNC machine after it has first been switched
on, we also recommend homing the CNC machine after loading or
configuring any offsets.
The machine datum
position is set by
Denford and can never
be moved, since it
defines the physical
movement capability of
the CNC machine.
Note -x
The sequence of
events required to
home the Engraver will
depend on the type of
CNC machine control
software being used
- please refer to your
separate CNC Machine
Control Software User’s
Manual for specific
details.
Note -x
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PCB Engraver Operator Manual
Jog mode is used for manually controlling the CNC machine, moving the
three machine axes, changing tools, operating optional equipment and
configuring any offsets.
Axis Definitions.
X Axis - The X axis slides run at 90 degrees to the Yand Z axes, horizontally left
and right, when viewed from the front of the machine.
Minus (-) X movements run towards the left end of the machine and positive (+) X
movements run towards the right end of the machine.
Jog Keys to move axis - arrow keys left and right
Y Axis - TheY axis slides run at 90 degrees to the X and Z axes, horizontally
forwards and backwards, when viewed from the front of the machine.
Minus (-) Ymovements run towards the front of the machine and positive (+) Y
movements run towards the back of the machine.
Jog Keys to move axis - arrow keys up and down
Z Axis - The Z axis slides runs at 90 degrees to the X and Yaxes, vertically up and
down, when viewed from the front of the machine.
Minus (-) Z movements run down, towards the floor of the machine and positive (+) Z
movements run up, away from the floor of the machine.
Jog Keys to move axis -Page up and Page down
4:Manual Control -Axis Definitions (Jog)
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PCB Engraver Operator Manual
Mains Power Switch.
To supply power to the CNC machine, depress left-hand side of the
switch immediately above the power inlet socket. To cut power to the
CNC machine, depress right-hand side of switch.
Do not cut the mains power when machining or processing of any
operational instructions is taking place.
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 activate 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 clockwise until it
springs back out.
4: Machine Operators Panels
Depending on ancillary
equipment supplied with
machine there may be
more than one power
supply to the machine.
When isolating machine
always ensure that all
power sources have
been disconnected.
Warning -x
Table of contents
