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Planmeca PlanMill 40 Technical Manual
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Planmeca PlanMill 40 Technical Manual

Planmeca PlanMill 40 Technical Manual

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Summary of Contents for Planmeca PlanMill 40

  • Page 1 technical manual...

  • Page 3: Table Of Contents

    Tank level sensors and filter basket ..................44 2.10 Orientation sensor ........................ 47 Chapter C: Calibration Overview .......................... 49 Tools required ........................50 Tool changer calibration ....................51 Profiler sensor calibration ....................57 Origin calibration ......................60 Technical manual Planmeca PlanMill 40...
  • Page 4 If the close action is too fast proceed as follows..........139 2.5.4 If the close action is too slow proceed as follows........... 140 Tool changer closed sensor adjustment ................140 2.6.1 Raising Z-axis and setting Z-brake ..............141 Planmeca PlanMill 40 Technical manual...
  • Page 5 2.13.10 Spindle housing ..................... 195 2.13.11 Quick release adapter ..................197 2.14 Software configuration ......................199 2.14.1 Pulling log files ....................199 2.14.2 Installing software/firmware ................199 2.14.3 PlanMill 40 touch screen calibration ............... 199 Technical manual Planmeca PlanMill 40...
  • Page 6 IEC 60364 - equipment is used according to the operating instructions. Planmeca pursues a policy of continual product development. Although every effort is made to produce up-to-date product documentation this publication should not be re- garded as an infallible guide to current specifications. We reserve the right to make changes without prior notice.

  • Page 7: Chapter A: General And Technical Data

    Once the image is retrieved, the CAD/CAM module of Planmeca Romexis Software on the PlanScan Laptop is used for designing a restoration. After the restoration design is ready, it is transmitted to the Jobserver for toolpath calculus via a TCP/IP network connection.

  • Page 8: Symbols On Product Labels

    The following images show each safety and warning label and describe where on the apparatus each can be found. Be certain to read all product labelling. NOTE If any of the labels are missing or illegible, please contact Planmeca After Sales for replacement labels. NOTE Label examples are not shown in their actual size.
  • Page 9 Chapter A: General and technical data 2 Symbols on product labels Of/Off Power Technical manual Planmeca PlanMill 40...

  • Page 10: Associated Documentation

    3 Associated documentation Planmeca PlanMill 40 comes with the following manuals: • User’s manual Instructs how to operate the PlanMill 40 as part of the Planmeca Chairside CAD/CAM solution. • Installation manual Instructs how to install the components of the Planmeca Chairside CAD/CAM solution.

  • Page 11: Warnings And Precautions

    Failure to adhere to all safety warnings may result in personal injury, equipment damage, or data loss. WARNING Do not use the Planmeca products for any purpose other than its intended and labelled use. WARNING This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.
  • Page 12 WARNING Do not block any of the Planmeca product’s cooling vents. Doing so may result in overheating and damage to the products and will void the product warranty.
  • Page 13 Comply with all applicable regulations when disposing of waste materials from the Planmeca products. CAUTION The unit must be serviced by qualified personnel only, trained by Planmeca or by approved dealers. Repairs and parts replaced by unqualified personnel carry no warranty.

  • Page 14: Technical Specifications

    5 Technical specifications Chapter A: General and technical data 5 Technical specifications The PlanMill 40 milling unit uses standard electrical current and compressed air, but it does not connect to a water supply or drain. Table 1: Technical specifications and operating condition...

  • Page 15: Approvals

    Assisted Design and Manufacturing of Dental Restorations European Directives 2006/42/EC for Machinery 5.2 Approvals North America Product Safety Mark (NRTL) - UL C/US International CB Scheme Test Certificate (UL) Quality System Certifications ISO 13485 Registered Firm CMDCAS (Canada) Japan GMP Technical manual Planmeca PlanMill 40...

  • Page 16: Glossary

    Collective term for the restoration data and its metadata and tool path as they are transferred together from the Design Center, through the job server, to the PlanMill 40. Mandrel The lockable metal piece to which the ceramic block is glued.

  • Page 17: Mechanical Design

    7 Mechanical design 7 Mechanical design The PlanMill 40 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, electronics box (often referred to as the E-box), circulations system, pneumatics system, and the enclosure.

  • Page 18: Electronics Box

    The motion controller board is DSP-based and handles the real time control of the four servo motors. It is under the direct control of the SBC via the PlanMill 40 application. The DSP spindle controller/interface board provides direct control of the spindle motors and low level monitoring of all sensors.

  • Page 19: Circulation System

    An LCD touch display is connected to the electronics box via a video cable. This touch display provides the user interface to the PlanMill 40 software and other operating system features while eliminating the need for either a keyboard or mouse.

  • Page 20: Pneumatics System

    The two filter units ensure all particulates beyond a specific size are removed from the supply air, and the regulator reduces the incoming pressure to 3.5 bar (50 psi) for on board use. Planmeca PlanMill 40 Technical manual...
  • Page 21 This piloted valve is also controlled by a manifold solenoid valve. The piloted valve is used in this case to provide the 60 l/min (0.06 m /min, 2 CFM) flow rate not capable by the manifold valve alone. Figure 5: Pneumatic system Pneumatic assembly Figure 6: Pneumatic assembly Technical manual Planmeca PlanMill 40...

  • Page 22: Enclosure

    This feature is important in case of malfunction that prevents the normal drawer unlock procedure. Removing first the rear cover provides an access to unlock the drawer manually and to remove the top cover retaining screws. Figure 7: Enclosure assembly Planmeca PlanMill 40 Technical manual...

  • Page 23: Chapter B: Preventive Maintenance

    User maintenance kits There are few different maintenance kits available for procedures that should be performed on a scheduled basis to keep the Planmeca PlanMill 40 operating properly, see the figures below. Figure 8: Planmeca PlanMill 40 user maintenance kit The user maintenance kit includes the following tools: •...
  • Page 24 • Twisted wire brush 4 mm • Wire brush, spindle shaft Figure 9: Planmeca PlanMill 40 technician 4 months maintenance kit 2 x Ellipsoidal milling bur (yellow 2 x O-ring, small, cap stripes) 2 x IPS Empress CAD for PlanMill HT...

  • Page 25: Additional Tools

    Tool changer Nose seal for PlanMill HT A1 I12 NOTE The Planmeca PlanMill 40 technician 12 months maintenance kit includes 1 x PlanMill 40 technician 4 months maintenance kit (parts 3, 4, 7 and 8 in the figure above). Additional tools •...

  • Page 26: Preventive Maintenance Schedule

    Replace large and small o-rings on the quick release nozzle cap 4 months / adapters mounted to the spindle housings: 1 year • 2.7 "Cleaning collet and spindle caps" on page 35 Perform touch screen calibration, if necessary. 1 year Planmeca PlanMill 40 Technical manual...

  • Page 27: Maintenance Icons

    Chapter B: Preventive maintenance 1.3 Maintenance icons One of the functions of the PlanMill 40 GUI home screen is to provide users with warnings and maintenance information. Each of these icons will turn red when attention is required. Figure 11: Maintenance icons By pressing on these icons, prompts appear to guide the user through the maintenance.

  • Page 28: Maintenance Procedures

    Disconnect the compressed air supply from the PlanMill 40. Remove the PlanMill 40 top cover and left side cover, see instructions in section 2.1 "Mill covers" on page 94. Visually inspect the water trap, the air filter bowl and coalescing oil filter bowl for moisture.

  • Page 29: Inspecting Profile Sensor And Verifying Profile Sensor Signal

    The profile sensor is located in the bottom of the tool changer arm. It is the device which the PlanMill 40 uses to determine the actual length and diameter of an individual tool (burr). Refer to section 2.10 "Profile sensor" on page 148 for removal and replacement instructions if the profile sensor is found to be damaged or the signal is not acceptable.
  • Page 30 From the Mill Options screen touch Replace tools and SELECT. Figure 15: Mill Options After milling the calibration jobs there are ellipsoidal burrs in left and right collets. Touch the Left tool icon and then the SELECT button. Planmeca PlanMill 40 Technical manual...
  • Page 31 Figure 16: Select tool At the New Shape screen, touch conical and then the SELECT button. Figure 17: New Shape The lid will open and the collet will open. Follow the instructions on the screen. Technical manual Planmeca PlanMill 40...
  • Page 32 The tool changer will open, seat the tool and then profile the tool. If it is successful the display will look like in the following figure. Figure 19: Select Tool Select the conical burr in the left side and then touch the SELECT button. Planmeca PlanMill 40 Technical manual...
  • Page 33 From the New Shape screen, touch tapered and then touch the SELECT button. Figure 21: New Shape The lid will open and the collet will open. Follow the instructions on the screen. Figure 22: Replace Tool Technical manual Planmeca PlanMill 40...

  • Page 34: Inspecting Tool Changer 6-Pack, Bumper And Nose Seal For Damage Or Wear

    2.7 "Nose seal" on page 144 and section 2.9 "Tool holder" on page 147 for repair instructions. Select the Maintenance Icon in the lower left corner of the display. Select Advanced and enter passcode 1234. Select Verify Tools. Planmeca PlanMill 40 Technical manual...

  • Page 35: Verifying Correct Interlock Switch Function

    Touch the High Level button. Observe the box labelled Mechanical Control in the upper left corner of the display. LID: CLOS CLOS should be displayed. Touch the box labelled Mechanical Control in the upper left corner of the display. Technical manual Planmeca PlanMill 40...

  • Page 36: Fluid Tank Cleaning

    15. LID: CLOS CLOS should be displayed. 2.6 Fluid tank cleaning The fluid tank requires periodic cleaning and coolant replacement. The PlanMill 40 software reminds the operator to service the fluid tank on a periodic time basis however, the operator or technician may choose to clean the tank at any time by following the procedure below.

  • Page 37: Cleaning Collet And Spindle Caps

    The Collet Cleaning button turns red when the collets and spindle caps are scheduled to be cleaned. Touch the button at any time to see how many milling hours are estimated before the caps need to be cleaned. Technical manual Planmeca PlanMill 40...
  • Page 38 Due to the relatively small diameter of the nozzles periodic removal of the cap and clearing of the nozzles may be required. The PlanMill 40 software reminds the operator to clean the nozzle caps on a periodic basis; however the operator or technician may choose to clean the caps at any time by following the procedure below.
  • Page 39 Curved Collet Wrench - the curve Use the wrench to hold of the collet wrench enables you the spindle in place while the to reach the grooves on the spindle collet tool turns the collet. Technical manual Planmeca PlanMill 40...
  • Page 40 10. Use a DRY paper towel to wipe the inside of the collet shaft. To keep your milling unit running smoothly it is very important to clean the collets and spindles. Dirt will cause the tools to “walk” (not be seated properly) and can cause broken tools. Planmeca PlanMill 40 Technical manual...
  • Page 41 13. Insert the Nozzle Cleaning Brush in the small holes on the spindle cap at an angle. This will push any ceramic build-up out of the hole. 14. Clean the cap with water and soft brush. Technical manual Planmeca PlanMill 40...
  • Page 42 18. To attach the spindle cap, align the grooves so that the spindle cap extension is pointing upwards. 19. Then turn the spindle cap clockwise until the extension points downward and the cap groove aligns with the housing groove. Planmeca PlanMill 40 Technical manual...

  • Page 43: Spindle Packing

    Select Advanced and enter passcode. Select Technician Console. Figure 30: Technician Console screen If tools are currently in the spindles, perform the following steps, otherwise skip the next three steps. Select the Tool Changer button. Technical manual Planmeca PlanMill 40...
  • Page 44 Select the High Level button to enter the high level diagnostics window. Select Mechanical Control box. Figure 32: HIGH LEVEL screen 10. Select the Open Lid button. 11. Remove the 6 Philips drive flat head screws. Planmeca PlanMill 40 Technical manual...
  • Page 45 Positions window. Upon driving the spindle inward the inner seal should slide with the spindle exposing the packing material. Figure 34: Using axis position controls to move spindles inward 15. Reselect the Mechanical Control box. 16. Select the Open Lid button. Technical manual Planmeca PlanMill 40...

  • Page 46: Tank Level Sensors And Filter Basket

    The tank floats and strainer should be cleaned once a week to prevent mold growth or build-up of ceramic material and for optimal circulation. Planmeca PlanMill 40 Technical manual...
  • Page 47 Figure 36: Example of dirty suction strainer and tank level sensors Tools and items required: • paper towels • clean water • nylon bristled brush (toothbrush) On Mill Options screen touch Support Console. Figure 37: Mill Options screen On Support Console, select HIGH LEVEL. Technical manual Planmeca PlanMill 40...
  • Page 48 Clean the strainer with a nylon brush and water. Wipe the floats with a wet paper towel to remove any debris. Wipe down the bottom of the mill. NOTE Do not use any other brush types or chemicals to clean the floats/strainer as they may cause damage. Planmeca PlanMill 40 Technical manual...

  • Page 49: Orientation Sensor

    The text will change to Stop Pump. 15. After approximately 30 seconds, press Stop Pump. 16. Press Reinitialize. 17. Press Return to Menu. 18. Press Exit Console. 2.10 Orientation sensor The orientation sensor is located in the PlanMill 40’s mandrel holder. Technical manual Planmeca PlanMill 40...
  • Page 50 Clean this area very carefully with the “orientation purge air” on. To switch the purge air on go to the mechanical control box and select the Orient Purge On button. Figure 41: HIGH LEVEL screen Planmeca PlanMill 40 Technical manual...

  • Page 51: Chapter C: Calibration

    Chapter C: Calibration 1 Overview The PlanMill 40 unit must be calibrated to operate correctly and achieve the high degree of accuracy required for the dental restorations. To check the calibration of the PlanMill 40, see instructions in section 5 "Verifying calibration"...

  • Page 52: Tools Required

    Chapter C: Calibration 1.1 Tools required • Planmeca PlanMill 40 Calibration Kit Kit contents: 1 - Calibrator Kit Case 2 - Calibrator Cable 3 - Cylindrical Calibration Block 4 - Tool Holder Calibration Fixture 5 - 2 Calibration Pins 6 - Three Step Calibration Pin...

  • Page 53: Tool Changer Calibration

    Before beginning, inspect the tool holder on the tool changer to make sure it is not skewed or cannot be moved easily. The tool holder should be tight and secure before beginning. Start the PlanMill 40 application if it is not running. On the mill screen, touch Maintenance icon in the lower left corner.
  • Page 54 (approximately 6 seconds) then release. Figure 44: Uncheck Drop off tools checkbox 10. Mill homing begins. Wait for homing to complete, the lid lights to turn red, then touch the Auto Both button. Planmeca PlanMill 40 Technical manual...
  • Page 55 2 Tool changer calibration Figure 58: Select Auto Both 11. Lid opens; connect Calibrator to the PlanMill 40 USB port. Wait for he Calibrator connected LED to light up then touch the Auto Both button. Figure 45: Connect the Calibrator 12.
  • Page 56 Figure 47: Insert calibration pin in right collet 14. Enter the Tool Holder Calibration Fixture number in the Fixture # field the touch the Auto Both button. Enter all digits of the Tool Holder Calibration Fixture number to the Fixture # field. Planmeca PlanMill 40 Technical manual...
  • Page 57 Left to calibration pin in the left collet as close to the collet as possible. Attach the alligator clip on the black lead labeled Right to the calibration pin in the right collet as close to the collet as possible. Technical manual Planmeca PlanMill 40...
  • Page 58 20. Wait for mill to home and the lid lights to turn green. The tool changer calibration is complete. 21. Continue calibration with profiler sensor calibration, follow instructions in the section 3 "Profiler sensor calibration" on page 57. Planmeca PlanMill 40 Technical manual...

  • Page 59: Profiler Sensor Calibration

    Leave all values in the (Step 3) Origin box at their defaults at this time. NOTE If the mill is being calibrated due to the installation of a new profile sensor select the "New Sensor" check box. Technical manual Planmeca PlanMill 40...
  • Page 60 Wait for homing to complete. Then touch Right Tool Profiler button." 12. Repeat steps 4 through 11 following the instructive messages appearing in the text box to complete the right tool profiler calibration. 13. Tool profiler sensor calibration is complete. Planmeca PlanMill 40 Technical manual...
  • Page 61 Chapter C: Calibration 3 Profiler sensor calibration 14. Continue calibration with origin calibration, follow instructions in the section 4 "Origin calibration" on page 60. Technical manual Planmeca PlanMill 40...

  • Page 62: Origin Calibration

    USB connection. A continuity signal is monitored by the upper level software through this USB connection. Critical dimensions of the components in the calibration kit are entered and saved in the PlanMill 40 software to minimise any errors associated with manufacturing variations in the calibration kit components. A specialised calibration sequence is initiated in the software once the connections have been made.
  • Page 63 Lid opens and a message appears in the text box: "Connect calibrator to mill using USB cable. Wait for the LED next to origin button to light up, then touch Origin button." Follow the instructions. Technical manual Planmeca PlanMill 40...
  • Page 64 Figure 56: Insert Calibration Pin in left collet The following message will appear in the first text box: "Insert calibration pin in the right collet. Hold in place and touch the origin button." Follow the instructions. Planmeca PlanMill 40 Technical manual...
  • Page 65 13. Attach the blue wire to the left pin and the black wire to the right pin. Make sure the clips are as closed to the collets as possible. Allow some slack on the wires by pushing them down into the grind chamber so they do not pull loose during calibration. Technical manual Planmeca PlanMill 40...
  • Page 66 16. Once the auto-touch calibration process has completed, the lid opens and the following message will appear in the first text box. "Remove all calibrator wires and block. Disconnect the calibrator USB cable. Close the Lid and touch Origin button." Follow these instructions. Planmeca PlanMill 40 Technical manual...
  • Page 67 Follow these instructions. Figure 62: Remove Calibration Pins 18. Message will appear: "Calibration is complete. Wait for re-initialization to complete (as indicated by green LED’s) then mill the Refine Calibration job, and perform refine_2 calibration." Technical manual Planmeca PlanMill 40...
  • Page 68 19. Close the lid and touch the Origin button. Origin Calibration is complete. 20. Select the Command tab and then the Close button. 21. Verify calibration results, follow instructions in the section 5 "Verifying calibration" on page 67. Planmeca PlanMill 40 Technical manual...

  • Page 69: Verifying Calibration

    Using a micrometer, measure the pair of values for the Y offset (Y dimple sides & Y plain sides), the pair of values for the Z offset (Z dimple sides & Z plain sides), and the bar width (W). Figure 64: Calibration bar Technical manual Planmeca PlanMill 40...
  • Page 70 Y plain side measurement Z plain side measurement - 7.000 mm --------------------------------------- ---------------------------------------- --------------- 0.0xx mm 0.0xx mm 0.0xx mm Allowed tolerance: Allowed tolerance: Allowed tolerance: ± 0.030 mm ± 0.030 mm ± 0.030 mm Planmeca PlanMill 40 Technical manual...

  • Page 71: Refine 2 Calibration

    11. Once the calibration bar is re-milled, record and measure the W, Y and Z offsets. 12. Repeat this procedure until the calibration bar is within tolerance. This is usually achieved in two to three bars. Technical manual Planmeca PlanMill 40...
  • Page 72 6 Refine 2 calibration Chapter C: Calibration Planmeca PlanMill 40 Technical manual...

  • Page 73: Chapter D: Troubleshooting

    2.4 "Troubleshooting mill motion system" on page 89 Loud thud when tool changer opens Tool changer opens too fast Reduce exhaust flow at "close" flow control valve: 2.5.1 "If the open actuation is too fast proceed as follows." on page Technical manual Planmeca PlanMill 40...

  • Page 74: Nose Seal

    Chapter C: "Calibration" on page 49 Poor profile sensor Recalibrate: calibration Chapter C: "Calibration" on page 49 Motion system problem Test motion system: 2.4 "Troubleshooting mill motion system" on page 89 Fails profile sensor calibration Planmeca PlanMill 40 Technical manual...

  • Page 75: Spindles Problems

    Replace spindle motor: 2.13.9 "Spindle and spindle motor" on page 182 Tool is stuck/jammed in Use "stuck tool" removal tool in tool kit and replace collet: collet 2.7 "Cleaning collet and spindle caps" on page 35 Technical manual Planmeca PlanMill 40...
  • Page 76 2.7 "Cleaning collet and spindle caps" on page 35 Can't remove tool from collet Collet is in "closed" position Open collet first, then attempt to remove tool: 2.7 "Cleaning collet and spindle caps" on page 35 Can't remove collet from spindle Planmeca PlanMill 40 Technical manual...
  • Page 77 Replace tools at or before 160 minutes of usage. 160 minutes Damaged collet Replace collet: 2.7 "Cleaning collet and spindle caps" on page 35 Defective spindle Replace spindle: 2.13.9 "Spindle and spindle motor" on page 182 Broken tool detection doesn't work Technical manual Planmeca PlanMill 40...
  • Page 78 Motion system problem Troubleshoot mill motion system: 2.4 "Troubleshooting mill motion system" on page 89 Mill detects broken tool Perform full calibration or contact Planmeca After Sales: Chapter C: "Calibration" on page 49 Broken block Incorrect block size Load correct size block.

  • Page 79: Grind Chamber Lid Problems

    Defective fluid pressure Replace fluid pressure switch: switch 2.11.2 "Water pressure switch" on page 153 Top cover pressed against Adjust top cover away from lid: 2.1.1 "Top cover" on page 94 Lid latch doesn't close Technical manual Planmeca PlanMill 40...

  • Page 80: Mandrel Holder Problems

    Debris inside mandrel Remove debris holder 2 "Maintenance procedures" on page 26 Damaged/worn mandrel Replace mandrel cam. Damaged/worn mandrel Replace tool changer assembly: holder 2.4 "Tool changer" on page 127 Mandrel cam doesn't clamp block securely Planmeca PlanMill 40 Technical manual...

  • Page 81: Circulation System Problems

    Defective power supply Replace power supply module: module 2.2.1 "Power supply module" on page 100 Defective fluid pressure Replace fluid pressure sensor cable: sensor cable 2.11.2 "Water pressure switch" on page 153 Circulation pump is noisy Technical manual Planmeca PlanMill 40...
  • Page 82 Add defoamer to coolant per instructions on bottle label. create more foam than others Various contaminants in Use di-ionized water instead of tap water. water supply (tap water) Tank gasket damage General wear Replace tank gasket. Planmeca PlanMill 40 Technical manual...

  • Page 83: Motion System Problems

    Replace air pressure switch: switch 2.12.7 "Air pressure switch" on page 164 Defective CPU module Replace CPU module: 2.2.2 "CPU module" on page 102 Defective pneumatic control Replace pneumatic control cable: cable 2.12 "Pneumatics system" on page 155 Technical manual Planmeca PlanMill 40...

  • Page 84: Electronics Problems

    2.2.7 "LCD touch display assembly" on page 109 Tool path time out Reboot job server computer. Job server processing is Contact Planmeca After Sales to possibly increase tool path slow timeout settings on mill. Possible bad restoration Contact Planmeca After Sales to evaluate and possibly correct prep or design prep or design.
  • Page 85 2.2.5 "Fuse power entry module" on page 106 Defective power supply Replace power supply module: module 2.2.1 "Power supply module" on page 100 Defective main power Replace lower e-box: assembly (lower ebox) 2.2.9 "Lower electronics box (E-box)" on page 113 Technical manual Planmeca PlanMill 40...

  • Page 86: Troubleshooting

    Evaluate all of the tubing for possible blockage. This includes the use of a soft bristle tube brush inside the spindle housing coolant channel. Contact Planmeca After Sales to install modified GRF files. Mill two or three jobs, including the problematic job. If the problem persists continue to the next step.

  • Page 87: Troubleshooting Firmware Update Requiring Warning

    If using neither of the two USB ports on the lower electronics box eliminates the error message then replace the accelerometer processor assembly. 2.3 Troubleshooting mill “Fails to Initialize” error Navigate the PlanMill 40 application to: Technician Console --> High Level. Check I/O status. •...
  • Page 88 2 defective sensors/cables. Although rare, a defective CPU module can cause this as well. Figure 67: Home & limit sensor astatus check Planmeca PlanMill 40 Technical manual...
  • Page 89 12. If the 10th LED from the top is not lit, then the servo and spindle motors will not have power. This is probably due to a defective 48 volt power supply. 13. Navigate the PlanMill 40 application to: Technician Console --> Motion. Technical manual...
  • Page 90 If an axis is found that can’t be physically moved from home to end-limit and then back to home, then check for obstructions that may prevent the movement (i.e. Cables, loose hardware, damaged sliding wall, pre-Rev E hinge plate assembly in the lid adapter assembly, etc.). Planmeca PlanMill 40 Technical manual...

  • Page 91: Troubleshooting Mill Motion System

    If the problem persists replace the CPU module. 2.4 Troubleshooting mill motion system Navigate the PlanMill 40 application to: Technician Console Re-initialize the motion system. If initialization fails, perform troubleshooting procedure in section 2.3 "Troubleshooting mill “Fails to Initialize” error" on page 85.
  • Page 92 Replace servo motor and retest. and/or defective cable. Replace cable if needed. 0.100 or greater Loose motor coupling, defective Tighten motor coupling and retest. encoder, and/or defective cable. Replace servo motor and/or cable if needed. Planmeca PlanMill 40 Technical manual...
  • Page 93 • home/end limit sensors and/or cables • CPU module (motion controller, interface PCB, hard drive) • lower E-box (48 volt power supply) • power module • Amp module • E-box backplane PCB • servo motor/cable Technical manual Planmeca PlanMill 40...

  • Page 94: Troubleshooting Popping Noise

    See the following flow diagram for instruction on which fittings to test for air leaks. Pneumatic circuit for collet operation Planmeca PlanMill 40 Technical manual...

  • Page 95: Chapter E: Basic Repair Procedures

    PlanMill 40. Each procedure is illustrated and lists the tools required. For identification of replacement parts with Planmeca part numbers, refer to the Calibration and maintenance kits for Planmeca PlanMill 40 milling unit, Export News 13/ 2014 or contact Planmeca After Sales.

  • Page 96: Mill Covers

    2.1.1 Top cover Tools required • metric Allen key set Figure 71: PlanMill 40 top cover assembly Removal Select Advanced, enter code 1234, select Technician Console, select High Level, select Mechanical Control. Touch the Unlock Drawer button.
  • Page 97 Figure 72: Disconnect switch cables CAUTION Use care lifting top cover off PlanMill 40 to avoid damaging the wiring to the stop switch and on/off switch. Once the cables are disconnected, raise the top cover up and lift off the machine.

  • Page 98: Side Panels

    Figure 76: Fit top cover evenly and snugly to display bezel 10. Close the tank drawer and the grind chamber lid. 2.1.2 Side panels The following procedures apply to both left and right side panel. Figure 77: Side cover Planmeca PlanMill 40 Technical manual...

  • Page 99: Rear Cover

    The air line must be released of pressure prior to disconnecting the hose or damage to the orange one-touch fitting can occur. Remove six screws from the back and carefully detach the rear cover from the mill chassis. Disconnect the fan connection. Technical manual Planmeca PlanMill 40...

  • Page 100: Tank Drawer

    Allow the system a few seconds to drain after the pump turns off, pull the drawer open. Remove the fluid tank from the drawer. At the center of the left and right drawer slides is a release button which allows the drawer slide to separate into two pieces. Planmeca PlanMill 40 Technical manual...

  • Page 101: Electronics Box

    The electronics box consists of upper and lower sections; the upper section holds the three field serviceable modules. The following procedures will illustrate how to properly access these three modules. Figure 81: Mill electronic box modules Technical manual Planmeca PlanMill 40...

  • Page 102: Power Supply Module

    Ensure that the +5VSTDBY and heartbeat LEDs are lit. Turn on power supply. Fan should turn on. Ensure that all LEDs are lit: NOTE The following legend defines the meaning of each LED as displayed top to bottom. Planmeca PlanMill 40 Technical manual...
  • Page 103 +42V MOTOR POWER SUPPLY - power status of the motor power supply +12V PUMP/FAN POWER - power status of the fluid pump and fan power Verify system initializes and homes all axes with no errors. Technical manual Planmeca PlanMill 40...

  • Page 104: Cpu Module

    Secure the CPU module in upper electronics box with five button head screws using the 2 mm Allen key. Verify Plug in system and press the Power button to boot the system. Planmeca PlanMill 40 Technical manual...

  • Page 105: Amplifier Module

    Depending on the units software version it may or may not automatically start the PlanMill 40 application. If the unit does not automatically start the PlanMill 40 application, simply double tap the PlanMill 40 MillingCenter icon on the touch screen to start the application.

  • Page 106: Fan (Electronics Box Exhaust)

    The exhaust fan is located inside the upper electronics box. It is powered off the backplane board and exhausts air out of the box. Tools required • 3 mm Allen key • #2 Philips screwdriver Removal Power the milling unit down. Planmeca PlanMill 40 Technical manual...
  • Page 107 Remove the four thread-forming screws, which secure the fan assembly. Figure 88: Fan screws Remove fan from upper e-box assembly. NOTE The accelerometer processor board is secured by the two outer screws. Gently set this assembly aside. Technical manual Planmeca PlanMill 40...

  • Page 108: Fuse Power Entry Module

    Exercise care when tightening the screws, do not over torque and strip out the plas- tic housing. Verify Connect power source. Turn on system. Ensure fan is running and air is blowing outward. 2.2.5 Fuse power entry module Tools required • small flat screwdriver Planmeca PlanMill 40 Technical manual...
  • Page 109 Power down and unplug milling unit from AC power. Locate power entry module, using a small flat screwdriver pry open the left side of the power entry cover, it hinges on the left. Figure 90: Power entry module Power entry module opened Technical manual Planmeca PlanMill 40...

  • Page 110: Cable Restraint Plate

    Y and Z-axis assemblies a cable restraint plate is installed to ensure no cables can contact and become damaged by the movement of the motion base assembly. To access any of the cables this plate must be removed. Figure 93: Cable restraint plate Planmeca PlanMill 40 Technical manual...

  • Page 111: Lcd Touch Display Assembly

    This assembly includes a 4” diagonal, 640 x 480 LCD display with touch screen overlay, processor boards, sheet metal enclosure and plastic bezel. This assembly should be replaced as a unit and the original returned to Planmeca After Sales for refurbishment. Figure 94: Touchscreen display Tools required •...

  • Page 112: Mounted Accelerometer Processor Assembly

    The accelerometer processor board has a jumper which must in placed in one of 3 positions depending upon the configuration of the milling machine in which it is being installed. For PlanMill 40 move the jumper to the “A” position. Planmeca PlanMill 40...
  • Page 113 The following is a close up of the accelerometer processor board, which shows the location of the jumper, installed in the position for a 40K (Config 1) milling unit. Figure 95: Jumper location (PlanMill 40, Move to “A”) Tools required •...
  • Page 114 LCD touch display in order to gain access to the accelerometer sensor which is mounted on the right side spindle motor. Use wire cutters to carefully the cable ties that help secure the 2 grey cables to the accelerometer sensors. Planmeca PlanMill 40 Technical manual...

  • Page 115: Lower Electronics Box (E-Box)

    Turn on the milling unit and wait for it to start the milling application. Verify that the milling application starts and the mill initializes normally. Contact Planmeca After Sales regarding possible need to cut a calibration job so that Planmeca After Sales can evaluate tool break detection threshold settings for possible adjustment.
  • Page 116 Secure these screws in a safe place. They will be used to reinstall the lower box to the system. Disconnect the 4-pin 115/230 Vac cable (black/white/white/black) from “P1” at the lower right-hand corner of the backplane PCB assembly. Planmeca PlanMill 40 Technical manual...
  • Page 117 Figure 102: Remove screws from bottom of upper E-box 12. Remove (Qty 6) screws (M5x.8x8) from the bottom of upper E-box. Figure 103: Remove screws from bottom of upper E-box 13. Remove (Qty 2) screws (M3x.5x8) from the lower Y-axis chain mount. Technical manual Planmeca PlanMill 40...
  • Page 118 Figure 105: Remove screws securing lower E-box to bottom plate 15. Carefully work lower E-box unit out from under the upper E-box unit. Figure 106: Remove lower E-box 16. Install replacement lower E-box by reversing the above procedure. Planmeca PlanMill 40 Technical manual...

  • Page 119: Grind Chamber Lid/Adapter Assembly

    The following procedure is for removal and reinstallation of the entire lid/adapter assembly. Tools required • #0 Philips screwdriver • metric Allen key set • diagonal wire cutters • wire ties Removal Remove mill top cover, see section 2.1 "Mill covers" on page 94. Technical manual Planmeca PlanMill 40...
  • Page 120 Loosen (5) M3 screws and remove one cable retainer on each side of the lid/adapter. NOTE Observe the locations of cable retainers for reassembly. Remove (4) M3 screws from front and rear of the lid adapter. Planmeca PlanMill 40 Technical manual...

  • Page 121: Lid

    Make sure the lid operates freely and smoothly with no rubbing on the adapter. Also verify the latch engages easily and fully. 11. Replace mill covers, see section 2.1 "Mill covers" on page 94. 2.3.2 Lid The grind chamber lid can be replaced independently of the adapter. Technical manual Planmeca PlanMill 40...
  • Page 122 Remove the clip-ring from the air cylinder knuckle and disengage the knuckle from the hinge bracket. NOTE The air cylinder will still be attached to the motion base, but there should be enough movement to disengage the knuckle from the bracket. Planmeca PlanMill 40 Technical manual...
  • Page 123 The following diagram is to be used as a template to check the springs and tweak or bend them as needed to achieve the desired preload. Technical manual Planmeca PlanMill 40...
  • Page 124 Verify proper operation by accessing the Open Lid tools in the software or by using the manual override button on the lid open solenoid. NOTE Make sure the lid operates freely and smoothly with no rubbing on the adapter. Also verify the latch engages easily and fully. Planmeca PlanMill 40 Technical manual...

  • Page 125: Lid Latch

    1.5 mm Allen key Removal Remove the top cover, see section 2.1 "Mill covers" on page 94. Open the lid. Locate the interlock switches on the left and right sides of the lid adapter, close to the hinge. Technical manual Planmeca PlanMill 40...

  • Page 126: Led Boards

    Figure 117: Switch installed and lever arm pressing actuator button 2.3.5 LED boards There are two LED boards which illuminate the grind chamber adapter using multi-colored LED’s. The left and right boards are serviceable individually; the procedure is the same for each side. Planmeca PlanMill 40 Technical manual...

  • Page 127: Sliding Wall

    In the event of a leak the following procedure can be performed to replace or repair the wall. Tools required • Philips head screwdriver • metric Allen key set Technical manual Planmeca PlanMill 40...
  • Page 128 Remove the bellows by pulling forward and lifting up. The bellows is seated in the Bellows Slide and must be pulled up to be removed. Figure 120: Removing the bellows Remove the (4) screws from each slide rail. Remove (3) screws on bellows slide insert. Planmeca PlanMill 40 Technical manual...

  • Page 129: Tool Changer

    NOTE Proper installation of these components is critical to the overall performance and operation of the milling unit. The following procedure is to remove and reinstall the entire tool changer assembly. Technical manual Planmeca PlanMill 40...
  • Page 130 Place a wooden shipping block under the tool changer chassis and the lower E-box. Lower the Z-axis smoothly on the top of the wooden block. The block should leave the Z-axis elevated to ease the tool changer removal. Planmeca PlanMill 40 Technical manual...
  • Page 131 Remove the cam lock from the mandrel holder. Remove the remaining (8) M3 flat head Philips screws from the bellows flange. Figure 124: Removing bellows flange Technical manual Planmeca PlanMill 40...
  • Page 132 Carefully grasp the front flange of the bellows and lift it over the stop pin for the cam lock on the mandrel holder. Then pull the flange forward exposing the (3) M3 Philips flat head screws securing the rear flange of the bellows assembly to the sliding wall assembly. Planmeca PlanMill 40 Technical manual...
  • Page 133 Figure 127: Pull up and forward carefully to remove the bellows assembly 10. Using firm but careful effort pull up and forward to remove the bellows assembly. Technical manual Planmeca PlanMill 40...
  • Page 134 13. Extend the Y-axis forward to allow access to the front mounting screws NOTE Remember to never put pressure on the back face of the servo motor, this cover is thin sheet metal and can bend, damaging the encoder. Planmeca PlanMill 40 Technical manual...
  • Page 135 Figure 131: Removing screws securing front of tool changer assembly 15. Locate and remove the remaining M6 flat head Allen screw on the lower left side of the Y-axis tube about 2/3 back, remove this screw. Figure 132: Remove M6 llat head allen screw Technical manual Planmeca PlanMill 40...
  • Page 136 Figure 134: Installing screws securing front of tool changer assembly Fully insert the tool changer assembly until all (6) mounting holes align with the Y-axis tube. Planmeca PlanMill 40 Technical manual...
  • Page 137 Use care not to damage the tubing with the pliers. Reconnect the purge orientation sensor tubing. Reconnect the tool changer electrical connector and secure with (2) retaining screws. Figure 136: Installing the bellows assembly Technical manual Planmeca PlanMill 40...
  • Page 138 Figure 139: Securing rear bellows flange 11. Apply a small amount of thread sealant to the (3) M3 Philips flat head screws and install the screws. Planmeca PlanMill 40 Technical manual...

  • Page 139: Tool Changer Actuation Adjustments

    It may be necessary to check the actuation speed of a tool changer due to wear and tear or due to repair or replacement. To check the tool changer actuation speed, access the Technician Console, High Level screen. Technical manual Planmeca PlanMill 40...

  • Page 140: If The Open Actuation Is Too Fast Proceed As Follows

    Reset the close tool changer valve stem to a good starting position by releasing the locking nut and turning the valve stem clockwise until valve is fully closed. Then open the valve 3 full turns. Planmeca PlanMill 40 Technical manual...

  • Page 141: If The Open Actuation Is Too Slow Then Proceed As Follows

    Reset the open tool changer valve stem to a good starting position by releasing the locking nut and turning the valve stem clockwise until valve is fully closed. Then open the valve 3 full turns. Technical manual Planmeca PlanMill 40...

  • Page 142: If The Close Action Is Too Slow Proceed As Follows

    It may be necessary to check and adjust the tool changer closed sensor due to it becoming loose or tool changer repair or replacement. If the tool changer closed senor needs adjusted some form of the warning shown below may be displayed. Planmeca PlanMill 40 Technical manual...

  • Page 143: Raising Z-Axis And Setting Z-Brake

    2.6.1 Raising Z-axis and setting Z-brake To access the tool changer closed sensor it is necessary to raise the Z-axis and use the Z- brake to hold the Z-axis in position. Go to the Technician Console, High Level. Technical manual Planmeca PlanMill 40...
  • Page 144 Figure 148: Raising the Z-axis Use the UP button to raise the Z-axis to the top. Figure 149: Opening the lid Select MECHANICAL CONTROL and touch the OPEN LID button. This will open lid and engage the Z-brake. Planmeca PlanMill 40 Technical manual...

  • Page 145: Adjusting Tool Changer Close Sensor Position

    Return to the Chapter D: "Troubleshooting" on page 71 of this manual and continue troubleshooting. Technical manual Planmeca PlanMill 40...

  • Page 146: Nose Seal

    Return to the Mechanical Control window and select the Open Lid button. 10. Remove the two flat head screws securing the rubber nose seal and inner and outer backup plates. 11. Remove the plates and rubber seal. Planmeca PlanMill 40 Technical manual...

  • Page 147: Tool Bumber

    Loosen the button head screw located on the top center of the tool holder (6-pack). Note, it is not necessary to fully remove the screw to replace the tool bumper. 10. Push the orange tool bumper to either side and out of the tool changer arm. Technical manual Planmeca PlanMill 40...
  • Page 148 Figure 154: Install bumper centered left to right Ensure the tool bumper is properly located and tighten the button head screw on top of the tool holder. Verify Drop off and pick up tools in each pocket to ensure 6 pack alignment. Planmeca PlanMill 40 Technical manual...

  • Page 149: Tool Holder

    NOTE Be sure to seat the tool holder back and to the left of the tool changer arm, when tightening the screw. Complete mill calibration, refer to the Chapter C: "Calibration" on page 49. Technical manual Planmeca PlanMill 40...

  • Page 150: Profile Sensor

    Remove the two profile sensor securing screws located in the recessed holes located on the right side of the tool changer arm. Planmeca PlanMill 40 Technical manual...
  • Page 151 Connect the sensor to the cable, position the cable assembly so the cap can sit flush on the tool changer arm. Reinstall the cap using the (4) flat head screws Reinstall the tool holder, see section 2.9 "Tool holder" on page 147. Technical manual Planmeca PlanMill 40...

  • Page 152: Circulation System

    • small cable ties • adjustable clip ring pliers Removal Remove the top cover and right side panel, see section 2.1 "Mill covers" on page 94. Disconnect the inline pump power connector. Planmeca PlanMill 40 Technical manual...
  • Page 153 Pump Stand. They are located on top of the pump and can be removed using a 3 mm Allen key. Figure 161: Circulation pump mounting screws (viewed from back of PlanMill 40) Lift the pump up and out of the machine taking care not to damage the solenoid valve assembly behind the pump.
  • Page 154 Turn the pump on and check for leaks using the following command: Technician Console --> High Level --> Mechanical Control --> Start Pump button. Verify leak free operation, correct any problems. 10. Reinstall the left side panel and top cover. Planmeca PlanMill 40 Technical manual...

  • Page 155: Water Pressure Switch

    Reconnect the inline connector. Turn the pump on and check for leaks using the following command: Technician Console --> High Level --> Mechanical Control --> Start Pump button. Technical manual Planmeca PlanMill 40...

  • Page 156: Float Switch

    Lower the float switch free of the bracket, feed the electrical cable down through the mounting hole. Install Feed cable up through mounting bracket. Install jam nut over cable and onto float switch, tighten nut snug. Planmeca PlanMill 40 Technical manual...

  • Page 157: Pneumatics System

    Use the procedure below if removal of the entire assembly is required. Figure 165: Pneumatic assembly Tools required • metric Allen key set • small diagonal cutters Technical manual Planmeca PlanMill 40...
  • Page 158 See drawer removal procedure. Figure 167: Loosen mounting screws Remove the upper mounting screw securing the bracket to the left frame rail. CAUTION After removal of screws in next step, the pneumatics assembly will be free. Planmeca PlanMill 40 Technical manual...
  • Page 159 Depress the button on the close tool changer solenoid to energize the air cylinder closed hold the button down. • Depress the button on the open tool changer solenoid and release the other button. Example 2 If the tool changer is open: Technical manual Planmeca PlanMill 40...

  • Page 160: Pneumatics Tubing Routing

    END 1 / END 2 6.35 mm (1/4”) 304 mm END 3 / END 4 3.18 mm (1/8”) 436 mm END 5 / END 6 3.18 mm (1/8”) 210 mm END 7/ END 8 6.35 mm (1/4”) 290 mm Planmeca PlanMill 40 Technical manual...

  • Page 161: Solenoid Valve

    Remove top cover, see section 2.1 "Mill covers" on page 94. Disconnect the air supply line from the back of the mill. CAUTION The air line must be released of pressure prior to disconnecting the hose or damage to the orange one-touch fitting can occur. Technical manual Planmeca PlanMill 40...

  • Page 162: Pilot Valve

    The following procedure applies to replacing any of the three valves. Pay attention to the routing of the tubes for the valve you are replacing and any cable ties used to secure the tube. Tools required • metric Allen key set • small diagonal cutters Planmeca PlanMill 40 Technical manual...

  • Page 163: Regulator, Filter And Water Separator

    (3.45 bar/50 psi) and filter out any debris in the line. Additionally, the water separator removes liquid water from the line. Each of these components can be replaced individually or as a group, the procedure is the same. Technical manual Planmeca PlanMill 40...
  • Page 164 Verify that there are no air leaks. Reinstall rear cover, side panel and top cover, see section 2.1 "Mill covers" on page Adjusting pressure regulator Pressure regulator can be adjusted by setting the adjusting knob. Planmeca PlanMill 40 Technical manual...

  • Page 165: Pressure Multiplier

    (3.45 bar/50 psi) air to provide 6.9 bar (100 psi) to the spindles for opening the collets. Verify that there are no air leaks. Reinstall rear cover, side panel and top cover, see section 2.1 "Mill covers" on page Technical manual Planmeca PlanMill 40...

  • Page 166: Air Pressure Switch

    Reconnect the inline electrical connector. Reconnect the air supply line, apply pressure and verify that there are no leaks. Reinstall the top and left side panel, see section 2.1 "Mill covers" on page 94. Planmeca PlanMill 40 Technical manual...

  • Page 167: Motion Base Assembly Repair

    Chapter E: Basic repair procedures 2 Basic repair procedures 2.13 Motion base assembly repair Figure 175: PlanMill 40 motion base assembly 2.13.1 X-axis servo motor and coupling The following procedure applies to replacing either the right or left X-axis servo motor. The procedure is the same for both left and right axes except where noted.
  • Page 168 Install CAUTION Installation of a new servo motor requires a careful alignment procedure, described in the following steps. Failure to follow the alignment procedure can cause prema- ture failure of mill components. Planmeca PlanMill 40 Technical manual...
  • Page 169 (blue connector with 5 wires) goes in the middle. Inserting the connectors incor- rectly can cause severe damage to the motor or amplifier. Verify Power up the mill and enter the PlanMill 40 application. On mill screen touch Maintenance Icon. Select Advanced and enter passcode 1234.

  • Page 170: Y-Axis Servo Motor And Coupling

    Disconnect servo motor hall-effect sensor cable from the interconnect board. Disconnect servo motor encoder cable from the interconnect board. Remove (2) M6 flat head Allen screws from the top and side of the Y-axis which secure the motor mount to the black Y-tube. Planmeca PlanMill 40 Technical manual...
  • Page 171 Attempting to remove motor with coupling attached to the ball screw will break or damage coupling. 10. Use a 4 mm Allen key and remove (4) screws securing the servo motor to the motor mount and carefully slide the motor out of chassis. Technical manual Planmeca PlanMill 40...
  • Page 172 Install the servo motor and coupling onto the motor mount and ball screw and snug the (4) mounting screws attaching the servo to the motor mount. Snug the coupling clamp screw (on ball screw end of the coupling). Planmeca PlanMill 40 Technical manual...
  • Page 173 Move the Y-axis forward and back to its limits, verify free non-binding operation for full travel. Select the Open Tool Changer button; verify smooth operation of tool changer. 10. Navigate to: Technician Console --> Motion Diagnostics --> Encoder Check. Technical manual Planmeca PlanMill 40...

  • Page 174: Z-Axis Servo Motor And Coupling

    Loosen but do not remove the clamp screw on the ball screw end of the coupling (with the power off and cables disconnected the coupling may be slightly rotated manually using a pencil eraser in order to access the clamp screw). Planmeca PlanMill 40 Technical manual...
  • Page 175 The proper distance between the motor face and the servo coupling is 7 mm. Torque to 2.03 nm (18 in-lbs). NOTE Use a 7 mm Allen key as a spacer to set coupling motor shaft. Technical manual Planmeca PlanMill 40...
  • Page 176 Select High Level button. Select the Axis Positions box. Move the Z-axis up and down to its limits; verify free non-binding operation for full travel. Navigate to: Technician Console --> Motion Diagnostics --> Encoder Check. Planmeca PlanMill 40 Technical manual...

  • Page 177: Home And Limit Sensors Identification

    L and XR -axes are fully in-board past the origin, with tools installed the tips of each tool barely clears the nozzle cap on the opposite spindle. • Y-axis is fully forward past the origin. • Z-axis is fully up. See appropriate procedure following for sensor to be replaced. Technical manual Planmeca PlanMill 40...

  • Page 178: X-Axis Home Sensor

    Secure with two M3 screws. Connect home sensor electrical connector to the interconnect board. Perform complete mill calibration procedure, see Chapter C: "Calibration" on page 49. Install covers. Verify Make sure the mill initializes and homes correctly. Planmeca PlanMill 40 Technical manual...

  • Page 179: X-Axis Limit Sensor

    Disconnect the limit sensor electrical connector from the interconnect board. Remove two M3 screws connecting limit sensor to carriage Figure 191: X-axis home and limit sensors Install Position the limit sensor flush against the shoulder etched into the carriage. Technical manual Planmeca PlanMill 40...

  • Page 180: Y-Axis Home And Limit Sensor

    Use the same procedure for both the Home and Limit sensors. CAUTION Replacement, adjustment or disturbance of a Home Sensor or the associated flag requires subsequent complete mill calibration. Tools required • 2.5 mm Allen key • small diagonal cutters • replacement wire ties Planmeca PlanMill 40 Technical manual...
  • Page 181 Make sure the cable is free from the flag during operation. Power unit on and verify the mill homes this and all axes properly. Perform full mill calibration procedure, see Chapter C: "Calibration" on page 49. Replace top cover. Technical manual Planmeca PlanMill 40...

  • Page 182: Z-Axis Home And Limit Sensor

    Once the sensor mount bracket has been removed, all calibration procedures must be performed. Remove the (2) screws securing the sensor to the sensor mount bracket. Remove the cable from the plastic p-clip and lift the sensor free of the assembly. Planmeca PlanMill 40 Technical manual...
  • Page 183 Select Advanced and enter passcode 1234. Select Technician Console. Select High Level button. Select the Mechanical Control box. Select the Axis Positions box. If the home sensor was replaced. Verify axis homes properly. If the limit sensor was replaced: Technical manual Planmeca PlanMill 40...

  • Page 184: Spindle And Spindle Motor

    Use wire cutters to remove the cable ties securing the spindle motor cable. Note the routing of the cable around the machine. Clip any remaining cable ties. Remove the cable restraint plate from the electronics box, see section 2.2.6 "Cable restraint plate" on page 108. Planmeca PlanMill 40 Technical manual...
  • Page 185 Place second 22 mm flat open end wrench here 13. Loosen the cable to motor connector by turning anticlockwise with the key on the end flat while holding the key on the middle flat in place. Technical manual Planmeca PlanMill 40...
  • Page 186 Figure 199: Disconnecting the spindle motor cable 15. The metal housing of the connector will slide back when fully unscrewed. Grasp the plastic connector and pull straight away from the motor to disconnect it from the motor. Planmeca PlanMill 40 Technical manual...
  • Page 187 Figure 202: Saddle cap 20. Remove 6 screws securing spindle saddle cap to the carriage. Technical manual Planmeca PlanMill 40...
  • Page 188 22. Use the small adjustable crescent key to remove the one touch fitting from the spindle. Figure 204: Tubing support bracket Tubing support bracket 23. Remove the two M4 screws from the tubing support bracket. Planmeca PlanMill 40 Technical manual...
  • Page 189 Figure 205: Slide tubing support bracket away from spindle 24. Slide the tubing support bracket away from the spindles. Figure 206: Remove the one touch fitting 25. Remove the spindle by pulling it out of the spindle housing. Technical manual Planmeca PlanMill 40...
  • Page 190 Figure 208: Verify spindle housing O-rings are in place Look inside the spindle housing and verify the two O-rings are in their respective grooves. Check that the one-fitting feeding the cooling liquid to the X-carriage is secure and doesn't leak. Planmeca PlanMill 40 Technical manual...
  • Page 191 Ensure that there is a gap between the spindle saddle cap and the carriage everywhere except for the 2 mm lip which should be flush with the carriage. Technical manual Planmeca PlanMill 40...
  • Page 192 Figure 212: Seating the spindle Recheck to make sure the one touch fitting is centered in the hole in the saddle cap. Seat the spindle by tightening the spindle seating screw until it is flush with the carriage. Planmeca PlanMill 40 Technical manual...
  • Page 193 11. Reconnect the yellow tubing to the one touch fitting on the top of the spindle. Figure 214: Attach motor to spindle 12. Screw the spindle motor into the spindle and snug using 22 mm flat open end key. Technical manual Planmeca PlanMill 40...
  • Page 194 • Center the mounting bracket on the centerline of the fluid tubing support bracket which is located on the front of the carriage, see the figure below. Planmeca PlanMill 40 Technical manual...
  • Page 195 18. Attach blue tubing to one touch fitting on the spindle motor cap. 19. Route the spindle motor cable securing to the frame where appropriate. 20. Reconnect the spindle motor connector to the electronics box secure with (2) retaining screws. Technical manual Planmeca PlanMill 40...
  • Page 196 Touch START LEFT SPINDLE or START RIGHT SPINDLE according to which side was replaced. Touch the ++ button under LT or RT according to which side was replaced until 50000 is displayed as the RPM. Figure 216: Starting the spindle Planmeca PlanMill 40 Technical manual...

  • Page 197: Spindle Housing

    22 mm flat open end keys • metric Allen key set • 3.175 mm (1/8”) pin key Removal Remove the burrs from the collets. Remove the 2 spindle housing securing screws from the carriage. Technical manual Planmeca PlanMill 40...
  • Page 198 Figure 218: Removing inner seal cap, rope packing and inner seal flange Rope packing Inner seal flange Inner seal Slide the spindle housing up and out through the grind chamber. Remove the one touch fitting from the spindle housing to use with new spindle housing. Planmeca PlanMill 40 Technical manual...

  • Page 199: Quick Release Adapter

    Touch the Collet Service icon and select Yes to continue. After the lid opens use the quick release nozzle cap removal and installation tool to remove the quick release nozzle cap by rotating clockwise to approximately the 1:00 o’clock position. Technical manual Planmeca PlanMill 40...
  • Page 200 Figure 220: Quick release adapter removal Remove these 5 screws Remove the quick release adapter from the face of the spindle housing. Figure 221: Ensure black O-ring remains in groove Ensure black O-ring remains in groove Planmeca PlanMill 40 Technical manual...

  • Page 201: Software Configuration

    Pulling system log files may be necessary for troubleshooting and diagnosis. Log files will consist of design center logs, job server logs and PlanMill 40 logs. These log files will be found in the root directory of each piece of Planscan equipment; c:\D4D\logs.
  • Page 202 Figure 223: Selecting Touch Panel The Touch Panel Settings screen will open. Select the Calibration tab. Figure 224: Selecting Calibration Tab Ensure the 9 point calibration radio button is selected and touch Calibrate Now button. Planmeca PlanMill 40 Technical manual...
  • Page 203 Figure 226: Touch red “+” mark with finger After touching the 9th red "+" mark, touch the Update button in the dialog box that appears. Figure 227: Selecting Update button Exit Touch Panel Settings. The touch screen calibration is now complete. Technical manual Planmeca PlanMill 40...
  • Page 205 Planmeca Oy | Asentajankatu 6 | 00880 Helsinki | Finland tel. +358 20 7795 500 | fax +358 20 7795 555 | sales@planmeca.com | www.planmeca.com...
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