BobsCNC KL7 Series Assembly Manual

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K L 7 S e r i e s

Controller Assembly

Manual

MANUAL 6 of 8

Version 2.1

Page 1

Table of Contents

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Page 1 K L 7 S e r i e s Controller Assembly Manual MANUAL 6 of 8 Version 2.1 Page 1...
Page 2: Table Of Contents
Table of Contents Controller Assembly Safety Information………………………………………………………………………………..3 Parts List……………………………………………………………………………………………….4-9 Assembly Instructions: Attaching Power Supply to Bottom Plate……………………………………………..10-13 Attaching Drivers/UNO Board to Shelf………………………………………………...14-18 Connecting Power Supply Wires….……………………………………………………...19-24 Front Panel Assembly with Emergency, Hold & Resume Switches………..25-26 Attaching Power Switch to Left Side Panel…………………………………………...27 Controller Encloser Assembly……………………………………..……………………...28-30 Connecting Power and Emergency Stop Switches…...………………………..31-33 Installing Shield and Connecting Control Wires………..…………….…………..34-49...
Page 3: Controller Assembly Safety Information
Hints will provide needed information, shortcuts, and insights that will make assembly and machine operation easier and safer. Hint Please review each assembly manual before beginning to assemble the KL7 series CNC Router. Page 3...
Page 4 Please refer to the 24” x 18” Controller Wiring Diagram enclosed with your KL7 series CNC Router Kit. Page 4...
Page 5: Parts List
Parts List Parts for assembly include: Wood Components Part # Description Photo Front Panel Back Panel Wire Clamp Right Side Panel Left Side Panel Driver/Uno Shelf Page 5...
Page 6 Part # Description Photo Bottom Plate Top Plate Page 6...
Page 7 Hardware and Electrical Components Part # Description Photo Small Zip Ties M4 x 16 Machine Screws M4 Nuts M2.5 x 16 Machine Screws M2.5 x 16 Nuts 3mm Spacer 8mm Spacer KL-350-148 110V AC 48V DC Power Supply 24 V Servo Driver Uno Screw-Shield Power Supply Switch Emergency Off Switch...
Page 8 Part # Description Photo #14 Black 440mm AC Power Wire (fork/ fork) (fork/female) #14 White 210mm AC Neutral Wire (fork/ fork) #14 White 140mm AC Neutral Wire (fork/ female) #14 Green 210mm AC Ground Wire (fork/ fork) ]E13 #14 Green 140mm AC Ground Wire (fork/ female) #14 Black 210mm...
Page 9 Part # Description Photo #22 Black 40mm Jumpers 1 ea. #22 Brown, Blue 80 Power Cord Page 9...
Page 10: Attaching Power Supply To Bottom Plate
Attaching Power Supply to Bottom Plate Make certain the Power Supply Selector CAUTION Switch is set to 110V as seen below. Failure to do so will negatively affect machine performance. Step 1.0 Switch power selector to the 110VAC as shown. Select switch voltage as shown Turn the C7 Bottom Plate over so that the lasered letter are face down.
Page 11 Use blue painter’s tape to hold the Machine Screws Step 1.2 temporarily in place as shown below. Gently rotate the Back Plate so the Machine Screw Step 1.3 threads are visible. Slip a 8mm Spacer over each of the four of the Screws as shown. Page 11...
Page 12 Spacers are used to create an air space to CAUTION facilitates air flow around each Power Supply and the Uno Controller. Failure to use the spacers may cause the Power Supply to overheat and/or fail. Carefully orient the receiver holes on the bottom of the Step 1.4 Power Supply over the Screws and Spacers.
Page 13 Step 1.6 With the Power Supply beneath the Bottom Plate, carefully remove the painter’s tape to expose one M4 X 16 Machine Screw and tighten securely with a Phillips head screwdriver. (repeat for until all four M4 X 16 Machine Screws are secure.
Page 14: Attaching Drivers/Uno Board To Shelf
Attaching Drivers/UNO board to Shelf Step 2.0 Place DIP switch to the correct position as shown. Make certain the “1” and “4” DIP (Dual In- CAUTION Line Package) Switches are set as shown. If the switches are not set correctly the Servo Motors will not operate properly.
Page 15 Align DIP Switch end of the driver to face the Axis Step 2.2 Designation (X1, X2, Y and Z). Elevate the Screw head and slip the Drive base slot around the Screw. Then holding Base snug against the Screw, insert a M4 x 16 Screw through the opposite end and secure with a Nut.
Page 16 Carefully center the four 3mm Spacers above each of Step 2.4 the mounting holes on the UNO Template as shown. Gently orient the mounting hole of the UNO Board over Step 2.5 the Spacers and place one M2.5 x 16 Machine Screw through each of the four mounting holes as shown.
Page 17 Hold Screw heads in place with pieces of blue painter’s Step 2.6 tape. Thread a M2.5 Nut onto each of the Screws and secure. Step 2.7 Do not over-tighten the Screws and Nuts to protect the UNO board. Page 17...
Page 18 The completed installation is shown below. The orientation of the Servo Drivers and the Micro Controllers is important. Page 18...
Page 19: Connecting Power Supply Wires
After every wire connection is made, securely tighten the terminal screw and firmly tug on the attached wire to ensure that it is securely connected. Always refer to the KL7 Series Controller Wiring Diagram when following the instructions in this manual.
Page 20 Connect the #14 Green 140 mm AC Ground Wire (fork/ Step 3.1 female) to earth ground on Power Supply as shown. NOTE: The female connector will be connected in a later step. Page 20...
Page 21 Connect Power Supply neutral terminals using the #14 Step 3.2 White 210mm AC Neutral Wire (fork/fork) as shown. Add #14 White 140mm AC Neutral Wire (fork/female) Step 3.3 to the neutral terminal on Power Supply as shown. NOTE: The female connector will be connected in a later step.
Page 22 Connect Power Supply load terminals using the #14 Step 3.4 Black 210mm AC Power Wire (fork/fork) as shown. Connect the #14 Black 440mm AC Power Wire (fork/ Step 3.5 fork) to load terminal on Power Supply as shown. NOTE: The forked terminal will be connected in a later step.
Page 23 Connect the Power Supply (-V) DC ground terminals Step 3.6 using the #22 Black 210mm wire as shown. NOTE: The DC ground wire must be routed neatly beneath the AC wires as shown below. Connect a #22 Black 130 mm wire to the Power Supply Step 3.7 (-V) DC ground terminal as shown below.
Page 24 Attach the Red/Black #18 350 mm wires to the Power Step 3.8 Supply as shown. Note the red wires to +V and the black wires to the –V as shown. There are two sets of wires for each Power Supply. Attach the #18 Black/Red 350 mm wires to the second Step 3.9 Power Supply as shown.
Page 25: Front Panel Assembly With Emergency, Hold & Resume Switches
Front Panel Assembly with Emergency Stop, Hold, and Resume Switches Step 4.0 To attach the Emergency Stop Switch to the Front Panel, first disconnect the red button from the switch base by depressing and turning the twist lock. Next, use a small Step 4.1 Phillips screwdriver to back out the...
Page 26 Attach the Yellow “Hold” Step 4.3 button by first removing the plastic nut from the back of the button switch. Insert the switch wires and the threaded base through the hole marked “Hold” on the front panel and secure by firmly reattaching the plastic nut.
Page 27: Attaching Power Switch To Left Side Panel
Attaching Power Switch to Left Side Panel Attach the Power Switch to the Left Side Panel and secure Step 5.0 with two M2.5 x 16 Screws and Nuts. NOTE: Make sure the switch is on the top with the receptacle on the bottom as shown.
Page 28: Controller Encloser Assembly
Controller Encloser Assembly Attach the C1 Front Panel to the C 7 Bottom Plate and Step 6.0 secure with two M4 x 16 Machine Screws and Nuts as shown. Attach the C2 Back Panel to the C7 Bottom Plate and Step 6.1 secure with two M4 x 16 Machine Screws and Nuts as shown.
Page 29 Align the tabs on the C6 Driver/UNO Shelf to the C1 Step 6.2 Front Panel into the corresponding slots and carefully slide into place. Turn the Controller Box with the left side down. Align Step 6.3 the tabs and slots of the C4 Right Side Panel, Drive Shelf and Bottom Plate and slide into place, then secure with five M4 x 16 Machine Screws and Nuts Page 29...
Page 30 Repeat the process to attach the C5 Left Side Panel to Step 6.4 the Back Panel and Bottom Plate and secure with five M4 x 16 Machine Screws and Nuts as shown below. Page 30...
Page 31: Connecting Power And Emergency Stop Switches
Connecting Power and Emergency Stop Switch Connect the #14 Green Step 7.0 140mm AC Ground Female end to Power Supply Switch lower blade as shown. Connect the 120 V #14 Step 7.1 White 140mm AC Neutral Female end to Power Supply Switch right side blade as shown.
Page 32 Separate the plastic Step 7.3 terminal block from the Emergency Stop Switch with Phillips screwdriver as shown. Attach #14 Black 440 mm Step 7.4 AC forked connector from the Power Switch to the Emergency Stop Terminal Block as shown. Step 7.5 Attach #14 Black 440 mm AC forked connector on the Power Supply to the...
Page 33 Secure the #14 black wires to the Back Panel with Step 7.7 two Zip Ties and shown below. ZIP ties Page 33...
Page 34: Installing Shield And Connecting Control Wires
Installing Screw Shield and Connecting Control Wires Step 8.0 Carefully fit the pins of the Screw Shield into the UNO Controller sockets ensuring the rearward pins and sockets match as shown. Align rearward pins and sockets (labeled A5 and D0). Page 34...
Page 35 Step 8.1 Attach #22 Black 130 mm DC Ground Wire from the Power Supply to the GND on the Screw Shield as shown below. Page 35...
Page 36 Step 8.2 Using the #22 black 40mm jumpers, connect driver pins 2 and 4, as shown. Step 8.3 Using the #22 black 40mm jumpers connect driver pins 4 and 8 as shown. Step 8.4 Insert one #22 black 80mm jumper in pin number 8 as shown.
Page 37 Step 8.5 Repeat for all four Drivers as shown. Page 37...
Page 38 Step 8.6 Attach the two black Home and Resume Switch wires to the “GND” terminal as shown. Attach the Yellow “Hold” wire to the number 5 (A1) Screw Shield terminal and the Green “Resume” wire to the number 4 (A2) terminal as shown. Page 38...
Page 39 Daisy-chain the four Drivers using the #22 red 80mm Step 8.7 wires by connecting to the number 7 screw terminal (ALM+) as shown below. Page 39...
Page 40 Connect the #22 red 180mm alarm wire with the ferrite Step 8.8 coil to the number 7 screw terminal of the X1 Driver. Connect the other end to the A0 Terminal on the Screw Shield as shown. Page 40...
Page 41 Step 8.9 Attach the #22 Green 160mm wire from the number 1 (PL+) screw terminal on the X1 driver to the D2 terminal on the Screw Shield as shown. X1 Driver Page 41...
Page 42 Step 8.10 Attach the #22 Brown 160mm wire from the number 1 (PL+) screw terminal on the X2 driver to the A4 terminal on the Screw Shield as shown. X2 Driver Page 42...
Page 43 Step 8.11 Attach the #22 Orange 250mmwire from the number 1 (PL+) screw terminal on the Y Driver to the D3 terminal on the Screw Shield as shown. Y Driver Page 43...
Page 44 Step 8.12 Attach the #22 White 320mm wire from the number 1 (PL+) screw terminal on the Z Driver to the D4 terminal on the Screw Shield as shown. Z Driver Page 44...
Page 45 Step 8.13 Attach the #22 Yellow 160mm wire from the number 3 (DIR+) screw terminal on the X1 Driver to the D5 terminal on the Screw Shield as shown. X1 Driver Page 45...
Page 46 Step 8.14 Attach the #22 Gray 160mm wire from the number 3 (DIR+) screw terminal on the X2 Driver to the A3 terminal on the Screw Shield as shown. X2 Driver Page 46...
Page 47 Step 8.15 Attach the #22 Blue 250mm wire from the number 3 (DIR+) screw terminal on the Y Driver to the D6 terminal on the Screw Shield as shown. Y Driver Page 47...
Page 48 Step 8.16 Attach the #22 Purple 320mm wire from the number 3 (DIR+) screw terminal on the Y Driver to the D7 terminal on the Screw Shield as shown. Z Driver Page 48...
Page 49 Step 8.17 Neatly Zip Tie the control wires as shown Page 49...
Page 50: Connecting The Home Switches
Connecting the Home Switches Step 1 Label and lay out the Home Switch Cables and remove outer sheathing from each Cable to expose 4 inches of the wires within. Repeat for the remaining Home Switch Cables. NOTE: The Home Switches are cut to the same length as the Servo Motor Cables.
Page 51 Step 2 Trim each of the wires, leaving exposed wire lengths as shown in the table. Description Exposed length Brown and Blue 1/2 inch wires Black X2 and Z 1/2 inch wires Black X1 and Y 3/16 inch Step 3 Repeat for all four of the Home Switch Cables.
Page 52 Step 4 Align all 4 blue wires and twist them together as shown. Step 5 With the locking lever open insert the bundled blue wires and close the locking lever as shown. Locking lever open Locking lever closed Page 52...
Page 53 Repeat the aligning, trimming and twisting all four of the Step 6 brown wires, then insert into the connector as shown. Open the locking levers and insert the #22 brown and blue Step 7 80 mm wires in the opposite side of the connector and lock them into place by closing the lever as shown.
Page 54 Align, twist, and trim the X2 and Z black wires to 3/16 inches Step 8 of exposed length as shown. Step 9 Attach the twisted pair (X2/Z) to the D12 pin. Tighten securely in place and test by tugging on the wire. Page 54...
Page 55 Attach the Y Black Home wire to the D10 pin. Tighten securely Step 10 in place and test by tugging on the wire. Attach the X1 Black Home wire to the D9 pin. Tighten Step 11 securely in place and test by tugging on the wire. Page 55...
Page 56 Attach the blue ground wire to the Gnd pin. Tighten securely Step 12 in place and test by tugging on the wire. Attach the brown power wire to the 5VDC pin. Tighten Step 13 securely in place and test by tugging on the wire. 5 VDC Page 56...
Page 57: Connecting The Servo Motors
Connecting the Servo Motors Step 1 Route the Z Servo Motor/Encoder Cables as shown. Step 2 Position Servo Motor Cable Connectors as shown. 6-Pin Encoder Connector 5-Pin Motor Connector Page 57...
Page 58 Step 3 Connect the Z Servo Motor and Encoder Cables as shown. Step 4 Connect the red power supply wire to the +Vdc as shown. +Vdc Page 58...
Page 59 Step 5 Position both the power supply ground and jumper ground to the GND of the Connector as shown. Step 6 Connect both the power supply ground and jumper ground to the GND of the Connector as shown. Two black wires connected to GND Page 59...
Page 60 Step 7 Zip tie the Z Servo Motor and Power Cables as shown. Step 8 Repeat the connecting process for the remaining three Servo Drivers as shown. (X1,X2 and Y) Page 60...
Page 61 Step 9 Place the C3 Wire Clamp into position and secure with 2 M4 x 16 Machine Screws and Nuts as shown. Inside View Outside View Page 61...
Page 62: Final Controller Assembly
Final Controller Assembly Step 1 Place C8 Top Plate into position. You will need to secure with eight M4 x 16 Machine Screws and Nuts once you verify that the CNC functions correctly. This can be done later. Step 2 Insert the Power Cord Page 62...
Page 63 Front View Back View Page 63...
Page 64: Attaching The Home Switch Magnets
Attaching the Home Switch Magnets Step 1 Plug in the USB to the Controller and to the computer. NOTE: Connect the USB to your computer to power up the Home Switches. Once connected you will be able to determine the polarity, orientation, and placement of the Home Switch magnets.
Page 65 Attaching the Home Switch Magnets Step 2 Position each side of the magnet close to the Home Switch until the LED illuminates. Draw an X on the side of the magnet that triggers the LED. Repeat this process for the remaining three magnets. Page 65...
Page 66 Step 3 Attach all 4 magnets in position using the double sided tape. Note: The position of the X1, X2 and Y placement is designated by a small drilled hole. The Z Magnet must be placed directly under the Home Switch as shown.