Me Can Um Eric Charly 4 U Manual

Charlyrobot CNC Milling Machine Charly 4U
560009 Charly 4U Last update February 28, 2007 1 / 46

CNC MILLING MACHINE
Charly 4U

Model type 4

CHARLYROBOT SA
BP22 192, route de lusine
F74350 CRUSEILLES
Tl. +334.50.32.80.00. - Fax +334 50 44 00 41
Hot-Line +334.50.32.74.46.
E-mail : charlyrobot@charlyrobot.com
Internet : www.charlyrobot.com


SUMMARY

1. SAFETY INSTRUCTIONS.............................................................................................................. 3
2. DECLARATION OF EC CONFORMITY FOR ALL CHARLYROBOT DEVICES............................ 4
3. STANDARDS.................................................................................................................................. 5
3.1.Mechanical Protection................................................................................................................... 5
3.2.Electrical Protection ...................................................................................................................... 5
4. HANDLING OF THE MACHINE...................................................................................................... 6
4.1. Sitting-storage.............................................................................................................................. 6
4.2. Required environment.................................................................................................................. 6
5. PRESENTATION OF THE MACHINE ............................................................................................ 7
5.1. General description...................................................................................................................... 7
5.2. Appropriate condition of use ........................................................................................................ 7
5.3. Inappropriate use ......................................................................................................................... 7
5.4. Travel caracteristics ..................................................................................................................... 7
5.5. Main power................................................................................................................................... 8
5.6. Dashboard.................................................................................................................................... 8
5.7. Organs description....................................................................................................................... 9
5.8. Security organs - protections ..................................................................................................... 10
5.9. Recommanded computer hardware........................................................................................... 10
5.10. Machine linking ........................................................................................................................ 11
6. MACHINE USE ............................................................................................................................. 12
6.1. Axis definition............................................................................................................................. 12
6.2. Commisionning........................................................................................................................... 12
6.3. Machine parameters .................................................................................................................. 12
6.4. Tool sensor................................................................................................................................. 13
6.5. Fixing the parts for machining.................................................................................................... 13
7. SPINDLES..................................................................................................................................... 14
7.1. Spindle 800W............................................................................................................................. 14
7.2. High Frequency Spindle............................................................................................................. 15
7.3. Vacuum-pump sensor ................................................................................................................ 15
8. MAINTENANCE............................................................................................................................ 16
8.1. Consignment .............................................................................................................................. 16
8.2. Cleaning ..................................................................................................................................... 16
8.3. Element of maintenance ............................................................................................................ 16
8.4. Axis accessibility ........................................................................................................................ 17
8.5. Cleaning and greasing the axis.................................................................................................. 18
8.6. Maintenance frequency.............................................................................................................. 18
8.7. Sofware updates ........................................................................................................................ 18
9. PROBLEMS AND SOLUTIONS.................................................................................................... 19

OPTIONS
1. MICROLUBRIFICATION............................................................................................................... 20
2. AIR BLOWING.............................................................................................................................. 21
3. START / STOP.............................................................................................................................. 22
4. ROTATIVE AXIS........................................................................................................................... 23
5. VACUUM TABLE ..................................................................................................................... 24-25
6. VACUUM PUMP ........................................................................................................................... 26
7. DEPTH REGULATING NOSE SYSTEM .....................................................Note of Nuse 200 368

ANNEXIS
ELECTRICAL DIAGRAMS (options included) ......................................................................................


1. SAFETY INSTRUCTIONS

Before the mounting and commissioning, read carefully the procedures and the safety
instructions in this manual.

The instructions must be read, understood, and observed by the qualified operators

In addition to the instructions, do observe the general safety instructions of your country!

All the mounting, the commissioning and the maintenance must be done by qualified operators. Do
observe the national laws preventing the accident as the EN standards and IEC.

The qualified persons indicated in this safety instructions are those, whose skills coincide to their
activity and who know the installation, the mounting, the commissioning and how to operate the
machine.

Do observe the instructions for the transport, storage and handling. Any damage noticed during the
delivery must be immediately indicated to the carrier. In this case inform the supplier before the
commissioning.

The following conventions are used for the safety instructions in this manual. Failure to respect these
instructions can cause serious and even fatal injury, or damage the products, the equipment and
related systems.

DANGER

ATTENTION

CAUTION

PROHIBITION

Indicates instructions which, if they are not observed, risk causing serious
even fatal injuries.

Indicates important instructions

Indications and advice

Indicates actions that must never implemented

Charlyrobot 2005

All rights reserved. No element of this publication may be reproduced or stored in a documentation
system or transmitted, in any form or means whatever, mechanical, photocopy, recording or other,
without prior written authorisation from Charlyrobot SA. No responsibility in respect of patents will be
assumed concerning the use of information in the present document. Moreover, as Charlyrobot SA is
continuously developing its high quality products and adapting them to the very latest knowledge, the
information contained in this manual may at any time be subject to modifications without prior notice.
The greatest care went into drawing up this manual. Nevertheless, Charlyrobot SA declines all
responsibility for any possible errors or omissions. Charlyrobot SA also declines all responsibility for
any damage caused by the use of the information contained in the present publication.


E-Mail : hotline@charlyrobot.com
Fax : +334.50.44.00.41
Hotline +334.50.32.74.46
Charlyrobot SA BP22 192, route de lusine
F74350.CRUSEILLES

http:\\www.charlyrobot.com

DECLARATION OF ECCONFORMITY
FOR ALL CHARLYROBOT DEVICES

Declare that :

Brand : Charlyrobot
Type : Charly 4U
Serial number : from number 1455

Is conformed to the Machines directive (Directive 98/37/CE), and to the corresponding national
laws.
Is conformed to the following EC directives :
Low-voltage directive 73/23/CEE
Electromagnetical compatibility directives 89/336/CEE
At Cernex, June 22, 2004

Michel WEINSTOERFFER
General Manager


3. STANDARDS

Mechanical protections

Corresponding standards :

EN292-1, 2 & 3 General design principles
EN1050 Risks appreciation
EN294 Security distances
EN 349 Minimal spacing
EN841 Security distances

Electrical protections

Corresponding standards :

EN954-1 Control devices
EN60204-1 Electric component of the machines, protection with lack of energy.
73/23/CEE Low-voltage directives
EN418 Order sure stop
89/336/CEE Electromagnetic compatibility.
EN61082-1 to 3 Electrical diagrams
CEI60417 Electric symbols
EN953/EN1088 Mobile guards with device of inter locking
EN1037 Prevention of starting inopportune and consignment


4. HANDLING OF THE MACHINE

Open the box carefully and place the machine (weight 81 Kg) on a stable table and robust enough to
hold it. The depth of the table must be at least 800mm.
Any other displacement of this machine will require 2 persons minimum.
Remember to disconnect Charlyrobot before any displacement.

4.1. Sitting Storage

CAUTION

To prevent any electrical or mechanical problems on the machines equipment, precautions have to be
taken when positioning and storing it. Machine must not be placed in an environment that is too hot (<
40C), or too humid or too cold (> 16C). Also, the digital milling machine has to be in a well
ventilated place (e.g.: do not place it inside a box).

4.2.Required environment


5. PRESENTATION OF THE MACHINE

This manual has been made to clarify the use of the Charly4U. It is intended to any operator whom
might work on the machine.

CAUTION

Any operator must have read this manual before using the machine.

5.1 General description

The Charlyrobot is a machining appliance for soft materials, it drills and trims electronic circuits, cuts
and engraves plastic plates and boxes, engraves and drills front panels in aluminium and machines
parts in 3D.

5.2. Appropriate condition of use

CAUTION

This appliance was designed to work with soft materials in general, i.e. wood, plastics, aluminium,
epoxy and resins, all types of non metallic and non ferrous metal plates, excluding those that might
present particular hazards, direct or indirect, of fire or explosion, during their implementation.

5.3. Inappropriate use

PROHIBITION

This machine is not intended for large cuts for alloys, nor for machining very hard materials like steel
for example, or any types of metallic and ferrous metal plates, or materials that might present
particular hazards, direct or indirect, of fire or explosion, during their implementation.
The maximum tool diameter is 15 mm.

Any other use different from that stipulated in the preceding paragraph is strictly forbidden.

5.4 Technical caracteristics

Travel ranges XYZ X 310 mm x Y 220 mm x Z 160 mm

Drive XYZ Balls screw 12 mm step of 5 mm class G9

Displacement speed
The maximum displacement speed is 15 to 20 mm/sec when machining and
100 mm/sec in displacement speed.

Electronics caracteristics
Digital controls: CNR3 Plug & Play Power supply 230V - 50Hz (110-115V / 50-60Hz for USA)


5.5. Main Power

Standard : 230V + Earth - 16A
USA : 110/115V + Earth - 16A

5.6. Dashboard

Machine

Control panel

5 8 7 6 2 1
51 10 9
52

Protection
hood
Control
panel
Spindle
hood
3
4 High Frequency
spindle abacus

5.7. Organs description

LANDMARK ORGAN NAME FUNCTION
1

Emergency stop
button
Allow to switch off the machine in
case of emergency or for a normal
stop
2

Run
To switch on the machine (if the main
power switch is on)
3

Electrical Plug
This plug allows to connect the
alimentation cable to the machine
4

RS232 plug To connect the PC
5

800W Speed
adjustment
This single rotation potentiometer
allows to adjust the speed of 800W
spindle
51

HF spindle
adjustment
This potentiometer allows to adjust the
speed of HF spindle (except spindle
for tools changer)
52

Speed adjustment
for HF spindle with
an analogical drive
by the CNC
OPTION
This overdrive allows to decrease the
speed of HF spindle (if the pushbutton
rep.9 is pressed).
6

Start a machining
file
OPTION
To start a machining file manually
7

Stop a machining
file
OPTION
To stop a machining file manually
8 Micro-lubrification
OPTION
To run the micro-lubrification
10

Vacuum table
OPTION
To run the vacuum table
9

Overdrive
Pushbutton
OPTION
It has to be pressed to use the
overdrive rep.52


5.8 Security organs - Protections

Main power switch lockable (Mark 1) situated on the electrical equipment box (lock non provided)
Main power protection by circuit breaker (inside electrical equipment box).

The moving part is equipped with an integral security cover, doors are equipped with safety inter
locking switch..
When the spindle is rotating all doors are locked, to avoid any access to the moving parts.You will
need to wait 7 secondes after stopping the spindle to be able to open the protection hood.

DANGER
Any abnomaly concerning the function of the protection hood, please inform imperatively
Charlyrobot as the machine will be out of order.

5.9 RECOMMANDED COMPUTER HARDWARE

1 PC (minimum specifications : Pentium II or equivalent, RAM 256 minimum Mo , 25 Mo free
on hard disk, Windows 98 or higher.
1 floppy disk 3"
1 CD ROM
1 serial port available or a USB port (in this case, plan an adaptator USB serial Charlyrobot
reference 980069)


5.10. Machine linking

CAUTION : The computer and the machine must not be powered

COMPUTER CONNECTION

Connection on the port (RS232)

Connect the PC to the RS232 plug mark.4 on the left side of the machine, help by the serial cable
provided. This cable has 2 Sub-D 9 pins.
The link PC/ Machine must be a serial link.
Several connections are possible and depend of your computer's outputs :

- You have 2 serial port 9DB named COM1 and COM2 :
Connect your mouse on COM1 or COM2 and the machine on the available port left.

- You have one specific mouse port type mini-DIN also called PS2 :
Connect your mouse on this PS2 port and the machine on the serial port COM1

- You have 2 serial port, one is 9DB, the other 25DB (generally the COM2).
To plug on the port COM2, you need to use an adaptator 9DB/25DB.

Connection on port USB (compatibility USB1 and USB2)
CAUTION
You MUST install the driver of the adaptator BEFORE plugging the USB port.

Install the driver of the adaptator (CD ROM delivered with the machine). Follow the procdure.
Plug the port USB of the adaptator on a free USB port on your computer. Connect the plug RS232 to
the plug RS232 marked 4 on the left side of the machine, help by the serail cable provided with the
machine.

ELECTRIC CONNECTION

Connect the provided power cable on the mark 3. on the left side of the machine and the plug-in the
other side to an electric plug.

CAUTION
Make sure the electric plug in the wall is linked to the Earth.
Beware, the computer and the machine must be on the same electric line.

6. MACHINE USE

6.1 Axis definition

General configuration of the axis, that can be different according to the customer application or when
rotary axis are set up.

6.2 Commissioning

The commissioning is effective when the provided power cable is connected to an electrical plug.

The commissioning of the machine is executed when you push the green button (mark.2)
The green button blinks. It remains lit when Gpilote starts. Any other blinking might signify an anomaly
of the machine.

The emergency stop button mark.1 assure the out of use of the machine, it means it stops any
movement of the axis and the spindle (reset of the machine necessary by the software). You need to
use it when you want to stop your work on the evening.
To unlock it, you need to turn a quarter of a round.

6.3. Machine parameters

Install the sofware CharlyGraal by following the procedure explained in the manual CharlyGraal.
The installation is a Plug&Play type (automatic recognition)
Try to do severals movements : if the machine doesn't work properly, check the differents points
proposed on the chapter 9: Problems & solutions.


6.4. Tool sensor

The tool sensor allows to make an automatic measure of the tool length.

ATTENTION

The position of the sensor will be set in the Gpilot sofware settings.

6.5. Fixing the parts for machining

Use the tools usually used in the trade : vice, grips (be careful with the slippering risks), mechanical
support, two-faces adhesive or vacuum table (according to the dimension and the surface quality).

Plug for the tool
sensor
Tool sensor

7. SPINDLES

7.1. Spindle 800W

Alimentation : 230V - 50Hz (110-115V / 50-60Hz for the USA)
Speed : 10 000 to 24 000 rpm
Clamp : Type 401E 3,18 and 6 provided with the spindle
Available from 2mm to 8mm from Charlyrobot
Maxi noise at 24000 rpm: 87 dB

Dismantling the spindle tool :

Unlock once then unscrew the head nut by hand until you come up against a hard point. Unlock again
to free the tool and you can now remove it.

Changing a spindle tool

Press with the head nut the clamp which is on the bench to free the clamp from the head nut. Once
free, place this clamp in the new head nut click the whole part (required) in the spindle.

BEWARE
Never mount the clamp directly into the spindle before placing it in the head nut.
The clamp is not a chuck, therefore the tool diameter must be the same as the clamp diameter

Wrench 14
Wrench 17
Head nut
Tool
Clamp to dismantle
New clamp
Head nut

7.2. High Frequency spindle 1,1kW

Alimentation : 230V - 50Hz (110-115V / 50-60Hz for the USA)
Speed : 0 to 24000 rpm
Clamp : Type ER20 4 and 6 provided with the spindle
Available from 1 to 13 from Charlyrobot
Maxi noise at 24000 rpm : 87 dB

Bringing a new high frequency spindle into service requires running in. This was carried out in our
workshops.

Daily pre-heating procedure for the spindle

- 2 minutes at 50% of the maximum spindle speed
- 2 minutes at 80% of the maximum spindle speed
- 1 minute at 100% of the maximum spindle speed

Premature wear or deterioration of the spindle if you dont follow this procedure, which will not be
covered under the terms of the guarantee.

Use condition

Use tools appropriate to the spindle: the higher the rotation speed, the more balanced the tools and
clamps must be, according to the maximum rotation speeds.
Frequently check the state of the ER20 clamps.
As a general rule, a complete service is indispensable after 2000 hours of operation. The use of
unbalanced or very long tools should be avoided, because they are prejudicial to the lifetime of the
spindle.

7.3. Vacuum-pump sensor

This device allows in the case of machining plates, to aspire very close to the tool. Can not be used for
machining in 3D, neither when using an automatic tool changer.
The aspiring hose (option) needs to be linked to the entry on the right side of the machine.

CAUTION
Connect the aspiring hose to the Earth. If this one is in plastic, place a metalic collar around
and link it to the body of the machine.

Vacuum pump sensor
Vacuum
entry

8. MAINTENANCE

CAUTION

Any action or attempt at shunt, mechanical or electric modification aiming at modifying the systems
operation or the doors safety, is strictly prohibited. Such actions are likely to expose the personnel to
serious dangers of crushing.

8.1. Consignment

Before carrying out any operation of maintenance, be sure the machine is well put in consignment.
When operating, you will handle tools being able to wound you : ACT WITH PRECAUTION

8.2. Cleaning

CAUTION

Regularly clean machining area with a vacuum cleaner. Never clean the glazed parts with an alcoholic
product but rather with soapy water using a soft cloth (avoid paper).
For the rest of the machine, use a sponge moistened with water or white spirit.
Never use acetone or trichloroethylene.

PROHIBITION

To clean the machine, only use white spirit for the painted parts. Any other solvent, in particular
acetone or trichlorethylene, is prohibited because they would damage the painting, the joints and the
trims.

Clean the glazed parts with clear or soapy water (household soap), the use of an alcoholic product or
solvent is to be proscribed.

The working areas and other layings and panels can, on the other hand, being cleaned with a product
for washing windows or with all cleaning without solvent.

8.3. Element of maintenance

Greasing
- Hand greasing pump with a nozzle for greaser type hydraulic
- Grease : Charlyrobot ref. 22019 (or ref. PREP-00 branded BP)
Fuses
Refer to the electric schemas of the machine
Using part
- Switch of the ending range reference 100203
- Belt for X axis reference EME00263
- Belt for Y axis reference EME00265
- Engine coals 800W spindle reference 590453

8.4. Axis accessibility

X axis

Y axis

Axe Z

To acces to the X axis,
take appart the rear
hood by unscrewing the
3 screws on each side of
the machine.
To acces to the Y
axis, lay down the
machine on the side
and unscrew the 7
screws holding the
protection plate.
To acces to the Z axis, take
appart the left side by
unscrewing the 4 screws on
the side and the one on the
bottom
Greasing
acces to the
balls screw
Greasing
acces to the
balls screw
Greasing
acces to the
guide shoe
Greasing
acces to the
guide shoe
Greasing
acces to the
balls screw
Greasing
acces to the
guide shoe

8.5. Cleaning and greasing the axis

The devices used to drive the axis Charlyrobot are greased before the delivery.
So you can machine form now on without any problem.
Therefore, an frequent overhaul is necessary.
To clean and grease each axis, you need to do the manipulations described on the above sections.
Blow away the dusts and chips, particulary on the guide shoes, balls screw and the switches.
To lubricate the motions parts, use the hand greasing pump on the greasing points (2 on each axis)

8.6. Maintenance frequency

Parts type Priodicity

Security parts Every day
Cleaning Every day
Axis cleaning Every day
Axis greasing Every 6 month

8.7. Software updates

For an update of your equipment, you need to provide to the hotline service of Charlyrobot the
informations writen on the label on the side of the machine but also:

Custumer number
CharlyGraal Version
Gpilote Version
Type of the machine

Note : You can find some updates on our web site at :

http://www.charlyrobot.com


9. PROBLEMS AND SOLUTIONS

The machine doesn't work

- Is it connected to the power supply?

The light must be on mark 2. If not, free the emergency stop button mark.1 by pulling it towards you
then press the start button. Check also the main electric and pneumatic switch, then press the start
button.
Is the protection hood correctly close?
Check if the protection hood is correctly close because the machine can not start if it's open.

Problems of communication

- Is the P.C./machine connection cable connected ? => Only use the Charlyrobot cable supplied.

- Are the PC and the machine connected up to the same line?

- Connect the collector pipe to earth. If it is made of plastic, place a metal collar at the machine side
end and connect it to ground with a 6 mm gauge yellow and green wire.

The spindle won't start up

Check that the switch on the spindle is turned to the I position, and don't forget to close the cover
again.

The cover won't open
CAUTION

You must wait for 7 seconds for the spindle to stops before you can open the cover.

Note : If there are any other problems, don't hesitate to contact our technical service

Hot-Line Charlyrobot

Tel : +33 4 50 32 74 46
Fax : +33 4 50 44 00 41
E-mail : hotline@charlyrobot.com


OPTIONS
1 MICRO-LUBRIFICATION (option)

Commissionning of the micro-lubrification :

Automatic start : turn the selector mark.8 on automatic position This allows the
performance during the machining.
Manual start : turn the selector mark.8 on manual position This allows the performance
of the micro lubrification permanently.

Position 0
Automatic start
Position
manual
start
Lubricant tank
Setting of the
lubricant flow
Setting the
frequency of
watering
Setting of
the air flow

2 AIR BLOWING(option)

Commissionning of the air blowing :

Automatic start : turn the selector mark.8 on automatic position This allows the
performance during the machining.
Manual start : turn the selector mark.8 on manual position This allows the performance
of the air blowing permanently.

Position 0
Automatic start
Position
manual
start

3 START / STOP (option)

Pushing button mark.6

Pushing button mark.7

To use this fonction, report to the chapter : USE THE AUTOMATIC MODE START/STOP in the
Gpilote machining sttings.


4.ROTATIVE AXIS

The rotative 4th axis is positionned parallely to the X axis. It name is A in the geometry language.
It is equiped of a concentric 4 jaws chuck and a tail-stock.
The height of the tail-stock is 60 mm.
The maximum dimensions of a piece is 100mm and a length of 200mm.

Tightening Loosening

To close the jaws, introduce the key of chuck in the female square mark 0 on the chunk and turn it
clock-wise untill the piece is blocked.
To open the jaws, proceed by turning the key reversly.

CAUTION

Never leave the key of the chuck on the chuck after any operation.
Tail-stock
Key of chuck
Female square

5 VACUUM TABLE (option)

The vacuum table aims at maintain the parts while machining. Its efficiency is linked to a maximum
leakage not to be exceeded. It means that every non-used or uncovered areas must be masked.

ATTENTION
The micro-lubrication is incompatible with the vacuum table. The plate in medium (porous material)
owes, in this case, being replaced by a PVC plate.

Commissioning of the vacuum table :

Automatic start : turn the selector mark.10 on automatic position .
This action allows operation throughout machining. When machining is finished, the table with
continuous depression to function during fifteen minutes approximately (adjustment by defect,
temporization can be modified).

Manual start : turn the selector mark.10 on manual position
This allows the performance of the vacuum table permanently.

Position 0
Automatic start
Position
manual start
How to connect the depressure table to the vacuum pump:

1. Remove the back cover like indicated in chapter 8.4. Axis X
2. Fix the casing for the depressure table using the 5 screws BHC M6x20, nut outside
3. Connect the 25 pipe of the vacuum pump on the connection located outside the
casing, and tighten the collar
4. Connect the 25 pipe of the depressure table on the connection located inside the
casing, and tighten the collar
5. Connect the gray tube 4 on the rapid coupling located inside at the bottom left of the
casing.

Outside brass
connection
Casing for
depressure table
BHC screws
M6x20 + M6 nut
Vacuum pump
25 pipe
Inside brass
connection
25 pipe

6 VACUUM PUMP (option)

Electrical Wiring

1. Connect the main circuit breaker according the wiring diagram N550366C
2. Engage the main circuit breaker to position 1
3. Check the correct rotation of the motor
4. Put back the back cover like indicated in chapter 8.4. Axis X

Cleaning

Reconditioning

Preconised grease : Charlyrobot ref. 22018 (or Shell ref. Corena ISO-VG-100)

Clean the filter
from inside
Grease level
Maxi
Grease level
Mini
Main circuit
breaker
Position 1
Connections
ANNEXIS
ELECTRICS DIAGRAMS



















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Charlyrobot CNC Milling Machine Charly 4U

560009 Charly 4U Last update February 28, 2007 1 / 46

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