PILLAR MACHINE H49 User manual

H49
USER MANUAL
PILLAR MACHINE, LLC
1810 W 5000 S
Salt Lake City, UT 84129
801-965-1900 | 800-369-5746

TABLE OF CONTENTS
Machine Specicaons
Safety Precauons
Inial Setup
Operang Procedures
Control Panel
The Glue / Water System
Dowel Length Adjustment
Seng X-Axis Backlash
Programming
Main Screen
Main Screen in Edit Mode
Maintenance Screen
Maintenance Schedule
Maintenance Tips
Diagram Glossary
Electrical Cabinet
Exploded Views
Horizontal Clamps
Glue Valve
Dowel Feed Bowl
Bowl Driver
Spare Parts List
Bowl Driver Instrucons
Motor RPM vs Hz Conversion Chart
Warranty

MACHINE SPECIFICATIONS
Model: H49
Voltage: 220 VAC 3 Phase
60 Hz 12 Amp
Air: 90 psi @ 20 CFM
Dust Collecon: 350 CFM
MATERIAL RESTRICTIONS
Work Piece Length………………………... Up to 49"
Work Piece Width…………………..….… Unlimited
Work Piece Thickness……….……....... Up to 1”
DRIVES
X Axis - Rack and inion
Y Axis - Mechanical by use of Digital Readou
Z Axis - Mechanical by use of Digital Readou
MACHINE DIMENSIONS
Length - 78” Depth - 52” Height - 76”
Weight 1400 lbs. (approximae)
H-49 CNC HORIZONTAL POINT TO POINT MACHINING CNR
The model H-49 is a horizontal point to point bore and dowel inseron machining center. It is designed to CNC posion the spindle, bore a hole,
then CNC posion the inserter, inject glue or water (for pre glued dowels), and re the dowel into the hole. A part is placed into the work zone
referencing the back and side fences. The green palm buon is pressed and the clamps secure the part into place. The machining is now ready
to begin in the work zone. There are 2 zones standard in the base model H-49 allowing for pendulum processing. While the one part is being
machined, the other zone can be loaded and queued for machining.
SPINDLE CONFIGURATION
The machine is equipped with a 1 HP High Frequency 18,000 RPM Direct Drive Router Spindle mounted onto a 1/2" machined aluminum sur-
face. All wiring to the carriage is carried in an enclosed E Track to prevent damage to crical components. The 18,000 RPM spindle speed guar-
antees the boring bit concentricity, ensuring an accurate hole size for maximum glue contact. The high RPM also allows for rapid plunge boring
to be accomplished without losing the integrity of the boring surface. Pre-glued dowels can be used due to the accuracy and integrity of the
hole.
CLAMPS
The HP-49 comes standard with 4 quick adjust vercal clamps. Each clamp has 314 psi clamping force for maximum clamping capability.
GLUE INSERTER
The Glue Inserter is designed to accurately dispense glue into the hole in a predened metered amount. The glue nozzle is made of a self-
sealing nonsck Delrin material to allow for either glue or water to be used in the machine. It consists of an enclosed system using needle and
seat at valve, high pressure pump to 1,500 psi, with steel braided lines, innite adjustment to all valves.
DOWEL INSERTER
Our patented dowel inseron system is a straight forward design. It has proven to reliably insert dowels without the need for realigned. Dowel
depth is set via a mechanical digital readout located on back of machine and is easily adjustable for dierent length dowels. The "Direct Reject
System" automacally detects an improperly sized dowel and noes the operator via the operator interface for dowel removal. The dowel
reject slide is opened, the dowel is removed, and then normal operaon is resumed.

SAFETY PRECAUTIONS
INITIAL SETUP
Please keep in mind these simple safety reminders when working on or around this ma-
Make all electrical connecons in accordance with local electrical code.
Disconnect power before servicing
Before opening or working in control panel, always turn o main power.
Always make sure power is o when changing drill bits or working around drill head.
Always wear safety glasses when running this machine
Always have hands clear from moving parts when operang machine.
Aer removing the outer crate, remove the plasc wrap covering the machine. Remove any blocks that are holding the machine
to the skid and carefully remove the machine from the skid.
You can fork from the front or back of the machine, just make sure the forks go far enough through to catch both the front and
back of the frame.
Place the machine into the general vicinity where it will be.
If necessary, level the machine using the 4 machine pads under each corner.
Install computer/touchscreen. See installaon procedures on the following page.
Connect the proper air supply. 3/8” diameter line is recommended.
The pressure should be 90-100 PSI @ 10-15 CFM to the machine.
Connect the proper power supply to the machine including grounding. 208/220 VAC 3 Phase.
Connect the proper dust collecon to the machine. (2 1/2” outlet)
Install the correct tooling.

OPERATION PROCEDURES
1
2
3
Control
1—Main Power Switch
The main power disconnect switch box is located on the le side of the machine near the air regulator. The lever must be in the
up, or ‘ON’ posion for the machine to operate.
2—Emergency Stop
The ‘E-stop’ buon is located in the center of the machine. Use this switch to stop the machine in an emergency. It will lock in
the down posion and the knob must be twisted to reset.
3—Zone Start Switches
The ‘Zone Start Switch’ is located above the fence of each zone and will begin the operaon of the machine if the ‘Program Run’
buon on the main screen has been acvated and a part is in posion in the respecve zone to be started. The ‘Zone Start
Switch’ buon will illuminate and stay illuminated unl the operaon has been carried out in that parcular zone, or the Emer-
gency Stop buon has been pushed. The H49 has two zone.

GLUE / WATER SYSTEM
Convenonal Dowels and Glue
Purging the System
Purge the glue valve before you use the machine to remove air in the system.
Prepare the glue pot.
Place glue in the glue pot. Make sure the pick-up tube goes into the glue when placing the lid back on the pot.
Tighten the pot lid down evenly. Now turn the pot pressure up to 20-30 PSI on the gauge.
Adjust glue pump pressure.
There is a glue pump with a regulator mounted on the side of the machine just above the pressure pot. Run the
glue pump at a pressure that will keep the glue owing properly. You do not need to use excessive pressure on
the system. Recommended glue pump pressure is around 70 PSI. Adjust air pressure to obtain desired amount
of glue ow. For water, the pump is not needed. Pot pressure set to 20 PSI is sucient.
Purge the System.
Place a small container under the clamp bar just in front of the nozzle. Press the purge buon located on the
main screen of the touchscreen. You should start to see glue coming out of the nozzle in about 2-3 seconds.
Run for 5 seconds to make sure the air is out of the line.
This is a sealed system and does not have to be ushed out aer each use.
Flushing the System
Flush the system with hot water once or twice a month, depending on use.
Remove the glue from the pot, clean the pot and ll a small container with hot water. Place the container in the pressure pot.
Place the pick-up tube in the container of water. Install lid and ghten the clamps.
The pressure should be set between 10-15 PSI since water is thinner than glue.
Place another small container under the clamp bar directly in front of the nozzle. Press the purge buon on the main screen. Wa-
ter will come out of the nozzle in about 2-3 seconds. Connue unl water comes out clear. This should only take about 10
minutes to complete.

GLUE / WATER SYSTEM
Connued
Using Pre-glued Dowels and Water
You must use dislled or boled water. Regular tap water in most cases contains too many mineral deposits that may cause
the nozzles to leak. Upon installaon of the water in the pressure pot, you will need to purge the system to get liquid to each
nozzle.
Purging the System
Place the water into the plasc bucket provided, then in the pressure pot. Place the lid on and ghten the clamps.
The pressure should be set between 10-15 PSI. You do not have to use the glue pump mounted just above the
pressure pot if you are using only water.
Next, place the white purge cup provided under the clamp bar and just in front of the nozzle. Press the blue purge
buon on the control panel. You should start to see water coming out of the nozzle in about 2-3 seconds. Let it run for
5 seconds to make sure all the air is out of the line.
DOWEL LENGTH ADJUSTMENT

SETTING X-AXIS BACKLASH
When re-installing the X axis servo, it will be necessary to reset the backlash. Backlash should be adjusted to .003 using a dial indi-
cator.
1. Re-install the servo and adjust inial backlash unl most of the play has been removed. Tight-en the four bolts holding the ser-
vo assembly adjustment plate.
2. Place a dial indicator with the dial on the side of the Carriage.
3. Enable the servo, now give a rm "shove" to the carriage in one direcon and zero the dial. Then "shove" in the opposite direc-
on and check your dial reading.
4. Adjust the backlash by loosening the 4 bolts holding the servo assembly adjustment plate and moving the 1/4-20 backlash ad-
justment bolt located just above the servo assembly adjustment plate (see photo below).
5. Tighten the 4 bolts holding the servo assembly adjustment plate and perform steps 3 & 4 as necessary to achieve .003" back-
lash.
6. Re-home the machine.
NOTE: If the adjustment is too loose the machine will not cut accurately. If the adjustment is too ght, the servo may make a
"whining" noise.

PROGRAMMING

PROGRAMMING
Program Funcons
Home Machine: The home machine buon is used when the machine is rst started
up. This allows the machines axis to nd their home posion. (Machine must be Re-
Homed when the Estop has been pressed or when the machine has faulted.)
Edit Mode: Edit mode is used when the operator wants to program a new part into
the machine for use. The password to enter into edit mode is 311. Pressing End Edit
will exit edit mode and only allow the user to open and run programs.
Dry Run: The Dry Run feature is used when the operator wants to run a program with-
out the tools spinning.
Spindles Up: The Spindles Up feature is used when the operator wants to run the pro-
gram without the pneumac for the spindles ring.
Feed Rate Override: The Feed Rate Override is used when the operator wants
to slow the speed in which the machine is processing the part. This feature
can be used when the machine is in operaon.
Units Buon: This buon is used to switch between Standard and Metric
Graphic View Buon: This buon is used to switch between graphic views. (On machines
with mulple side operaons.)
Shut Down Buon: This buon will shut down the program, and the PC.

PROGRAMMING
Connued
Inserng Operaons: To insert an operaon, begin by pressing
the Add buon.
Then select one of the operaons to perform.
Once the operaon is selected press the Insert Operaon buon
to insert the operaon.
Find the operaon that has just been added. Highlight the opera-
on that is to be edited by pressing on the screen where the op-
eraon is located. Once highlighted, press the Edit buon to edit
the operaon that has been added.

PROGRAMMING
Connued
Part Dimensions: This is where the operator will enter the di-
mensions for the part that is being programmed. Part length is
mainly used to describe how many clamps are used per
workzone, as well as dene the graphic image that represents
your part.
Operaons: This is where the operator will Add, Edit and Delete
the operaons for the program being designed.
Opmize Ops for Speed: This will opmize the operaons to be
performed as fast as the machine can see possible.
Perform Ops in Sequence: This will tell the machine to perform
the operaons in the sequence in which the operator inputs
them. Not applicable to standard doweling machines.
Purge Glue Buon: This buon will purge the glue valve.
(used to drain glue system)
Glue Time: The Glue Time is used to set the amount of me the
glue valve stays open. Thus delivering more or less glue/water.
(measured in Milliseconds.)

PROGRAMMING
Connued
Horizontal Standard Drill Operaon:
Insert the Horizontal Standard Drill Operaon.
Highlight the operaon, then press edit.
Choose what spindle to use to perform the operaon, standard
HPJ uses H1
Drill hole opts to drill a hole at the described locaon.
Insert dowel will drive a dowel into the described locaon.
The X Posion is located from the side fence to the center of the
hole. Zone 2 and 4 will mirror the operaon.
The Close Buon is used to accept the osets entered.
Repeat funcons can be used to standardize, or simplify
your recipe library. Instead of creang unique programs for
each part, you can describe paerns to trigger o of spe-
cic part size condions. Greater than, less than, equal to,
etc.

PROGRAMMING
Connued
Vercal drill operaons can be selected on your HPJV. This allows us to use
the vercal drill to place holes in the top face of the board. Drill depth is
referenced from the face of the board, and adjusted by a mechanical DRO.
It is important to remember the centerline adjustment for the enre car-
riage also impacts this drill depth reading.
Use X posion to place the vercal hole in relaon to the side fences. And
the mechanical DRO adjustment sets the hole posion from the backfence.
Repeat and part length condions may also be set on this operaon.

MAINTENANCE
To enter into the maintenance screen press the Maintenance
buon, then enter the password 411.
This is the I/O secon. It is used to check communicaon between
the sensors and the program.
The boxes with the red lights are the inputs.
(Sensors, lights, etc.)
The boxes with the green lights are the outputs. Pressing the
buon will re the output associated with the buon.
(Example: Pressing the Clamp 1 buon will re all the clamps asso-
ciated with Zone 1.)
This secon is good for troubleshoong for the operator and the
technician involved with technical support.
This is the Osets secon.
It is used to correct any calibraon problems with the programs
being made on the main page.
Changing these numbers will change the locaons of holes, routes,
depths, etc.
If unsure about using this secon please contact tech support for
help.
This is the Backup secon. It is used to backup osets and pro-
grams. In case of program, PC or machine failure. It is always rec-
ommended to keep a backup of these les on a separate PC other
than the one provided with the machine.
Maintenance Screens

MAINTENANCE
This is the Axis secon. It is used to manually control the axis.
The Enable buon will enable the selected axis. Pressing again will
disable the axis.
Manual posion will move the axis to the input positon once the
go buon is pressed.
The Oval shaped buon in the center is a slider bar. This allows the
operator to manually jog the carriage in a Posive or Negave
direcon. It will only move the selected axis.
The Units buon changes the machine between Standard and
Metric. Changing this in the Maintenance Screen changes the units
for every program made. Unlike the units buon on the main page
that will only change it per program made.
The Exit to Windows buon is used to exit out of the program to
the Windows desktop.
The Return to Main buon will switch back to the main screen of
the program where the programs are made.
Maintenance Screens Connued

MAINTENANCE
Parts Requiring Maintenace
Cabinet Fan Intake Filter Daily
Table Surface Areas Daily
Backstops and Fences for part locating Daily
All sensors and Proximity Switches Daily
X and Y linear slide bearings and Rails (Carraige and Drill) Daily 80 Hrs
X Axis rack and pinion gears (Carriage) Daily 80 Hrs
Z Axis linear slide bearings and rails (Opiton) Daily 80 Hrs
Z Axis ball screws (Option) Daily 80 Hrs
MAINTENANCE KEY:
Daily: Maintenance listed below should be performed as often as needed
during operation on a daily basis.
Hours (Hrs.): Maintenance listed below should be performed each time the
machine has been in operationfor that length of time.
Example: Clean rails and grease each bearing with 1 pump of grease at zerk
fitting every 80 hours of operation.
Clean
dust and
chip
buildup
Clean
grease
and
grime.
Apply
spray-on
dry lube.
Clean
grease
and
grime.
Give 1
pump
grease at
zerk
RECOMMENDED GREASE TYPE:
MOBIL TH SCHyPM NGLI Grade 1/5 or equivalent HIGH PERFORMANCE LITHIUM BASED GREASE.
RECOMMENDED SPRAY-ON DRY LUBRICANT:
SPRAYON S00708 T.F.E. DRY LUBE, or GRAPHITE BASE LUBRICANT
AIR SYSTEM LUBRICATOR:
Use a high grade, light hydraulic oil in the air lubricator bowl. Set the drip rate for approximately one drop every 100 cycles.
(completely close valve and open 1/8 to 1/4 turn)
BARE STEEL PARTS:
Spray on Boeshield T-9 Waterproof Lubricant and wipe evenly with a clean rag to coat Clamp Bar once a month or as need-
ed to prevent rust. (Pillar Machine part # S4410)
NOTE:
All support bearings on Ball Screws are sealed bearings and do not require addional lubricaon.

MAINTENANCE
HINTS TO KEEP YOUR GLUE SYSTEM RUNNING SMOOTHLY
CHANGES IN THE VISCOSITY (Thickness) OF YOUR GLUE:
When maintaining your glue system, you should be aware that the viscosity of your glue may change throughout the year. You
may need to make slight adjustments to your glue system during dierent mes of the year because of these changes.
The viscosity of glue is changed by various factors… Such factors are temperature, humidity, and adding or
subtracng a thinning agent. Below you will nd a few points to help your glue system funcon properly.
Be aware of temperature and humidity changes. This is something you will have to be aware of when it comes to
using glue through any type of automac dispensing devise. Glue will not ow the same during 40 F shop tem-
pera tures. In the winter as it does during 80 F shop temperatures in the summer. When its colder you may have to
increase the mer seng. Don’t forget to turn it down when it’s warm or you will have a glue mess to clean up.
Keeping the glue mixed. The white or PVA (Poly Vinyl Acetate) glue you will be using is a water based product. It
consists of solids and water that must remain mixed together to keep it’s consistency . A good quality glue does not
separate as easily as a poor quality glue might. When lling the pressure pot always shake or sr the glue before
pouring it into the pressure pot.
DON’T OVER GLUE:
There is a ne line between too much and not enough glue in the dowel hole. Don’t get in the habit of having a big squeeze out
around the dowel. This will cause a big mess on your parts as well as the machine.
KEEP THE MACHINE CLEAN FROM GLUE:
Take the necessary me to celan the excess glue from the table, nozzles or any other area it may get while its sll fresh. Again, it
will be me well spent. A clean machine will run beer.
TO KEEP THE GLUE SYSTEM FLOWING PROPERLY:
You will need to ush out the system on a regular basis. This will stop glue solids from bulking up and restricng the ow. This
should be done once or twice a month depending on use.
See Glue / Water System page for instrucitons on ushing the system.
NOTE: THERE IS A MINI REGULATOR MOUNTED JUST ABOVE THE GLUE SOLENOID VALVE ON THE CARRIAGE WHICH CONTROLS
THE BACK PRESSURE ON THE GLUE NEEDLE VALVE. DO NOT EXCEED 25 PSI. DOING SO CAN DAMAGE THE NEEDLE INT EH GLUE
VALVE INJECTOR, CAUSING IT TO LEAK.

ELECTRICAL CABINET
AE2911 FUSE HOLDER
BE2655 24 V POWER SUPPLY
CE2351 VARIABLE FREQUENCY DRIVE
DE7102 DOWEL BOWL CIRCUIT BOARD
EE3480 SERVO AMPLIFIER
FE2185 RELAY 24 V 6 AMP
GE2116 RELAY 24 V
HE7210 I/O CONTROLLER
IE7205 BREAKOUT BOARD
JE7102 DOWEL BOWL CONTROLLER
KE7201 MOTION CONTROLLER
LE7494-7COMPUTER

EXPLODED VIEWS