Planmeca PlanMill 30 S Service Manual
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Planmeca PlanMill 30 S Service Manual

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Planmeca PlanMill 30 S
Confidential Document
Not for Distribution
Do Not Copy
Service Manual
20173100.A

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Summary of Contents for Planmeca PlanMill 30 S

  • Page 1 Planmeca PlanMill 30 S Service Manual Confidential Document Not for Distribution Do Not Copy 20173100.A...

  • Page 2: Document Revisions

    Document Revisions Date Revision Document Changes 27-July-2018 Initial Release This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 3: Table Of Contents

    Introduction ........................6 Labels .......................... 6 Symbols .......................... 7 Product Identification Labels ..................... 8 Attention Labels ........................ 9 1.4.1 External Components and Connectors ................. 9 1.4.2 Protected Earth Ground Label .................... 9 1.4.3 UL Listings ........................... 1 0 System Overview ...................... 1 1 Specifications ......................... 1 2 Configurations ........................ 1 3 Special Tools .
  • Page 4 Receiving at Distribution Center .................. 4 2 System Requirements ..................... 4 4 8.1.1 Site Installation ........................ 4 4 8.1.2 External Connections ...................... 4 4 Planmeca PlanMill 30 S Installation ................ 4 5 Moving the Planmeca PlanMill 30 S ................. 4 5 Mill Lockdown Removal .................... 4 6 Setting up the Network .................... 4 9 10 Calibration ........................ 5 1 10.1 Origin .......................... 5 1...
  • Page 5 13.7 12 Volt Power Supply....................... 9 3 13.8 Quad Motion Driver Board.................... 9 5 13.9 Single Board Computer (SBC) ................... 9 8 13.10 Fan ..........................102 13.11 Lid Interlock ........................103 13.12 LCD Display Assembly ....................104 14 Motion Base ......................... 1 05 14.1 Linear Motor Coil ......................105 14.3 Motor Magnets ......................109 14.4 Encoders ........................114 14.4.1 X Axis Encoder ........................ 1 14 14.4.2 Y Axis Encoder ........................ 1 17 14.5 Servo Motor ........................120 15 Pneumatics System ...................... 1 22...

  • Page 6: Introduction

    1 Introduction This manual is for the technician who will service the Planmeca PlanMill 30 S. The following chapters provide procedures for setting up, troubleshooting, calibrating, and repairing the mill. After reading this chapter, the technician should be familiar with; • The features and functions of the Planmeca PlanMill 30 S • The specifications and requirements of the system • The tools and equipment required to maintain the system • Procedures for contacting Planmeca and E4D Technologies for additional assistance 1.1 Labels Label Identification Note Helpful information that may not be obvious to the casual reader Caution Indicates a potentially hazardous situation which, if not avoided may result in minor or moderate injury or damage to property Warning Indicates a potentially hazardous situation which could result in death or serious injury This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or...

  • Page 7: Symbols

    1.2 Symbols Symbol Definition Alternating Current IEC 60417-5032 Caution: ISO 7000-434A Date of Manufacture This product must NOT be disposed of with other waste. It is the user’s responsibility to dispose of their waste electrical and electronic equipment by handing it over to an approved processer, or by returning it to E4D Technologies for reprocessing. For more information about where you can send your waste equipment for recycling, please contact your local city office or E4D Technologies. Manufacturer OFF Power IEC 60417-5008 ON Power IEC 60417-5007 ON/OFF Power IEC 60417-5010 Operating Instructions ISO 7000-1641 Protective Earth IEC 60417-5019 European Conformity This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 8: Product Identification Labels

    1.3 Product Identification Labels 1.3.1 Affixed to the mill are product identification labels that contain identification and safety information. Be certain to read all product labeling. 1.3.2 The mill’s serial number and Windows software keys are located next to the tank or on the back of the mill. Note: Please contact E4D Technologies if any of the labels are illegible or missing. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 9: Attention Labels

    1.4 Attention Labels 1.4.1 External Components and Connectors When connecting external components to the mill, attach only components that have been tested for compliance with IEC 60601-1 or UL. 1.4.2 Protected Earth Ground Label This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 10: Ul Listings

    1.4.3 UL Listings UL Laboratory Equipment Testing LISTED In Accordance with UL 61010-1 30SC E253493 This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 11: System Overview

    2 System Overview The Planmeca PlanMill 30 S from E4D Technologies is a state of the art computer driven 4 axis milling machine with a single spindle designed to create dental restorations based on digital images acquired from the design components of the Planmeca FIT System. Operators use the scanner to scan the image of a prepped tooth or teeth into the system. Software on the system is used to design and refine a restoration before being transmitted to the Milling Center via a TCP/IP network connection. The mill then uses the digitally captured data to create the restoration. You connect the mill to the other components via a conventional wired Ethernet network. The mill can also be a shared resource for multiple Planmeca FIT systems. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 12: Specifications

    3 Specifications The Planmeca PlanMill 30 S uses the standard electrical current and compressed air but, does not connect to a water supply or drain. Model Number: PlanMill 30S Electrical Ratings 120-240 VAC,1500W, 50-60 Hz Air Supply 55 PSI, minimum 1 cfm, filtered dry air Data connection Cat 5 Ethernet cabling -4° F to 140° F (-20° C to 60° C) Storage Temperature 5% to 95% RH, “non-condensing” Operating Temperature Indoor use only 41° F to 104° F (5° C to 45° C) Transient overvoltage category II per IEC 60364 Maximum altitude 6,592 ft. (2000 meters) Maximum 80% non-condensing relative humidity for temperatures up 88° F (31° C) Pollution degree 2 Dimensions 17.5 in. (455mm) tall 26 in. (661mm) wide 20 in. (508mm) deep Minimum Required Clearances Sides 2 in. Rear 1 in. Top 12 in. Weight 135 pounds (61 kg) Electrical and Mechanical Safety UL 61010-1:2015 3 Edition CSA C22.2 No 61010-1:2012 3 Edition This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or...

  • Page 13: Configurations

    ISO 13485 Registered Firm 4 Configurations 4.1 20100102 Planmeca PlanMill 30 S Config 1 This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 14: Special Tools

    5 Special Tools 20105502 Mill Accessories Kit 20137601 Nozzle Cap Removal Tool 10165802 Stuck Tool Removal Bar 90026701 Twisted Wire Brush 20144901 Collet Removal Tool 90026801 Mini Brush This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 15: Mechanical Design

    6 Mechanical Design The milling center is composed of a number of sub-assemblies. Each sub-assembly is relatively self-contained in form and function. The major sub-assemblies include the Motion Base, Control System, Circulation System, Pneumatics System, and the Enclosure. 6.1 Motion Base The motion base of the milling unit includes the physical structure and various components to allow for three linear positioning axes, rotating mandrel axis, a tool changer, an automatic chucking spindle, and a grinding chamber. This structure is supported and isolated from the rest of the machine by four rubber isolation dampers to minimize external vibrations to the rest of the machine and to minimize any effects of an uneven support surface. Grind Chamber Spindle Isolation Dampers This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 16: Xyz Motion Stage

    6.2 XYZ Motion Stage As the name implies, the motion stage has 3 linear degrees of freedom in the X, Y, and Z directions. Each stage uses precision mechanics combined with close loop servo motor control to precisely position each axis simultaneously during the tool path execution. The XYZ stage is assembled such that the Z carriage carries both the X & Y, and the Y carriage carries the X, and the X carries the spindle. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 17: Z-Carriage

    6.3 Z-Carriage The z carriage utilizes four precision linear bearings which travel along to two linear rails that are mounted in a vertical orientation to the main baseplate. A Z carriage is mounted to the 4 linear bearing and may translate along the linear rails via a rotary servo motor and ballscrew assembly. Each of these components is of high precision and provides the ability to precisely position the axis with micron level resolution. Additionally, the preload of the bearings and ballscrew was specifically selected to provide the stiffness required to maintain positional accuracy during machining operations. The servo motor is directly coupled to the ballscrew and utilizes a rotary encoder which allows for closed loop control to endure long term positional repeatability. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 18: Y-Carriage

    6.4 Y-Carriage Two Y axis linear rails are mounted to the Z carriage in the horizontal orientation and have a Y carriage mounted to two linear bearings which translate (front to rear) along the rails. The preload of the bearings was specifically selected to provide the stiffness required to maintain positional accuracy during machining operations. The linear servo motor is directly coupled to the Y carriage and utilized a linear encoder also directly coupled to the carriage. These two components provide for closed loop control with direct feedback indicating actual position of the carriage assembly and elimination any concern of backlash or slop in the axis. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 19: X-Carriage And Spindle

    6.5 X-Carriage and Spindle An X axis linear rail is mounted to the Y carriage in the horizontal orientation and has two linear bearings which may translate (left-right) along the rail. The preload of the bearings was specifically selected to provide the stiffness required to maintain positional accuracy during machining operations. The linear servo motor is directly coupled to the X carriage and utilizes the same linear encoder as the Y axis and is also directly coupled to the X carriage. These two components provide for closed loop control with direct feedback indication the actual position of the carriage and eliminating any concern of backlash or slop in the axis. The simplicity of the liner motor drive system used on both the Y and X axes provides for ease of assembly and long service life with minimal components. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 20 The X carriage is designed specifically to clamp the automatic chucking spindle. The spindle is capable of spinning grit grinding tools at speeds of up to 100,000 RPM. These tools are used for machining fully and partially sintered ceramic and composite materials. A collet is part of the spindle that clamps onto the grinding tool. The collet may be opened and closed pneumatically through software control. When combined with the tool changer assembly, this automatic chucking feature provides the ability for the machine to automatically change the tool when necessary without operator intervention. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 21: Tool Changer Assembly

    6.6 Tool Changer Assembly The milling center includes a tool changer, which provides the ability for the machine to change tools under software control, without operator assistance. Since the tools have different lengths, the machine incorporates a means to detect the length of the tool to both detect the specific type of tool being used and to compensate for the wear of the tools between subsequent jobs. This is accomplished by pushing the non-spinning tool or grinder onto a ceramic block and detecting the obstruction through the control system. Because of the high stiffness of the mechanics and the sensitivity of the positional feedback of the control system very high sensitivity for the length detection can be achieved. The block from which the dental restoration is machined is held by a mandrel that is glued to the block and inserted into the mandrel holder that is mounted to the tool changer assembly and is spatially fixed. The mandrel holder includes a quick-release mechanism (cam) to allow blocks to be easily inserted and removed. The block/mandrel assembly can be installed in either a horizontal or vertical position. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 22: Grind Chamber

    6.7 Grind Chamber The grind chamber allows both operator access to the mandrel holder and spindle for simple operations when it is open and also protects the operator from flying debris and provides coolant containment during the grinding process when closed. It encloses the working volume of the milling machine and utilizes a spring open operated lid with pneumatic latch release which provides the operator access when open. The lid may be closed manually by the operator. When closed, two magnets incorporated in the lid activate dual UL safety interlock switches which complete the electrical circuit allowing power to be provided if commanded by the software. Conversely, the switches provide a safety mechanism for the machine when the lid is opened by positively opening the electrical circuit and preventing electrical power to the servo and spindle motors. The grind chamber mounts to the vertical baseplate and has the tool changer assembly protruding into the grind chamber from the rear, thus filling the rear section. The lower section provides a drain which allows coolant and small debris to exit the chamber and drain back into the tank. The lid encloses the top region of the chamber, both sides of the chamber utilize sliding wall assemblies to allow free movement of the spindle through their XYZ range of travel. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 23: Rear Utility Panel

    6.8 Rear Utility Panel The rear of the milling center is a sheet metal panel. The panel has several components attached to its inside face which include: • 48VDC Power Supply • Power entry module • SBC • Pneumatics module with air multiplier Access to these components for service is enhanced with the ability to “fold back” the panel from the frame on an integrated hinge with built in stop. Both the SBC and the pneumatics module slide onto the Utility Panel from the top and are secured with two screws easily accessed from the top. The power supply and power entry module both secure to the panel with screws from the rear or outside face of the panel. Should additional access be required, the panel can easily be lifted off the hinge and free of the frame rails. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 24: Pneumatics System

    6.9 Pneumatics System Several components on the milling unit require pressurized air to operate. The control and use of pressurized air with these components is known as the pneumatics system. This machine is divided into two systems, high and low pressure. The high-pressure system handles all the actuators in the system. Actuators are devices that move in one way or another. These items typically require high pressure (85 psig) but little flow (<0.2 SCFM). The low-pressure system is used to provide purge air to the spindle and consumes quite a bit more flow (1 CFM) but at a lower pressure (35psig). This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 25: High Pressure System

    6.9.1 High Pressure System Major components of the high-pressure system include: • Air board • Air multiplier • Water separator unit • Filter/regulators • Solenoid control valves • Pneumatic actuator Pressurized air is supplied via an external source which is connected directly to the rear of the machine. The quality of the provided air should be such that liquid water is prevented from condensing out of the compressed air during use. This is obtained by use of a dryer on the compressed air being used. The water separator unit acts as a small reservoir for the system while also allowing a means to collect and remove liquid water from the system. Control of the pressurized air to the actuators is handled by the bank of software controlled electrically driven solenoid valves mounted on a common manifold. Each solenoid is digitally controlled by the computer and can provide pressurized air on demand to the pneumatic actuator. Each actuator’s rate of operation can be fine-tuned by using adjustable inline flow control valves that can control the volumetric flow to and from the component, thus controlling the rate of extension and retraction. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 26: Low Pressure System

    6.9.2 Low Pressure System Purge air flow to the spindle is controlled via a solenoid valve on the manifold. When the valve is opened, air is allowed to flow through a fixed orifice Flow Control and an air filter then onto the spindle where it flows past the bearings providing a cooling effect and out through the nose of the spindle where is positive pressure is created minimizing the likelihood of foreign fluid or debris entry into the spindle. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 27: Circulation System

    6.10 Circulation System Milling fully or partially sintered ceramic requires a wet grinding process. The milling center utilizes a circulation system to deliver and recycle water-based coolant to the grinding surface. The major components of the circulation system include: • Circulation tank • Pump • Sensors • Plumbing • Coolant The milling center software monitors the age of the coolant and the amount of milling that has occurred. The operator is prompted when it is time the change the coolant. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 28 This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 29: Electrical

    6.11 Electrical The milling center electrical system consists of a main Power Utility Bridge board and several satellite boards which perform various sub functions of the mill. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 30 This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 31: Control System

    6.12 Control System The milling center control system is the description given to the electrical components used to drive and control the electro-mechanical components of the machine via software. This system consists of the following components: • Single board computer (SBC) • LCD touch display • Quad motion driver (QMD) • Bridge board • Power supply • Power entry module • Air board • Water board tool break board • Tool changer board This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 32: Single Board Computer (Sbc) & Lcd Touch Display

    6.12.1 Single Board Computer (SBC) & LCD Touch Display The SBC runs an embedded Windows 8 O.S. configured specifically for operating the milling machine with only the necessary operating system features enabled and boots directly into the milling center application. Interaction with the operator is solely through an LCD and touchscreen display screen using the graphical user interface (GUI) for operation of the machine. In addition to running the milling center application, the SBC also runs the tool path generation program (Job Server) and ACS Soft Controller for low level motion control. The jobs are received from the Design Center application via a wired or wireless network connection then displayed in the job list. Upon being selected by the operator, the job is sent to the job server where the toolpath coordinates are generated and provided back to the milling center for execution by the ACS Soft Controller (SC). The SC is uniquely configured to operate independently on 1of the 4 cores of the Intel I7 CPU. It uses a separate real-time operating system (RTOS) thus it is completely independent of the Windows 8 O.S. which runs on the 3 remaining cores. The SC handles all communication and control of the low-level motion control hardware and communicates to it through a dedicated deterministic Ethernet protocol called EtherCAT. The milling center application communicated with the SC through the use of an API as well as buffered programs which are executed directly on the SC. The LCD Touch Display incorporates a high resolution (800 x 480) true color (64-bit) display with an active touch panel and two capacitive touch user buttons. The touch panel supports both multi-touch and gesturing inputs. The LCD and touch display are for normal operator interaction with the system. While the two user buttons are for powering Up/Down the machine and executing a stop operation through the software. Specifically, the green power button operates as a soft start and soft shutdown button and emulates the operation of the power button on a typical PC. The red stop button is always available to the operator and initiates a stop requires through the software to neatly abort any operation which may be in process. Each button provides an increased illumination visual feedback to the operator to indicate when it is being pressed. The input signals from these buttons and the LED feedback are controlled by the PIC processor. Although not required for normal operation, additional provisions are provided on the side of the milling machine to allow the operator to connect and external monitor, keyboard, and/or mouse. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 33: Quad Motion Driver (Qmd)

    6.12.2 Quad Motion Driver (QMD) Quad motion driver describes the EtherCAT 4-axis servo amplifier controller module. The module contains two Dual Axis ACS Universal Drive Modules (UDMCpc) each capable of driving 2 axes with feedback, a pcb, and mounting plate/hardware. Two QMD’s are required for the motion base for the left and right sides. Mounting of the QMD can be configured so that the same components can be configured and installed on either the LHS or RHS of the machine. One QMD drives a complete XYZ linear positioning stage and the corresponding spindle. In addition to controlling these motors, there is both dedicated and user specified digital inputs/outputs (DIO) used for other simple operations on the system. QMD’s reside on the EtherCAT network and are fully controlled by the SC. These IO signals are passed to the bridge board where they can be easily distributed as needed via the satellite boards. Additionally, the UDMpc modules provide a Safe Torque Off (STO) functionality to prevent the moving of motors when the lid to the mill is open. These signals are passed to the bridge board. Each QMD mounts to the vertical baseplate via the mounting plate which serves both as a physical mount and a heat sink. The tow UDM’s are mounted directly to this plate, which provides an efficient heat sink to the baseplate. The PCB plugs directly into both of the UDM’s and provides the required electrical connections to other systems in the machine. Additionally, the PCB incorporates a number of electrical capacitors which provide moderate electrical capacitive storage. The stored electrical energy provides extra power to the motion controllers during peak power usage. This strategy reduces the overall power requirements of the mill while still providing high performance. Each UDMpc can control 2 motors at up to 10 Amps / 20 Amps Peak per axis. Two of these modules are used on the mill to control the positioning axes and the spindle. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 34 6.12.2.1 XYZ Motor Control The XYZ motion control is performed by the UDMpc with an advanced PIV cascaded structure at a 20 KHz update rate. Motor position is provided by magnetic encoders for the X and Y axes with a resolution rate of 1 um. The motor position feedback of the Z axis is provided by a 2000/count per revolution encoder. The Z axis ballscrew moves at 2mm per revolution providing an effective resolution of 1 um. 6.12.2.2 Spindle Control The spindle motors are controlled through the UDM’s using a proprietary DSP program along with E4D developed buffer programs. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 35: Bridgeboard

    6.12.3 Bridgeboard The Bridgeboard connects to the QMD and provides electrical connections to all other electrical components in the control system for communication and supply electrical power. The EtherCAT connection between the UDM and the SC also is provided through the bridgeboard. The bridgeboard also contains the power supply monitoring circuits, redundant Safety Torque Off (STO) monitoring, the 48 to 24 volt power supply, and fan controller circuits. The bridgeboard incorporates an embedded PIC processor running E4D developed firmware which handles monitoring and communications between lower level boards such as the water, air, and lighting chamber boards. The PIC processor generates PWM signals required by the water pump and RGB chamber lighting. Communication between the firmware and the milling application is provided through a proprietary digital interface established between the QD<’s and the Bridgeboard PC. The pic firmware is structured as a main “super-loop”, running constantly, that checks each time through a set of tasks that may need to be performed. The code is written such that it does not stop and wait on something to happen or finish. The state is checked, stored, and then left alone unless or until immediate action can be taken. The code takes advantage of the free- running hardware microsecond and millisecond timers to track elapsed time, to mark past events, and to schedule future actions. Handling of the mill power supply, tool changer, and ACS SPI (serial peripheral interface) communication is performed by dedicated state machines for each, while handling of high level functionality, such as polled inputs, ADC measurements, and debug output, are performed from the main loop. Two priorities of interrupts are used judiciously in an effort to meet real time deadlines and also to perform small tasks effectively in parallel with the main super-loop. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 36: Air Utility Board

    6.12.4 Air Utility Board The air utility board contains driving circuits for the pneumatic solenoids, the water separator drain valve, high and low pressure measurement sensors, and a driving circuit to control and optional air compressor. 6.12.5 Water Utility Board The water utility board contains driving circuits for PWM control of the coolant pump and grind chamber RGB LED’s. It also contains the circuitry to read the water pressure, high and low water level sensors, and tank and lid interlock sensors. 6.12.6 Stepper Rocker Board The stepper rocker board is used to control and monitor the position of the mandrel during the milling process. The board contains the circuitry to position and rotate the mandrel during the milling process. 6.12.7 Tool Break Detection System 6.12.7.1 Tool Break Sensor Board If the grinding bur breaks and is undetected while milling a job, the job will be incomplete and a new ceramic block must be used when a new tool is installed. However, if burr breakage can be detected, it is possible for the mill to change to another tool and resume milling a few steps before the breakage was detected. An accelerometer is mounted to the spindle in order to detect tool breakage during grinding the monitoring the signature frequencies of the spindle. 6.12.7.2 Tool Break Processor Board An embedded microcontroller on the tool break processor board is responsible for high speed sampling of the accelerometer output. The processor packages the data in frames which are passed to the milling center software where FFT analysis is performed to detect changes in the signature frequencies of the spindle. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 37: Power Supply & Power Entry Module

    6.12.8 Power Supply & Power Entry Module The milling center is designed to utilize most common worldwide AC power sources available from 100 – 240 Vac 50 – 60 Hz. A suitable power cord is provided for the region to which it is sold and interfaces to the milling machine at the power entry module. This module provides an internal thermal circuit breaker to protect house power from excessive power draw in the event of a failure on the system. A main disconnect switch is also integrated into the power entry module and will remove all power from the machine. The power entry module connects directly to the 1000W 48VDC main power supply that supplies power to the UDM servo amplifiers on the QMD’s. A second smaller 48 VDC to 24 VDC power supply is mounted on the bridge board and provides power to all other components including: • UDM logic • Solenoids • Waterboard • Airboard The SBC utilizes an internal 24 VDC to 12 VDC power supply to power the computer. Numerous alarm signals from the power supply monitoring circuits are monitored by the PIC processor and passed up to the milling center software where alarm information can be displayed and logged. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 38: Enclosure

    6.13 Enclosure The machine is enclosed with a combination of injection-molded plastic covers and sheet metal panels. This design provides both and ergonomically appealing package and protects the operator or others from harm resulting from the moving components within the machine. There are basically five pieces which make up the complete cover assembly: • Top cover • Front door • Rear panel • Left side panel • Right side panel Each of these components is secured to a sheet metal frame attached to the bottom plate of the mill. The design of the covers is such that the majority of service operations can be addressed by removing just the top cover. Access to the securing bolts for the top cover is provided by opening of the front door. Should additional access be required, each side panel can be easily lifted free once the top cover has been removed. The rear cover can be easily rotated back and/or lifted free of the frame. Cooling fans are positioned on both side panels and take advantage of the natural heat transfer and adequately cool all electronic components located inside the unit. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 39: Safety Warnings

    6.14 Safety Warnings Warning Failure to adhere to all safety warnings may result in personal injury, equipment damage, or data loss. • This equipment is intended to be grounded. Connect the milling center to an earth grounded outlet only. • A detachable, non-locking power cord has been provided with this equipment as the disconnect device. Do not block access to the power cord. In case of emergency, remove the power from the device by unplugging the cord at either end. • To prevent electrical shock, exercise care when covers are removed. • The mill weighs 135 pounds. When lifting or moving the mill, follow the guidelines in the manual. • Always ensure that the mill is sitting on a surface capable of supporting the weight of the mill. • Use caution when handling the mill’s grinding tools. • Do not make any unauthorized repairs or modifications to the system software or hardware. This includes altering or bypassing any safety switches or mechanisms. • Do not install or operate the milling center in an environment where and explosion hazard exists, e.g., high oxygen area. • Comply with all applicable regulations when disposing of waste materials from the milling center. • Do not attach any equipment or devices to the milling center unless their use has been specifically authorized by E4D Technologies. • Medical electrical equipment requires precautions regarding EMC (Electromagnetic Compatibility). The E4D System must be installed and placed into service accordingly to the EMC information provided in the documentation that accompanies the E4D System. •...

  • Page 40: Warranty & Support

    6.16 Warranty & Support Warranty & Support of the Planmeca FIT System is warrantied as described in the User Manual. Technicians should refer the owners to the User Manual’s Safety Warnings so that they do not void their warranties. For technical assistance on the milling center, the owner should contact Planmeca USA. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 41: System Setup

    7 System Setup This chapter provides instructions for setting up the Planmeca PlanMill 30 S Milling Center. After reading this chapter you should be familiar with; • Requirements for setting up the mill. • Procedures for installing and setting up the system. • Operational checklist of the mil to verify proper function. 7.1 Getting Started This procedure outlines the process for installation, starting with the receipt of the Planmeca equipment at the distribution center, to the install at the customer site. After installation, the service technician will be responsible for verifying that all of the equipment has been installed correctly and is working. 7.2 Safety Requirements • Service personnel will observe their company’s safety procedures. • To prevent injury from sharp-edged packaging and shipping debris, receiving and or inspection personnel should wear safety gloves for unpacking. • All Milling Centers must have the shipping lock down system removed prior to normal usage. 7.3 Tools & Equipment Required • Metric Allen Wrench Set. • Box Cutter • Bubble Level, a length of six inches is recommended • 9/16” or 14mm wrench This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without...

  • Page 42: Receiving At Distribution Center

    • If damage is apparent, photograph damage prior to proceeding. • Remove all packaging material and locate the contents on the shipping list. • If disposition is not acceptable, contact Planmeca for corrective action. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 43 This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 44: System Requirements

    8 System Requirements The following Requirements must be met to install the Planmeca PlanMill 30 S. 8.1.1 Site Installation The Planmeca PlanMill 30 S is designed to operate on a flat, level, stable surface in an environment free from excessive moisture or dust. The unit should be located away from patient access area. The unit weighs approximately 135 pounds. Ensure that the surface on which the unit will set has the ability to support the weight of the unit adequately and safely. The location should provide sufficient clearance around the unit, both for operator access and adequate ventilation. Suggested clearances are; • Front: 24 inches (61cm) • Sides: 2 inches (5cm) • Rear: 2 inches (5cm) • Top: 16 inches (41cm) 8.1.2 External Connections The Planmeca PlanMill 30 S utilizes several external connections for proper operation. These include the electrical power connection, compressed air supply connection, wired Ethernet connection and USB receptacles. Only E4D approved connections should be made to the milling unit. The use of unapproved devices or supplies not complaint with E4D specifications can void the warranty. 8.1.2.1 Electrical AC Power The Planmeca PlanMill 30 S requires a suitable AC power outlet located nearby. Direct connection of the mill to the wall outlet using the appropriate power cord is required. Use of extension cords, power strips or other components is not allowed. 8.1.2.2 Air Supply A compressed air supply is required to provide filtered dry air at a regulated pressure between 50 and 130 psig (3.5 – 10 bars) with a minimum flow rate of 1 CFM. An air supply hose is provided.

  • Page 45: Planmeca Planmill 30 S Installation

    9 Planmeca PlanMill 30 S Installation The following procedure is provided to give guidance in locating and installing the Planmeca PlanMill 30 S. Once the proper requirements have been met for the location the unit may be positioned in place and prepared for operation. Caution The Planmeca PlanMill 30 S weighs approximately 135 pounds (61 kg) 9.1 Moving the Planmeca PlanMill 30 S Lifting the mill requires at least 2 people. You are advised to use a suitable cart rather than moving the mill by hand. Lifting and carrying should be kept to a minimum. Those lifting the mill should: • Stand close to the mill with their feet approximately shoulder width apart, with one foot slightly in front of the other for optimum balance. • Squat down by bending at the knees, not at the waist, keeping their backs as vertical as possible. • Be certain not to lift the mill using the plastic housing. • Firmly grasp the mill before beginning the lift. • Refrain from twisting your body during the lift process; ensure use of legs not your back to lift. • Keep the mill as close to the body as possible to minimize stress on the back. • If turning is required, turn by shuffling feet not by twisting your body. • If it is necessary to place the object below the level of the waist each person lifting should follow these procedures in reverse order, keeping your back vertical and bending at the knees. Position the mill, being careful to avoid obstacles. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without...

  • Page 46: Mill Lockdown Removal

    9.2 Mill Lockdown Removal The internal structure of the mill is locked down during shipping. This lockdown consists of placement of Styrofoam blocks on the motion base assembly. 9.2.1 Remove the locking bolts from the system (9/16” or 14mm) 9.2.2 Connect the power cord directly from the mill to proper AC outlet. 9.2.3 Connect the compressed air line to the mill via the “one- touch” fitting on the back of the mill. Then connect the other end of the airline to the customer’s compressed air source. A quick disconnect fitting or equivalent is recommended but it not provided with the mill. 9.2.4 Do not power on the mill. 9.2.5 Open the door and use the manual lid latch release to open the lid 9.2.6 Remove the Styrofoam inserts and desiccant from the grind chamber. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 47 9.2.7 Attach T-Handle Bracket to right side cover panel using the adhesive strips. 9.2.8 Open front lower door and place bubble level on base plate. Use the 4 adjustable feet to level the mill if necessary. 9.2.9 Insert filter into the water tank. 9.2.10 Place water tank into the mill. 9.2.11 Turn on the power switch at the rear of the mill. 9.2.12 Press the green power button on the display. 9.2.13 The software will boot to the Windows desktop then launch the milling center software. 9.2.14 Once the software has opened, the Milling Jobs screen will appear. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 48 9.2.15 Touch the Options button or the maintenance icon. 9.2.16 Either of these selections will take you to clean fluid tank wizard. 9.2.17 The software will state that the tank will need to be cleaned in 3 hours with continue or next selection. Select Next. 9.2.18 Follow the onscreen instructions to complete this process. 9.2.19 Ensure that the mill and job server are connected to the network. See procedure for setting up the network if necessary. 9.2.20 Mill Calibration Job 9.2.21 Upon successful completion of the calibration job, the mill is ready for use. 9.2.22 Using the tool manager function load the tool changer with ellipsoidal, conical, and tapered tools. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 49: Setting Up The Network

    9.3 Setting up the Network 9.3.1 Right click on the computer icon on bottom right of monitor. 9.3.2 Select change adaptor settings. 9.3.3 There will be two connections available. One will be the virtual adaptor and the other will be the local area connection. Select the local area connection. 9.3.4 Select Properties 9.3.5 Select Internet Protocol Version (TCP/IPv4). 9.3.6 Select Properties and enter the following. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 50 9.3.7 IP address should be set to 10.11.12.30. 9.3.8 Subnet Mask should be set to 255.255.255.0. 9.3.9 Default Gateway should be set to 10.11.12.1. 9.3.10 Preferred DNS should be set to 8.8.8.8. 9.3.11 Alternate DNS should be blank. 9.3.12 Click okay and save settings. 9.3.13 Go to task manager and restart both the E4D and E4D proxy services. 9.3.14 Start milling center application and verify communication. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 51: Calibration

    10 Calibration The milling machine must be calibrated to operate correctly and achieve the high degree of accuracy for dental restorations. The calibration procedure combines both the origin calibration and the tool changer calibration into one routine. 10.1 Origin The origin of the mill is a point in space which defines X=0, Y=0, and Z=0 for each of the axis and the toolpath is used to grind the dental restorations. The point is located on the front face of a mandrel (without a block) and centered both horizontally and vertically. We use the tip of the tool to define this point. 10.2 Tool Changer The tool changer calibration procedure aligns the tool changer with the spindle to allow for proper pickup and drop off of the tools into the tool holder pockets. This process also provides the mill with the means to measure the lengths of the grinding tools following replacement or post grinding process. The calibration process automatically calibrates the tool changer. Tools Required: • Tool Extractor • 30S Calibration Kit o USB Thumb Drive o Probe Tool o Calibration Die Note: Serial number on the USB must match the number on the calibration die. 10.3 Calibration Process. 10.3.1 From the job screen, select Options. 10.3.2 This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 52 10.3.3 From the options screen select Calibration. 10.3.4 The calibration wizard will initiate, tap Next. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 53 10.3.5 Tap Next to release the tool held in the spindle. The collet will open, the tool will be ejected from the collet and the lid will open. Using the tool extractor remove all of the tools from tool changer then tap Next. 10.3.6 Insert the USB drive into a USB slot on the mill. Slots are located on the right side of the mill. The number on the dye should match the number on the USB drive. Once verified, insert the dye into the mandrel holder and tighten cam. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 54 10.3.7 Remove the USB drive. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 55 10.3.8 Insert the probe and hold in place with finger. While holding, tap Next and close the lid. 10.3.9 The calibration process will initiate. The mandrel will be calibrated, followed by the spindle, and then the tool changer. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 56 10.3.10 Upon completion the following screen will occur. Tap Next to complete. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 57 This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 58: Calibration Bar

    10.4 Calibration Bar 10.4.1 The calibration bar is the milling of a block using a preloaded calibration job and then measuring for specified dimensions. Tools Required: • Digital micrometer • I12 block • Ellipsoidal tool 10.4.2 Load a new ellipsoidal tool into the spindle. 10.4.3 From the Job Options screen, select Calibration Jobs. 10.4.4 The screen will Display Calibration Jobs / Refine Calibration. 10.4.5 Select the Refine Calibration Job. 10.4.6 The lid will open. 10.4.7 Insert an Empress I12 block. 10.4.8 Close the lid. 10.4.9 The calibration job will start. 10.4.10 Remove the block and use a micrometer to measure the pair values for the Y Offset (y dimple sides and Y plains sides, the pair offset for Z Offset (Z dimple and Z plain sides), and the bar width (W). This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 59 10.4.11 The difference in these pairs of values indicate the accuracy of the offset calibration values. The acceptance criteria for the results are +/- 30um (0.030 mm). If the allowed tolerance is exceeded for the Y, Z, or W, then proceed to the Refine Calibration Procedure. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 60: Refine Calibration

    10.5 Refine Calibration 10.5.1 From the jobs screen, select Options. 10.5.2 Select Cal-Bar. 10.5.3 Input measured values. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 61 10.5.4 Select the Use Refinement box , select Save, select Mill Center. 10.5.5 Go to calibration jobs and mill calibration bar. 10.5.6 Upon completion, measure bar for verification. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 62: Maintenance And Status Icons

    11 Maintenance and Status Icons • Open Lid • Water Level • Water Pressure • Air Pressure • Maintenance Icon 11.1 Clean Fluid Tank. 11.1.1 Touch the Clean Tank and Collets icon. 11.1.2 Touch the Tank option. 11.1.3 Follow the onscreen instructions. 11.1.3.1 The tank and filter should be cleaned once a week to prevent mold growth or build- up of ceramic material. High volume offices will need to perform this process more frequently. 11.2 Empty or low fluid level. 11.2.1 Add water to the tank before starting the next job. 11.2.2 Pour water into grind chamber slowly until the water level turns shows as full and starts blinking on the display. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 63: Spindle Cap And Collet Cleaning

    11.3 Spindle Cap and Collet Cleaning. 11.3.1 Tap the icon. 11.3.2 Touch Clean Caps or Clean Caps/Collets. 11.3.3 Software will enter the cap and collet cleaning wizard. 11.3.4 Select Guided or Advanced. 11.3.5 Follow the onscreen instructions. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 64: Annual Maintenance

    11.4 Annual maintenance 11.4.1 Clean water tank. 11.4.2 Clean nozzle caps. 11.4.3 Replace collets. 11.4.4 Replace suction hose. 11.4.5 Replace O-rings. 11.4.6 Replace bumper. 11.4.7 Calibration bar. 11.4.8 Clean chassis fans. Part Number Part Name 20177303 Preventative Maintenace Kit 10151101 Grinder Ellipsoidal Tip RTI 4mm Shank 10180224 Mandrel-Blk ASM, LT A3, IPS e.max 90073001 O-Ring, Size #2-032, Teflon Coating 9003002 O-Ring, Size #2-022, Teflon Coating 20123202 Sycotec Spindle 4mm Collet 90060901 Suction Hose 3/8” ID x 5/8” OD x 22” Long 20144201 Tool Bumper 20173201 Snubber Assembly (includes black cable ties – not shown) 90077501 Collet Grease Kit This document is the property of D4D Technologies, LLC (dba E4D Technologies).

  • Page 65: Basic Repair Procedures

    12 Basic Repair Procedures 12.1 Mill Covers Most service operation will require removal of one or more of the covers enclosing the mill. It is not necessary to have power to the mill in order for the covers to be removed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 66 12.2 Top Cover Tools Required • 3mm hex wrench Removal: 12.2.1 To remove the top cover, open the front door, locate and loosen the 4 M5 hex head screws securing the top cover. It is not necessary to completely remove the screws. 12.2.2 Pull the lid latch release lever and open the grind chamber lid. 12.2.3 Carefully raise the cover and lift off the mill. Replacement: 12.2.4 Ensure grind chamber lid is open. 12.2.5 Lower the top cover in place ensuring the sides align properly with the left and right covers and the opening is properly aligned with the grind chamber. 12.2.6 Slide the cover down so that the slots in the cover properly align with the 4 M5 hex screws. Once the cover is aligned tighten the 4 M5 hex screws. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 67: Side Covers

    12.3 Side Covers Tools Required • 3mm hex wrench Removal: 12.3.1 Remove the top cover 12.3.2 The side covers are not secured with screws. The cover has 3 tabs that fit into slots on the mill frame. 12.3.3 Lift the cover and slide away from the mill to remove. Replacement: 12.3.4 Align the tabs on the cover with the slots on the mill frame the slide the cover down to lock in place. 12.3.5 Install top cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 68: Rear Cover

    12.4 Rear Cover Tools Required • 5mm hex wrench Removal: 12.4.1 Remove top cover. 12.4.2 Remove side cover. 12.4.3 Locate and remove the 4 M5 hex screws. 12.4.4 Once the 4 5mm hex screws have been removed the top portion of the cover will lay back from the mill at a 25° angle. 12.4.5 Some repair procedures may require the rear cover to be laid flat. 12.4.6 Power off mill. 12.4.7 Disconnect HDMI Cable. 12.4.8 Remove the Cat5 cable from the Bridge Board. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 69 12.4.9 Disconnect the cables on the Accelerometer Processing board and the Step Rocker board. 12.4.10 Disconnect the Cables going to the Bridge Board. 12.4.11 Tilt cover towards mill. Lift cover up and out of hinge plate. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 70 Replacement: 12.4.12 Lift the rear cover and secure into the hinge plate. 12.4.13 Attach the Bridge Board Cables. 12.4.14 Attach the accelerometer cables. Ensure that the cables are connected to the proper slots. 12.4.15 Attach Step Rocker cables. 12.4.16 Attach the HDMI cable. 12.4.17 Close and secure rear cover. 12.4.18 Reinstall side covers. 12.4.19 Reinstall top cop cover. Verification: 12.4.20 Power on mill and ensure proper initialization. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 71: Water Level Sensors

    12.5 Water Level Sensors Tools Required: • 3mm hex wrench • Pliers or adjustable wrench High Level Sensor Low Level Sensor Removal: 12.5.1 Using the proper Shutdown Sequence power down the mill. 12.5.2 Remove the top cover and open the rear cover. 12.5.3 Remove the water tank. 12.5.4 Looking from the front side of the mill remove the plastic nut securing the sensor to the shroud of the sensor being replaced. 12.5.5 Disconnect the sensor cable. 12.5.6 Remove the sensor from the backside of the mill. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 72 Replacement: 12.5.7 Insert the replacement sensor from the backside of the mill. The sensor will have 2 nuts. The nut closest to the rear of the sensor MUST not be moved as they have an offset of 25mm so that water levels are detected appropriately. 12.5.8 Once the sensor has been put into the shroud from the front side of the mill, attach the plastic nut to the sensor. Snug the sensor plus ¼ turn. 12.5.9 Connect the sensor to the cable. 12.5.10 Reinstall rear cover. 12.5.11 Reinstall top cover. Verification: 12.5.12 Insert water tank and power up mill. 12.5.13 Ensure proper initialization. 12.5.14 Sensor performance may be verified by level of water in the water tank or by removing the water tank and touching the sensor with finger. The LED associated with the appropriate sensor will illuminate on the water board when water or your finger is sensed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 73: Interlock Switches

    12.6 Interlock Switches 12.6.1 The mill has 2 interlock switches that are used to recognize that the water tank is properly installed in the mill. Tools Required: • 3mm hex wrench • 2mm hex wrench • Wire cutters Removal: 12.6.2 Using the proper Shutdown Sequence, power down the mill. 12.6.3 Remove the top cover and open the rear cover. 12.6.4 Disconnect the cable associated with the interlock switch. 12.6.5 Cut the tie wrap securing the interlock cable to the shroud. 12.6.6 Remove the 2 M2X10 screws securing the interlock switch to the shroud. 12.6.7 Remove the interlock switch. Replacement: 12.6.8 Put the replacement interlock switch into place. 12.6.9 Bias the interlock switch forward towards the front of the mill then secure using the 2 M2X10 screws. If replacing both switches please note that the switches are orientation specific. 12.6.10 Connect the sensor to the cable. 12.6.11 Reinstall rear cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 74 12.6.12 Reinstall top cover. Verification: 12.6.13 Insert water tank and power up mill. 12.6.14 Ensure proper initialization. 12.6.15 Sensor performance will be verified by the mills ability to sense the water tank during initialization. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 75: Pump

    12.7 Pump 12.7.1 The pump is located on the far-right side of the system mounted to the baseplate. Tools Required • 5mm hex wrench • 4mm hex wrench Removal: 12.7.2 Power off mill. 12.7.3 Remove top cover. 12.7.4 Remove side cover. 12.7.5 Open rear cover and lay flat. 12.7.6 Remove the 4 4M screws that secure the pump to the base of the mill. 12.7.7 Remove the clamp securing the hose. 12.7.8 Remove the tubing at the “one-touch” fitting on the pump. 12.7.9 Slide the pump out of the back of the mill. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 76 12.7.10 Remove the 3/8” or 10mm bolts securing the pump to the bracket. 12.7.11 Carefully remove the “one-touch” fitting. Replacement: 12.7.12 Attach the “one-touch” fitting to the new pump. 12.7.13 Secure the pump to the bracket. 12.7.14 Slide the pump into the mill. 12.7.15 Connect the tubing to the “one-touch” fitting. 12.7.16 Slide the hose onto the barb and secure with clamp. 12.7.17 Secure the pump to the baseplate using the 4M screws. 12.7.18 Lift the rear cover, reattach and secure all connections. 12.7.19 Close and secure rear cover. 12.7.20 Install side covers. 12.7.21 Install top cover. Verification: 12.7.22 Power on mill and verify proper initialization. Using Diagnostics to check the following: 12.7.23 Turn pump on 12.7.24 Ensure there are no water leaks. 12.7.25 Ensure there are no fluid pressure errors. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 77: Water Utility Board

    12.8 Water Utility Board 12.8.1 The water utility board is located on the far left front side of the mill. Tools required • 2.5mm hex wrench • 3mm hex wrench Removal: 12.8.2 Power off mill. 12.8.3 Remove top cover. 12.8.4 Remove left side panel. 12.8.5 Disconnect tubing at the “one-touch” fitting. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 78 12.8.6 Disconnect cables. 12.8.7 Remove the 3 M3 hexscrews. 12.8.8 Remove the board. Replacement: 12.8.9 Align and install replacement board. 12.8.10 Connect all cables. 12.8.11 Attach tubing to “one-touch” fitting. 12.8.12 Install top cover. Verification: 12.8.13 Power on mill, ensure proper initialization. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 79 12.8.14 Use diagnostics to check the following; • Check float sensors to ensure proper water levels are detected. • Run pump to ensure proper function and water pressure. • Open and close lid to ensure lid latches are functioning This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 80: Snubber

    12.9 Snubber The snubber prevents and suppresses excessive water pressure from reaching the pressure transducer on the water utility board. Tools Required: • 3mm hex wrench • Wire cutters Removal: 12.9.1 Power off mill. 12.9.2 Remove top cover. 12.9.3 Cut tie wrap securing snubber to frame 12.9.4 Disconnect snubber from one-touch fittings. Replacement 12.9.5 Connect snubber to one-touch fittings. 12.9.6 Secure with tie wrap. 12.9.7 Install top cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 81 Verification: 12.9.8 Power on mill, ensure proper initialization. 12.9.9 Go to technician console. 12.9.10 Set spindle rpm to 30000. 12.9.11 Turn on pump. 12.9.12 Ensure there are no leaks. 12.9.13 Check water pressure to ensure pressure is reading properly or mill a restoration to verify performance and no fluid pressure errors are observed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 82: Electronics

    13 Electronics 13.1 Accelerometer Board 13.1.1 The accelerometer board is used as the monitoring system for tool break detection. The accelerometer boards are located on the XR axis. It is mounted directly to the X axis bracket. Tools Required: • 2.5 mm hex wrench • 3mm hex wrench Removal: 13.1.2 Power off mill. 13.1.3 Remove top cover. 13.1.4 Remove the 2 M3 screws. 13.1.5 Remove accelerometer board. 13.1.6 Disconnect power cable. Replacement: 13.1.7 Connect power cable. 13.1.8 Align and secure accelerometer board to bracket. 13.1.9 Torque to 5in-lbs. 13.1.10 Install top cover. Verification: 13.1.11 Power on mill and ensure proper initialization. 13.1.12 Mill restoration to verify performance. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 83: Accelerometer Processing Board

    13.2 Accelerometer Processing Board The accelerometer processing board is used as part of the tool break detection process. The accelerometer processing board is located on the outer box of the CPU mounted to the rear cover assembly. Tools Required: • 2.5 mm hex wrench • 3 mm hex wrench Removal: 13.2.1 Power off mill. 13.2.2 Remove top cover. 13.2.3 Remove right side cover. 13.2.4 Open rear cover. 13.2.5 Remove M3 screws securing the board to the CPU. 13.2.6 Disconnect USB cable. 13.2.7 Disconnect Accelerometer board cable. 13.2.8 Disconnect USB cable. Replacement: 13.2.9 Connect USB cable. 13.2.10 Connect accelerometer board cable. 13.2.11 Ensure that the cable is connected to the proper connector. 13.2.12 Align and secure accelerometer processing board to CPU. 13.2.13 Close and secure rear cover. 13.2.14 Install side covers. 13.2.15 Install top cover.

  • Page 84: Bridge Board

    13.3 Bridge board 13.3.1 The Bridge board is mounted on the back side of the grind chamber. This board provides power to the Quad Motor Driver Boards. Tools Required: • 3mm hex wrench Removal: 13.3.2 Power off mill. 13.3.3 Remove top cover. 13.3.4 Remove side covers. 13.3.5 Open rear cover. 13.3.6 Disconnect the following connectors. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 85 13.3.7 Pull the Bridge Board away from the Quad Motion Driver Boards then lift out of the mill. 13.3.8 Remove the 2 M3 X 12 Cap screws. 13.3.9 Remove the 4 M3 X 8 Cap screws and the plastic washers. Replacement: 13.3.10 Place replacement Bridge Board into mill. It is imperative that the UDMI ports on the Bridge Board are aligned with the UDMI pins on both the left and right Quad Motion Driver Boards. 13.3.11 Once the UDMI ports are aligned, push the left and right levers down. 13.3.12 Reconnect the following cables: • Fans • Power Port • Front Panel Port • Air Utility Signal Port • Tool Changer Sensors • Water Utility Port • COM Port • Ethernet • PWR ALM Standby • Air Utility Power Port 13.3.13 Close and secure Rear Cover. 13.3.14 Install side covers. This document is the property of D4D Technologies, LLC (dba E4D Technologies).
  • Page 86 13.3.15 Install Top cover Verification: 13.3.16 Power on mill and ensure proper initialization. 13.3.17 Upon completion of initialization check for errors. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 87: Led Array Grind Chamber Board

    13.4 LED Array Grind Chamber Board 13.4.1 The LED Array Grind Chamber Board is mounted to the front side of the grind chamber just behind the manual lid latch. This board provides power and signal to the Aux LED boards and interlock switches. Tools Required: • 5mm hex wrench • 2.5mm hex wrench Removal: 13.4.2 Power off mill. 13.4.3 Remove top cover. 13.4.4 Remove Aux LED connectors. 13.4.5 Remove interlock connectors. 13.4.6 Remove J1 connector. 13.4.7 Remove 2 M3 screws securing board to mill. 13.4.8 Remove board. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 88 Replacement: 13.4.9 Align and secure LED Array Grind Chamber Board. 13.4.10 Connect Aux LED connectors. 13.4.11 Connect interlock connectors. 13.4.12 Connect J1 connector. 13.4.13 Install top cover. Verification: 13.4.14 Power on mill and ensure proper initialization. 13.4.15 Verify LED performance during the initialization. 13.4.16 Use Diagnostics to open and close the lid to verify interlock performance. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 89: Led Aux Board

    13.5 LED Aux Board 13.5.1 The LED Aux Board is located just below the lid assembly on the front side of the mill. This board provides the LED colors used by the mill as the different processes are performed. Tools Required: • 3mm hex wrench • 2.5mm hex wrench Removal: 13.5.2 Power off mill. 13.5.3 Remove top cover. 13.5.4 Disconnect Aux LED connector. 13.5.5 Remove 2 M3 screws. 13.5.6 Remove board. Replacement: 13.5.7 Align and secure replacement board. 13.5.8 Connect Aux LED connector. 13.5.9 Install to cover. Verification: 13.5.10 Power on mill and ensure proper initialization. 13.5.11 Verify LED performance during initialization. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 90: Power Supply Module

    13.6 Power Supply Module 13.6.1 The power supply module is located at the back of the mill on the bottom left inside portion of the rear cover. Tools Required: • 2.5mm hex wrench • 3mm hex wrench • 5mm hex wrench • Small crescent or adjustable wrench Removal: 13.6.2 Power off mill. 13.6.3 Unplug mill. 13.6.4 Remove top cover. 13.6.5 Remove side covers. 13.6.6 Open rear cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 91 13.6.7 On the back of the rear cover, remove the 4 M3 screws securing the power supply module to the rear cover. 13.6.8 Disconnect the 12V power supply cable. 13.6.9 Disconnect the AC Inlet cable. 13.6.10 Disconnect wires at terminals. 13.6.11 Remove the power supply from the mill. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 92 13.6.12 Remove the 4 M3 screws (2 on each side) securing the shroud to the power supply module on the power entry end. Replacement: 13.6.13 Attach shroud to the new power supply. 13.6.14 Connect wires to terminals. 13.6.15 Connect AC Inlet cable. 13.6.16 Connect 12V power supply cable. 13.6.17 Secure power supply to rear cover. 13.6.18 Close and secure rear cover. 13.6.19 Install side covers. 13.6.20 Install top cover. Verification: 13.6.21 Plug in mill. 13.6.22 Power on and ensure proper initialization. 13.6.23 Upon completion of initialization check for errors. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 93: Volt Power Supply

    13.7 12 Volt Power Supply 13.7.1 The12 Volt power supply module is located on the shroud of the 48V power supply. Tools Required: • 2.5mm hex wrench • 3mm hex wrench • 5mm hex wrench Removal: 13.7.2 Power off mill. 13.7.3 Unplug mill. 13.7.4 Remove top cover. 13.7.5 Remove side covers. 13.7.6 Open rear cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 94 13.7.7 Cut tie wrap, disconnect the blue air hoses and remove the in-line air filter. 13.7.8 Unplug the 12V power supply cable from the 48V power supply. 13.7.9 Remove the (2) M4x5 SCH CAP 80002400 screws securing the power supply shroud to the 48V power supply. These screws will be used to re-install the shroud, do not discard. 13.7.10 Disconnect all associated power cables then remove the 12V supply from the mill. Remove the 4 screws securing the 12V power supply to the shroud and discard. Replacement: 13.7.11 Install the new 12 Volt Power Supply using the new screws provided and reconnect all cables. 13.7.12 Reinstall shroud 13.7.13 Reinstall in-line air filter and zip tie back to the shroud. 13.7.14 Reconnect all cables. Verification: 13.7.15 Plug in mill. 13.7.16 Power on and ensure proper initialization. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 95: Quad Motion Driver Board

    13.7.17 Upon completion of initialization check for errors. 13.8 Quad Motion Driver Board. 13.8.1 There are two Quad Motion Driver Boards in the mill. These boards are located on the back side of the Grind Chamber. Each board is responsible for drive and control of motors on their respective side of the milling center. These boards will be sent out as assemblies and are removed in the same manner but they are not interchangeable. Tools Required: • 3mm hex wrench • #2 Phillips screwdriver Removal: 13.8.1.1 Power off mill. 13.8.1.2 Remove top cover. 13.8.1.3 Remove side covers. 13.8.1.4 Remove bridgeboard. 13.8.1.5 Facing the mill from the back, disconnect 48V input connector. 13.8.1.6 Facing the mill from the front, disconnect the following connectors. 13.8.1.7 Remove ground cable from frame rail. 13.8.1.8 Remove the 2 M5X12 Cap screws. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 96 Replacement: 13.8.1.9 Slide the bottom of the QMD into the QMD Support Bracket. 13.8.1.10 Secure the QMD in place using 2 M5X12 Cap screws 13.8.1.11 Secure the Ground Cable to the frame rail. 13.8.1.12 Reattach all cables. 13.8.1.13 Close and secure rear cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 97 13.8.1.14 Install side and top covers. Verification: 13.8.2 Power up mill and ensure proper initialization. 13.8.3 Upon completion of initialization check for errors. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...

  • Page 98: Single Board Computer (Sbc)

    13.9 Single Board Computer (SBC) The Single Board Computer is mounted to the rear panel of the mill and is a single circuit board computer with a microprocessor, memory, input/output, and other features. This unit provides computer functionality, job server functions, milling center function’s, and contains the ACS software. The ACS software is the motion control software used by the mill. This unit has 4 USB ports. One of the ports used by the ACS dongle which provides access for the ACS software. Tools Required: • 2.5mm hex wrench • 3mm hex wrench Removal: 13.9.1 Power off mill. 13.9.2 Unplug mill. 13.9.3 Remove top cover. 13.9.4 Disconnect Cat 5 cable. 13.9.5 Remove side covers. 13.9.6 Open rear cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 99 13.9.7 Remove the 2 M3 screws to the bracket securing the SBC to the rear cover. 13.9.8 Remove the Accelerometer Processing Board. 13.9.9 Remove the Step Rocker Board. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible...
  • Page 100 13.9.10 Disconnect HDMI cable. 13.9.11 Disconnect power cable. 13.9.12 Disconnect HDMI cable. 13.9.13 Disconnect COM PORT cable. 13.9.14 Remove ACS dongle. 13.9.15 Disconnect both the Internal and External Ethernet Cat5 cables. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 101 Replacement: 13.9.16 Connect power cable. 13.9.17 Connect HDMI cable 13.9.18 Install ACS dongle 13.9.19 Install Accelerometer Processing Board. 13.9.20 Align and secure the SBC to the rear cover. 13.9.21 Close and secure rear cover. 13.9.22 Reinstall side covers. 13.9.23 Reinstall top cover. Verification: 13.9.24 Power on and ensure proper initialization. 13.9.25 Upon completion of initialization, check for errors. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 102: Fan

    13.10 Fan There are two fans on the mill and they are located on both sides just behind the side covers. Tools Required: • 3mm hex wrench Removal: 13.10.1 Power off mill. 13.10.2 Remove top cover. 13.10.3 Remove the side cover of the fan that needs to be replaced. 13.10.4 Loosen and remove the 4 M3 screws securing the fan. 13.10.5 Unplug the fan power connector from the Bridge Board. 13.10.6 Remove the fan. Replacement: 13.10.7 Plug fan power connector into Bridge Board. 13.10.8 Install and secure the fan to the mill. 13.10.9 Install side cover. 13.10.10 Install top cover. Verification: 13.10.11 Power on mill and ensure proper initialization. 13.10.12 Check system for errors. 13.10.13 Ensure replacement fan is operational. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 103: Lid Interlock

    13.11 Lid Interlock 13.11.1 The mill has two magnetic switches mounted to the exterior of the grind chamber. These switches are used by the software to indicate the status of the lid assembly. Tools Required: • 3mm hex wrench Removal: 13.11.2 Remove top cover. 13.11.3 Loosen the 2 M4 screws securing the switch to the side of the grind chamber. 13.11.4 Disconnect the connector from the LED Aux Board. Replacement: 13.11.5 Align and secure the replacement switch with the 2 M4 screws. 13.11.6 Connect the connector on the LED Aux Board. Verification: 13.11.7 Power on mill ensure proper initialization. 13.11.8 Using the Diagnostics menu check magnetic switch performance. Open and close the lid. Ensure that the software shows the appropriate response. 13.11.9 Install top cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 104: Lcd Display Assembly

    13.12 LCD Display Assembly 13.12.1 7-inch wide Glass/Film/Film PCAP Solution with a resolution of 30 X 18 (x/y). Tools Required: • 3mm hex wrench Removal: 13.12.2 Power off mill. 13.12.3 Remove top cover. 13.12.4 Remove the 4 O-rings securing the corners of the LCD Display Assembly to the mill. 13.12.5 Disconnect the HDMI cable. 13.12.6 Disconnect the power cable. Replacement: 13.12.7 Connect the power cable. 13.12.8 Connect the HDMI cable. 13.12.9 Align LCD Display Assembly with the foam padding on the mill. 13.12.10 Secure the LCD Display Assembly to the mill with the 4 O-rings. 13.12.11 Install top cover. Verification: 13.12.12 Power on mill and ensure proper initialization. 13.12.13 Check LCD Display Assembly performance. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 105: Motion Base

    14 Motion Base 14.1 Linear Motor Coil 14.1.1 X Axis The X Axis linear motor coil is located on the front of the carriage assembly. Tools Required: • 2.5mm hex wrench • 3mm hex wrench • Wire cutting pliers Removal: 14.1.1.1 Power off mill. 14.1.1.2 Remove top cover. 14.1.1.3 Remove side cover. 14.1.1.4 Loosen and remove the 2 M3 screws securing the motor coil. 14.1.1.5 Remove all zip ties on the cable and bundle shielding. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 106 14.1.1.6 Disconnect the power cable from the QMD Board. 14.1.1.7 Disconnect the power cable from the spindle motor. Replacement: 14.1.1.8 Connect the motor power cable to QMD Board. 14.1.1.9 Connect power cable to spindle. 14.1.1.10 Carefully side the replacement motor into the magnet. 14.1.1.11 Install the 2 M3 screws securing the motor. 14.1.1.12 Ensure that the cable is routed in the same manner it was prior to removal to prevent any restrictions to the movements of the X and Y axes. 14.1.1.13 Reinstall the bundle shielding and secure both the cable and shielding with zip ties. 14.1.1.14 Slide the carriage assembly left to right to ensure there is no binding. Verification: 14.1.1.15 Power on mill and ensure proper initialization. 14.1.1.16 Install side cover. 14.1.1.17 Install top cover. 14.1.1.18 Perform Mill Calibration. 14.1.1.19 Mill calibration bar and refine if needed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 107 14.1.2 Y Axis The Y Axis Linear Motor Coil is located on the bottom side of the carriage assembly. Tools Required: • 2.5mm hex wrench • Wire cutting pliers Removal: 14.1.2.1 Power off mill. 14.1.2.2 Remove top cover. 14.1.2.3 Remove side cover. 14.1.2.4 Pull the Z Axis up. 14.1.2.5 Push the Y Axis into to the towards the grind chamber. 14.1.2.6 Remove all tie wraps and bundle shielding from the cable. 14.1.2.7 Disconnect the power cable from the QMD Board. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 108 14.1.2.8 Remove the 2 M3 screws securing the motor coil. 14.1.2.9 Carefully side the motor coil out of the magnet. 14.1.2.10 The Y axis Linear Motor Coil shares the power cable with the Y Axis Encoder. See Y Axis Encoder Removal. Replacement: 14.1.2.11 Connect the motor coil power cable to QMD Board. 14.1.2.12 Carefully side the replacement motor into the magnet. 14.1.2.13 Install the 2 M3 screws securing the motor. 14.1.2.14 Reinstall the encoder. 14.1.2.15 Ensure that the cable is routed in the same manner it was prior to removal to prevent any restrictions to the movements of the X and Y axes. 14.1.2.16 Reinstall the bundle shielding and secure both the cable and shielding with zip ties. 14.1.2.17 Slide the carriage assembly front to back to ensure there is no binding. Verification: 14.1.2.18 Power on mill and ensure proper initialization. 14.1.2.19 Install side cover. 14.1.2.20 Install top cover. 14.1.2.21 Perform Mill Calibration. 14.1.2.22 Mill calibration bar and refine if needed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 109: Motor Magnets

    14.3 Motor Magnets 14.3.1 X Axis Magnet Tools Required: • 2.5mm hex wrench Removal: 14.3.1.1 Power off mill. 14.3.1.2 Remove top cover. 14.3.1.3 Remove side cover. 14.3.1.4 Remove the 2 M3 screws securing the motor coil. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 110 14.3.1.5 Remove the 3 M3 screws securing the magnet. Only the M3 hex heads need to be removed. 14.3.1.6 Carefully pull the magnet and motor towards you and off the alignment pins. 14.3.1.7 Carefully lift both the motor and the magnet from the mill. 14.3.1.8 Slide the motor free of the magnet. Replacement: 14.3.1.9 Slide the motor into the replacement magnet ensuring that the magnet is orientated properly. 14.3.1.10 Align the magnet on the pins and secure using the M3 screws. 14.3.1.11 Align the motor and secure using the M3 screws. Verification: 14.3.1.12 Power on mill and ensure proper initialization. 14.3.1.13 Install side cover. 14.3.1.14 Install top cover. 14.3.1.15 Perform mill calibration procedure. 14.3.1.16 Mill calibration bar and refine in needed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 111 14.3.2 Y Axis Magnets The Y Axis has 2 magnets in which the linear motor uses. If replacement is needed both should be replaced. Tools Required: • 2.5mm hex wrench Removal: 14.3.2.1 Power off mill. 14.3.2.2 Remove top cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible 111...
  • Page 112 14.3.2.3 Remove side cover. 14.3.2.4 Slide the carriage forwards to that access to the magnet and the securing screws is possible. Rear Magnet 14.3.2.5 Remove the 2 M3 screws securing the magnet. Only the hex head screws should be removed. 14.3.2.6 Pull the magnet up and off the alignment pins. Ensure that the motor is not currently in the magnet being removed. 14.3.2.7 Ensure that the replacement magnet is oriented in the proper position. Front Magnet 14.3.2.8 Push the carriage towards the back of the mill so that access to the magnet and the securing screws is possible. 14.3.2.9 The X-Axis Linear Motor and Magnet will need to be removed to access the front magnet. Refer to X Axis Linear motor and Magnet removal procedure. 14.3.2.10 Move the X axis magnet and linear motor to provide access to the Y magnet. 14.3.2.11 Pull the magnet up and off the pins. Ensure that the motor is not currently in the magnet being removed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 113 Replacement: 14.3.2.12 Ensure that the replacement magnet is oriented in the proper position. 14.3.2.13 Align with the pins then secure using the 3 M3 screws. 14.3.2.14 Align the X axis magnet with the pins and reinstall the 3 M3 screws. 14.3.2.15 Align and reattach the linear motor. Verification: 14.3.2.16 Power on mill and ensure proper initialization. 14.3.2.17 Install side cover. 14.3.2.18 Install top cover. 14.3.2.19 Perform mill calibration procedure. 14.3.2.20 Mill calibration bar and refine in needed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 114: Encoders

    14.4 Encoders 14.4.1 X Axis Encoder Located on the rear of the X carriage Tools Required: • 2.5mm hex wrench • 0.005 Blue Shim • 0.0075 Trans. Matte Shim • Wire cutting pliers Removal: 14.4.1.1 Power off mill. 14.4.1.2 Remove top cover. 14.4.1.3 Remove side cover. 14.4.1.4 Push the carriage assembly towards the grind chamber the slide the assembly forward so that both mounting screws can be accessed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 115 14.4.1.5 Remove the 2 M3 screws securing the encoder. Replacement: 14.4.1.6 Connect power cable to the QMD Board. 14.4.1.7 Ensure that the cable is routed in the same manner it was prior to removal to prevent any restrictions to the movements of the X and Y axes. 14.4.1.8 Reinstall the bundle shielding and secure both the cable and shielding with zip ties. 14.4.1.9 Loosely attach the replacement encoder to the carriage with the 2 M3 screws. 14.4.1.10 Place the 0.0075 Trans. Matte Shim between the encoder and the strip on the carriage then tighten the screws. 14.4.1.11 Once the encoder has been aligned and secured you will then need to use the 0.005 Blue Shim. Move the carriage left to right several times to ensure that there is proper clearance. The encoder should This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 116 NOT touch the Shim during movement. Verification: 14.4.1.12 Power on mill and ensure proper initialization. 14.4.1.13 Install side cover. 14.4.1.14 Install top cover. 14.4.1.15 Perform Mill Calibration. 14.4.1.16 Mill calibration bar and refine if needed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 117: Y Axis Encoder

    14.4.2 Y Axis Encoder Tools Required: • 2.5mm curved hex wrench • 0.005 Blue Shim • 0.0075 Trans. Matte Shim • Wire cutting pliers Removal: 14.4.2.1 Power off mill. 14.4.2.2 Remove top cover. 14.4.2.3 Remove side cover. 14.4.2.4 Ensure that the Z axis is up so that access from underneath the carriage is possible. 14.4.2.5 Push the Y carriage towards the rear of the mill to allow for needed work space. 14.4.2.6 Reaching in from underneath the carriage assembly through the slot in the baseplate, loosen and remove the 2 M3 screws securing the encoder. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 118 14.4.2.8 Remove zip ties and cable bundle shielding. 14.4.2.9 Disconnect cable from QMD Board. 14.4.2.10 The Y axis linear motor shares the power cable with the Y axis encoder so the linear motor will need to be removed as well. See Y Axis Linear Motor Removal Procedure. Replacement: 14.4.2.11 Connect cable to QMD Board 14.4.2.12 Ensure that the cable is routed in the same manner it was prior to removal to prevent any restrictions to the movements of the X and Y axes. 14.4.2.13 Reinstall the bundle shielding and secure both the cable and shielding with zip ties. 14.4.2.14 Loosely attach the replacement encoder to the carriage with the 2 M3 screws. 14.4.2.15 Place the 0.0075 Trans. Matte Shim between the encoder and the strip on the carriage then tighten the screws. 14.4.2.16 Once the encoder has been aligned and secured you will then need to use the 0.005 Blue Shim. Move the carriage front to back several times to ensure that there is proper clearance. The encoder should NOT touch the Shim during movement. 14.4.2.17 Reinstall the Y axis Linear Motor. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 119 Verification: 14.4.2.18 Power on mill and ensure proper initialization. 14.4.2.19 Install side cover. 14.4.2.20 Install top cover. 14.4.2.21 Perform Mill Calibration. 14.4.2.22 Mill calibration bar and refine if needed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible 119...

  • Page 120: Servo Motor

    14.5 Servo Motor Tools Required: • 2.5mm hex wrench • 4mm hex wrench • Pliers • #1 Phillips screw driver. Removal: 14.5.1 Power off mill. 14.5.2 Remove top cover. 14.5.3 Loosen the M3 screw on the ball screw side of the coupling. Coupler Ball screw 14.5.4 Loosen the 4 M5 mounting screws securing the motor. 14.5.5 Remove the motor. 14.5.6 Loosen the M3 screw on the motor side of the coupling. 14.5.7 Remove the coupling. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 121 Replacement: 14.5.8 Install coupling on the replacement servo motor. 14.5.9 The distance between the top of the coupling and the base of the motor should be set at 5mm. 14.5.10 Tighten the screw on the coupling. 14.5.11 Set the replacement motor in place and install the mounting screws. 14.5.12 Tighten the ball screw side of the coupling. 14.5.13 Loosen the 4 mountings screws on the motor, allow the motor to center on the shaft, then retighten. 14.5.14 Loosen the coupling on the ball screw side to relieve any axial stress and retighten. 14.5.15 Connect power cable and ground wires to motor. 14.5.16 Install bracket. 14.5.17 Install lid spring. (Left side servo motor only) 14.5.18 Adjust spring so that lid opens and closes properly. Verification: 14.5.19 Power up mill and ensure proper initialization. 14.5.20 Use Diagnostics to verify lid and motor performance. 14.5.21 Install top cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 122: Pneumatics System

    15 Pneumatics System 15.1 Air Utility and Air Map Boards The Air Utility and Air Map Boards are mounted on the inside of the mill back panel. These boards may be replaced individually. Tools Required: • 2.5mm hex wrench • 3mm hex wrench • 4mm hex wrench Air Map Board Air Utility Board Removal: 15.1.1 Power off mill. 15.1.2 Remove external air. 15.1.3 Remove top cover. 15.1.4 Remove side covers. 15.1.5 Open rear cover. 15.1.6 Air Map Board 15.1.6.1 Remove the 4 M3 screws securing board. 15.1.6.2 Remove the board. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 123 15.1.7 Air Utility Board 15.1.7.1 Disconnect tubings at the “one-touch” fittings. 15.1.7.2 Disconnect Power Cable. 15.1.7.3 Disconnect Solenoid Valve Port Cable. 15.1.7.4 Disconnect Water Separator Solenoid Cable. 15.1.7.5 Disconnect Signal Port Cable. 15.1.7.6 Remove the 4 M3 screws. 15.1.7.7 Remove the board. Replacement: 15.1.8 Align and install replacement board. 15.1.9 Connect all cables. 15.1.10 Attach tubings to “one-touch” fittings if replacing the Air Utility Board. 15.1.11 Close and secure rear cover. 15.1.12 Install side covers. 15.1.13 Install top cover. Verification: 15.1.14 Connect external air 15.1.15 Power on mill and ensure proper initialization. 15.1.16 Check system for air leaks and monitor software errors. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 124: In-Line Filter

    15.2 In-Line Filter This filter is located on the pneumatics assembly just below separator bowl mounted to the rear cover. Tools Required: • 3mm hex wrench • Wire cutters Removal: 15.2.1 Power off mill. 15.2.2 Remove top cover. 15.2.3 Remove side covers. 15.2.4 Open rear cover. 15.2.5 Remove zip tie securing the filter to the mill. 15.2.6 Disconnect tubings at the “one-touch” fittings. 15.2.7 Remove filter. 15.2.8 Remove the fittings from the filter. Replacement: 15.2.9 Attach fittings to the new filter. 15.2.10 Install replacement filter. 15.2.11 Zip tie filter into place. 15.2.12 Attach all tubings to the “one –touch” fittings. 15.2.13 Close and secure rear cover. 15.2.14 Install side covers. 15.2.15 Install top cover. Verification: 15.2.16 Power on mill and ensure proper initialization 15.2.17 Check system for air leaks and monitor software for errors.

  • Page 125: Pressure Multiplier

    15.3 Pressure Multiplier The air pressure multiplier or booster is an automatic device that compresses air to give an outlet pressure that is double to the inlet pressure. Tools Required: • 3mm hex wrench • 4mm hex wrench This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible 125...
  • Page 126 Removal: 15.3.1 Remove the 2 M4 X 10 cap screws from the rear of the Utilities Panel or rear cover. 15.3.2 Remove the air tubing from the one-touch fittings. 15.3.3 Remove the screws securing the pressure multiplier to the mounting plate. 15.3.4 Remove the fittings from the pressure multiplier. Replacement: 15.3.5 Install the fittings onto the new pressure multiplier. Teflon tape or Loctite 565 should be used to ensure a good air tight fit. 15.3.6 Secure the pressure multiplier to the mounting plate. 15.3.7 Attach air lines. 15.3.8 Secure pressure multiplier and the mounting plate to the Utilities Panel or rear cover. Verification: 15.3.9 Reconnect power and incoming air. 15.3.10 Boot up mill. 15.3.11 Ensure that mill initializes proper, no air leaks are present, and no pneumatic errors are seen. 15.3.12 Go to technician console. 15.3.13 Perform a high pressure pneumatic function to verify performance. 15.3.14 Reinstall all covers. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 127: Regulator

    15.4 Regulator Tools Required: • 3mm hex wrench • Channel locks or pliers Removal: 15.4.1.1 Power off mill. 15.4.1.2 Disconnect external air from mill. 15.4.1.3 Remove top cover. 15.4.1.4 Remove side covers. 15.4.1.5 Open rear cover. 15.4.1.6 Remove air lines (at the “one touch” fittings) to the regulator. 15.4.1.7 Remove fitting from regulator. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 128 15.4.1.8 Remove regulator from threaded fitting connecting it to the separator. 15.4.1.9 Remove regulator. Replacement: 15.4.1.10 Install one-touch fitting be sure to use Teflon tape or Loctite 565 to ensure a good seal. 15.4.1.11 Connect regulator to fitting on separator be sure to Loctite. 15.4.1.12 Reconnect air lines. Verification: 15.4.1.13 Power on and ensure proper initialization. 15.4.1.14 Recheck system for air leaks. 15.4.1.15 Set regulator to proper setting. 15.4.1.16 Left side 50 psi. 15.4.1.17 Install covers. 15.4.1.18 Monitor software for errors. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 129: Solenoids

    15.5 Solenoids Electrical Air Solenoids are used to control pressurized air throughout the system. There are 7 solenoid valves mounted on a single manifold. Each solenoid valve may be individually replaced. Tools Required: • 3mm hex wrench • #1 precision Phillips screwdriver Removal: 15.5.1.1 On the Planmill 30 S mill, the entire manifold assembly will be replaced. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 130 Removal: 15.5.1.2 Remove and mark the airlines going to the Festo Manifold. 15.5.1.3 Remove the manifold mount from the rear Utilities Panel or rear cover. 15.5.1.4 Remove the 4 M4 X 30 screws securing the Festo Manifold to the manifold mount. 15.5.1.5 Remove the Festo Manifold. Replacement: 15.5.1.6 Mount the replacement Festo Manifold to the manifold mount. 15.5.1.7 Secure the manifold mount to rear Utilities Panel or rear cover. 15.5.1.8 Attach air lines to the appropriate valve. Verification: 15.5.1.9 Reconnect air supply. 15.5.1.10 Power on mill and ensure proper initialization. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 131: Relief Valve

    15.6 Relief Valve Tools required: • 2.5mm hex wrench • 3mm hex wrench Removal: 15.6.1 Power off mill. 15.6.2 Remove top cover. 15.6.3 Remove side covers. 15.6.4 Open rear cover. 15.6.5 Disconnect both tubings at the “one-touch” fittings. 15.6.6 Disconnect the power connector from the Air Supply Board. 15.6.7 Remove the 2 M3 screws securing the valve. Replacement: 15.6.8 Install and secure the new valve using the 2 M3 screws. 15.6.9 Connect power connector to the Air Supply Board. 15.6.10 Connect all tubings. 15.6.11 Close and secure rear cover. 15.6.12 Install side covers. 15.6.13 Install top cover. Verification: 15.6.14 Power on mill and ensure proper initialization. 15.6.15 Check system for air leaks and observer software for errors. This document is the property of D4D Technologies, LLC (dba E4D Technologies).

  • Page 132: Spindle

    15.7 Spindle Tools Needed: • 2mm hex wrench • 2.5mm hex wrench Removal: 15.7.1 Using the milling center software open the collet and remove the tool. This process can also be completed by using the solenoid override. 15.7.2 Remove the nozzle cap of the spindle being replaced. 15.7.3 Insert a blank or a broken tool into the collet. 15.7.4 Shutdown milling center software. 15.7.5 Shutdown mill. 15.7.6 Remove top cover. 15.7.7 Remove side cover. 15.7.8 Remove the 2mm screws from the cable retaining bracket. 15.7.9 Remove the 2 M3 screws securing the spindle. 15.7.10 Disconnect the air line into the spindle at the one touch fitting. 15.7.11 Disconnect the airline then remove the one touch fitting from the cylinder. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 133 15.7.12 Remove the brake by remove set screw then unscrew the brake from the carriage. 15.7.13 Disconnect the spindle power cable. 15.7.14 Remove the spindle from the mill. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible 133...
  • Page 134 Replacement: 15.7.15 Slide the spindle into the mill. 15.7.16 Connect the spindle power cable. 15.7.17 Reinstall and secure the air cylinder. 15.7.18 Reinstall the one touch fitting to the air cylinder. 15.7.19 Connect tubing to the one touch fitting for both the spindle and the air cylinder. 15.7.20 Secure the spindle using the 2 M3 screws. There should be no gap between the spindle and the carriage. 15.7.21 Secure all cables using the 2mm hex screws and the retainer bracket. 15.7.22 Reinstall nozzle cap. Verification: 15.7.23 Power on mill and ensure proper initialization. 15.7.24 Check system for air leaks and observe software for errors. 15.7.25 Remove blank and insert tool into the collet. 15.7.26 Using the Technician Console, perform the spindle break in procedure. 15.7.27 Perform Mill Calibration. 15.7.28 Mill calibration bar and refine if needed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 135: Tool Changer

    16 Tool Changer 16.1 Tool Changer The tool changer assembly can be serviced as a complete assembly or individual components can be changed as required. Tools Required: • 2.5mm hex wrench • 4mm hex wrench Tools Required: • 2.5mm hex wrench • 3mm hex wrench • 4mm hex wrench Removal: 16.1.1.1 Power off mill. 16.1.1.2 Remove top cover. 16.1.1.3 Remove side covers. 16.1.1.4 Open rear cover. 16.1.1.5 Remove the 4 M4 X 12 screws on the tool changer cover. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 136 This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible 136...
  • Page 137 16.1.1.6 Remove the 4 M5X50 screws securing the tool changer to the mill. 16.1.1.7 Disconnect stepper motor cable. 16.1.1.8 Pull the tool changer forward and out of the mill through the grind chamber. Replacement: 16.1.1.9 Lubricate the vertical baseplate seal with grease. Ensure that all 4 corners are sealed. 16.1.1.10 Put the replacement tool changer into position. 16.1.1.11 Attach the tool changer to the vertical baseplate using the 4 M5X50 screws. Apply Loctite 242/248 and torque to 46in-lbs. 16.1.1.12 Attach to changer cover to tool changer with the 4 M4 X 12 screws. 16.1.1.13 Reattach all cables. Ensure that the cables are not pinched. 16.1.1.14 Close and secure rear panel. 16.1.1.15 Reinstall side and top covers. Verification: 16.1.2 Power on mill and ensure proper initialization. 16.1.3 Perform mill calibration procedure. 16.1.4 Mill calibration bar and refine if needed. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 138: Bumper

    16.2 Bumper Tools Required: • 3mm hex wrench • Phillips screwdriver. Removal: 16.2.1 Remove Philips screws securing the fixed arm cover. 16.2.2 Remove cover. 16.2.3 Loosen the M4 screw securing the bumper. Bumper 16.2.4 Remove the bumper from the fixed arm. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 139 Replacement: 16.2.5 Slide the replacement bumper into the tool changer arm. 16.2.5.1 The bumper should be flush with the arm on the left side. 16.2.6 Tighten the setscrew to 10 in-lbs. Verification: 16.2.7 Pick up and drop off tools. 16.2.8 Ensure that the tools are being seated properly after bumping. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible 139...

  • Page 140: Tool Length Detection Block

    16.3 Tool Length Detection Block Tools Needed: • Phillips screwdriver • 3mm hex wrench Removal: 16.3.1 Remove the 2 Philips screws securing the fixed arm cover. 16.3.2 Loosen the M4 screw securing the tool length detection block. Tool Length Detection Block 16.3.3 Remove the tool length detection block from the fixed arm. Replacement: 16.3.4 Slide the replacement tool length detection block into the tool changer arm. 16.3.5 The tool length detection block should be flush with the arm on the left side. 16.3.6 Tighten the setscrew to 10 in-lbs. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 141 Verification: 16.3.7 Perform full mill calibration. 16.3.8 Cut calibration bar and refine into spec. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible 141...

  • Page 142: Tool Holder

    16.4 Tool Holder Tools Needed: • Phillips screwdriver • 3 mm hex wrench 16.4.1 Remove the Phillips screws securing the fixed arm cover. 16.4.2 Remove the M4 (80002404) screw securing the tool holder being replaced. 16.4.3 Remove the tool holder. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 143 Replacement: 16.4.4 Attach the tool holder to the fixed arm with M4 X 8 screw. Apply Loctite 242 and torque to 23 in-lbs. 16.4.4.1 If replacing the tool holder in the rear position, there should not be a ball plunger screw on the top side. Verification: 16.4.5 Perform full mill calibration. 16.4.6 Cut calibration bar and refine into spec. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible 143...

  • Page 144: Sliding Wall

    16.5 Sliding Wall Tools Required: • 2.5 mm hex wrench • Precision Phillips screw driver • 3 mm hex wrench Removal: 16.5.1 Power down mill. 16.5.2 Remove top and side covers. 16.5.3 Remove spindle (See spindle procedure). 16.5.4 Remove the 6 Phillips screws securing the sliding wall to the grind chamber. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 145 16.5.5 Remove the 2 screws securing the vertical slide carrier mount to the wall. 16.5.6 Remove the 2 screws securing the bellows housing. 16.5.7 Slide the bellows over the cap adaptor. 16.5.8 Pull the sliding wall towards the grind chamber and out of the mill. Replacement: 16.5.9 The new sliding wall will come preassembled. 16.5.10 Secure the sliding wall to the grindchamber. Secure with Loctite. 16.5.11 Secure the vertical slide mount. 16.5.12 Attach the white bellows housing to the carriage assembly. Do not overtighten the button head screws. The plastic should NOT spread during the tightening process. Secure with Loctite. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 146 16.5.13 Attach the bellows edge onto the cap adaptor. Ensure that the bellows is straight up and down within the grove and not canted. 16.5.14 Install spindle and associated parts. 16.5.15 Manually slide the X Carriage/spindle ASM left-to-right (hard stop to hard stop). Movement should be free of any binding or drag of the bellows. Verification: 16.5.16 Power up mill and ensure proper initialization. 16.5.17 Perform full calibration 16.5.18 Mill calibration bar and refine if needed. 16.5.19 Check sliding wall and bellows to ensure there are no leaks. 16.5.20 Reinstall all covers. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 147: Alignments

    17 Alignments 17.1 Z-Ballscrew Alignment Tools Required: • 4mm Allen wrench • Adjustable wrench Process: 17.1.1 Remove top and side covers. 17.1.2 Manually lift the Z carriage as high as it will travel until it sticks. 17.1.3 Using an M4 Allen wrench loosen the (A) 3 motor mount screws and retighten them. 17.1.4 Loosen the (B) 2 nut mount screws and then retighten. 17.1.5 Manually push the Z carriage down, the pull back up. The carriage should travel up until it hits the hard stop. 17.1.6 If you are unable to reach the hard stop, the procedure will need to be repeated. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.

  • Page 148: Diagnostic Interface

    18 Diagnostic Interface 18.1 See addendum. 19 Software Installation. 19.1 Close Milling Center Software 19.2 On the computer desktop, right click the START taskbar and select Start Task Manager. 19.3 Task Manager- click Services tab and stop Services, D4DJsProxyService & D4DService. To stop a service, right click the service and select STOP. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 149 19.4 Navigate to Control Panel\ Program Features. Uninstall Mill Center & E4D Proxy Job Server. To uninstall a program, right click the program and select Uninstall. 19.5 Copy the latest installers (MillCenter, ProxyJobServer, JobServer) to support Folder. 19.6 Install all of the Software. The services will restart automatically once the software is installed. 19.6.1 JobServer.exe 19.6.2 ProxyJobServer.exe 19.6.3 MillCenter.exe 19.7 Navigate to Control Panel\Programs and Features. Verify the installed date and version for E4D Mill Center & E4D Proxy Job Server. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies.
  • Page 150 19.8 GOTO C:\Program Files\E4D Technologies LLC\MillCenter\millcenter\ Verify the following folders get created. This document is the property of D4D Technologies, LLC (dba E4D Technologies). This document shall not be disclosed, copied, reproduced, or used for any purpose without prior or written permission from an authorized representative of E4D Technologies. This is a computer controlled document. Manual revisions are not permissible 150...

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