Printed Circuit Board Isolation Routing System

Project Number: P14311

Printed Circuit Board Isolation Routing System Maintenance Manual

Original Publishing Date: Latest Revision Date: Revision History: A Table of Contents I. Safety Reminders II. Bypassing the Interlock system to perform maintenance III. Bosch Colt PR20EVSK Palm Router A. Spindle and Collet Cleaning B. Changing Milling/Drilling Bits C. Carbon Brushes Check and Replacement D. Bearings Check and Replacement IV. Vacuum Work Table A. Cleaning Vacuum Body B. Replacing the Sacrificial Layer V. Zen Toolworks CNC Mill A. Cleaning and Lubrication B. Fastener Tightness Check C. Leadscrew/Backlash Nut Check and Replacement VI. Vacuum System A. Removal and Disposal of Waste B. Vacuum Check and Replacement I. Safety Reminders The safety alert symbol is used to identify safety information about hazards that can result in personal injury. A signal word (DANGER, WARNING, or CAUTION)is used with the alert symbol to indicate the likelihood and the potential severity of the injury.

DANGER represents a hazard which, if not avoided, will result in death or serious injury. WARNING represents a hazard which, if not avoided, could result in death or serious injury. CAUTION represents a hazard which, if not avoided, could result in minor or moderate injury. NOTICE indicates a situation that could result in damage to the product.

DANGER Electrical Hazards- System runs on 120 VAC power. Touching exposed electronics or wiring during operation can result in electric shock, causing serious injury or death. ● If exposed electronics or wiring is visually identified, use the emergency stop button to put the PCB Isolation Routing system into emergency state ● Do not touch items or perform maintenance unless system power source (120VAC power cord) is disconnected.

WARNING Rotating parts can contact and entangle fingers/hands, hair, clothing, or accessories. Traumatic amputation or severe laceration can occur. Operate equipment with guards and interlock activated ● Keep fingers/hands away from rotating parts ● Tie up long hair and remove jewelry ● Do not wear loose fitting clothing, dangling drawstrings, or items that could become entangled

WARNING Running the components of the PCB Isolation Routing System produces heat. Specific components, such as the stepper motors, router, electronics enclosures, and vacuum exhaust can become particularly hot. Thermal burns can occur on contact. ● Allow stepper motors, router, electronics enclosures and vacuum exhaust to cool before touching ● Remove accumulated debris from vacuum exhaust and milling bed

CAUTION Copper and substrate particulate debris will be generated by drilling and milling operations. Debris can cause irritation and injury to eyes if blown onto operator’s face during operation or clean-up. ● Always wear safety glasses during operation, especially when enclosure door is open, or if performing system maintenance

NOTICE During operation, the PCB Isolation Routing system produces noise at average rating of 84 dBA. If using equipment for prolonged period of time (8 hours or greater), hearing can be impacted. ● Wear hearing protection when possible, especially if using the PCB Isolation Routing system for extended periods of time.

II. Bypassing the Interlock system to perform maintenance There may be certain maintenance conditions that require electrical power to be provided to critical moving components while the enclosure door is open. For this condition to be possible, the interlock system must be bypassed.

Some conditions were bypassing the interlock may be required include:  Maintenance to the router or vacuum system  Cleaning the enclosure of machining debris  Zeroing without the use of the webcamera

WARNING Bypassing the interlock should only occur in necessary maintenance operations. If power to the system is not required to perform the maintenance task, then the operator should NOT bypass the interlock system.

To bypass the interlock system: 1. Open the door to upper half of the enclosure 1.1. Note: Lights should turn to a purple hue, signifying that the system is in an interlock state. 2. Insert the interlock cheat tool into the interlock to depress the switch button

3. Click on the system reset button in the Mach3 software. Once this has been done, the operator will be notified by the return to normal system lights and milling/drilling programs can be restarted. 4. Perform required maintenance activities 5. Remove interlock cheat tool to finish maintenance and restart interlock system 6. Close the door to enclosure to re-actuate the interlock. 7. Click on the system reset button in the Mach3 software. Once this has been done, the operator will be notified by the return to normal system lights and milling/drilling programs can be restarted.

III. Maintenance Instructions A. Bosch Colt PR20EVSK Palm Router A.1. Spindle and Collet Cleaning A.1.a) Hold down the spindle lock on the router and rotate the spindle until the spindle lock can be fully depressed. Use the collet tool to loosen the collet nut until it can be turned by hand, usually about ¼ turn.

A.1.b) Lift debris collection bracket and secure with binder clip. Remove the entire collet/collet nut assembly from underneath the dust collection bracket. A.1.c) Override interlock system with maintenance key. Activate the router and run at top speed. A.1.d) Using a cotton swab moistened with one drop of Son of ColletCare, clean the inside of the taper bore of the spindle from inside to outside, repeat until cotton swab comes out clean. A.1.e) Reinstall collet assembly and bit.

WARNING Never use a finger wrapped in a paper towel to clean the spindle bore or serious injury could result. ● Only use cotton swabs to clean the spindle bore

A.2. Changing Milling/Drilling Bits

A.2.a) Hold down the spindle lock on the router and rotate the spindle until the spindle lock can be fully depressed. Use the collet tool to loosen the collet nut until it can be turned by hand, usually about ¼ turn.

A.2.b) Lift debris collection bracket and secure with binder clip. Remove entire collet/collet nut assembly from underneath the dust collection bracket.

A.2.c) Remove previous bit from collet/collet nut assembly and replace with new bit. Bit depth ring should be flush with collet face. Removing collet from the collet nut is not necessary. (A.2.c.1) Note: For more information on the collet see: http://www.precisebits.com/tutorials/er_collet_system.asp A.2.d) Thread collet/collet nut assembly onto the spindle until hand tight while holding the

spindle lock. A.2.e) Remove binder clip holding debris collection bracket in upright position. Hold down the spindle lock on the router and using the collet tool, tighten the collet about ¼ turn. WARNING Running the spindle and collet assembly without a bit securely installed can result in damage to the collet and spindle. Unsecured components can be thrown from the router and cause operator injury. ● Ensure collet assembly, with bit installed, is secure before starting router

A.3. Carbon Brush Check and Replacement a) Bosch recommends that the carbon brushes contained in the router be checked every six months. b) Remove brush caps with flathead screw driver and remove carbon brushes. c) Inspect brushes and replace if less than 1/4" carbon remains. d) Installation is reverse of removal. B. Enclosure and Vacuum System B.1. Replacing the Sacrificial Layer on Vacuum Table B.1.a) Move the spindle to the highest point on the Z-axis. Also bring the vacuum table as far forward as possible by adjusting the Y-axis. Finally center the spindle in the middle of the vacuum table by adjusting the X-axis. B.1.b) Remove all four screws in each corner of the vacuum table; this can be done with a XXX Allen wrench. B.1.c) Remove the old sacrificial layer and replace with a new one. B.1.d) Place the screws back in their respective holes and tighten them until they are firmly secure. B.2. Cleaning the workstation of Debris a) Open enclosure to access machinery b) Remove any registration pins, boards, ball bearings, or miscellaneous tools from the workspace. c) Disconnect the vacuum hose from the vacuum table d) Turn on the vacuum within the Mach3 program by pressing the “Mist On” button. e) Use the vacuum hose to remove debris from the enclosure. a.3. Removal and Disposal of waste from Vacuum System a.3.a) Open the front bottom door of the enclosure. a.3.b) Unplug all hoses connected to the vacuum and remove the vacuum from the enclosure. a.3.c) Unlatch the clips holding the top portion of the vacuum to the bottom and remove it. a.3.d) Inside the bottom portion of the vacuum, you will see a bag. Remove the old bag and replace it with a new one. a.3.e) Re-attach the top portion of the vacuum and re-latch the clips. a.3.f) Place the vacuum back inside the enclosure and reconnect all hoses.