Page 1 Evolution 5 Assembly Manual Rev. 1.13...
Page 2 The Evolution Series CNC Router. Welcome to the Family. We’re excited that you purchased the Evolution 5 CNC Router Kit from BobsCNC, and we know you’re just as excited to put it together. This manual gives you step by step instructions to ensure your success in assembling the Evolution 5 CNC Router and provides all the information you need to get your machine up and running.
Page 3: Table Of Contents
Table of Contents Information/Warning Boxes ............................5 Safety Precautions and Warnings ..........................6 Getting Started ................................. 7 Required Tools: ................................7 To Operate the EVOLUTION 5 CNC Router, you need will need: ............7 Recommended for the electronic setup include: ................... 7 Assembly Recommendations: ............................
Page 4 Wood Components (Included with Kit)......................104 Required Hardware ............................... 104 Illustrated Step by Step Instructions ......................106 T-Slot Spoilboard ............................... 138 Wood Components .............................. 138 Required Hardware ............................... 138 Completed Views ............................... 145 Tramming ..................................150 Clamping System ............................... 152 Wood Components (Included with Kit)......................
Page 5 EVOLUTION 5 Specifications Laser cut 6mm Baltic Birch Frame components. Fully Engineered Frame with rigid Box and Beam Gantry. Fully supported 5/16-inch stress proof steel Rails with SG20U Bearings. GT2 Belt Drive on X and Y axis. 2 mm pitch, 4 start Acme Threaded Rod on Z axis. Home Switches with Self Squaring Gantry.
Page 6: Information/Warning Boxes
Safety is the First Priority. Always wear proper protective equipment and use "safety sense" when assembling and operating your Evolution 5 CNC Router. Information/Warning Boxes CAUTION Indicates a possible risk of injury that can result from failure to follow this instruction WARNING Indicates the possible damage...
Page 7: Safety Precautions And Warnings
Safety Precautions and Warnings Evolution Series CNC Routers have a 110 v. Power Supply and use bits that spin at 30,000 rpm with cutting edges that are sharp and hazardous. The operator must understand the potential hazards and is responsible to take appropriate safety precautions before operating the Router.
Page 8: Getting Started
Getting Started Required Tools: A pair of long nose pliers. Diagonal Cutters or sharp knife to trim nylon ties. Calipers or measuring tape to measure part placement. Small standard screwdriver to connect electronics. #2 Phillips screwdriver to mount home switches and stepper motors. #3 Phillips screwdriver to build the main components.
Page 9: Assembly Recommendations
Assembly Recommendations: Use a large, flat, clean work surface for assembling your EVOLUTION 5. All Screws (unless noted) should be installed snug, then rotated 1-2 ½ turns. Apply LOCTITE to all M4 X 16 mm Machine Screws that are used to secure plywood pieces except for the 4 screws that clamp the router in step 10 of the final assembly.
Page 10: Z Spindle Mount Assembly
When a component has a T-Slot the nut is always placed in the slot as shown. The Machine Screw is threaded through the adjoining component into to the nut and tightened as noted above. T-Slot CAUTION This kit contains numerous small components that pose a choking risk for small children and pets.
Page 11 Z Frame Support Z Frame Z Spindle Bottom Mount Z Spindle Interlock Bottom Z Spindle Interlock Top...
Page 12: Required Hardware
Z Spindle Top Mount Z Spindle Support Required Hardware Part # Description Photo Acme Block Nut 8“ Zip Tie M6 x 30 Machine Screws M6 Locknuts Eccentric Adjustment Spacer Eccentric Washer Bearing Fender Washer...
Page 13: Illustrated Step By Step Instructions
SG20U Bearings M4 x 30 Machine Screws M4 x 16 Screws M4 Nuts M4 Lock Nuts Illustrated Step by Step Instructions The Z Carriage Assembly holds the Router securely in a carriage that travels up and down the Z-axis on a set of Rails. These first steps will show you how to build the Spindle (Router) Mount.
Page 14 Step 1 Attach the Z Spindle Bottom Mount (Z4) to the Z Frame (Z3) with three M4 x 16 Machine Screws and Nuts as shown. Step 2 Loosely attach Spindle Interlock Bottom (Z5) to the Z Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown. Do not tighten the machine screws and nuts or use LOCKTITE.
Page 15 Step 3 Loosely attach the Spindle Interlock Top (Z6) to the Z Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown. Do not tighten the Machine Screws and Nuts or use LOCKTITE. They will be tightened in a later step after the Router has been mounted.
Page 16 tightened in a later step after the Router has been mounted. The Interlock Bottom and Top must be able to move slightly from front to back, this allowance will make installing the Router easier. You only need to make sure that the Machine Screws and Nuts are engaged to keep the Screws from falling out.
Page 17 Step 7 Fit the tabs on the Acme Block Nut (ZD2) into the slots on the back side of the Frame Assembly as shown. The ACME Block Nut tabs are designed to be a snug fit. If the ACME Block NUT fit is too tight, use sandpaper to sand the outer faces of the rectangular slots as shown with the red arrows below until the block fits snuggly unto the slots.
Page 18 as shown. Be careful to keep the Acme Block Nut securely in place. Step 9 Wrap an 8” Zip Tie around the Frame Supports as shown. Make sure the Zip Tie Lock is positioned on the Router side of the Assembly.
Page 19 Test fit the Router in the Support Assembly as shown. This will help align the interlocking center pieces prior to final assembly and tightening. Remove the Router after dry fitting is completed. Video Link: https://www.youtube.com/watch?v=SkQ55V6ymEs&t=69s...
Page 20 Step 10 Attach four SG20U Bearing Assemblies to the Z Frame. Loosely tighten the nuts. These will be adjusted and tightened at a later step. When putting the Bearing Assembly together, make sure the hub on the Bearing faces the wood.
Page 21 Prior to putting the Bearing Assembly together, mark the point of the inboard edge of the Eccentric Adjustment Spacer using a permanent marker as shown below. This mark will help orient the Nut for tramming. Mark this inboard point...
Page 23 Step 11 Attach the two (Z1) Z Frame Mount Supports to the (Z8) Z Spindle Support and secure with two M4 x 16 Machine Screws and Nuts. Step 12 Attach the Spindle Support Assembly to the Z-Frame Assembly with six M4 x 16 Machine Screws and Nuts as shown.
Page 24 The finished Z Assembly should look like this:...
Page 25: Y Carriage Assembly
Y Carriage Assembly Required Wood Components Part # Description Photo Z Stepper Motor Mount Rail Top Support Bearing Retainer Plate Y Carriage Frame Y Carriage Side Support Belt Retainer...
Page 26: Required Hardware
Z Rail Stop Carriage Bottom Support Rail Support Required Hardware Part # Description Photo Bearing Retainer Washer CB11 Stepper Motor Aluminum Helical Coupler SG20U Bearing ACME Rod...
Page 27 Small Shim Washer M6 x 30 Machine Screw M6 Locknut Eccentric Adjustment Spacer Eccentric Washer Bearing Fender Washer M4 Lock Nut M4 x 16 Machine Screw M4 Nut 626-2RS Bearing 6mm Split Locking Collar Stress Proof Steel Z-Rail M2.5 x 16 Machine Screw...
Page 28 M2.5 Lock Nut CB13 Home Switch M3 x 10 Machine Screw Illustrated Step by Step Instructions Step 1 Attach the Belt Retainer (Y6) to the back side of the Y Carriage Frame (Y4) and secure with four M4 x 16 Machine Screws and Lock Nuts as shown below.
Page 29 Step 2 Attach the SG20U Bearings Attach the two upper SG20U Bearings to the Y Carriage Assembly as shown. NOTE: The assembly order for the Upper Bearing is; Machine Screw, SG20U Bearing (with hub facing toward the Bearing Washer), Bearing Washer, Plywood, Bearing Washer secured with a Lock Nut.
Page 30 Upper Bearing Lower Bearing Step 3 Attach the Carriage Bottom Support (Y8) to the Y Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown.
Page 31 Step 4 Attach one Rail Support (Y9) to the Y Frame Assembly with three M4 x 16 Machine Screws and Nuts as shown. Step 5 Attach the second Rail Support (Y9) to the Y Frame Assembly with three M4 x 16 Machine Screws and Nuts as shown.
Page 32 Step 6 Attach the Rail Top Support (Y2) to the Y Frame Assembly with two M4 x 16 Machine Screws and Nuts as shown. Step 7 Attach the Z Rail Stop (Y7) to the Y Frame Assembly with two M4 x 16 Machine Screws and Lock Nuts as shown.
Page 33 Step 8 Attach one Y Carriage Side Support (Y5) to the Y Frame Assembly with seven M4 x 16 Machine Screws and Nuts as shown. Step 9 Follow the same process to attach the second Y Carriage Support (Y5) to the Y Frame Assembly using seven M4 x 16 Machine Screws and Nuts as shown.
Page 34: Illustrated Step By Step Instructions
Y and Z Carriage Assembly Illustrated Step by Step Instructions WARNING Prior to installing the Lower Rails, adjust the Eccentric Spacers so that the lower Bearing Assemblies are at their outboard position. Step 1 Lay the Y Carriage Assembly with the Bearings facing down. Fit Z Carriage Assembly into Y Carriage Assembly as shown.
Page 35 Step 2 Hold the Assemblies together and carefully insert a Short Rail through the Upper Rail Support, threading it behind the upper SG20U Bearing as shown. Gently thread the Z Rail through the Rail Support and behind the lower SG20U Bearing, through the second Rail Support, finally seating the Rail into the Lower Rail Support and Rail Stop Assembly.
Page 36 Step 4 Attach the Stepper Motor to the Z Stepper Motor Mount (Y1) using four M3 x 10 Machine Screws. Note: The Stepper Motor wires are facing towards the protrusion. Step 5 Thread the Stepper Motor wiring harness through the Motor Mount as shown.
Page 37 Step 6 Slide the 626-2RS Bearing(ZD3) onto the shaft of the ACME Rod, next, insert 2 Shim Washers and secure in place with the 6mm Split Locking Collar by holding the Locking Collar tightly against the Bearing, then tighten the Set Screw as shown. Step 7 Insert the ACME Rod through the hole in the Rail Top Support and thread into the ACME Nut as shown.
Page 38 Step 8 Place the Bearing Retainer Plate (Y3) over the Bearing and secure in place with three M4 x 16 Machine Screws, Bearing Retainer Washers and Lock Nuts. [NOTE: Washers must be placed so that they cover the Outer Bearing Race to secure it in place as shown.
Page 39 Step 9 Slide the Aluminum Helical Coupler(ZD5) over the shaft of the Stepper Motor. Make sure the Set Screw fits against the flat of the Stepper Motor Shaft. Gently snug the Set Screw to keep it from rotating off the flat but loose enough so that it can slide up and down.
Page 40 Step 10 Slide the Aluminum Helical Coupler so that it is centered top and bottom between the Locking Collar and bottom of the Z Stepper Motor Mount and tighten the upper and lower Set Screws. Secure the Z Motor Mount to the tabs of the Y Carriage Assembly using four M4 x 16 Machine Screws and Nuts.
Page 41 Step 12 Route the Home Switch Wires as shown below. Step 13 Secure the Z Axis Stepper Motor wires with two Zip Ties to the Stepper Motor Mount as shown.
Page 42: Gantry Assembly
Gantry Assembly Required Wood Components Part # Description Photo Gantry Frame Gantry Side Support Gantry Cross Brace Y Rail Support Controller Mount Gantry Back Brace Gantry Back Support Gantry Top/Bottom Brace Gantry Side Y Stepper Motor Mount...
Page 43: Required Hardware
Y Belt Idler Mount Y Belt Adjuster Gantry Side Lower Brace 21mm Pulley Gauge Required Hardware Part # Description Photo M3 X 10 Machine Screws M6 X 30 Machine Screws M2.5 x 16 Machine Screws M2.5 Lock Nuts M6 Lock Nuts Eccentric Adjustment Spacer Eccentric Washer...
Page 44 SG20U Bearing M4 x 16 Machine Screws M4 Nuts Small 4” Zip Ties M5 x 30 Machine Screw M5 Nut M5 Lock Nuts Idler Fender Washer Flanged Bearing F625Z GT2 Pulleys Bearing Retainer Washers USB Cable...
Page 45 CB11 Stepper Motors CB12 Power Supply with Cord 8” Zip Tie CB16 Controller CB13 Home Switches...
Page 46: Illustrated Step By Step Instructions
Illustrated Step by Step Instructions Step 1 Align and insert the tabs of one Gantry Side Support (G2) into the slots of one Gantry Side (G10). Secure with five M4 x 16 Machine Screws and Nuts as shown. NOTE: Make sure the side with the alignment markings is facing up.
Page 47 Step 3 Align and insert the tab and slots of the Gantry Side Lower Brace (G14) and secure with three M4 x 16 Machine Screws and Nuts as shown. Step 4 Align and insert the tab and slots of one Gantry Cross Brace (G3) as shown and secure in place with two M4 x 16 Machine Screws and Nuts.
Page 48 Step 5 Align and insert the tab and slots of the second Gantry Cross Brace (G3) as shown and secure in place with two M4 x 16 Machine Screws and Nuts. Step 6 Repeat process to assemble second side. [NOTE: Both sides will mirror each other as shown].
Page 49 Prior to putting the Gantry Assembly together, note that the four ½” (12mm) holes at the bottom of the Gantry Frame (G1) must be oriented on the bottom of the Gantry Assembly. They provide access to adjust the Y Carriage Bearings in a later step. Bearing Adjustment Access Holes...
Page 50 Step 7 Align and insert the tabs of the seven Y Rail Supports (G4) into the slots in the (G1) Gantry Frame and secure with fourteen M4 x 16 Machine Screws and Nuts. Finished Assembly should look like this.
Page 51 Step 8 Align and insert the tabs of the Gantry Frame Assembly into the slots in the Gantry Bottom Brace (G9) and secure with fifteen M4 x 16 Machine Screws and Nuts as shown. NOTE: The Bearing Adjustment Access Holes in the Gantry Frame are at the bottom.
Page 52 Step 10 Align and insert the tabs of the Controller Mount (G5) into the slots of the Gantry Frame Assembly and secure with two M4 x 16 Machine Screws and Nuts as shown.
Page 53 Step 11 Align and insert the tabs of the Gantry Frame Assembly into the slots of the Gantry Top Brace (G9) and secure with twenty-one M4 x 16 Machine Screws and Nuts as shown. Step 12 Align and insert the tabs of the Gantry Back Brace (G7) into the slots of the Gantry Frame Assembly and secure with three M4 x 16 Machine Screws and Nuts as shown.
Page 54 Step 13 Build three Idler Bearing Sub-Assemblies. Slide two F625Z(H51) Flanged Bearings on a M5 x 30 Machine Screw as shown. NOTE: install the flanges of the Bearings so that each flange is oriented to the outside from the other as shown. Thread a M5 Nut onto the Machine Screw snug against the Bearings as shown.
Page 55 Slide an Idler Fender Washer onto the Machine Screw against the M5 Nut. Insert the Bearing assembly through Y Belt Idler Mount (G12) and secure with an Idler Fender Washer and M5 Lock Nut as shown.
Page 56 Place a 1 ½” strip of painter’s tape on one side of the Y Belt Adjuster. Insert a M4 Nut and a Bearing Retainer Washer in the appropriate slots and cover with another length of tape. Insert the M5 Lock Nut into the hex shaped hole in the Y Belt Adjuster (G13).
Page 57 Step 14 Align the Idler Adjustment Assembly into the slots of the Gantry Frame Assembly as shown. Secure the Adjustment Assembly in place with one M4 Machine Screw and Nut as shown. In the photo below, the Bearing Adjustment Access Holes are oriented to the top to simplify installation.
Page 58 Step 15 Align and insert the tabs of the Y Stepper Motor Mount (G11) into the slots of Gantry Frame Assembly and secure with one M4 x 16 Machine Screw and Nut as shown. In the photo below, the Bearing Adjustment Access Holes are oriented to the bottom to simplify installation.
Page 59 Step 16 Align and insert the tabs of the Gantry Frame Assembly into the slots of the left Gantry Side Assembly and secure with seven M4 x 16 Machine Screws and Nuts. [NOTE: The Stepper Motor Mount will be secured in a later step]. Left Hand Side Left Front View Completed...
Page 60: Front View (Right Hand Side) Completed
Step 17 Align and insert the tabs of the Gantry Frame Assembly into the slots of the Right Gantry Side Assembly and secure with seven M4 x 16 Machine Screws and Nuts. [NOTE: The Stepper Motor Mount will be secured in a later step]. (Photo is taken from the back of the Assembly to illustrate tabs and slots).
Page 61 Step 18 To install the lower Eccentric Bearing Assembly on the Gantry Side Assembly, turn the Gantry Assembly so that it is resting on the top side as shown.
Page 62 Lower Bearing Order: M6 x 30 Machine Screw, SG20U Bearing (with hub facing toward the Bearing Washer), Bearing Washer, Plywood, Eccentric Washer, Eccentric Adjustment Spacer, secured with M6 Lock Nut. Loosely tighten the Nuts. These will be adjusted and tightened at a later step.
Page 63 Upper Bearing Order: M6 x 30 Machine Screw, SG20U Bearing (with hub facing toward the Bearing Washer), Bearing Washer, Plywood, Bearing Washer, secured with a M6 Lock Nut. Install the Idler Bearing Assembly and secure with an M5 Lock Nut as shown.
Page 64 Step 19 Repeat the three steps to install the Bearing Assemblies to the opposite Gantry Side Assembly as shown. Step 20 Install the Arduino Controller to the Gantry Assembly using four Zip Ties as shown. NOTE: when threading the Zip Ties through the attachment holes, do not tighten until all four Zip Ties are installed.
Page 65 Step 21 Installing the X1 Home Switch. The X1 Home Switch is located to the right of the Controller when viewed from the back. Begin by labeling the pin cover using easy to read tape or other label material. Mark the label as “H X 1.”...
Page 66 Route the Wire through the access hole in the bottom of the Gantry Side Assembly, through the access hole at the bottom of the Gantry Back Brace(G7), through the Home Switch (HS) opening in the Controller Mount, and thread in the Gantry Back Brace(G7).
Page 67 Mount the X1 Home Switch using two M2.5 x 16 Machine Screws and Lock Nuts. Secure the Home Switch Wires with a Zip Tie as shown. Zip Tie X1 Home Switch Installed.
Page 68 Step 22 Installing the X2 Home Switch. The X2 Home Switch is located to the left of the Controller when viewed from the back. Begin by labeling the pin cover using easy to read tape or other label material. Mark the label as “H X 2.” Route the X2 Home Switch Wire through access hole in the bottom of the Gantry Side Assembly, through the access hole at the bottom of the Gantry Back...
Page 69 Mount the X2 Home Switch using two M2.5 x 16 Machine Screws and Lock Nuts. Secure Home Switch Wires with a Zip Tie as shown. Zip Tie X2 Home Switch Installed...
Page 70 Step 23 Installing the Y Home Switch. The Y Home Switch is in installed the upper left corner of the Gantry Assembly when viewed from the Front or to the right of the Controller when viewed from the back. Begin by labeling the pin cover using easy to read tape or other label material.
Page 71 Route the Wire through access slot in the top of the Gantry Side Assembly, through the access hole in the top of the Gantry Side support(G2), through the Gantry Side Assembly, through the access hole in the top of the Gantry Back Brace(G7) and, through the Home Switch (HS) opening in the Controller Mount.
Page 72 Mount the Y Home switch on the top left side of the front of the Gantry using two M2.5 x 16 Machine Screws and Lock Nuts as shown. Connect the Y Home Switch plug to the “Y-” pin on the Arduino Controller as shown.
Page 73 Step 24 Use the 21mm Belt Pulley Gauge(GA1) to install the Idler Pulley. Make sure the legs of the Gauge are set flat on the Motor Housing. Insert the Pulley onto the Motor shaft. Snug one of the Set Screws against the flat on the shaft and lift the top flange of the Pulley against the top of the Gauge opening as shown.
Page 74 Step 25 Installing the Y Stepper Motor Assembly. Insert the Y Stepper Motor Assembly into the Stepper Motor Mount from the back side of the Gantry Assembly. Make sure the Stepper Motor Wires are oriented toward the top of the Gantry as shown. Secure the Stepper Motor in place with four M3 x 10 Machine Screws.
Page 75 Connect the Y Stepper Motor Plug onto the 4 Pins on the left side of the Y Driver as shown. Secure Wires to the Controller Board with a Zip Tie as shown. [NOTE: The color code orientation must be as shown]. Step 26 Installing the X1 Stepper Motor Assembly.
Page 76 Route the Stepper Motor Wires up through the Gantry Side Assembly as shown. Continue routing the Stepper Motor Wires across the Gantry and through X1 Wire slot in the Controller Mount as shown.
Page 77 Connect the X1 Plug to the X1 Driver pins located to the left of the Driver as shown. [NOTE: follow the color orientation of the X1 plug as shown]. Step 27 Installing the X2 Stepper Motor Assembly. Insert the X2 Stepper Motor Assembly into the right side of the Gantry Assembly when facing the front and secure with four M3 x 10 Machine Screws.
Page 78 Route the X2 Stepper Motor Wires up through the Gantry Side Assembly as shown. Continue routing the Stepper Motor Wires across the Gantry and through X2 Wire slot in the Controller Mount as shown.
Page 79 Connect the X2 Plug to the pins located to the left of the X2 Driver as shown. Step 28 Installing the Power Supply and USB Cable. Tuck the Power Supply(CB12) into the back of the Gantry Assembly as shown.
Page 80 Route the Power Wire through the Controller Mount as shown.
Page 81 WARNING Polarity is important. Ensure proper connection as illustrated in the steps below, or you will damage your Controller. Attach the Power Wires to the Power Terminal on the Arduino Uno. Secure the Power Cord to the Controller Mount with a Zip Tie as shown.
Page 82 Route the Power Cord as shown and secure with Zip Ties shown. Connect the USB Cable to the Arduino Uno and route the Cable through the back of the Gantry and secure to the Gantry Side with Zip Ties as shown.
Page 83 Wire Management: Bundle and secure the Stepper Motor Wires to the back of the Gantry Back Support with a Zip Tie as shown.
Page 85: Frame Instructions
X Frame Instructions Required Wood Components Part # Description Photo Rail Support Frame Corner Brace Frame Mid Support Frame Mid Support Frame Side Support Front Frame Side Support Rear Frame End Support Wire Harness Support...
Page 86: Required Hardware
Frame Corner Support EX12 Coupling Plate Required Hardware Part # Description Photo M4 x 16 Machine Screw M4 Nut...
Page 87: Illustrated Step By Step Instructions
Illustrated Step by Step Instructions Step 1 The X Frame consists of a Front and Rear Assembly. To build the Front Assembly: Align the tabs of the Rail Supports (X1) into the slots in the Frame Side Support Front(EX5). Secure with three M4 x 16 Machine Screws and Nuts for each Rail Support as shown.
Page 88 Step 2 Align the tabs of two Frame Corner Supports (previously removed) into the lower slots of the Frame Side Assembly and secure with two M4 x 16 Machine Screws and Nuts as shown. Repeat to complete the second Frame Side Assembly. Left Side Right Side Step 3...
Page 89 Completed Front Side Panel Assembly...
Page 90 Step 4 Align the slots in one of the Frame Side Assemblies with the tabs in the Frame Mid Support(X4) as shown and secure with two M4 x 16 Screws and Nuts. Inside View Outside View...
Page 91 Step 5 Repeat the process until three Frame Mid Supports have been installed and secured on the right side. Step 6 Repeat this procedure to install the remaining Side Support Assembly.
Page 92 Step 7 Align the slots in the X6 Frame End Support with the tabs in the X Frame Assembly and secure each side with six M4 x 16 Screws and Nuts. Completed Front Frame Assembly...
Page 93 The two Frame Side Support Rear panels have a square access hole and four ½” (12mm) holes. The four holes must be oriented on the bottom of the Assembly. They provide access for belt routing and bearing adjustment needed in later steps. Step 1 To build the Rear Assembly of the X Frame: Align the tabs of the Rail Supports (X1) into the slots in the...
Page 94 Step 2 Align the tabs of the remaining four Rail Supports (X1) into the slots in the Frame Side Support Rear(X5). Secure with three M4 x 16 Machine Screws and Nuts for each Rail Support as shown. Repeat to complete both Rear Side Support Assemblies.
Page 95 Step 3 Align the tabs of the two Frame Corner Supports (X8) into the lower slots of the Side Assembly and secure with two M4 x 16 Machine Screws and Nuts for each side as shown. Step 4 Align the tabs of the two Frame Corner Braces (X2) into the upper slots of the Side Assembly and secure with two M4 x 16 Machine Screws and Nuts for each side as shown.
Page 96 Completed Rear Side Panels...
Page 97 Step 5 Align the slots in the Right Side Assembly with the tabs in the in the Frame Mid Support (X4) as shown and secure with two M4 x 16 Screws and Nuts. Step 6 Align the slots of the right Side Assembly with the tabs of the remaining three Frame Mid Supports as shown and secure with two M4 x 16 Screws and Nuts for each.
Page 98 Step 6 Align the slots of the left Side Assembly with the tabs of the four Frame Mid Supports as shown and secure with two M4 x 16 Screws and Nuts for each.
Page 99 Step 7 Align the slots in the Frame End Support (X6) with the tabs in the Front X Frame Assembly and secure with six M4 x 16 Screws and Nuts. Completed Rear Frame Assembly...
Page 100 Step 8 Using the Extension Frame Mid Support (EX4), align the tabs of the Wire Harness Support (X7) with the slots and secure with two M4 x 16 Machine Screws and Nuts for each end as shown. Align and mount the Frame Mid Support (X4) to the Mid Frame Assembly.
Page 101 Step 9 Align the tabs of the Mid Frame Assembly into the slots of the Coupling Plate(EX12) (one for each Side of the Mid Frame Assembly) and press them together as shown. Step 10 Align the mounting holes of the Coupling Plates(EX12) with the holes in the Front X Frame Assembly.
Page 102 Step 11 Insert the tabs of the Frame Mid Support (X4) into the slots of the Front X Frame Assembly and secure with four M4 x 16 Machine Screws and Locking Nuts for each side as shown.
Page 103 Step 12 Align the unused mounting holes of the Coupling Plate with the holes in the Rear X Frame Assembly. The ends of the Rear X Frame Assembly will fit between the Coupling Plates. Secure each side with four M4 X 16 Screws and Lock Nuts.
Page 104 IMPORTANT NOTE: Before tightening the Lock Nuts, hold a straight edge across the top each side. Make sure the top edges of the entire X Frame Assembly are flat when tightening. Completed X Frame Assembly...
Page 105: Final Assembly
Final Assembly Wood Components (Included with Kit) Part # Description Photo Belt Retainer Short Belt Retainer Long Rail Stop Belt Adjusting Plate Rail Stop Required Hardware Part # Description Photo Heat Shrink Tubing CB15 Pin Connector GT2 Belt Stress Proof Steel X Rail Stress Proof Steel Y Rail...
Page 106 M4 x 30 Machine Screw M4 Nut Makita Router...
Page 107: Illustrated Step By Step Instructions
Illustrated Step by Step Instructions Step 1 Carefully position the Gantry Assembly on the X Frame Assembly as shown.
Page 108 Step 2 Carefully insert the upper Stress Proof Steel X Rail into the X Frame Assembly through each of the upper Rail Supports and beneath each of the Upper Bearings of the Gantry Side Assembly as shown. Repeat this for other side.
Page 109 WARNING Prior to installing the Lower Rails, adjust the Eccentric Spacers so that the lower Bearing Assemblies are at their lowest position. Step 3 Observe the SG20U Bearing while turning the hex head of the Eccentric Adjustment Spacer until you see that the Bearing is set to its lowest position.
Page 110 Step 4 Carefully insert the lower Stress Proof Steel X Rail into the X Frame Assembly through each of the Rail Supports and above each of the Lower Bearings of the Gantry Side Assembly as shown. Repeat for the other side.
Page 111 Step 5 Adjusting the Eccentric Spacers Clockwise Counterclockwise NOTE: To raise the SG20U Bearing against the Rail on the Left Side, rotate the Eccentric Adjustment Spacer clockwise. To raise the Bearing on the Right Side, rotate the Eccentric Adjustment Spacer counterclockwise.
Page 112 Adjust the right-side Eccentric Spacer upward with a 13mm wrench until it fits snugly against the Rail. Using your fingers, try to turn the Bearing. The Bearing should only move if the Gantry moves. Note the position of the mark that was made on the right-side Eccentric Adjustment Spacer.
Page 113 Using a 13mm wrench, raise the left lower Bearing to the corresponding mark. Using your fingers try to turn the left lower Bearing. The Bearing should only move if the Gantry moves. Once the Bearings are snug against the Rail, tighten the Locknut with a 10mm wrench and Phillips Head screwdriver as shown.
Page 114 Step 6 Installing the X GT2 Belts. (Photos of right-side installation). WARNING Belt routing is important. Ensure proper placement as illustrated in X1 Side View (page 129) and X2 Side View (page130) Cut two of the GT2 Belts to a length of 60 7/8 inches. Insert one end of the Belt into the Short Belt Retainer (X9).
Page 115 Insert the Belt Retainer and Belt into and through the Rail Stop. Then insert the Assembly into the bottom slot at the back of the X Frame Assembly. NOTE: Using a Zip Tie, snug the Belt in the Retainer. Make sure the square lock of the Zip Tie is located on the top of the Belt Retainer.
Page 116 Routing the free end of the Belt through the Gantry. Note: Slide the Gantry Assembly in front of the square access hole in the X Frame. This opening provides the access you need to loop the Belt around the Idler and Flange Bearings. We suggest that you watch the short video demonstrating how to correctly route and install the Belts around the Flange and Idler Bearings.
Page 117 The following photos illustrate the proper path for routing the Belt. The photos were taken before the Gantry was installed on the X Frame for Illustration purposes only! The Gantry Assembly must be installed on the X Frame Assembly before attempting to install the Belts.
Page 118 Loop the Belt over the Belt Pulley so that the Belt teeth engage the teeth of Pulley. Finished Belt Routing viewed through the access port. Repeat for the other X Belt.
Page 119 Step 7 Securing the X1 and X2 Belts Insert two M6 x 30 Machine Screws through the Belt Adjustment Plate (X11) and secure with a M6 Nut. Add one M6 Nut to each Machine Screw as shown. Insert the Long Belt Retainer (X10) through the Belt Adjusting Plate into the Rail Stop (X3) as shown.
Page 120 Insert the Belt Tightening Assembly into the upper slot of the X Assembly as shown. At the front of the machine be sure to insert in the upper slot. Insert the end of the Belt into the Belt Retainer. Be sure to seat the Belt completely in the Retainer as...
Page 121 Step 8 Attaching the Y Carriage Assembly and Y Axis GT2 Belt Insert the upper Y Axis Stress Proof Steel Rail into the Gantry Side and carefully thread the Rail through the upper Rail Supports and into opposite Gantry Side as shown.
Page 122 Cut one of the GT2 Belts to a length of 56 1/2 inches. Lay the Y Carriage Assembly on the X Frame Assembly and insert the ends of the Y Axis Belt into the Belt Retainer making certain the Belt is not twisted.
Page 123 Carefully loop the Belt around the Y Carriage Assembly, making sure the ends remain secure in the Y Belt Retainer. Then hang the upper Bearings of the Y Carriage Assembly onto the upper Y Rail as shown, being careful to keep the Belt between the upper and lower Bearings.
Page 124 the lower SG20U Bearings, and across into the opposite Gantry Side. Attach the Rail Stops to each end of the Gantry Side using two M4 x 30 Machine Screws and Nuts for each side as shown. Loop the Belt over the Idler Pulley as shown. Make sure the Belt is not twisted and that the Belt teeth are oriented as shown.
Page 125 Loop the other end of the Belt over the Belt Pulley as shown. Make sure the teeth in the Belt engage the teeth of the Pulley.
Page 126 Adjust the Y Carriage Eccentric Spacers equally on both sides using the alignment marks to tighten Bearings against the Rail as shown. Counterclockwise Clockwise Align the access hole in the Gantry with the Bearing Screw. Using a 10mm socket and a Phillips Screwdriver tighten the Lock Nuts to secure the 4 Bearing positions.
Page 127 Completed Y Axis Belt Installation Step 9 Wiring the Self Squaring Gantry. Separate the red and black Wire on the X2 Home Switch Wire as shown. Turn the pin connector over to view the locking mechanism that holds the wires in place.
Page 128 Using the sharp point of a thin blade. Insert the blade beneath the wire lock and gently lift to remove the black wire. Repeat these steps with the Z Home Switch.
Page 129 Connect the black Z axis Home Switch Wire to the black X2 Home Switch Wire using the Pin Connecter as shown. Cover the splice with the heat shrink tubing. Using a lighter or heat gun, carefully heat the tubing so that it shrinks securely around the pin connector as shown.
Page 130 Below is a schematic of the wiring of the self-squaring gantry. Note the black line represents the spice connect the Z and X2 black wires. Both red wires are connected to the controller via a DuPont connector to the Z+ pin terminal.
Page 131 Plug the Z Stepper Motor connector to the Z Driver and secure with a Zip Tie as shown. Step 10 Installing the Router NOTE: The manual shows installing a Makita RT0701C Router. Insert the Router into the Holder and with downward pressure gently twist the Router body until it is fully seated in the Holder as shown.
Page 132 Tighten the four Screws in the Router Z Mount. Align each Screw with one of the elongated access holes in the back of the Gantry. Note: To align the access hole with the Phillips head screws it will be necessary to raise or lower the Z Carriage. This can be done by manually rotating the Helical Coupler at the top of the Z Axis as shown.
Page 133 Tighten the 2 M4 X 30 Machine Screws and Lock Nuts to clamp the lower Router Mount.
Page 134 To secure the Router Cord to the Router Carriage and Gantry, first lower the Router Carriage as low as possible. Use Zip Ties to secure the Router Power Cord to the top of the Router Carriage Assembly as shown. Be careful to route the Cord without putting stress on the stress relief as shown.
Page 135 Facing the back of the Gantry, slide the Router Carriage all the way to the right. Allow enough slack in the Cord so that the Router Carriage can travel from the right side of the Gantry to the left without binding as shown.
Page 136 Final Wire Management. Zip Tie the Power Cord to the side of the Gantry as shown. Then tie them together and secure them to the Gantry Lower Side Brace as shown. In the same way tie the USB Cord to its Wire Harness Support as shown.
Page 137 Repeat these steps to tighten the X2 Belt. Step 12 Tighten the Y Belt Insert the M4 x 30 Machine Screw through the large hole in the Y Rail Stop as shown. Thread the Screw into the Nut of the Y Adjuster Assembly. Tighten the Belt by turning the Screw clockwise.
Page 138 Tighten the Screw on the Idler Pulley to secure Belt tension as shown Make sure the Nut closest to the Belt Adjusting Plate is tight. Using a 10mm wrench, hold the adjustment Nut and turn the Machine Screw to tighten the Belt.
Page 139: T-Slot Spoilboard
T-Slot Spoilboard Wood Components Part # Description Photo Fastening Strip T-Slot Small Board T-Slot Large Board Spacer Strips (set) Required Hardware Part # Description Photo 1.25” Woodscrews M4 X 16 Machine Screws M4 Square Nuts...
Page 140 Step 1 Insert four M4 Square Nuts into each of the T-Slots in the SB1 Fastening Strip. Step 2 Use one of the T Slot Small Strip Board (SB3) to determine on which side of the frame support to install the mounting strips. are properly positioned to attach the T-Slot boards.
Page 141 Step 3 Carefully align the T-Slots with the mounting holes in the Rail Support and secure with four M4 x 16 Screws. Make sure the Fastening Strip is mounted on the inside of the X Frame Front. Before tightening, make sure the Fastening Strips are mounted so that the X Frame supports are slightly proud.
Page 142 Step 3 Repeat to install the next fastening strip until all eleven strips are installed.
Page 143 Step 4 Before installing the Spoilboard, it is important to make sure the X Frame is square. The simplest way to do this is to measure diagonally from one corner of the cutting area to the other. If the measurements are exactly the same the X-Frame is square. If not, gently rack the frame until the measurements are equal.
Page 144 Step 6 Install the T-Slot Small Board (SB3) along the left side of the frame with the notch facing down as shown. Next, install the Spacer Strip Assembly so that it lies beneath the bottom notch of the T-Slot Board. The Spoilboard will fit flush with the front of the CNC.
Page 145 Step 8 Make sure the T Slot Small Boards are tight against each side. Then using the 1¼ inch Wood Screws, secure the Spoilboard to the X-Frame Assembly. We recommend counter sinking the cabinet screws approx. 3/16” below the surface of the T-Slot Boards.
Page 146: Completed Views
Completed Views Front View Back View...
Page 147 Belt Adjuster X1 Side View X1 Home Switch...
Page 148 Belt Adjuster X2 Side View X2 Home Switch...
Page 149 Z Home Switch Y Home Switch...
Page 151: Tramming
The simplest method to do this is to use a square as shown. If the Spindle is not perpendicular, the Evolution Series CNC Routers can be trammed on the X axis by adjusting the four Eccentric...
Page 152 The Spindle (Router) can be trammed on the Y axis by placing shims behind the SG20U Bearing Fender Washer. Placing the shim on the top will tilt the axis clockwise. Placing the shim on the bottom will tilt the axis counterclockwise.
Page 153: Clamping System
Clamp (long) Clamp (short) Required Hardware Part # Description Photo 1/4- 20, 2” Screw & Wingnut The Evolution Series uses wooden clamps that screw into the inserts in the spoilboard to hold the workpiece in position during the cutting process.
Page 154: Congratulations! You Just Completed The Assembly Of Your Evolution 5
Congratulations! You Just Completed the Assembly of Your Evolution 5. Please review the Software Setup Guide for Software installation and setup. Updating Firmware Evolution 5 Firmware Value Change Connect the CNC to the USB and connect to UGS Platform. Type in $130=1283 in the command textbox of the console window of UGS and press the enter key.
Page 155: Appendix ($130=1283)
Appendix ($130=1283) Evolution 5 Firmware Values Value Description 10 (step pulse, usec) 25 (step idle delay, msec) 0 (step port invert mask:00000000) 0 (dir port invert mask:00000000) 0 (step enable invert, bool) 1 (limit pins invert, bool) 0 (probe pin invert, bool) 1 (status report mask:00000011) 0.01 (junction deviation, mm) 0.002 (arc tolerance, mm)
Page 156: Evolution Washer Dimensions
$110 10000 (x max rate, mm/min) $111 10000 (y max rate, mm/min) $112 2000 (z max rate, mm/min) $120 500 (X-axis acceleration, mm/sec^2) $121 500 (Y-axis acceleration, mm/sec^2) $122 500 (Z-axis acceleration, mm/sec^2) $130 1283 (X-axis maximum travel, millimeters) $131 610 (Y-axis maximum travel, millimeters) $132 85 (Z-axis maximum travel, millimeters)

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