Project Number: P14311

Printed Circuit BoardIsolation Routing System

Operator’s ManualSafety and Operation Instructions

Original Publishing Date: 5/13/2014Latest Revision Date: 5/13/2014

Revision History: A

1

Table of ContentsI. General Information

II. Operator SafetyA. Safety Systems

1. Emergency Stop Buttona) Purposeb) Resetting the Emergency Stop Button

2. Interlock Systema) Purposeb) Resetting the interlock system to resume work

III. PCB Isolation Routing System Equipment LocationsIV. Operation Instructions

A. Powering on the PCB Isolation Routing SystemB. Mach3 ControlsC. Converting PCB files to G-codeD. Machine Set upE. Registration Hole DrillingF. Through Hole DrillingG. Trace MillingH. PCB Removal and Clean-upI. Powering down the PCB Isolation Routing System

2

I. General InformationThis manual contains safety information to make you aware of the hazards and risks associated with the PCB Isolation Routing System and how to avoid them. It also contains operation instructions for isolation routing processes. It is important that you read and understand these instructions. Save the original instructions for future reference.

II. Operator SafetyThe safety alert symbol is used to identify safety information about hazards that can result in personal injury. A signal word (DANGER, WARNING, or CAUTION)is used with the alert symbol to indicate the likelihood and the potential severity of the injury.

DANGER represents a hazard which, if not avoided, will result in death or serious injury.

WARNING represents a hazard which, if not avoided, could result in death or serious injury.

CAUTION represents a hazard which, if not avoided, could result in minor or moderate injury.

NOTICE indicates a situation that could result in damage to the product.

DANGERElectrical Hazards- System runs on 120 VAC power. Touching exposed electronics or wiring during operation can result in electric shock, causing serious injury or death.

● If exposed electronics or wiring is visually identified, use the emergency stop button to put the PCB Isolation Routing system into emergency state

● Do not touch items or perform maintenance unless system power source (120VAC power cord) is disconnected.

3

WARNINGRotating parts can contact and entangle fingers/hands, hair, clothing, or accessories.Traumatic amputation or severe laceration can occur.Operate equipment with guards and interlock activated

● Keep fingers/hands away from rotating parts● Tie up long hair and remove jewelry● Do not wear loose fitting clothing, dangling drawstrings, or items that

could become entangled

WARNINGRunning the components of the PCB Isolation Routing System produces heat. Specific components, such as the stepper motors, router, electronics enclosures, and vacuum exhaust can become particularly hot.Thermal burns can occur on contact.

● Allow stepper motors, router, electronics enclosures and vacuum exhaust to cool before touching

● Remove accumulated debris from vacuum exhaust and milling bed

CAUTIONCopper and substrate particulate debris will be generated by drilling and milling operations. Debris can cause irritation and injury to eyes if blown onto operator’s face during operation or clean-up.

● Always wear safety glasses during operation, especially when enclosure door is open, or if performing system maintenance

CAUTIONDuring operation, the PCB Isolation Routing system produces noise at average rating of 84 dBA. If using equipment for prolonged period of time (8 hours or greater), hearing can be impacted.

● Wear hearing protection when possible, especially if using the PCB Isolation Routing system for extended periods of time.

A. Safety SystemsThe safety systems (including the emergency stop button and interlock system) were designed in conjunction with the mobile enclosure to protect the operator from moving components and milling/drilling debris.

4

1. Emergency Stop Button a) Purpose

Featuring a bright red mushroom style pushbutton, the emergency stop button is located on the outer left side of the enclosure, next to the On/Off switch and easily accessible to the user. The purpose of this button is to shut off critical moving components within the PCB Isolation Router unit. In the event of an emergency event as defined by the operator, when the button is depressed, the following components will lose power and will no longer function: Router, Stepper Motors, and the Vacuum System (including Vacuum Table and Debris Management System). A visual indication that the emergency button has been activated is the red lighting within the enclosure as well as the flashing reset button in the Mach3 display, indicating that it is safe to open the enclosure to remedy the emergency problem.

b) Resetting the Emergency Stop ButtonTo reset the system after the emergency stop button has been depressed and the emergency event has been completed:

1. Turn the emergency button clockwise to un-depress and return to its normal state. You will notice at this time that the emergency mode is still active, visually indicated by the flashing red system lights.

2. Click on the system reset button in the Mach3 software. Once this has been done, the operator will be notified to return to normal system white lighting and the milling or drilling programs can be restarted.

2. Interlock Systema) Purpose

The interlock switch provides an essential safety function that disables critical moving components when the door of the enclosure is opened. When the door is closed, the switch is engaged by a compliant actuator. When the door is opened and the actuator is removed, the switch is no longer

5

depressed, sending a signal to the computer to disable electricity to moving components such as the router, stepper motors, and vacuum table. Similar to the emergency stop button, a visual indication that the interlock system has been deactuated is the purple lighting within the enclosure as well as the flashing reset button in the Mach3 display.

=b) Resetting the interlock system to resume work

To reset the interlock system, the following steps must be completed:1. Close the door to re-actuate the interlock system. You will notice at this

time that the interlock state is still active, visually indicated by the flashing yellow system lights.

2. Click on the system reset button in the Mach3 software. Once this has been done, the operator will be notified to return to normal system lights and milling/drilling programs can be restarted.

III. PCB Isolation Routing System Equipment Locations

6

IV. Operation InstructionsA. Powering ON the PCB Isolation Routing System

1. Check to make sure power cord is plugged into 120 VAC wall outlet in lab.

2. Press the On/Off Rocker switch to the ON position (“--” side pressed).

3. Open the lower enclosure and turn on the computer by pressing the On/Off button on the computer tower.

7

Lower Enclosure-Computer TowerShop VacuumAC Outlets

Upper Enclosure-CNC Milling System with:

Router Vacuum Table Limit Switch and Optical

Sensor assemblies Debris Management

system

Interlock SystemLighting System

External Components-On/Off SwitchEmergency Stop ButtonElectronics Assembly boxesMonitor Display

4. Turn on computer monitor pressing the On/Off by to view software applications.

5. Confirm that Router and Vacuum On/Off switches are depressed to the “On” position, and that they are plugged into their AC outlets in the lower half of the enclosure.

8

6. Start Mach3 software by clicking on the “Mach3 Loader” shortcut on desktop.

a) Load the “IO profile” settings when prompted by the software at start-up.

7. Start Windows LifeCam application by clicking on the shortcut on desktop.

9

B. Mach3 ControlsIn Figures 1 and 2 below, important Mach3 controls and displays are shown. These control buttons will be important during isolation routing processes.

Figure 1: Mach3 Main Window (left side)

10

Figure 2: Mach3 Main Window (right side)

11

Figure 3 shows the Jog GUI which can be displayed by pressing the ‘TAB’ button on the keyboard. From this window, movement of the router and vacuum table along the X, Y and Z axes can be controlled.

Figure 3: Jog GUI

12

In Figure 4, a description of optional Xbox controller functions is displayed. Please note that Xbox controller does not provide any additional functions than Mach3, but can implemented with the system for ease of use.

Figure 4: Xbox Controls

C. Converting PCB Files to G-code1. There are many software applications that convert

commonly used PCB design files (such as Eagle and Gerber data) into G-code. G-code is the common name for the most widely used numerical control (NC) programming language. Used mainly in automation, it is part of computer-aided engineering. This conversion is necessary to be able to create prototype boards using the P14311 system. While each conversion software is slightly different, a few things to keep in mind while creating design files and converting them to G-code include:

a) The PCB design file must include at least 3

13

registration pin holes that are consistent with the .5” hole grid pattern on the vacuum table top shown below.

b) One of the registration pin holes should be located at the origin (0, 0) in the design if possible.

c) The registration holes should be located exterior to the traces within the design file.

d) The depth of both the registration and through holes should be incorporated into the design file, and be appropriate for thickness of the copper board being used.

2. Save the converted G-code files on the computer desktop or flash drive that can be inserted in the computer USB port.

D. Machine Set-up1. Open the door to the upper enclosure to gain access to

machine.2. Insert required drill bit into collet in router.

a) Hold down the spindle lock on the router and using

14

the collet tool, loosen the collet until it can be turned by hand, usually about ¼ turn.

b) Lift debris collection bracket and remove collet/collet nut assembly from the router spindle.

c) Insert the 1/8” drill bit. Bit depth ring should be flush with collet face. Removing collet from the collet nut is not necessary.

d) Lift debris collection bracket and thread collet/collet nut assembly onto the spindle until hand tight.

e) Hold down the spindle lock on the router and using the collet tool, tighten the collet about ¼ turn.

(1)Note: make sure that the ring is still flush with the the collet once the bit is tightened.

2. Place copper board in the lower left corner on the surface of the vacuum table.

3. Place supplied ball bearings into the exposed holes on the vacuum table.

15

4. Close the door to the upper enclosure and lock it in place.5. Press the “reset” button in the Mach3 display to reset the

interlock system.6. Turn on the Vacuum in the program by either:

a) Open the Diagnostics tab, and click “Mist Toggle”.b) Or if using the Xbox controller, press the A button.

7. Turn on the router by either:a) Clicking on the “Spindle CW F5” in the Mach3

display.b) Or if using the Xbox controller, press the B button.

If using the Computer to control movement along the axes (See steps and figure 3 above):

8. Open the Mach3 Jog GUI by pressing “TAB” on the computer keyboard.

9. Jog the vacuum table in the Y direction to origin location.10. Jog the router in the X direction to the origin

location.11. Click the “Zero X” and “Zero Y” buttons in the

Mach3 display.12. Jog the router in the “Z-” direction until the bit is

close to coming into contact with copper board.13. Switch to jogging in single step mode and continue

moving the Z-axis toward the surface until the bit is

16

touching the copper board.14. Click the “Zero Z” button in the Mach3 display.15. Jog the Z axis in the “Z+” direction away from the

surface.If using the Xbox controller to control movement along the axes (see steps and figure 4 above):

16. Jog the vacuum table in the Y direction to origin location using the left joystick.

17. Jog the router in the X direction to the origin location using the left joystick.

18. Press the “X” and the “Y” button on the controller to zero the X and Y origin.

19. Jog the router in the “Z-” direction until the bit is close to coming into contact with copper board using the right joystick.

20. Switch to jogging in single step mode by pressing the “start” button on the controller, and then continue moving the Z-axis toward the surface until the bit is touching the copper board.

21. Press the “Back” button on the controller to zero the Z axis at the origin.

22. Jog the Z axis in the “Z+” direction away from the surface using the right joystick.

B. Registration Hole Drilling1. Prior to drilling holes for the registration pins, confirm that

at least 3 registration pin holes that are consistent with the grid pattern (1” x 1”) are included in the G-code file. One of the registration pin holes should be located at 0,0 in the design if possible, and located exterior to the milling traces.

2. Load the Registration hole G-code into Mach3

17

a) Click the “Open G-code” button in Mach3b) Find the location of the save G-code files in the pop-

up file window.c) Click on registration hole file. d) Click “Open” and G-code should now be displayed in

Mach3 window. 3. Click the “Cycle Start” button in the Mach3 display to start

the registration hole drilling program.4. After the registration holes are complete, jog the z-axis in

the “Z+” direction to allow for clearance between the board and the drill bit.

C. Through Hole Drilling1. Open the door to the upper half of the enclosure to gain

access to the machine.2. Change the drill bit to the required size for through-hole

drilling.a) Hold down the spindle lock on the router and using

the collet tool, loosen the collet until it can be turned by hand, usually about ¼ turn.

b) Lift debris collection bracket and remove collet/collet nut assembly, with previous bit still installed, from the router spindle.

c) Remove previous bit, and insert the required drill bit. Bit depth ring should be flush with collet face. Removing collet from the collet nut is not necessary.

d) Lift debris collection bracket and thread collet/collet nut assembly onto the spindle until hand tight.

e) Hold down the spindle lock on the router and using the collet tool, tighten the collet about ¼ turn.

(1)Note: make sure that the ring is still flush with the the collet once the bit is tightened.

18

3. Close the door to the upper enclosure and lock it in place.4. Press the “reset” button in the Mach3 display to reset the

interlock system.5. Load the Through-hole G-code into Mach3

a) Click the “Open G-code” button in Mach3b) Find the location of the save G-code files in the pop-

up file window.c) Click on through-hole file. d) Click “Open” and G-code should now be displayed in

Mach3 window. 6. Click the “Cycle Start” button in the Mach3 display to start

the through-hole drilling program.7. After the through-holes are complete, jog the z-axis in the

“Z+” direction to allow for clearance between the board and the drill bit.

D. Trace Milling1. Open the door to the upper half of the enclosure to gain

access to the machine.2. Remove the sacrificial vacuum table layer from the

vacuum table to be able to mill boards on the flat aluminum vacuum table workspace.

3. Insert the three registration pins into the registration holes on the vacuum table.

19

4. Place the copper board on the registration pins and the vacuum table.

5. Insert the desired trace mill bit into the router collet. a) Hold down the spindle lock on the router and using

the collet tool, loosen the collet until it can be turned by hand, usually about ¼ turn.

b) Lift debris collection bracket and remove collet/collet nut assembly, with previous bit still installed, from the router spindle.

c) Remove previous bit, and insert the required drill bit. Bit depth ring should be flush with collet face. Removing collet from the collet nut is not necessary.

d) Lift debris collection bracket and thread collet/collet nut assembly onto the spindle until hand tight.

e) Hold down the spindle lock on the router and using the collet tool, tighten the collet about ¼ turn.

(1)Note: make sure that the ring is still flush with the the collet once the bit is tightened.

6. Close the door to the upper enclosure and lock it in place.7. Re-zero the X- and Y-axis above a known registration pin,

ideally one located at the (0, 0) origin in the design file. Make sure that the Z-axis is zeroed above the board first.

8. Move the chassis away from the pin, turn on the router, and slowly lower the Z-axis until the mill bit begins to mill away copper on the surface. Then click the “Zero Z” button in Mach3, or the Back button on the Xbox controller.

9. Raise the Z-axis to an arbitrary height above the board that will visibly clear any registration pins before actually milling for safety.

10. Press the “reset” button in the Mach3 display to reset the interlock system.

20

11. Load the Trace Milling G-code into Mach3a) Click the “Open G-code” button in Mach3b) Find the location of the save G-code files in the pop-

up file window.c) Click on trace milling file. d) Click “Open” and G-code should now be displayed in

Mach3 window. 12. Click the “Cycle Start” button in the Mach3 display to

start the trace milling program.13. After the trace milling is complete, jog the z-axis in

the “Z+” direction to allow for clearance between the board and the mill bit.

E. PCB Removal and Clean-up1. Open enclosure to access machined PCB.2. Remove registration pins holding down the board and

return them to storage drawer.3. Remove PCB from vacuum table surface. 4. Disconnect the vacuum hose from the vacuum table, and

use the vacuum to remove debris from the enclosure.

F. Powering down the PCB Isolation Routing System1. Close Mach3 software application, and save fixtures when

prompted.

21

2. Close Windows LifeCam application.3. Shutdown Computer.

a) Go to Start Menu --> Shutdown.4. Once computer has powered down, press the On/Off

Rocker switch to the OFF position (“O” side depressed)

22