MEKANIKA Pro Series User manual

CNC MILLING MACHINE
PRO-SERIES - USER MANUAL
www.mekanika.io

MAINTENANCE
Prior to commissioning the Mekanika Pro CNC Milling Machine, it has to be ensured that the machine is in a
technically perfect and well-maintained condition. Always ensure that the machine is not powered if you want
to perform adjustment or maintenance works. For this purpose, disconnect the power plug.
Sharp-edged cutting tools must also be dismounted prior any maintenance work to avoid a risk of injury.
Remove workpieces you have clamped onto the machine table, including the clamping system.
Only use high quality tools during your maintenance work.
Lubrication of Ball Screws and linear rails
A linear system has to be suciently lubricated in order to work properly and to avoid excessive wear or over-
heating. The required lubrication interval is determined by the environmental conditions. Generally, lubrication
is required every 100 to 200 operating hours. A guideline for the lubrication interval is approx. 1 cm³ lubrication
per ball screw nut. We recommend using lithium-based greases, which perform well in high-load applications
and have good stability against oxidation.
The Mekanika Pro CNC machine is, to a good extent, maintenance-free. Handle your CNC system with
care in order to ensure a long service life. Regular maintenance has a substantial impact on the service life of
your machine. Frequently clean the CNC system with a cloth.
Ball screws and linear guides are to be regularly checked, cleansed of dirt and lubricated if necessary.
Clean the electronics area, including screen, keyboard and mouse from dust and impurities.
Regularly clean the fan lter of the control unit. A clogged lter might result in overheating inside the box, po-
tentially leading to permanent damage to the electronic components.
All parts of the machine and of the control box can be purchased individually as spare parts.
Please contact us directly about this.
When ordering spare parts, please provided the information on the machine model, size and part number avail-
able in accordance with the building instructions.
GENERAL INFORMATION
RECOMMENDED MAINTENANCE WORK
SPARE PARTS
19

TABLE OF CONTENT
GENERAL INFORMATION
Contact for Customer Information
Notice
Meaning of Terms Used
GENERAL INSTRUCTIONS
Foreword
General Safety Warnings for the Use of Machines
Protective Measures
Personal Protective Equipment
Emergency Stop Button
Residual Risk
Check-list for Safety When Using the Machine
Safety Symbols
MACHINE DESCRIPTION
Workplace
Intended Use of the Machine
ASSEMBLY & SYSTEM SETUP
Environmental Conditions
Machine Positioning
Machine Assembly
Machine References
Recommended Workplace Layout
OPERATION
Commissioning and Safe Operation
Machine Work Surface
Clamping the Workpiece
Operation of the CNC System
TECHNICAL DATA
Dimensions and Weight
Technical Specications
TRANSPORTATION AND STORAGE
Transport
Packaging
Storage
MAINTENANCE
General information
Recommended Maintenance Work
Spare Parts
4
4
4
4
5
5
5
8
9
9
9
10
10
11
12
12
13
13
13
13
14
15
16
16
16
16
16
17
17
17
18
18
18
18
19
19
19
19
TRANSPORTATION & STORAGE
If you want to transport the machine, please pay special attention to its dimensions. You might need additional
people for transportation. Never lift heavy loads above people!
Avoid a unilateral load of the machine frame!
If you do not want to reuse the packaging material of the machine and its components, please separate it
according to the disposal conditions on site and take it to a collection centre for recycling or dispose of it.
If the machine or its components is not used for a longer period of time, please observe the following points
regarding storage:
• Only store the machine and the components in closed rooms.
• Protect the machine and the components against humidity, wetness, cold, heat and direct sun radiation.
• Store the machine and its components dust-free and cover it if necessary.
• The storage place must not be subjected to vibrations.
TRANSPORT
PACKAGING
STORAGE
18 3

GENERAL INFORMATION
CONTACT FOR CUSTOMER INFORMATION
NOTICE
MEANING OF TERMS USED
All instructions, warranties and other collateral documents are subject to change at the sole discretion of
Mekanika SRL.
Please visit www.mekanika.io on your product page to access up-to-date informations and documents.
The following terms are used throughout this operating manual to indicate various levels of potential harm
when operating this machine. The safety symbols, and their explanations, deserve your careful attention and
understanding.
The safety warnings themselves do not eliminate any danger. The instructions or warnings they give are not
substitutes for proper accident prevention measures.
NOTICE
Procedures which, if not properly followed, create a possibility of physical property damage and a little or no
possibility of injury.
CAUTION
Procedures which, if not properly followed, create a probability of physical property damage and a possibility
of serious injury.
WARNING
Procedures which, if not properly followed, create a probability of property damage, collateral damage, serious
injury or death or create a high probability of supercial injury.
Read the entire operating manual in order to become familiar with the features of the machine and how to
operate them. Failure to operate the machine correctly can result in damage to the machine, personal property
and cause serious injury, electric shock and/or re.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE.
Mekanika SRL
55, Quai Fernand Demets
1070 Anderlecht
Belgium
E-mail: [email protected]
If you encounter any issue or have any question regarding your machine, contact us and we’ll get back to you
within 24 hours.
TECHNICAL DATA
Model Footprint Height Weight
PRO-S 850 x 850mm 650mm 55 kg
PRO-M 850 x 1250mm 650mm 62 kg
PRO-L 1250 x 1250mm 650mm 69 kg
DIMENSIONS & WEIGHT
TECHNICAL SPECIFICATIONS
Working Area 630 x 630mm | 630 x 1030mm | 1030 x 1030mm
Z Clearance Height 105mm (without spoilerboard)
Z Travel Distance 115mm
Linear Guides HBR20 linear rails with carriages
Drive system 16mm Ball screws
Accuracy 0,01mm - 0,05mm, with a repeatability of 0,01mm
Maximal Travel Speed 10.000mm/min
Motors (X, Y1, Y2, Z) 4 High-torque Nema23 stepper motors
Limit switches 6 NC PNP inductive sensors
Structure High quality aluminium proles and digitally manufactured steel plates
Controller & Software PlanetCNC software installed and pre-congured on a Raspberry Pi 4B
Interface 7” LCD Touchscreen & bluetooth keypad
Spindle AMB 1400 FME-P DI (software controlled spindle)
4 17

GENERAL INSTRUCTIONS
These operating instructions explain how the Mekanika Pro CNC Milling Machine works and inform you about
the correct handling of the machine.
Please read these operating instructions as well as all accompanying documents in their entirety before
commissioning of the system.
It is imperative to adhere to the safety instructions listed in these operating instructions at all times.
Should any doubts or the need for further information arise, do not hesitate to contact us prior to the use of the
machine.
GENERAL SAFETY WARNINGS FOR THE USE OF MACHINES
PERSONAL SAFETY
NOTICE
All persons who operate the machine must have read and fully understood
all relevant safety and operating instructions. Misunderstanding may re-
sult in personal injury.
CAUTION
Dress properly. Do not wear loose clothing or jewellery. Pin your hair above
your shoulders so that it cannot get caught in the linear guides or moving
parts.
CAUTION
Stay alert, watch what you are doing and use common sense when operat-
ing a machine. Do not use a machine while you are tired and/or under the
inuence of drugs, alcohol or medication. A moment of inattention while
operating a machine may result in serious personal injury.
CAUTION
Use personal protective equipment. Always wear eye protection. Protec-
tive equipment, such as a suitable dust mask or ear protection, reduces
the risk of injuries.
CAUTION
This tool is controlled by a computer. During operation, it cannot be con-
trolled directly. Lack of caution or expertise as well as program errors can
lead to unexpected movements.
CAUTION Do not touch the motors as they can heat up signicantly during opera-
tion.
CAUTION Never place any parts of the tool or accessories in your mouth as this can
lead to serious injuries.
FOREWORD
OPERATION
The machine and all connected components have to be wired correctly and be in perfect condition.
The operator must have completely read and understood the entire documentation of the relevant machine
model and its corresponding instructions. Furthermore, he must have been trained in operating the machine as
well as its accessories and has to be familiar with the use of a CNC Milling Machine and CNC software in general.
The workplace needs to be compliant with the applicable regulations and provisions of the respective industry.
The operator must use a dust shoe to prevent access to the cutting tool and be protected from ejection of chips
while machining.
All axes feature inductive sensors to provide end stop according to ISO 13854“Safety of machinery - Minimum
gaps to avoid crushing of parts of the human body“, in order to avoid hand or nger crushes.
COMMISSIONING AND SAFE OPERATION
The workpiece must be secured directly on the machine table using clamping devices.
If you want to mill through the material and produce cut-outs, we recommend the use of suitable material as
spoilerboard. It is placed under the workpiece and protects the machine table from potential damage.
The workpiece should be suciently clamped in order to prevent it from unintentional shifting during process-
ing.
Never hold the workpiece with your hands during the operating process. There is a high risk of serious injury!
The entire CNC system is controlled and operated via a Raspberry Pi.
The operator must have completely read and understood the entire documentation of the CNC control software
before commissioning the CNC system.
For further questions regarding the applied control software, please contact the respective software manufac-
turer at https://planet-cnc.com/
There is no spoilerboard included in our kit. At rst, a simple MDF wood panel is enough to get a grasp on CNC
machining. When being more experienced, we suggest building a threaded insert grid on a surfaced spoiler-
board. If you intend to machine hard material and use a lubrication system on the machine, we suggest you
purchase an aluminium T-slot proles worktable, as MDF will swell in contact with water.
MACHINE WORK SURFACE
CLAMPING THE WORKPIECE
OPERATION OF THE CNC SYSTEM
16 5

OPERATING
AREA
MATERIAL
LOADING
AREA
0,5 meter MAINTENANCE &
SETUP AREA
MAINTENANCE &
SETUP AREA
MAINTENANCE &
SETUP AREA
1 meter
RECOMMENDED WORKPLACE LAYOUT
ELECTRICAL
SAFETY
NOTICE Do not expose the machine to moisture. The machine is only suitable for
indoor use.
WARNING
Machine plugs must match the outlet. Never modify the plug in any way.
Be careful if you use adapter plugs with a grounded machine. Unmodi-
ed plugs and matching outlets will reduce the risk of electric defects and
malfunctions
WORK AREA SAFETY
NOTICE Keep work area clean and well lit. Cluttered or dark areas are prone to ac-
cidents.
NOTICE Operate the machine only in interior spaces on a solid, horizontal table or
workbench.
CAUTION Keep children and bystanders at a distance while operating a power tool.
Distractions can cause you to lose control and can result in accidents.
CAUTION
Do not operate the machine in explosive atmospheres, such as in the
presence of ammable liquids, gases or dust. Machines can create sparks
which may ignite the dust or fumes.
USE OF THE MACHINE
NOTICE Do not leave a running tool unattended, turn power o. Only when tool
comes to a complete stop and is disconnected from the mains it is safe.
NOTICE
Use the machine and accessories in accordance with these instructions,
taking into account the working conditions and the work to be performed.
Use of the machine for operations dierent from those intended could re-
sult in a hazardous situation with high probability of supercial injury.
NOTICE
Never use dull or damaged end mills. Sharp end mills must be handled
with care. Damaged end mills can snap during use. Dull end mills require
more force to cut the tool, possibly causing the end mill to break.
NOTICE
The speed and feed of the end mill when carving, routing or cutting is very
important. Always observe the speed and feed for the particular end mill
recommended.
NOTICE
Do not allow familiarity gained from frequent use of your rotary tool to be-
come commonplace. Always remember that a careless fraction of a second
is sucient to inict severe injury.
6 15

14 7
Z-AXIS
X-AXIS
Y-AXIS
MACHINE REFERENCES
AXES TERMINOLOGY
CONTROL BOX
USE OF THE MACHINE
NOTICE
Clean the spindle’s air vents every four hours by using compressed air.
Excessive accumulation of chips and dust inside the motor housing may
cause electrical failures.
CAUTION Do not reach in the area of the rotating tool. The proximity of the rotating
tool to your hand may not always be obvious.
CAUTION Never try to reach the limit sensors while the machine is moving, it could
lead to the crushing of your hand or ngers.
CAUTION Do not alter or misuse the tool. Any alteration or modication is a misuse
and may result in serious personal injury.
CAUTION
Disconnect the plug from the power source before you make any adjust-
ments, change accessories, or store the tool. Such preventive safety meas-
ures reduce the risk of starting the power tool accidentally.
CAUTION
Store the machine out of the reach of children and do not allow persons
unfamiliar with these instructions to operate the machine. Machines are
dangerous in the hands of untrained users.
CAUTION
If the workpiece or end mill gets jammed, immediately press the emergen-
cy stop button. Wait for all moving parts to stop and turn o the spindle
with the power switch, then free the jammed material. Do not try to do this
with the spindle turned on.
CAUTION Do not touch the end mill or collet after use. After usage they are too hot to
be touched with bare hands.
CAUTION
Before starting any machining operation, always have the workpiece se-
curely clamped. Never attempt to hold the workpiece with your hands or
using any accessories. These tools can jam easily in the material, and can
kickback, causing loss of control resulting in serious injury.
CARE OF THE TOOLS
NOTICE
Properly maintain the tools you use. Check for misalignment or binding of
moving parts, breakage of parts and any other conditions that may aect
the machine’s operation. If damaged, have the machine repaired before
use. Many accidents are caused by poorly maintained machines.
NOTICE Have your machine serviced by a qualied repair person using only identi-
cal replacement parts.
1 2
MOTORS
FAN & DUST
FILTER
LIMIT
SWITCHES PROBE Z
SPINDLE CONTROL (DI/VFD)
HDMI ETHERNET
POWER SUPPLY
EMERGENCY STOP
USB
X
X
Z
Z
Y Y
2
Y
1
Y
ENCLOSURE INPUTS

8 13
PROTECTIVE MEASURES
ADDITIONNAL SAFETY MEASURES
CAUTION
Depending on the application eld of the machine (private or commer-
cial), observe the applicable occupational safety and health, safety and
accident prevention and environmental regulations.
WARNING
Some dust created while machining certain types of material can
contain chemicals known to cause cancer, birth defects or other re-
productive harm. Always inform yourself on the material you have
at hand before machining it. Some examples of these chemicals are:
lead from non-ferrous metals with lead content, carbonate from car-
bon bre, arsenic and chromium from chemically-treated lumber.
Your risk from exposures to these varies, depending on how often you per-
form this type of work. To reduce your exposure to these chemicals: work
in a well ventilated area, and work with approved safety equipment, such
as those dust masks that are specially designed to lter out microscopic
particles.
The Mekanika Pro CNC Machine has been designed for advanced users and is only to be operated by technically
skilled adults.
The machine is only to be used in a technically perfect condition, which is to be ensured by the user prior to
each operation.
The emergency switch as well as, if applicable, additional safety devices, always need to be easily accessible and
fully functional.
The use of air and water lubrication systems is allowed. Please take into consideration that if you are using an
MDF spoilerboard (machine worktable), the MDF panel will swell and be damaged by the water.
ASSEMBLY & SYSTEM SETUP
The machine is solely suitable for the operation in dry, interior spaces.
Keep the environmental temperature of the machine dust-free. High dust exposure can cause damages to the
system.
The humidity should be within normal limits for humidity indoors (40 to 60 %). Protect the machine against
wetness and humidity.
The ideal environmental temperature for the system lies between 18°C to 25°C, respectively from
64°F to 77°F.
Particularly protect the electronics against overheating by avoiding direct sun radiation or indirect heating up
nearby a radiator.
Place the machine on a suitable table or on a machine stand. In order to provide a comfortable working height,
we recommend a working height of approx. 840 mm. For a torsion-free stand, the surface of the machine stand
needs to be solid and even. The machine is to be secured in a way that it cannot shift or fall down.
All movable parts of the machine must be able to operate collision-free.
The routing of the tool´s cables, such as with the milling motor, has to be eected in a way that the cable cannot
be clamped between the guide ways of the machine. For this purpose, use the cable chains we have set up for
the dierent axis.
The machine has to be easily accessible and operable. Especially the emergency switch has to be easily acces-
sible at all times.
Take care to ensure a sucient illumination of the machine`s location and the workplace surrounding the ma-
chine.
The control unit and the machine interface (screen & keypad) have to be placed in the vicinity of the machine in
order to have both in clear view at all time.
Please follow carefully our attached mounting guide and datasheet in order to properly mount your Mekanika
Pro CNC Milling Machine.
If you have any questions, please do not hesitate to contact us!
ENVIRONMENTAL CONDITIONS
MACHINE POSITIONING
MACHINE ASSEMBLY

12 9
The Mekanika Pro CNC Milling Machine is constructed for a permanent and regular application for profession-
als. Due to the machine stiness, a variety of dierent materials, such as wood and non-ferrous metals, can be
processed.
The plausible and reasonable scope of uses include:
• Manual movement mode, using a digital“jog”to move the machine along its 3 axes independently.
• Automatic“Homing”procedure, operated by the user by clicking a digital button. This procedure moves the
machine sequentially on each of its axes in the following order: Z, X, Y, until it encounters the limit switches.
• Automatic “Square Gantry” procedure, activated by the user by clicking a digital button. This procedure
moves the machine along its Y-axis, forward, until it touches its left and right limit sensors sequentially. The
purpose of this procedure is to square the machine’s gantry with the Y axis.
• Measure Tool Length procedure, activated by the user by clicking on a numerical button. This procedure
makes the machine descend at reduced speed along its Z axis until its tool comes into contact with a remov-
able sensor previously placed by the user.
• Normal operating mode, where the machine moves automatically according to a machine code, called
G-code, previously loaded by the user.
• Manual control mode using a terminal, the machine moves according to a machine code, called G-code,
entered directly by the user.
The plausible and reasonable scope of interventions include:
• Manual movement of the machine to access certain zones.
• Manual rotation of the ball screws to align the X axis (gantry) with respect to the Y axis.
• Changing the cutting tool on the milling spindle.
• Attachment/removal of the dust shoe.
• Attachment/removal of the raw material to be machined on the work surface.
• Switching on, pausing and stopping a machine code (G-code).
• Connection/disconnection of external machine cables.
• Opening of the cable entry chains to access the cables.
The workplace needs to provide enough space around the machine in order to work comfortably and to allow
the machine to fully use its traveling paths. Additionally, a safe distance to possibly nearby positioned machines
is to be maintained.
The location of the machine as well as the workplace surrounding the machine has to be suciently illuminated.
The control box and the interface items have to be placed in the vicinity of the machine in order to have both
in clear view.
WORKPLACE
INTENDED USE OF THE MACHINE
PERSONAL PROTECTIVE EQUIPMENT
EMERGENCY STOP BUTTON
When working with the machine, the operator has to wear at least the following personal protective equipment
and has to be compliant with the below-mentioned safety aspects:
• Safety glasses to protect the eyes against ying chips and other projections.
• Ear protection to protect the ears against noise.
• Safety shoes to protect the feet against falling objects.
• No wearing of clothes which can get caught in the machine, such as ties, scarves, wide sleeves. Roll up
sleeves to prevent caught in moving parts. Additionally, jewellery, watches, rings and especially long neck-
laces and rings are to be dispensed with.
• Shoulder-length or longer hair must be secured with a hairnet or a hat in order to prevent it from getting
caught in the linear guides and / or rotating tools.
Prior to all adjustments to the machine, such as to the spindle and to the control unit, its control or system-guid-
ed tools have to be disconnected from the power source.
Never hold the workpiece with your hands. It is mandatory to secure the workpiece on the worktable. Otherwise,
there exists a high risk of injuries!
The emergency stop is located in a separate housing and is securely connected with the machine. In order to
be able to intervene at all times, the emergency stop has to be positioned at a suitable place, as shown in the
assembly guide.
By pressing the emergency stop switch, the emergency stop is triggered. The control of the machine is immedi-
ately interrupted. Additionally, the control software receives the signal to stop the operating process, freezing
the user interface. The machine stops moving immediately and the spindle stops turning at the same moment.
If you want to deactivate the emergency stop status, reactivate the control by turning the emergency stop
switch to the right. The operating process has to be restarted.
If you have any questions on this matter, please do not hesitate to contact us.
RESIDUAL RISK
Despite all safety precautions against the contact with rotating or hot tools and the protection from crushes, a
residual risk remains due to a careless handling and automatic movements of the CNC system.

10 11
BE PREPARED WORK SAFE FINISH RIGHT
• Use appropriate personal
protective equipment :
- Safety Glasses
- Hearing protection
- Safety Shoes
• Remove rings, bracelets,
watches and necklaces
before work.
• Tie and conne long hair.
• Wear tight tting clothing
and roll up sleeves to
prevent snagging.
• Inspect the equipment to
ensure there are no obvious
defects, damaged chucks ,
dull or cracked tools.
• Ensure you have the required
knowledge of the use of a
CNC milling machine.
• Do not use gloves.
• Check where the emergency
stop button is located.
• Never plug or unplug
cables from the control
unit while the machine is
powered.
• Ensure that the workpiece
is rmly and securely
clamped.
• Check that the tools are
sharp and set correctly.
• Use a brush or a vacuum
cleaner to clean chips o
surfaces.
• Never reach into the
machine while it is running
and keep your hands away
from any moving part
during machining.
• Stand clear of the machine
whenever it is operational.
You should also warn other
people near the risk of
being too close to it
• Keep hands clear during
manual adjustments. When-
ever you are handling or
passing tools, avoid touch-
ing the cutting edges
• When you are nished with
your work, shut down the
Raspberry Pi before turning
o the power switch of the
control unit (not doing so
might corrupt the SD card).
• If the ball screws are dusty,
blow them with pressurised
air to keep them clean and
greased.
• Clean the oor and work
area around the machine.
• Clean and put away person-
al protection equipment.
• Tag any defective equip-
ment and contact us if you
encounter any trouble.
CHECKLIST FOR A SAFE USE OF THE MACHINE
SAFETY SYMBOLS
MACHINE DESCRIPTION
The Mekanika Pro CNC Milling Machine is a digitally controlled milling machine, which can be used for a regular
processing of wood, plastics and non-ferrous metals.
The machine has three axes, which are oset by 90°. This way, it is possible to travel to any point within the
working space. Each axis is equipped with one or two stepper motors and with one or two inductive sensors.
The stepper motors drive the movable axes elements via the ball screws. The position of the axis is determined
during the homing procedure, at the beginning of the job, with the aid of the inductive limit sensors.
The Mekanika Pro CNC Milling Machine is delivered as a kit and includes the following components:
• A 3-axis CNC router, with 4 motors and 6 inductive limit switches
• A plug-and-play electronic control unit, already assembled and tested, with its power cable (EU plug)
• A plug-and-play interface unit, composed of a touch screen and bluetooth keypad
• PlanetCNC software, pre-installed on a Raspberry Pi 4 and already congured (software used to control your
machine)
• A lifetime license of PlanetCNC
• A power cable for the control unit (EU plug)
• An AMB 1400 FME-P DI spindle, which is controlled by the software
• A touch probe device to locate your workpieces easily
• All the basic tools necessary to assemble the machine
• A USB key
In addition to the above mentioned items, you will need the following ones in order to be able to properly use
the machine:
• A spoilerboard. At rst, a simple wood panel is enough to get a grasp on CNC machining and we don’t think
it’s relevant to ship such an bulky object, which is easy to nd at your local hardware shop. When being
more experienced, we suggest building a threaded insert grid on a surfaced spoilerboard.
• A vacuum cleaner and a dust shoe, to help you work in a clean environment and to be protected from the
rotating tool while the machine is working.
• A CAM software. You will need a Computer Aided Manufacturing software to translate your 3D models into
a G-code readable by the machine. We suggest to use Fusion360.
• A table which can bear the weight of the machine.It needs to be robust and sti, as vibrations will aect
the precision of your cuts.