How to Perform Maintenance On LPKF Circuit Board Plotters · 2017. 1. 15. · On LPKF Circuit Board Plotters Requirements - LPKF Circuit Board Plotter - BoardMaster Software - 2.5

Maintenance Manual

How to Perform Maintenance On LPKF Circuit Board Plotters

Requirements - LPKF Circuit Board Plotter - BoardMaster Software - 2.5 mm Allen wrench (for earlier model machines) - 3mm Allen Wrench - 4mm Allen Wrench (for large table machines) - Spray Silicone, Teflon or Graphite - Small Brass Wire Brush - Isopropyl Alcohol - 3 in 1 oil or equivalent - Plastic Lubricant for lead screw LPKF p/n 102244

(for all models except 95sII, AutoMill, and 101 Hi-P) or

- Universal Lubricant for ball tread assembly LPKF p/n 106976 (for models 95sII, AutoMill, and 101 Hi-P only)

Content Note: This document is broken up into the following 6 sections of prescribed maintenance.

I) Lubricating the X-axis lead screw/ball tread assembly and guide bar wipers II) Lubricating the Y-axis lead screw/ball tread assembly and guide bar wipers III) Lubricating the Z-axis Linear Bearings IV) Removing, Cleaning, and Lubricating the Working Depth Limiter V) Cleaning the Collet Assembly VI) Replacing the Working Depth Limiter

Requirements ............................................................................................................. 1 Content ....................................................................................................................... 1 Section I: Lubricating The X-Axis (perform every 6 months)...................................... 2 Section II: Lubricating The Y-Axis (perform every 6 months)..................................... 4 Section III: Lubricating the Z-axis Linear Bearings (perform every 3 months) ........... 6 Section IV: Cleaning and Lubricating the Working Depth Limiter (perform every 3

months, or whenever the Working Depth Limiter becomes difficult to adjust. Also Perform Section V at the same time)................................... 7

Section V: Cleaning the Collet Assembly (perform whenever the Working Depth Limiter is being cleaned) ........................................................................ 13

Motor Types:............................................................................................................. 13 Section VI: Replacing the Working Depth Limiter (perform every 3 months, or

whenever the Working Depth Limiter becomes difficult to adjust) Also Perform Section V at the same time! ..................................................... 18

References ............................................................................................................... 18 Author ................................................................................................................... 18

M:\Support\How To Documents\Word Versions\Maintenance Manual.doc Page 1 of18

Maintenance Manual

Section I: Lubricating The X-Axis (perform every 6 months) 1) To lubricate the X-axis lead screw/ball tread assembly, it is first necessary to

remove the controller box. Please perform steps 1-8 from the How to Remove The Controller Box document. Once removed, you will be able to see the X-axis lead screw/ball tread assembly.

2) Apply a small amount of the appropriate lubricant (see Requirements) to the

lead screw on each side of the supernut (see figure 1-1) or to the ball tread assembly (see figure2-1).

Figure 1-1 Lead Screw

Supernut

Figure 2-1 Ball Tread Assembly

3) Due to the tight tolerances of the lead screw and supernut, it is not necessary to place the lubricant across the entire screw. If you do, the lubricant will build up and drip onto the table or board surface during operation (see figure 2-2).

Figure 2-2 Only lubricate aproximately 1 inch on

each side of the supernut.


4) Some machines will have a set of parallel bars under the table that have wiper pads that traverse with the axis (see figure 2-3). Other machines will have guide bars with linear bearings (see figure 3-1).

http://www.lpkfusa.com/downloads.asp?Path=downloads/support/docs&File=ht_remove_cb.pdf&ID=46


Maintenance Manual

1 wiper pad is shown in this picture. There is an arrow

pointing to where the second is located, but it can not be seen in this picture. There are 2 more located on the opposite side.

Figure 2-3

5) If you have wiper pads as shown in figure 2-3, place several drops of 3 in 1 or

equivalent oil on each of the 4 pads. 6) If you have linear bearings as indicated in figure 3-1, place several drops of 3

in 1 or equivalent oil on a rag and wipe it on the guide bars. This will apply a thin film of oil on the guide bars.

Figure 3-1

These are the guide bars. Wipe with an oiled rag to apply

a thin coat of lubricant.

7) Replace the controller box by performing steps 9-11 of the How to Remove

The Controller Box document.




Maintenance Manual

Section II: Lubricating The Y-Axis (perform every 6 months)

1) To lubricate the Y-axis lead screw/ball tread assembly, it is first necessary to

remove the Y-Axis hood. This is done by removing the four 3mm Allen screws securing the hood (see figure 3-2 and 3-3).

Figure 3-2 Figure 3-3

Remove these four screws to gain access to the Y-axis lead screw.

Note: Picture shown is from a newer machine. The cover on some

machines may be black. 2) Apply a small amount of the appropriate lubricant (see Requirements) to the

lead screw on each side of the supernut (see figure 1-1) or to the ball tread assembly (see figure2-1).

3) Due to the tight tolerances of the lead screw and supernut, it is not necessary

to place the lubricant across the entire screw. If you do, the lubricant will build up and drip onto the table or board surface during operation (see figure 4-1).


Maintenance Manual

Figure 4-1

The super nut is located under this plate.

Place the approriate lubricant on each side of

the super nut.

4) Some machines will have a set of parallel bars under the Y-axis hood that

have wiper pads that traverse with the axis (see figure 4-2). Other machines will have guide bars with linear bearings (see figure 5-1).

5) If you have wiper pads as shown in figure 4-2, place several drops of 3 in 1 or

equivalent oil on each of the 4 pads.

Figure 4-2

Here is one of the 4 wiper pads mentioned in step 11. There are 3 more

pads that cannot be seen in e.this pictur

6) If you have linear bearings as indicated in figure 5-1, place several drops of 3

in 1 or equivalent oil on a rag and wipe it on the guide bars. This will apply a thin film of oil on the guide bars.


Maintenance Manual

Figure 5-1

7) Replace the Y-axis hood.

Section III: Lubricating the Z-axis Linear Bearings (perform every 3 months)

1) Place a couple of drops of 3 in 1 or equivalent oil on the Z-axis linear bearings

(see figure 5-2).

These are the guide bars. Wipe with an oiled rag to apply

a thin coat of lubricant.

Figure 5-2

Micrometer Option for Z-axis depth

control. LPKF p/n 106279

Place a couple of drops of 3 in 1 or equivalent oil in ch linear bearing. ea

2) Manually push the head assembly up and down several times to distribute the

oil. 3) Plug all the connectors back into the controller box and turn on the power to

the LPKF Milling Machine. The head will come to rest in the exchange position.


Maintenance Manual

Section IV: Cleaning and Lubricating the Working Depth Limiter (perform every 3 months, or whenever the Working Depth Limiter becomes difficult to adjust. Also Perform Section V at the same time)

1) If there is a tool in the collet, remove the tool. 2) Now you must remove the entire motor so you can remove the Depth Limiter.

Please use the pictures below to determine what type of motor you have. (if you do not see the correct style motor holder for your machine, please skip to step 6. This motor holder is on most of the older machines and is more complicated to remove.)

91S/HS 92S (after 1997)

92SII C30

C30/S M30

& M30/S

You must loosen all 5 of these screws to move the motor up and down. The threeon top the block are 2.5mm, and the two on the side of the block are 3mm.

This is the quick change tool bar. You might have to remove this to raise the motor enough to allow the removal of the depth limiter.

Figure 6-1


Maintenance Manual

Figure 6-2

95S, 95sII, 101 Hi-P

& Automill

This collar is set to factory specifications.

Loosen these two screws to raise the motor.

Figure 7-1

Loosen these two screws and remove

the 3 pin din connector to remove the motor

91S/VS C60 93S M60 X60

& C100/HF


Maintenance Manual

C20 Figure 7-2 Remove this Connector.

Loosen these two quick release levers and pull the motor out. The collar on the motor is set to factory specifications

3) Loosen the appropriate Allen screws based on the pictures above and remove

the motor so the motor won’t inhibit the removal of the depth limiter.

4) Loosen the following screws to remove the Depth Limiter.

Remove the vacuum hose. loosen the 3mm allen

screw located here.

Figure 8-1

Do not adjust these ball

screws, they are set at the

factory.


Maintenance Manual

Figure 8-2

Remove the second 3 mm allen screw located here and

you will be able to remove the bracket below.

5) Slide the Depth Limiter away from the head. Look for the flat washer shown in

the picture below. If you don’t see it, it could be stuck to the opening the motor slides through (see figure 8-3) (Now skip to step 8).

Note: If you have the Illuminated Working Depth Limiter installed, the Working Depth Limiter cannot be completely removed due to wiring. It can be moved to the side enough to complete the maintenance properly.

Figure 8-3

Metal Washer (not present on all machines.)

6) Machines with the following style motor holding device must be removed in a

different fashion (see figures 9-1 and 9-2)


Maintenance Manual

Figure 9-1

Remove this 7 mm nut. Remove these two 3 mm Allen Screws.

Remove this 3 mm allen screw and you will be able to

ove the bracket below.rem

Look into the Depth Limiter and you will be able to see 4 2.5 mm allen

screws. Remove these 4 screws. In rder get the allen wrench to each ose screws, you must spin the Dep

Limiter around taking out one screw at a time. Once the all the screws are

loose, gently pull up on the motor and slide the Depth Limiter out.

o f the th

Remove this side of the vacuum hose.

Figure 9-2

2.5 mm allen screws (4)

7) Now unscrew the knurled wheel from the aluminum housing

(see figure 10-1).


Maintenance Manual

Figure 10-1

Knurled wheel

Aluminum housing

Most style machines Figure 10-2

OR

Older Machines Figure 10-3

Knurled Wheel (Aluminum housing

not shown.)


Maintenance Manual

8) Clean the threads on both the Knurled Wheel and the Aluminum housing with

a small brass wire brush.

9) Lubricate the threads with silicone, Teflon or graphite. Do not lubricate with oil. It will act like a magnet to the dust created when milling causing you to have to clean the Depth Limiter more often, possibly causing it to seize.

10) Screw the Knurled Wheel and the Aluminum housing back together.

11) Ensure the metal washer from figure 8-3 is put back on top of the Knurled

Wheel.

12) Do not put the motor assembly back in yet.

Section V: Cleaning the Collet Assembly (perform whenever the Working Depth Limiter is being cleaned)

Note: If needed, you can use alcohol as a cleaning agent for the collet.

Warning: Do not lubricate the inside of any collet. This can cause the tool to slip out of the collet assembly while milling.

1) Take the motor in your hand and determine which motor you have based on the pictures below.

Motor Types: • LPKF 91, LPKF 92 (No Picture Available) (13k rpm) • 101LC, LPKF 91s, LPKF92s, 91s, 92s (20k rpm)

Figure 11-1

• C20 (20k rpm)

Figure 11-2


Maintenance Manual

• C30, 92sII (30krpm)

Figure 11-3

• 91s/HS, 92s/HS, C30/s (black cap) (30k rpm)

Figure 12-1

• C30/s (silver cap), M30/s (30k rpm)

Figure 12-2

• 101LC-VS, 91s/VS, 93s (after 1997), C60, H60, M60, X60 (60k rpm)

Figure 12-3

• 93s (prior to 1997) (60k rpm), C100/HF (100k rpm)

Figure 12-4


Maintenance Manual

• 101 Hi-P, 101 AutoMill, 95s, 95sII (60k rpm)

Figure 12-5

2) For the motor not shown and the motor in figure 11-1, the collet assembly is a

seperable unit. Insert a small brush into the collet to clean it. (Now skip to section VI, step 54)

Figure 13-1

Insert a small brush into the collet here.

3) For the motors shown in figure 11-2, 11-3, 12-1, and 12-2, the collet assembly

and the motor are a balanced unit. Do not take them apart. Insert a small brush into the collet to clean it. (Now skip to section VI, step 1)

4) For the motors in figure 12-3, and 12-4, the collet itself is a

removable/replaceable part.

5) To remove the collet, depress the knob on the top of the motor as if you were doing a tool change.

6) Turn the knob in the counter clockwise direction until the collet slides out into

your hand.

Insert a small brush into the collet here.

Figure 13-2

Keyway

7) Insert a small brush into the collet to clean it (see figure 13-2).

8) This collet has a keyway in it (see figure 13-2). In order to place the collet and

the motor assembly back together, the Keyway must be aligned. M:\Support\How To Documents\Word Versions\Maintenance Manual.doc

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Maintenance Manual

9) With the collet in your hand, gently insert it into the opening in the motor.

10) If it does not slide smoothly all the way in, twist the collet around while

applying little pressure until the keyway in the collet and the keyway in the motor line up and the collet slides all the way into the motor assembly.

11) Turn the knob in the clockwise direction until the collet retracts into the motor.

12) Pull the knob on the top of the motor up. (Now skip to section VI, step 1)

13) For the motor in figure 12-5, the collet itself is a removable/replaceable part.

Machines that were shipped with this type of motor were also shipped with a cleaning kit for the motor. The cleaning kit is shown in figure 13-2.

Figure 13-2 1. Tool for cleaning the collet

2. Tool for removing the collet.

3. Lubricant for the end of the spindle.

14) Make sure that the motor is hooked up to it’s air source (see figure 13-3).

4. Tool for cleaning the motor without the collet installed.

Air source, this is the air line that is hooked up to the top of the motor. When air is

applied, it opens the collet. Air source fitting

Figure 13-3

15) Flip the motor over in your hand so you are looking at the collet and place the collet-removing tool (tool # 2 in figure 13-2) on the collet (see figure 14-1).

Collet removing tool.

Figure 14-1


Maintenance Manual

16) With the assistance of another person, you must now depress the green

button on the upper pneumatic block shown in figure 14-2. This will actuate the collet assembly and allow you to remove the collet.

Depress this button to actuate the collet.

This valve block might vary slightly depending

on the model of machine, but the order f the valves is the same

on each machine. o

Figure 14-2

17) While another person is depressing the green button, turn the collet removing

tool counter clockwise until you can pull the collet from the motor, then release the green button.

18) Use the cleaning tool (tool # 2 in figure 13-2) to clean the collet

(see figure 15-1).

Figure 15-1

19) Take the motor back in your hand and take the tool labeled # 4 in figure 13-2

and place it into the motor where the collet normally goes (see figure 15-2).

Figure 15-2

20) After moving the tool around to remove any debris, remove the tool.

21) Use the lubricant (# 3 in figure 13-2) and place a very small amount on the end

of the spindle. Do not put any lubricant inside the collet or where the collet goes (see figure 15-2).


Maintenance Manual


Place a small amount of lubricant here. Do not place any lubricant inside the collet or where

the collet goes.

Figure 16-1

22) Put the collet back into the motor.

23) Have someone depress the green button on the upper pneumatic block (see figure 14-2).

24) Using the collet-removing tool (tool # 2 in figure 13-2), turn the collet clockwise

until tight.

Section VI: Replacing the Working Depth Limiter (perform every 3 months, or whenever the Working Depth Limiter becomes difficult to adjust) Also Perform Section V at the same time!

1) Slide the depth limiter back under the motor block the same way it was taken out.

2) Replace the bracket and any other Allen screws that were taken off in order to

remove the Working Depth Limiter (see figure 8-2 or 9-1 for the location of the bracket and what screws need to be replaced or tightened).

3) Replace the vacuum house (see figure 8-1 or 9-1).

4) Try turning the Knurled Wheel to ensure it was reinstalled properly. It should

turn smoothly, but with an audible clicking noise.

5) Put the motor back into the motor holder.

6) Now you must reset your motor height. Please refer to the How To Set The Motor Height document to perform this procedure.

References All ProtoMat Manuals LPKF Laser & Electronics Technical Support

Author Jeff Bengtson

http://www.lpkfusa.com/downloads/support/docs/ht_motorheight.pdf

http://www.lpkfusa.com/downloads/support/docs/ht_motorheight.pdf