Buller Enterprises Panel Pro 5925 Operation And Maintenance Instructions Download Page 1

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PANEL PRO

Panel Pro

MODEL 5925

SN 2049 and subsequent

OPERATION AND MAINTENANCE INSTRUCTIONS

Buller Enterprises, Inc.

Summary of Contents for Panel Pro 5925

Page 2: ...L PRO Table of Contents Page Description of Panel Pro 5925 3 Set Up Panel Pro Hardware Setup 5 Software Setup 15 Cutting Files 22 EasyCAD 27 AutoCAD 41 Troubleshooting 47 Maintenance 50 3 Axis Operati...

Page 3: ...fabricate various adapters and brackets that have many corners and cutouts Panel Pro 5925 system is comprised of the Controller the software and the machine The SC3 Controller is the interface betwee...

Page 4: ...13 Optional EG2 engraver 14 Optional Diamond engraver 15 Optional King air panel spacer kit This manual is intended to help with set up and get you started with operation Detailed function and operati...

Page 5: ...The computer running the panel Pro may be on the same circuit It is just essential that there is the same ground on both the Panel Pro and the computer The Milwaukee router draws around 12 amps at tu...

Page 6: ...of the 6mm leg mounting screws barely started 7 Attach the legs with 4 6mm socket screws each using a 5mm Allen wrench with an extension A 5mm Allen bit is included in the tool box Two people are requ...

Page 7: ...ler clamp screw is through a hole in the lead screw guard Make sure there is no slippage between the coupler and lead screw 11 Install the X2 coupler similar to step 10 Install the 4 motor attach scre...

Page 8: ...ighten the coupler clamp screw Make sure it is tight and does not slip 16 The coolant system is used on the Panel Pro consists of 1 submersible pump 2 5 gallon pail 3 modified pail lid 4 7 ft 3 8 ID t...

Page 9: ...oz Koolmist per gallon Take note of the resulting color Future coolant additions can be made by approximating the color of the mix rather than exact measurement Check the coolant level before use by...

Page 10: ...r and the nut There is nothing attached to the drain Its purpose is to prevent coolant splashing beside the screen in the pail when a large volume of coolant is poured in the pan 19 The controller mou...

Page 11: ...Note in the picture the X2 axis lead screw guard is not installed and the spindle router power cord should run parallel with the Y Z cord If you have the urge to tie up cables take precaution to leave...

Page 12: ...d ER11 collet available in many sizes up to inch Place the collet into the nut without the end mill in place so the collet can compress and snap around the quarter moon shaped extractor ring in the co...

Page 13: ...ly the collet should be almost flush with the end of the collet nut With the collet nut removed look in the back at the threaded end Note there is a quarter moon shaped ring at the bottom To install t...

Page 14: ...Also plan to have at least a 17 monitor with about 1024 x 768 pixel setting Arrange the computer so that the right hand can be on the keyboard or mouse and the left hand can reach the middle of the P...

Page 15: ...aries The initial installation must be accomplished from the thumb drive Note the application key on the thumb drive envelope It will be required on the first time the program is run on each computer...

Page 16: ...When you re open EasyCAD the additional icons should appear If they still do not appear click the hammer icon on the bottom center of the EasyCAD screen At the top of the select screen tools dialog op...

Page 17: ...er running before each use Press the test button and the router should stop Press the reset button to resume operation Do not operate the machine if the floor in the area is wet If any coolant leak is...

Page 18: ...open the AvCAM program This is the preferred turn on sequence The first time the program is powered up the com port needs to be set If you are connected to Com1 and the SC3 controller is working prop...

Page 19: ...r of the screen you are already in jog mode On successful connection a message box will ask you if it is ok to move to machine home Unless you have a failed home switch you always want to allow the ho...

Page 20: ...il a piece of paper gets tight between the end mill and material Tap the z keyboard key to open the z dialog Tap Z again to set this position as Z zero Z retract is the position above z work zero that...

Page 21: ...nce we want to just cut that instrument the 0 0 position of the machine must be at the center of where you want the instrument cut out The R key may be used to set the work zero at the current locatio...

Page 22: ...ms several functions Cools the cutter bit Flushes chips off of the material Lubricates end mill Keeps aluminum from building up on the bit Material buildup will drastically increase cutting pressure b...

Page 23: ...e file The router turns on proceeds to the starting point lowers to the cutting position and commences cutting No further intervention is required Assure that coolant is flowing Adjust the spindle del...

Page 24: ...the Y axis so a 1 8 end mill just clears the bottom edge of the panel and enter 0625 in the Y axis form Using jog move to the left side of the panel Move the x axis with the mouse wheel so that the en...

Page 25: ...move through the list until the entity is highlighted that you want to start on Click cancel The Entity listed will be entered in the cut file start entity The file does not need to be simulated again...

Page 26: ...e menu item ie draw followed by a and the sub menus also separated by the forward arrow So a line command takes the form of draw line This is a good time to customize the drawing desktop for your pref...

Page 27: ...drawing programs simply turn pixels on or off on a screen They are simply visual and not scaleable since there is no definition of which pixels belong to what object Vector graphics involve entities s...

Page 28: ...es an instrument can be generated in AvCAM new cutout in about 30 seconds Drawing them by hand could take 30 minutes Layers Think of layers as a layer of vellum or translucent material that different...

Page 29: ...n usually on the right side of the screen Layers can be hidden by clicking the H on the layer you want to hide in the layer dialog The example on the left shows layer 1 hidden and all of the rest of t...

Page 30: ...new layer name Click new again and repeat with 1 On the lines with the layer names there are 3 boxes The first box if checked indicates the current layer on which any new entities will reside Next to...

Page 31: ...ntal line Now pick a side by left clicking on the side of the line that you want the offset line to appear Click on the top side a line appears parallel to the horizontal construction line offset by 1...

Page 32: ...t This actually uses the mod menu on the left and the snap buttons on the bottom tool bar should be left off out as above For instance you want to draw a line that starts precisely at the end of anoth...

Page 33: ...d arcs used to form that region must not have gaps or overlaps at their end points Also there cannot be entities that overlay another entity with a common endpoint Mount holes AvCAM uses the circles t...

Page 34: ...Ctr or Cp and the word cut as a naming convention IE BB538PltCut fc7 for future editing then as a panelcut dxf file This is the file that Panel Pro will use Avoid using N numbers for naming N numbers...

Page 35: ...serted instrument or panel or other group becomes part of that group It is often useful to draw construction lines base on panel edges The best practice is to draw a line from 0 0 to say 0 15 for a ve...

Page 36: ...by clicking mod intersection or F6 then clicking on the intersection of the two lines you want to place it on Another technique to adjust an instrument so that it moves directly onto an existing line...

Page 37: ...ke a line from 0 0 to 11 998 0 on layer 2 red color Draw another line from 12 706 0 to 0 0 for the bottom line Now draw vertical lines on your paper that are parallel with the left side line Make the...

Page 38: ...11 998 11 872 11 626 10 613 9 178 8 172 7 321 Now we will connect these points using the center snap F4 with a parabolic spline AvCAM does not support parabolic splines however when exported to a dxf...

Page 39: ...find that it is 2 188 2 188 the yoke hole diameter 75 is 2 938 the vertical coordinate of the hole Measure the left edge of the panel to the hole 1 398 1 398 75 2 148 You can place a circle at this c...

Page 40: ...e as a dxf See a later discussion on the save as procedures Drawing concepts The following describes the techniques used to hand draw an instrument It is presented to familiarize you with the techniqu...

Page 41: ...of the drawings were made back in the days of DOS based CAD systems At that time only numbered layers were used Layers separate out common items of interest AvCAM will cut the entities on any one sel...

Page 42: ...t Create a line from 0 1 605 to 1 605 1 605 to create the left half of the top line Note that it extends left which when connected into a polyline with the pedit command will rotate counter clockwise...

Page 43: ...ify a diagonal measurement We can use the chamfer command to trim the lines created by the offsets The construction lines drawn from corner to corner can be erased now Select the chamfer command It fi...

Page 44: ...irectly from the file open command You can save it as a dwg file if desired Make the panel outline For AvCAM place the outside perimeter entities on layer outside Similar techniques are used for Panel...

Page 45: ...sert the file ati3 at 3 6 Insert the file ati3 at 9 6 Insert the file ati3 at 3 11 Insert the file ati3 at 9 11 Or use the various snap options Blocks are supported in AvCAM with these limitations The...

Page 46: ...s Moving and running into obstacles without the router running End mill is not secure in the collet allowing the end mill to slip down to the non cutting area on the shank The router will sound like i...

Page 47: ...f a large number like 1000 is used the movement may be very slow The z axis is less than 2 above z zero Jerky or erratic movement If only one motor is mis behaving one of the two driver circuits may b...

Page 48: ...happens Tighten the coupler until there is no slippage Inspect the coupler for breaks cracks or loose hardware The screws holding the pieces together on the coupler above can work loose If that is th...

Page 49: ...e major crud has been removed blow out the collet and collet bore with an air hose Any chips in the collet system will cause the end mill to run out of true This will cause the end mill to break more...

Page 50: ...x2 contact their hard stops at the same time If they don t turn the controller power off or disable the drivers from the AvCAM machine menu Adjust Ballnut backlash The X and Y axis ball nuts have an...

Page 51: ...turn the lead screw and motor power off with the knob If it is too loose the knob will not turn the motor The 6mm screw should be tightened with LockTight 242 and left overnight to set up STORAGE Make...

Page 52: ...and z and the increment set to 001 per mouse wheel detent left mouse click on screen to move between 0002 001 and 01 inches per mouse wheel detent Place a strip of ordinary paper which is about 004 th...

Page 53: ...any clamps or obstructions If there are no obstructions then a setting like the 250 in the picture will save time It can be entered directly as a positive number in the text box or you can move the z...

Page 54: ...te layer for your countersink tool Call it something imaginative like countersink Countersinks are normally specified by the diameter of the widest part A number 8 countersunk screw may have a head di...

Page 55: ...untersinks it is a fair amount of effort to do so Consider having a microstop countersink for each size of screw It takes no set up time except the first time you set the depth and to change out tools...

Page 56: ...ts and interpolates the z error between points Unmeasured points have a correction of zero Even with a Correction table you may notice some inconsistency because of material flexing You should have a...

Page 57: ...them before the through cuts setting the z depth to your inset depth Important All entities that have a z axis coordinate of 0 will cut at the cut depth entered into the cut depth on AvCAM In this pic...

Page 58: ...fers it is preferable to have existing holes rather than cutting all of the material with the countersink so cut the inside cutouts and leave the outside layer un selected on this pass Set the end mil...

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Buller Enterprises Panel Pro 5925, Operation And Maintenance Instructions

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