vector-space.org - User contributions [en]

Table Saw User Guide

2026-10-09T19:13:44Z

Aspontarelli: /* REFERENCE */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Table Saw

'''Requires in-person training:''' Yes 

'''Procedure Number''': UG 110-03, Rev. 1

'''Last Revision:''' 4/22/2021

|}

= GENERAL =

The woodshop has two table saws, used for a wide variety of applications in cutting wood and some plastics.

[[File:Screenshot 2021-01-14 093448.png|thumb|left|Powermatic Table Saw (PM2000)]] 

= SAFETY =

* Wear polycarbonate safety glasses.
* Remove or secure all loose clothing, jewelry, and long hair.
* Use push sticks when hands would otherwise be within the miter slots.
* Do not wear gloves.
* Never touch the blade while machine is connected to power.
* Do not use machine without riving knife in place.
* Do not attempt to saw boards with loose knots or with nails or other foreign material.
* Do not attempt to saw twisted, warped, or bowed stock unless one edge has been jointed.
* Do not attempt to saw long or wide boards that can't be steadily guided through the saw.

= REFERENCE =

* Safety training video https://youtu.be/Uf_jbau4VwA
* Powermatic Instructions and Parts Manual [https://vector-space.org/wiki/images/3/31/M-PM231B_PM2000B_BT_Table_Saw_ED9.pdf PM2000 Table Saw Manual]

= PROCEDURE =

* Check the alignment of the riving knife, fence and miter slot to the blade.
* Check the saw blade for cracks or missing teeth. Do not use a cracked or dull blade or one with missing teeth or improper set. Make sure the blade is securely locked on the arbor.
* Always use the riving knife, blade guard, push stick and other safety devices for all operations where they can be used.
* On operations such as dadoing or molding where the blade guard cannot be used, use feather boards, fixtures and other safety devices.
* Reinstall the riving knife and blade guard immediately after completing the operation that required their removal.
* Be sure the saw blade rotates clockwise when viewed from the motor side (left side) of the machine.
* Turn the power off and do not leave the machine until it comes to a complete stop.
* Start – Press the green start switch.
* Stop – Press the red switch to stop.
* Rip Sawing - work piece is fed with the grain into the saw blade
* Crosscutting - workpiece is fed cross grain into the saw blade
* Bevel Cut – the saw blade is tilted at an angle less than 90 degrees to the table top
* Dado Cutting – is cutting a wide groove into a workpiece or cutting a rabbet along the edge of a workpiece.
* Listed below are conditions, which can cause kickbacks:
** Confining the cutoff piece when crosscutting or ripping.
** Releasing the work piece before completing the operation or not pushing the work piece all the way past the saw blade.
** Not using the riving knife when ripping or not maintaining alignment of the riving knife with the saw blade.
** Using a dull saw blade.
** Not maintaining alignment of the rip fence so that it tends to angle toward rather than away from the saw blade front to back.
** Applying feed force when ripping to the cutoff (free) section of the work piece instead of the section between the saw blade and fence.
** Ripping wood that is twisted (not flat), or does not have a straight edge, or a twisted grain.
* Do not use the miter gauge and rip fence in the same operation unless provision is made by use of a facing board on the fence so as to allow the cutoff section of the workpiece to come free before the next cut is started.

[[File:Screenshot 2021-01-14 095428.png]]

* The ''front handwheel'' (B) controls the raising and lowering of the blade (blade height).
* The ''side handwheel'' (D) controls the blade tilt.
* The blade can be adjusted for a tilt between 90º (vertical or a setting of 0º on the scale) and 45º left tilt (D).

'''Blade height'''

1. Loosen the ''lock knob'' (A) on the ''front handwheel'' (B).

2. Turn the ''handwheel'' (B) clockwise to raise and counterclockwise to lower the blade.

3. Tighten the ''lock knob'' (A).

'''Blade tilt adjustment'''

1. Loosen the ''lock knob'' (C) on the side handwheel (D).

2. Turn the ''handwheel'' (D) counterclockwise to adjust the saw blade down to 45º left tilt.

3. Turn clockwise to adjust the saw blade to maximum of 90º.

3. After selecting the position, tighten the ''lock knob'' (C).

'''Insert Adjustment:''' Adjust the setscrews in the insert with a 2.5mm hex wrench to ensure that the insert is stable and flush with the table top.

'''Miter Gauge'''

1. Operate miter gauge by loosening the lock knob (A) and turning the miter body (B) to the desired angle. To move gauge beyond index stops of 45 degree and 90 degree, flip down the stop (C).

2. Adjust index stops by turning one of three adjustment screws (D).

[[File:Screenshot 2021-01-15 101410.png]]

'''Riving Knife Adjustment -''' Lateral alignment: The saw blade and riving knife must be in line as close as possible with each other (lateral alignment) for the prevention of kickback. Upon initial blade guard and riving knife installation no further adjustment should be necessary. Alignment should be checked and adjusted, if required, after each blade change.

Check the alignment as follows:

1. Remove the blade guard and pawl.

2. Place a straightedge (A, Fig. 13) on the table so it rests against the blade (B, Fig 13) and riving knife (C, Fig. 13). Rotate the blade so the top of the blade tooth touches the straightedge. The saw blade and riving knife must be in line.

If adjustment is required:

3. Remove the table insert.

4. Loosen the lock handle (A, Fig. 14) and remove the riving knife, making a note as to which direction the riving knife needs to be moved to align it with the saw blade.

5. Use a 3mm hex wrench, make adjustments to any of the four set screws (D, Fig. 15) accessible through openings located in the corners of the floating clamp block (E, Fig. 15).

6. If necessary, repeat the above procedure.

[[File:Screenshot 2021-01-15 102303.png]]

'''Blade Alignment'''

1. Disconnect the saw from the power source.

2. Raise the blade guard up a way from the blade.

3. Choose a tooth on the far side of the blade (towards the rear) and position the tooth slightly above the table insert. Mark the tooth with a marker. Measure the distance from the side of the blade to the right T-slot edge using a combination square. Make sure to measure between the teeth not on the tooth.

4. Rotate the blade toward the front so that the marked tooth is just above the insert. Measure the distance from the side of the blade to the right T-slot edge. The two measurements should be the same.

5. If they are not the same, loosen four hex socket cap screws that hold the table to the base.

6. Make the needed adjustments and tighten the four hex socket cap screws firmly.

7. Check the alignment once again after tightening hardware.

'''Adjusting 45 degree and 90 degree Positive Stops'''

1. Disconnect saw from power source.

2. Raise the saw blade to its maximum height using the hand-wheel.

3. Set the blade at 90 degrees to the table by turning the blade tilting hand-wheel clockwise as far as it will go.

4. Place a combination square on the table against the blade and check to see that the blade is at a 90 degree angle to the table. Make sure square is not touching a blade tooth.

5. If blade is not at 90 degrees, open the motor cover door, loosen lock nut and turn adjusting stop screw on the front trunnion in, or out. The adjusting stop screw should stop against the front trunnion bracket when the blade is 90 degree to the table.

6. Tighten the lock nut.

7. Set the blade at 45 degrees to the table by turning the blade tilting hand-wheel counterclockwise as far as it will go. Place a combination square on the table against the blade. Make sure square is not touching a blade tooth.

8. If the blade is not 45 degrees, remove the raising and lowering handle. Loosen lock nut and turn adjusting stop screw on the front trunnion in, or out. The adjusting stop screw should stop against the front trunnion bracket when the blade is 45 degree to the table.

9. Check the accuracy of the pointer on the angle scale and adjust, if necessary.

'''Changing the Belt -''' Referring to Figure 21:

1. Disconnect the machine from the power source, unplug.

2. Lower the blade to its lowest point.

3. Loosen two hex cap bolts (A).

4. Take the tension off of the belt (B) by lifting up on the motor.

5. Remove the belt from the arbor and motor pulleys.

6. Replace and tension the belt. The weight of the motor should apply enough tension to the belt. Tighten the hex cap bolts (A).

7. Check the belt tension after the saw has been used for a few hours. Adjust as necessary.

[[File:Screenshot 2021-01-15 104616.png]]

= TROUBLESHOOTING =

'''Powermatic'''

{|
|width="33%"| '''Trouble'''
|width="33%"| '''Probable Cause'''
|width="33%"|
'''Remedy'''

|-
| Excessive vibration.
| Tilt or raising clamp knobs not tightened
| Tighten knobs.
|-
|
| Blade out of balance.
| Change blade.
|-
|
| Bad motor.
| Replace motor.
|-
|
| Loose arbor or motor sheave.
| Tighten set screws.
|-
| Cuts out-of-square when crosscutting.
| Miter gauge out of adjustment.
| Reset pointer
|-
|
| Miter slot misaligned.
| Realign table.
|-
| Motor stalls or workpiece binds or burns.
| Excessive feed.
| Reduce feed.
|-
|
| Bad motor.
| Replace motor.
|-
|
| Dull or incorrect blade.
| Replace blade.
|-
|
| Miter slot misaligned.
| Realign miter slot.
|-
|
| Fence misalignment.
| Realign fence.
|-
| Cuts not true at 90 or 45 degrees.
| Stop screws not set properly.
| Readjust stop screws.
|-
| Tilt or saw raising hand wheels difficult to turn.
| Lock knob not released
|
Loosen lock knob.

|-
|
| Worm and worm gear segment caked with sawdust and pitch.
|
Clean and re-grease.

|-
|
| Worm and worm gear segment out of alignment.
| Realign worm and worm gear segment.
|-
| Motor overheats.
| Motor overloaded.
| Correct overload condition such as reducing the feed rate.
|-
|
| Improper cooling of motor.
| Clean sawdust from fan and duct areas of motor.
|-
| Motor starts slowly or fails to come up to speed.
| Low voltage.
| Request voltage check from power company and correct low voltage condition.
|-
|
| Centrifugal switch not operating.
|
Replace switch.

|-
|
| Bad motor.
| Replace motor.
|-
|
Motor fails to develop full power.

| Power line overloaded.
| Correct overload condition.
|-
|
| Undersize wires in supply system.
| Increase supply wire size.
|-
|
| Low voltage.
|
Request voltage check from power company and correct condition.

|-
|
| Bad motor.
| Replace motor
|}

END OF THE PROCEDURE

Table saw maintenance and specifications

2026-10-09T19:13:19Z

Aspontarelli: /* Reference */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Table Saw
|width="33%"|
'''Procedure Number'''

MT 110-03, Rev. 1
|width="33%"|
'''Date'''

1/24/2021
|}

= General =
'''Powermatic Model PM2000 Table Saw'''

* Left tilt range is 0–45 degrees
* Maximum depth of cut (in.): 3-1/8 at 90-degrees; 2-1/8 at 45-degrees
* Maximum diameter of dado is 8 inches
* Maximum width of dado cut is13/16 inches

[[File:Screenshot 2021-01-14 093448.png]]

= Reference =

* Link to Instructions and Parts Manual [https://vector-space.org/wiki/images/3/31/M-PM231B_PM2000B_BT_Table_Saw_ED9.pdf PM2000 Table Saw Manual]
* https://www.woodcraft.com/products/jet-xactasaw-deluxe-table-saw-3hp-1ph-50-rip?gclid=Cj0KCQiA2uH-BRCCARIsAEeef3mySTa69vTv_Vhu-fzCgKBm6Sx_6_2HxkXGwHv55VeE5P5t_QiOcEgaAmYHEALw_wcB#

= Maintenance =

'''Cleaning'''

Note: The following maintenance schedule assumes the saw is being used every day.

'''Daily:'''

• Wipe down the table surface and grooves with a rust preventive.

• Clean the pitch and resin from the saw blade.

'''Weekly:'''

• Table surface must be kept clean and free of rust for best results. Apply a coat of paste wax to the surface to facilitate this. An alternative is to apply white talcum powder, rubbed in vigorously once a week with a blackboard eraser; this will fill casting pores and form a moisture barrier. This method provides a table top that is slick and allows rust rings to be easily wiped from the surface. Important also is the fact that talcum powder will not stain wood or mar finishes as wax pickup does.

• Clean the motor housing with compressed air.

• Wipe down the fence rails with a dry silicon lubricant.

'''Periodic:'''

• Keep the inside of the cabinet and trunnion area clean.

• Check for excessive play in the tilting and raising mechanism and in the saw arbor and re-adjust as required.

• Check for belt tension and wear. Readjust or replace belt as required.

'''Lubrication'''

• Grease the tilting worm gear, raising worm gear, castor system worm gear and the trunnion areas with a good grade non-hardening grease.

• Check all adjustments after lubricating.

'''Miscellaneous''' Always be aware of the condition of your machine. Routinely check the condition of the following items and repair or replace as necessary:

• Mounting bolts

• Power switch

• Saw blade

• Blade guard assembly

'''JET Blade Installation/Replacement'''

To install or replace a blade (refer to Figure 6), 27mm Wrench is needed.

[[File:Jet Planner Adjustment Fig 6.png]]

1. Disconnect machine from power source.

2. Raise the blade height all the way up and set the blade tilt to 0º.

3. Remove the table insert.

4. Rotate the arbor to line up the slot (C) with the arbor lock (D).

5. Press the arbor lock (D) in the direction shown by the arrow to engage it into the slot (C) in the arbor. At the same time remove the arbor nut (A), loosening with a 27mm wrench if necessary.

6. Remove the collar (B).

7. Install the blade, making sure the cutting teeth at the top of the blade point toward the front of the saw.

8. Replace the collar (B) and arbor nut (A).

9. Engage the arbor lock (D) and tighten the nut (A) with a 27mm wrench.

10. Lower the blade below the table.

= List of Specifications =

'''Powermatic Model PM2000 Table Saw'''

Model number ......................................................................................................................... PM2000

Stock Number

3HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791999

5HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791998

5HP, Prewired 230V (for 460V see Note below), 60Hz, 3 Phase, 3600 RPM, TEFC ................1791997

Table size with standard extensions (L x W/in.)...................................................................... 42 x 30 1/2

Table size without extensions (L x W/in.) ............................................................................... 22 x 30 1/2

Arbor diameter (in.) .......................................................................................................................... 5/8

Saw blade diameter (in.) ................................................................................................................... 10

Arbor speed (RPM) ....................................................................................................................... 4300

Left tilt range ................................................................................................................................ 0–45

Maximum depth of cut (in.) ........................................................3-1/8 at 90-degrees; 2-1/8 at 45-degrees

Maximum diameter of dado (in.)........................................................................................................... 8

Maximum width of dado cut (in.) ................................................................................................... 13/16

Drive system ....................................................................................................................... Poly-V Belt

Table height to floor (in.) ............................................................................................................. 34-1/2

Dust port diameter (in.) ....................................................................................................................... 4

Shipping weight (saw only) ......................................................... All Models: Net: 540 lbs, Gross: 604 lbs

'''JET'''

Stock Numbers ............................................................................................................... 708674 (3 HP, 1 Ph)

............................................................................................................................. 708676 (5 HP, 1 Ph)

............................................................................................................................. 708680 (5 HP, 3 Ph)

Blade Diameter .......................................................................................................................................... 10”

Arbor Diameter .......................................................................................................................................... 5/8”

Maximum Depth of Cut ................................................................................................................................ 3”

Maximum Thickness at 45 Cut ............................................................................................................. 2-1/8”

Table in Front of Saw Blade at Maximum Cut ........................................................................................... 10”

Maximum Width of Dado ....................................................................................................................... 13/16”

Maximum Diameter of Dado ........................................................................................................................ 8”

Dust Port Diameter ....................................................................................................................................... 4”

Dust Collection Minimum CFM required ................................................................................................... 350

Table Height ............................................................................................................................................... 34”

Table Size (with extension) ......................................................................................................... 29"D x 42"W

Table Size (without extension) .................................................................................................... 29"D x 20”W

Arbor Speed ................................................................................................................................... 4300 RPM

Sound Rating:

(without blade) ...................................................................................................................... 70 dB at 3 ft.

(with 10”x50T blade) ............................................................................................................ 85 dB at 3 ft.

Motor

SN 708674 .......................................................................................................... 3HP, 1Ph, '''230V only'''

SN 708676 ......................................................................................................... 5 HP, 1Ph, '''230V only'''

SN 708680 .................................................... 5HP, 3Ph, 230/460V, '''prewired 230V '''

Weight

Net ............................................................................................................................................ 330 lbs.

Gross ........................................................................................................................................ 407 lbs.

'''END OF THE PROCEDURE'''

Table saw maintenance and specifications

2026-10-09T19:13:05Z

Aspontarelli: /* Reference */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Table Saw
|width="33%"|
'''Procedure Number'''

MT 110-03, Rev. 1
|width="33%"|
'''Date'''

1/24/2021
|}

= General =
'''Powermatic Model PM2000 Table Saw'''

* Left tilt range is 0–45 degrees
* Maximum depth of cut (in.): 3-1/8 at 90-degrees; 2-1/8 at 45-degrees
* Maximum diameter of dado is 8 inches
* Maximum width of dado cut is13/16 inches

[[File:Screenshot 2021-01-14 093448.png]]

= Reference =

* Link to Instructions and Parts Manual [https://vector-space.org/wiki/File:M-PM231B_PM2000B_BT_Table_Saw_ED9.pdf PM2000 Table Saw Manual]
* https://www.woodcraft.com/products/jet-xactasaw-deluxe-table-saw-3hp-1ph-50-rip?gclid=Cj0KCQiA2uH-BRCCARIsAEeef3mySTa69vTv_Vhu-fzCgKBm6Sx_6_2HxkXGwHv55VeE5P5t_QiOcEgaAmYHEALw_wcB#

= Maintenance =

'''Cleaning'''

Note: The following maintenance schedule assumes the saw is being used every day.

'''Daily:'''

• Wipe down the table surface and grooves with a rust preventive.

• Clean the pitch and resin from the saw blade.

'''Weekly:'''

• Table surface must be kept clean and free of rust for best results. Apply a coat of paste wax to the surface to facilitate this. An alternative is to apply white talcum powder, rubbed in vigorously once a week with a blackboard eraser; this will fill casting pores and form a moisture barrier. This method provides a table top that is slick and allows rust rings to be easily wiped from the surface. Important also is the fact that talcum powder will not stain wood or mar finishes as wax pickup does.

• Clean the motor housing with compressed air.

• Wipe down the fence rails with a dry silicon lubricant.

'''Periodic:'''

• Keep the inside of the cabinet and trunnion area clean.

• Check for excessive play in the tilting and raising mechanism and in the saw arbor and re-adjust as required.

• Check for belt tension and wear. Readjust or replace belt as required.

'''Lubrication'''

• Grease the tilting worm gear, raising worm gear, castor system worm gear and the trunnion areas with a good grade non-hardening grease.

• Check all adjustments after lubricating.

'''Miscellaneous''' Always be aware of the condition of your machine. Routinely check the condition of the following items and repair or replace as necessary:

• Mounting bolts

• Power switch

• Saw blade

• Blade guard assembly

'''JET Blade Installation/Replacement'''

To install or replace a blade (refer to Figure 6), 27mm Wrench is needed.

[[File:Jet Planner Adjustment Fig 6.png]]

1. Disconnect machine from power source.

2. Raise the blade height all the way up and set the blade tilt to 0º.

3. Remove the table insert.

4. Rotate the arbor to line up the slot (C) with the arbor lock (D).

5. Press the arbor lock (D) in the direction shown by the arrow to engage it into the slot (C) in the arbor. At the same time remove the arbor nut (A), loosening with a 27mm wrench if necessary.

6. Remove the collar (B).

7. Install the blade, making sure the cutting teeth at the top of the blade point toward the front of the saw.

8. Replace the collar (B) and arbor nut (A).

9. Engage the arbor lock (D) and tighten the nut (A) with a 27mm wrench.

10. Lower the blade below the table.

= List of Specifications =

'''Powermatic Model PM2000 Table Saw'''

Model number ......................................................................................................................... PM2000

Stock Number

3HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791999

5HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791998

5HP, Prewired 230V (for 460V see Note below), 60Hz, 3 Phase, 3600 RPM, TEFC ................1791997

Table size with standard extensions (L x W/in.)...................................................................... 42 x 30 1/2

Table size without extensions (L x W/in.) ............................................................................... 22 x 30 1/2

Arbor diameter (in.) .......................................................................................................................... 5/8

Saw blade diameter (in.) ................................................................................................................... 10

Arbor speed (RPM) ....................................................................................................................... 4300

Left tilt range ................................................................................................................................ 0–45

Maximum depth of cut (in.) ........................................................3-1/8 at 90-degrees; 2-1/8 at 45-degrees

Maximum diameter of dado (in.)........................................................................................................... 8

Maximum width of dado cut (in.) ................................................................................................... 13/16

Drive system ....................................................................................................................... Poly-V Belt

Table height to floor (in.) ............................................................................................................. 34-1/2

Dust port diameter (in.) ....................................................................................................................... 4

Shipping weight (saw only) ......................................................... All Models: Net: 540 lbs, Gross: 604 lbs

'''JET'''

Stock Numbers ............................................................................................................... 708674 (3 HP, 1 Ph)

............................................................................................................................. 708676 (5 HP, 1 Ph)

............................................................................................................................. 708680 (5 HP, 3 Ph)

Blade Diameter .......................................................................................................................................... 10”

Arbor Diameter .......................................................................................................................................... 5/8”

Maximum Depth of Cut ................................................................................................................................ 3”

Maximum Thickness at 45 Cut ............................................................................................................. 2-1/8”

Table in Front of Saw Blade at Maximum Cut ........................................................................................... 10”

Maximum Width of Dado ....................................................................................................................... 13/16”

Maximum Diameter of Dado ........................................................................................................................ 8”

Dust Port Diameter ....................................................................................................................................... 4”

Dust Collection Minimum CFM required ................................................................................................... 350

Table Height ............................................................................................................................................... 34”

Table Size (with extension) ......................................................................................................... 29"D x 42"W

Table Size (without extension) .................................................................................................... 29"D x 20”W

Arbor Speed ................................................................................................................................... 4300 RPM

Sound Rating:

(without blade) ...................................................................................................................... 70 dB at 3 ft.

(with 10”x50T blade) ............................................................................................................ 85 dB at 3 ft.

Motor

SN 708674 .......................................................................................................... 3HP, 1Ph, '''230V only'''

SN 708676 ......................................................................................................... 5 HP, 1Ph, '''230V only'''

SN 708680 .................................................... 5HP, 3Ph, 230/460V, '''prewired 230V '''

Weight

Net ............................................................................................................................................ 330 lbs.

Gross ........................................................................................................................................ 407 lbs.

'''END OF THE PROCEDURE'''

Table saw maintenance and specifications

2026-10-09T19:10:56Z

Aspontarelli: /* Reference */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Table Saw
|width="33%"|
'''Procedure Number'''

MT 110-03, Rev. 1
|width="33%"|
'''Date'''

1/24/2021
|}

= General =
'''Powermatic Model PM2000 Table Saw'''

* Left tilt range is 0–45 degrees
* Maximum depth of cut (in.): 3-1/8 at 90-degrees; 2-1/8 at 45-degrees
* Maximum diameter of dado is 8 inches
* Maximum width of dado cut is13/16 inches

[[File:Screenshot 2021-01-14 093448.png]]

= Reference =

* Link to Instructions and Parts Manual [https://vector-space.org/wiki/File:M-PM231B_PM2000B_BT_Table_Saw_ED9.pdf]
*
* https://www.woodcraft.com/products/jet-xactasaw-deluxe-table-saw-3hp-1ph-50-rip?gclid=Cj0KCQiA2uH-BRCCARIsAEeef3mySTa69vTv_Vhu-fzCgKBm6Sx_6_2HxkXGwHv55VeE5P5t_QiOcEgaAmYHEALw_wcB#

= Maintenance =

'''Cleaning'''

Note: The following maintenance schedule assumes the saw is being used every day.

'''Daily:'''

• Wipe down the table surface and grooves with a rust preventive.

• Clean the pitch and resin from the saw blade.

'''Weekly:'''

• Table surface must be kept clean and free of rust for best results. Apply a coat of paste wax to the surface to facilitate this. An alternative is to apply white talcum powder, rubbed in vigorously once a week with a blackboard eraser; this will fill casting pores and form a moisture barrier. This method provides a table top that is slick and allows rust rings to be easily wiped from the surface. Important also is the fact that talcum powder will not stain wood or mar finishes as wax pickup does.

• Clean the motor housing with compressed air.

• Wipe down the fence rails with a dry silicon lubricant.

'''Periodic:'''

• Keep the inside of the cabinet and trunnion area clean.

• Check for excessive play in the tilting and raising mechanism and in the saw arbor and re-adjust as required.

• Check for belt tension and wear. Readjust or replace belt as required.

'''Lubrication'''

• Grease the tilting worm gear, raising worm gear, castor system worm gear and the trunnion areas with a good grade non-hardening grease.

• Check all adjustments after lubricating.

'''Miscellaneous''' Always be aware of the condition of your machine. Routinely check the condition of the following items and repair or replace as necessary:

• Mounting bolts

• Power switch

• Saw blade

• Blade guard assembly

'''JET Blade Installation/Replacement'''

To install or replace a blade (refer to Figure 6), 27mm Wrench is needed.

[[File:Jet Planner Adjustment Fig 6.png]]

1. Disconnect machine from power source.

2. Raise the blade height all the way up and set the blade tilt to 0º.

3. Remove the table insert.

4. Rotate the arbor to line up the slot (C) with the arbor lock (D).

5. Press the arbor lock (D) in the direction shown by the arrow to engage it into the slot (C) in the arbor. At the same time remove the arbor nut (A), loosening with a 27mm wrench if necessary.

6. Remove the collar (B).

7. Install the blade, making sure the cutting teeth at the top of the blade point toward the front of the saw.

8. Replace the collar (B) and arbor nut (A).

9. Engage the arbor lock (D) and tighten the nut (A) with a 27mm wrench.

10. Lower the blade below the table.

= List of Specifications =

'''Powermatic Model PM2000 Table Saw'''

Model number ......................................................................................................................... PM2000

Stock Number

3HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791999

5HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791998

5HP, Prewired 230V (for 460V see Note below), 60Hz, 3 Phase, 3600 RPM, TEFC ................1791997

Table size with standard extensions (L x W/in.)...................................................................... 42 x 30 1/2

Table size without extensions (L x W/in.) ............................................................................... 22 x 30 1/2

Arbor diameter (in.) .......................................................................................................................... 5/8

Saw blade diameter (in.) ................................................................................................................... 10

Arbor speed (RPM) ....................................................................................................................... 4300

Left tilt range ................................................................................................................................ 0–45

Maximum depth of cut (in.) ........................................................3-1/8 at 90-degrees; 2-1/8 at 45-degrees

Maximum diameter of dado (in.)........................................................................................................... 8

Maximum width of dado cut (in.) ................................................................................................... 13/16

Drive system ....................................................................................................................... Poly-V Belt

Table height to floor (in.) ............................................................................................................. 34-1/2

Dust port diameter (in.) ....................................................................................................................... 4

Shipping weight (saw only) ......................................................... All Models: Net: 540 lbs, Gross: 604 lbs

'''JET'''

Stock Numbers ............................................................................................................... 708674 (3 HP, 1 Ph)

............................................................................................................................. 708676 (5 HP, 1 Ph)

............................................................................................................................. 708680 (5 HP, 3 Ph)

Blade Diameter .......................................................................................................................................... 10”

Arbor Diameter .......................................................................................................................................... 5/8”

Maximum Depth of Cut ................................................................................................................................ 3”

Maximum Thickness at 45 Cut ............................................................................................................. 2-1/8”

Table in Front of Saw Blade at Maximum Cut ........................................................................................... 10”

Maximum Width of Dado ....................................................................................................................... 13/16”

Maximum Diameter of Dado ........................................................................................................................ 8”

Dust Port Diameter ....................................................................................................................................... 4”

Dust Collection Minimum CFM required ................................................................................................... 350

Table Height ............................................................................................................................................... 34”

Table Size (with extension) ......................................................................................................... 29"D x 42"W

Table Size (without extension) .................................................................................................... 29"D x 20”W

Arbor Speed ................................................................................................................................... 4300 RPM

Sound Rating:

(without blade) ...................................................................................................................... 70 dB at 3 ft.

(with 10”x50T blade) ............................................................................................................ 85 dB at 3 ft.

Motor

SN 708674 .......................................................................................................... 3HP, 1Ph, '''230V only'''

SN 708676 ......................................................................................................... 5 HP, 1Ph, '''230V only'''

SN 708680 .................................................... 5HP, 3Ph, 230/460V, '''prewired 230V '''

Weight

Net ............................................................................................................................................ 330 lbs.

Gross ........................................................................................................................................ 407 lbs.

'''END OF THE PROCEDURE'''

Table saw maintenance and specifications

2026-10-09T19:10:24Z

Aspontarelli: /* General */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Table Saw
|width="33%"|
'''Procedure Number'''

MT 110-03, Rev. 1
|width="33%"|
'''Date'''

1/24/2021
|}

= General =
'''Powermatic Model PM2000 Table Saw'''

* Left tilt range is 0–45 degrees
* Maximum depth of cut (in.): 3-1/8 at 90-degrees; 2-1/8 at 45-degrees
* Maximum diameter of dado is 8 inches
* Maximum width of dado cut is13/16 inches

[[File:Screenshot 2021-01-14 093448.png]]

= Reference =

* Link to Instructions and Parts Manual http://content.powermatic.com/manuals/1792000K_man.pdf
*
* https://www.woodcraft.com/products/jet-xactasaw-deluxe-table-saw-3hp-1ph-50-rip?gclid=Cj0KCQiA2uH-BRCCARIsAEeef3mySTa69vTv_Vhu-fzCgKBm6Sx_6_2HxkXGwHv55VeE5P5t_QiOcEgaAmYHEALw_wcB#

= Maintenance =

'''Cleaning'''

Note: The following maintenance schedule assumes the saw is being used every day.

'''Daily:'''

• Wipe down the table surface and grooves with a rust preventive.

• Clean the pitch and resin from the saw blade.

'''Weekly:'''

• Table surface must be kept clean and free of rust for best results. Apply a coat of paste wax to the surface to facilitate this. An alternative is to apply white talcum powder, rubbed in vigorously once a week with a blackboard eraser; this will fill casting pores and form a moisture barrier. This method provides a table top that is slick and allows rust rings to be easily wiped from the surface. Important also is the fact that talcum powder will not stain wood or mar finishes as wax pickup does.

• Clean the motor housing with compressed air.

• Wipe down the fence rails with a dry silicon lubricant.

'''Periodic:'''

• Keep the inside of the cabinet and trunnion area clean.

• Check for excessive play in the tilting and raising mechanism and in the saw arbor and re-adjust as required.

• Check for belt tension and wear. Readjust or replace belt as required.

'''Lubrication'''

• Grease the tilting worm gear, raising worm gear, castor system worm gear and the trunnion areas with a good grade non-hardening grease.

• Check all adjustments after lubricating.

'''Miscellaneous''' Always be aware of the condition of your machine. Routinely check the condition of the following items and repair or replace as necessary:

• Mounting bolts

• Power switch

• Saw blade

• Blade guard assembly

'''JET Blade Installation/Replacement'''

To install or replace a blade (refer to Figure 6), 27mm Wrench is needed.

[[File:Jet Planner Adjustment Fig 6.png]]

1. Disconnect machine from power source.

2. Raise the blade height all the way up and set the blade tilt to 0º.

3. Remove the table insert.

4. Rotate the arbor to line up the slot (C) with the arbor lock (D).

5. Press the arbor lock (D) in the direction shown by the arrow to engage it into the slot (C) in the arbor. At the same time remove the arbor nut (A), loosening with a 27mm wrench if necessary.

6. Remove the collar (B).

7. Install the blade, making sure the cutting teeth at the top of the blade point toward the front of the saw.

8. Replace the collar (B) and arbor nut (A).

9. Engage the arbor lock (D) and tighten the nut (A) with a 27mm wrench.

10. Lower the blade below the table.

= List of Specifications =

'''Powermatic Model PM2000 Table Saw'''

Model number ......................................................................................................................... PM2000

Stock Number

3HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791999

5HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791998

5HP, Prewired 230V (for 460V see Note below), 60Hz, 3 Phase, 3600 RPM, TEFC ................1791997

Table size with standard extensions (L x W/in.)...................................................................... 42 x 30 1/2

Table size without extensions (L x W/in.) ............................................................................... 22 x 30 1/2

Arbor diameter (in.) .......................................................................................................................... 5/8

Saw blade diameter (in.) ................................................................................................................... 10

Arbor speed (RPM) ....................................................................................................................... 4300

Left tilt range ................................................................................................................................ 0–45

Maximum depth of cut (in.) ........................................................3-1/8 at 90-degrees; 2-1/8 at 45-degrees

Maximum diameter of dado (in.)........................................................................................................... 8

Maximum width of dado cut (in.) ................................................................................................... 13/16

Drive system ....................................................................................................................... Poly-V Belt

Table height to floor (in.) ............................................................................................................. 34-1/2

Dust port diameter (in.) ....................................................................................................................... 4

Shipping weight (saw only) ......................................................... All Models: Net: 540 lbs, Gross: 604 lbs

'''JET'''

Stock Numbers ............................................................................................................... 708674 (3 HP, 1 Ph)

............................................................................................................................. 708676 (5 HP, 1 Ph)

............................................................................................................................. 708680 (5 HP, 3 Ph)

Blade Diameter .......................................................................................................................................... 10”

Arbor Diameter .......................................................................................................................................... 5/8”

Maximum Depth of Cut ................................................................................................................................ 3”

Maximum Thickness at 45 Cut ............................................................................................................. 2-1/8”

Table in Front of Saw Blade at Maximum Cut ........................................................................................... 10”

Maximum Width of Dado ....................................................................................................................... 13/16”

Maximum Diameter of Dado ........................................................................................................................ 8”

Dust Port Diameter ....................................................................................................................................... 4”

Dust Collection Minimum CFM required ................................................................................................... 350

Table Height ............................................................................................................................................... 34”

Table Size (with extension) ......................................................................................................... 29"D x 42"W

Table Size (without extension) .................................................................................................... 29"D x 20”W

Arbor Speed ................................................................................................................................... 4300 RPM

Sound Rating:

(without blade) ...................................................................................................................... 70 dB at 3 ft.

(with 10”x50T blade) ............................................................................................................ 85 dB at 3 ft.

Motor

SN 708674 .......................................................................................................... 3HP, 1Ph, '''230V only'''

SN 708676 ......................................................................................................... 5 HP, 1Ph, '''230V only'''

SN 708680 .................................................... 5HP, 3Ph, 230/460V, '''prewired 230V '''

Weight

Net ............................................................................................................................................ 330 lbs.

Gross ........................................................................................................................................ 407 lbs.

'''END OF THE PROCEDURE'''

Table saw maintenance and specifications

2026-10-09T19:06:55Z

Aspontarelli: /* Reference */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Table Saw
|width="33%"|
'''Procedure Number'''

MT 110-03, Rev. 1
|width="33%"|
'''Date'''

1/24/2021
|}

= General =
'''Powermatic Model PM2000 Table Saw'''

* Left tilt range is 0–45 degrees
* Maximum depth of cut (in.): 3-1/8 at 90-degrees; 2-1/8 at 45-degrees
* Maximum diameter of dado is 8 inches
* Maximum width of dado cut is13/16 inches

[[File:Screenshot 2021-01-14 093448.png]]

'''Jet Table Saw'''

Item 837474 Model 708675PK

Jet - 3HP 1PH 230V XACTASAW Deluxe Table Saw with 50" Rip Capacity

[[File:Screenshot 2021-01-14 094901.png]]

= Reference =

* Link to Instructions and Parts Manual http://content.powermatic.com/manuals/1792000K_man.pdf
*
* https://www.woodcraft.com/products/jet-xactasaw-deluxe-table-saw-3hp-1ph-50-rip?gclid=Cj0KCQiA2uH-BRCCARIsAEeef3mySTa69vTv_Vhu-fzCgKBm6Sx_6_2HxkXGwHv55VeE5P5t_QiOcEgaAmYHEALw_wcB#

= Maintenance =

'''Cleaning'''

Note: The following maintenance schedule assumes the saw is being used every day.

'''Daily:'''

• Wipe down the table surface and grooves with a rust preventive.

• Clean the pitch and resin from the saw blade.

'''Weekly:'''

• Table surface must be kept clean and free of rust for best results. Apply a coat of paste wax to the surface to facilitate this. An alternative is to apply white talcum powder, rubbed in vigorously once a week with a blackboard eraser; this will fill casting pores and form a moisture barrier. This method provides a table top that is slick and allows rust rings to be easily wiped from the surface. Important also is the fact that talcum powder will not stain wood or mar finishes as wax pickup does.

• Clean the motor housing with compressed air.

• Wipe down the fence rails with a dry silicon lubricant.

'''Periodic:'''

• Keep the inside of the cabinet and trunnion area clean.

• Check for excessive play in the tilting and raising mechanism and in the saw arbor and re-adjust as required.

• Check for belt tension and wear. Readjust or replace belt as required.

'''Lubrication'''

• Grease the tilting worm gear, raising worm gear, castor system worm gear and the trunnion areas with a good grade non-hardening grease.

• Check all adjustments after lubricating.

'''Miscellaneous''' Always be aware of the condition of your machine. Routinely check the condition of the following items and repair or replace as necessary:

• Mounting bolts

• Power switch

• Saw blade

• Blade guard assembly

'''JET Blade Installation/Replacement'''

To install or replace a blade (refer to Figure 6), 27mm Wrench is needed.

[[File:Jet Planner Adjustment Fig 6.png]]

1. Disconnect machine from power source.

2. Raise the blade height all the way up and set the blade tilt to 0º.

3. Remove the table insert.

4. Rotate the arbor to line up the slot (C) with the arbor lock (D).

5. Press the arbor lock (D) in the direction shown by the arrow to engage it into the slot (C) in the arbor. At the same time remove the arbor nut (A), loosening with a 27mm wrench if necessary.

6. Remove the collar (B).

7. Install the blade, making sure the cutting teeth at the top of the blade point toward the front of the saw.

8. Replace the collar (B) and arbor nut (A).

9. Engage the arbor lock (D) and tighten the nut (A) with a 27mm wrench.

10. Lower the blade below the table.

= List of Specifications =

'''Powermatic Model PM2000 Table Saw'''

Model number ......................................................................................................................... PM2000

Stock Number

3HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791999

5HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ......................................................................1791998

5HP, Prewired 230V (for 460V see Note below), 60Hz, 3 Phase, 3600 RPM, TEFC ................1791997

Table size with standard extensions (L x W/in.)...................................................................... 42 x 30 1/2

Table size without extensions (L x W/in.) ............................................................................... 22 x 30 1/2

Arbor diameter (in.) .......................................................................................................................... 5/8

Saw blade diameter (in.) ................................................................................................................... 10

Arbor speed (RPM) ....................................................................................................................... 4300

Left tilt range ................................................................................................................................ 0–45

Maximum depth of cut (in.) ........................................................3-1/8 at 90-degrees; 2-1/8 at 45-degrees

Maximum diameter of dado (in.)........................................................................................................... 8

Maximum width of dado cut (in.) ................................................................................................... 13/16

Drive system ....................................................................................................................... Poly-V Belt

Table height to floor (in.) ............................................................................................................. 34-1/2

Dust port diameter (in.) ....................................................................................................................... 4

Shipping weight (saw only) ......................................................... All Models: Net: 540 lbs, Gross: 604 lbs

'''JET'''

Stock Numbers ............................................................................................................... 708674 (3 HP, 1 Ph)

............................................................................................................................. 708676 (5 HP, 1 Ph)

............................................................................................................................. 708680 (5 HP, 3 Ph)

Blade Diameter .......................................................................................................................................... 10”

Arbor Diameter .......................................................................................................................................... 5/8”

Maximum Depth of Cut ................................................................................................................................ 3”

Maximum Thickness at 45 Cut ............................................................................................................. 2-1/8”

Table in Front of Saw Blade at Maximum Cut ........................................................................................... 10”

Maximum Width of Dado ....................................................................................................................... 13/16”

Maximum Diameter of Dado ........................................................................................................................ 8”

Dust Port Diameter ....................................................................................................................................... 4”

Dust Collection Minimum CFM required ................................................................................................... 350

Table Height ............................................................................................................................................... 34”

Table Size (with extension) ......................................................................................................... 29"D x 42"W

Table Size (without extension) .................................................................................................... 29"D x 20”W

Arbor Speed ................................................................................................................................... 4300 RPM

Sound Rating:

(without blade) ...................................................................................................................... 70 dB at 3 ft.

(with 10”x50T blade) ............................................................................................................ 85 dB at 3 ft.

Motor

SN 708674 .......................................................................................................... 3HP, 1Ph, '''230V only'''

SN 708676 ......................................................................................................... 5 HP, 1Ph, '''230V only'''

SN 708680 .................................................... 5HP, 3Ph, 230/460V, '''prewired 230V '''

Weight

Net ............................................................................................................................................ 330 lbs.

Gross ........................................................................................................................................ 407 lbs.

'''END OF THE PROCEDURE'''

File:M-PM231B PM2000B BT Table Saw ED9.pdf

2026-10-09T19:06:07Z

Aspontarelli:

PM2000 Table Saw Manual

Table Saw User Guide

2026-10-09T19:02:58Z

Aspontarelli: /* GENERAL */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Table Saw

'''Requires in-person training:''' Yes 

'''Procedure Number''': UG 110-03, Rev. 1

'''Last Revision:''' 4/22/2021

|}

= GENERAL =

The woodshop has two table saws, used for a wide variety of applications in cutting wood and some plastics.

[[File:Screenshot 2021-01-14 093448.png|thumb|left|Powermatic Table Saw (PM2000)]] 

= SAFETY =

* Wear polycarbonate safety glasses.
* Remove or secure all loose clothing, jewelry, and long hair.
* Use push sticks when hands would otherwise be within the miter slots.
* Do not wear gloves.
* Never touch the blade while machine is connected to power.
* Do not use machine without riving knife in place.
* Do not attempt to saw boards with loose knots or with nails or other foreign material.
* Do not attempt to saw twisted, warped, or bowed stock unless one edge has been jointed.
* Do not attempt to saw long or wide boards that can't be steadily guided through the saw.

= REFERENCE =

* Safety training video https://youtu.be/Uf_jbau4VwA
* Powermatic Instructions and Parts Manual http://content.powermatic.com/assets/manuals/1791997_man_EN.pdf

= PROCEDURE =

* Check the alignment of the riving knife, fence and miter slot to the blade.
* Check the saw blade for cracks or missing teeth. Do not use a cracked or dull blade or one with missing teeth or improper set. Make sure the blade is securely locked on the arbor.
* Always use the riving knife, blade guard, push stick and other safety devices for all operations where they can be used.
* On operations such as dadoing or molding where the blade guard cannot be used, use feather boards, fixtures and other safety devices.
* Reinstall the riving knife and blade guard immediately after completing the operation that required their removal.
* Be sure the saw blade rotates clockwise when viewed from the motor side (left side) of the machine.
* Turn the power off and do not leave the machine until it comes to a complete stop.
* Start – Press the green start switch.
* Stop – Press the red switch to stop.
* Rip Sawing - work piece is fed with the grain into the saw blade
* Crosscutting - workpiece is fed cross grain into the saw blade
* Bevel Cut – the saw blade is tilted at an angle less than 90 degrees to the table top
* Dado Cutting – is cutting a wide groove into a workpiece or cutting a rabbet along the edge of a workpiece.
* Listed below are conditions, which can cause kickbacks:
** Confining the cutoff piece when crosscutting or ripping.
** Releasing the work piece before completing the operation or not pushing the work piece all the way past the saw blade.
** Not using the riving knife when ripping or not maintaining alignment of the riving knife with the saw blade.
** Using a dull saw blade.
** Not maintaining alignment of the rip fence so that it tends to angle toward rather than away from the saw blade front to back.
** Applying feed force when ripping to the cutoff (free) section of the work piece instead of the section between the saw blade and fence.
** Ripping wood that is twisted (not flat), or does not have a straight edge, or a twisted grain.
* Do not use the miter gauge and rip fence in the same operation unless provision is made by use of a facing board on the fence so as to allow the cutoff section of the workpiece to come free before the next cut is started.

[[File:Screenshot 2021-01-14 095428.png]]

* The ''front handwheel'' (B) controls the raising and lowering of the blade (blade height).
* The ''side handwheel'' (D) controls the blade tilt.
* The blade can be adjusted for a tilt between 90º (vertical or a setting of 0º on the scale) and 45º left tilt (D).

'''Blade height'''

1. Loosen the ''lock knob'' (A) on the ''front handwheel'' (B).

2. Turn the ''handwheel'' (B) clockwise to raise and counterclockwise to lower the blade.

3. Tighten the ''lock knob'' (A).

'''Blade tilt adjustment'''

1. Loosen the ''lock knob'' (C) on the side handwheel (D).

2. Turn the ''handwheel'' (D) counterclockwise to adjust the saw blade down to 45º left tilt.

3. Turn clockwise to adjust the saw blade to maximum of 90º.

3. After selecting the position, tighten the ''lock knob'' (C).

'''Insert Adjustment:''' Adjust the setscrews in the insert with a 2.5mm hex wrench to ensure that the insert is stable and flush with the table top.

'''Miter Gauge'''

1. Operate miter gauge by loosening the lock knob (A) and turning the miter body (B) to the desired angle. To move gauge beyond index stops of 45 degree and 90 degree, flip down the stop (C).

2. Adjust index stops by turning one of three adjustment screws (D).

[[File:Screenshot 2021-01-15 101410.png]]

'''Riving Knife Adjustment -''' Lateral alignment: The saw blade and riving knife must be in line as close as possible with each other (lateral alignment) for the prevention of kickback. Upon initial blade guard and riving knife installation no further adjustment should be necessary. Alignment should be checked and adjusted, if required, after each blade change.

Check the alignment as follows:

1. Remove the blade guard and pawl.

2. Place a straightedge (A, Fig. 13) on the table so it rests against the blade (B, Fig 13) and riving knife (C, Fig. 13). Rotate the blade so the top of the blade tooth touches the straightedge. The saw blade and riving knife must be in line.

If adjustment is required:

3. Remove the table insert.

4. Loosen the lock handle (A, Fig. 14) and remove the riving knife, making a note as to which direction the riving knife needs to be moved to align it with the saw blade.

5. Use a 3mm hex wrench, make adjustments to any of the four set screws (D, Fig. 15) accessible through openings located in the corners of the floating clamp block (E, Fig. 15).

6. If necessary, repeat the above procedure.

[[File:Screenshot 2021-01-15 102303.png]]

'''Blade Alignment'''

1. Disconnect the saw from the power source.

2. Raise the blade guard up a way from the blade.

3. Choose a tooth on the far side of the blade (towards the rear) and position the tooth slightly above the table insert. Mark the tooth with a marker. Measure the distance from the side of the blade to the right T-slot edge using a combination square. Make sure to measure between the teeth not on the tooth.

4. Rotate the blade toward the front so that the marked tooth is just above the insert. Measure the distance from the side of the blade to the right T-slot edge. The two measurements should be the same.

5. If they are not the same, loosen four hex socket cap screws that hold the table to the base.

6. Make the needed adjustments and tighten the four hex socket cap screws firmly.

7. Check the alignment once again after tightening hardware.

'''Adjusting 45 degree and 90 degree Positive Stops'''

1. Disconnect saw from power source.

2. Raise the saw blade to its maximum height using the hand-wheel.

3. Set the blade at 90 degrees to the table by turning the blade tilting hand-wheel clockwise as far as it will go.

4. Place a combination square on the table against the blade and check to see that the blade is at a 90 degree angle to the table. Make sure square is not touching a blade tooth.

5. If blade is not at 90 degrees, open the motor cover door, loosen lock nut and turn adjusting stop screw on the front trunnion in, or out. The adjusting stop screw should stop against the front trunnion bracket when the blade is 90 degree to the table.

6. Tighten the lock nut.

7. Set the blade at 45 degrees to the table by turning the blade tilting hand-wheel counterclockwise as far as it will go. Place a combination square on the table against the blade. Make sure square is not touching a blade tooth.

8. If the blade is not 45 degrees, remove the raising and lowering handle. Loosen lock nut and turn adjusting stop screw on the front trunnion in, or out. The adjusting stop screw should stop against the front trunnion bracket when the blade is 45 degree to the table.

9. Check the accuracy of the pointer on the angle scale and adjust, if necessary.

'''Changing the Belt -''' Referring to Figure 21:

1. Disconnect the machine from the power source, unplug.

2. Lower the blade to its lowest point.

3. Loosen two hex cap bolts (A).

4. Take the tension off of the belt (B) by lifting up on the motor.

5. Remove the belt from the arbor and motor pulleys.

6. Replace and tension the belt. The weight of the motor should apply enough tension to the belt. Tighten the hex cap bolts (A).

7. Check the belt tension after the saw has been used for a few hours. Adjust as necessary.

[[File:Screenshot 2021-01-15 104616.png]]

= TROUBLESHOOTING =

'''Powermatic'''

{|
|width="33%"| '''Trouble'''
|width="33%"| '''Probable Cause'''
|width="33%"|
'''Remedy'''

|-
| Excessive vibration.
| Tilt or raising clamp knobs not tightened
| Tighten knobs.
|-
|
| Blade out of balance.
| Change blade.
|-
|
| Bad motor.
| Replace motor.
|-
|
| Loose arbor or motor sheave.
| Tighten set screws.
|-
| Cuts out-of-square when crosscutting.
| Miter gauge out of adjustment.
| Reset pointer
|-
|
| Miter slot misaligned.
| Realign table.
|-
| Motor stalls or workpiece binds or burns.
| Excessive feed.
| Reduce feed.
|-
|
| Bad motor.
| Replace motor.
|-
|
| Dull or incorrect blade.
| Replace blade.
|-
|
| Miter slot misaligned.
| Realign miter slot.
|-
|
| Fence misalignment.
| Realign fence.
|-
| Cuts not true at 90 or 45 degrees.
| Stop screws not set properly.
| Readjust stop screws.
|-
| Tilt or saw raising hand wheels difficult to turn.
| Lock knob not released
|
Loosen lock knob.

|-
|
| Worm and worm gear segment caked with sawdust and pitch.
|
Clean and re-grease.

|-
|
| Worm and worm gear segment out of alignment.
| Realign worm and worm gear segment.
|-
| Motor overheats.
| Motor overloaded.
| Correct overload condition such as reducing the feed rate.
|-
|
| Improper cooling of motor.
| Clean sawdust from fan and duct areas of motor.
|-
| Motor starts slowly or fails to come up to speed.
| Low voltage.
| Request voltage check from power company and correct low voltage condition.
|-
|
| Centrifugal switch not operating.
|
Replace switch.

|-
|
| Bad motor.
| Replace motor.
|-
|
Motor fails to develop full power.

| Power line overloaded.
| Correct overload condition.
|-
|
| Undersize wires in supply system.
| Increase supply wire size.
|-
|
| Low voltage.
|
Request voltage check from power company and correct condition.

|-
|
| Bad motor.
| Replace motor
|}

END OF THE PROCEDURE

CNC Plasma Cutter User Guide

2026-07-02T11:04:44Z

Aspontarelli: /* REFERENCE */

CNC Plasma Cutter User Guide

2026-07-02T10:58:27Z

Aspontarelli: /* SAFETY */

CNC Plasma Cutter User Guide

2026-07-02T10:43:15Z

Aspontarelli: /* GENERAL */

{|
|width="33%"|
'''Shop Area:''' Metal Shop

'''Tool:''' CNC Plasma Cutter

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 130-05, Rev. 1
|width="33%"|
'''Date'''

2/8/2021
|}

= GENERAL =
[[File:Dynatorch.jpg|thumb|Dynatorch CNC Plasma]]
The CNC Plasma cutter is used to cut 2D computer generated drawings from sheet and plate metals.

We have a Dynatorch XLS 5x10' CNC table powered by a Cutmaster 80 amp plasma cutter.

= SAFETY =

* The plasma cutter requires at least shade #5 eye protection. Welding helmets can also be used.
* Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Non-slip footwear or anti-skid floor strips are recommended.
* Closed toe shoes are required when working in a shop area.
* Make all machine adjustments or maintenance with the machine unplugged from the power source.
* Never cut or weld material with zinc in it. Especially galvanized material. It gives off toxic fumes.
* If you want to see the path the plasma cutter will take and check the positioning of your material without cutting it, leave the plasma cutter off. Only turning on the computer and the controller will allow you to import your code and move the plasma cutter without it actually cutting the material.

= REFERENCE =

* Langmuir Crossfire troubleshooting - https://www.langmuirsystems.com/troubleshooting
* Razorweld 45 manual - [http://www.razorweld.com/userfiles/file/RazorCUT45_Manual%20web.pdf www.razorweld.com/userfiles/file/RazorCUT45_Manual%20web.pdf]
* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/
* Generic Cutting Charts - https://www.plasma-automation.com/partsdatabase/CuttingCharts/hpr260.pdf
* Dynatorch overview video - https://www.youtube.com/watch?v=WQZbHtkBUCE
* Torch Height Control theory - https://www.hypertherm.com/en-US/learn/articles/torch-height-control-for-plasma-cutting/
* [[:File:dynatorch_manual.pdf|Dynatorch Software Manual]]
* [https://vector-space.org/wiki/images/0/0d/Cutmaster82_OperatingManual.pdf Cutmaster 82 Operating Manual]
* Troubleshooting Guide: https://www.thefabricator.com/thewelder/article/cuttingweldprep/troubleshooting-cnc-plasma-cutting-part-ii

= PROCEDURE =

The general workflow for using the CNC plasma is as follows.

# CAD Design
# CAM toolpath creation
# Machine Setup and Control

There are many different software options that can be used to make it through this workflow. Langmuir provides extensive [http://www.langmuirsystems.com/tutorials video tutorials] that cover the full workflow using Fusion 360. However the workflow used at Vector Space is Inkscape/FreeCAD -> SheetCAM -> Mach3.

== 1. CAD ==

There are a lot of options for creating 2D CAD drawings. Inkscape is recommended for artistic, freeform designs, while FreeCAD is recommended for technical drawings with precise dimensions. Both applications are available on all machines in the computer lab. Designs are typically saved in .dxf or .svg file format.

== 2. CAM ==

The purpose of the CAM process is to provide the tool with instructions on how to create the CAD drawing. In the case of the plasma cutter, this typically means how to follow the lines, and at what speed. The software we recommend for this step is called SheetCAM and can be found on all machines in the computer lab. The input to the CAM software is a drawing (.dxf or .svg) and the output is gcode (.tap or .ngc).

=== SheetCAM ===

The step-by-step instructions below assume that you have already created your drawing in Inkscape or FreeCAD and are ready to import it into SheetCAM to prepare the code for cutting with the plasma cutter.

==== Set post-processor ====

Depending on which plasma cutter you plan to use, make sure to select the correct post processor. The Crossfire uses "Mach3 Plasma", while the Dynatorch uses "Dynatorch".

* Options -> Machine -> Post processor drop down to "Mach3 plasma"

==== Import your drawing ====

* To begin a new project, Click the File menu – New Part. If you want to import a previously designed object from another program (dxf, svg, etc.), in the pop-up menu that opens, choose Yes when it asks if you want to Import a drawing, and then select your file from the explorer menu.
* Under the drawing options, pay special attention to Scaling and Position
** Scaling: Default is set yo 0.5 which is roughly half the size of the imported drawing. If you want it full size, change this to a “1”.
** Position: Default is set to the bottom left corner. This setting or any of the other corners would work best depending on if you have a blank piece of material. If you set the position to center, the plasma cutter will always start from the bottom left corner of your material and move to the object. If you are working around previous cuts, this makes the job much more difficult to position on the plasma cutter.
* If you did not import a drawing file, you can create your object using the SheetCAM controls.

==== Creating and assigning layers ====

Once you have completed your design or finished adjusting settings for the imported object, you can create different layers for objects if you want them cut in a certain order. For example, you may want the plasma cutter to cut the holes out first, then cut the rest of the design afterwards. To do this the program has the ability to assign objects to different layers.

When choosing to create your layers, be sure to choose them in the order that you want them to be cut. For example, choose the “Holes” layer first, and the rest of the design second. Think about how each layer will affect the rest of the project. Cutting the design first will probably drop it out of the material, so then it would be difficult to cut the holes after this happens.

* The program will assign all objects to one layer initially.
* To assign objects to a new layer, click the Mode menu and select Edit Contours.
* Left click and hold, then drag the mouse over one or more objects and then release the button.
* Right click on any of the selected objects. In the pop-up menu click Move to Layer, New layer (you will name it) or choose an existing layer to assign the object to a previously created layer.
* To edit the options for each layer:
** Click the Operation menu, Plasma Cut
** Pay attention to the following options in the pop-up menu:
*** Contour method: Do you want the cutting to happen on the inside, outside, or middle of the path lines. For example, you may want the holes to be cut on the inside, but the rest of the design on the outside.
*** Layer: Make sure you have selected the correct layer for the parameters you are setting.
*** Feed rate: The default for this is set to inches per minute (ipm), so if you wanted 20 mm/s, 40 ipm would be close to the same speed (47 ipm would be the exact same).
* Click “OK”. The path setting will now show up under “Operations” on the left sidebar off the program. You can double click to edit them later if necessary.
* When you have finished editing your object and adjusting settings for the layers, you can process the object to be run on the plasma cutter.

==== Processing your object ====

Once you have imported your object and adjusted the layers, it is time to process the image and create the code that will tell the plasma cutter how to cut the object. The code you create here will be imported into the Mach3 program installed on the plasma cutter computer.

* Click the File menu, choose Run post processor
* Name your file and save as a G-code file (.ngc)

== 3. Machine Setup and Control ==

=== Dynatorch ===

# Fill water table
## Close drain valve, Open supply valve
## Attach compressed air to drain line
## Slowly open brass shutoff valve at compressed air line
## Fill until water 1 inch from full
# Launch Dynatorch software. Software will search for motors, it should find two X motors, one Y, and one torch motor.
# Allow homing process to establish a home position.
# Manually jog the torch to the X-Y origin of your job. Jog buttons are found in the upper right area.
# Set the origin by click X-zero and Y-zero in the upper left
# Run a test cut
## Disable the torch by clicking the lightning bolt
## Click Cycle Start to start the job
# Make any adjustments, then enable the torch and restart the job.
# When finished, open drain valve to empty water table.

=== Langmuir Crossfire ===
The Crossfire tutorials explain how to [http://www.langmuirsystems.com/tutorials#cut3 setup the physical machine] prior to cutting and how to [http://www.langmuirsystems.com/tutorials#cut5 execute the GCODE] you created in the CAM process by using the Mach3 software. Always have a little extra material or get your material a little larger for testing before you start your final cuts. Create a simple object such as a small circle to test cut on your material to see how it comes out.

# Set nozzle above workpiece with 1/8in shim
# Jog the cutter where you want it and set x and y zero in Mach3
# Load gcode
# Test the programming by clicking cycle start

== Speed and Power ==

=== Dynatorch ===
The Dynatorch speeds can be found [https://www.weldersupply.com/Content/files/ProductPDFs/Cutmaster82CutChart.pdf here].

=== Langmuir Crossfire ===

The following table has been developed in-house for the Crossfire. Please add to it with any experience you have.

{|
| '''Material'''
| '''Thickness'''
| '''Speed (inch/min)'''
| '''Amperage (Amps)'''
|-
| Carbon Steel
| 1/8 in
| 60
| 45
|-
|
| 1/4 in
| 35
| 45
|-
| Aluminum
| 1/8 in
| 110
| 45
|-
|
| 1/4 in
| 60
| 45
|-
|
| 1/2 in
|
|
|-
| Stainless Steel
| 1/4 in
| 30
| 45
|}

= TUTORIAL =
The tutorials below serve as reinforcement of content learned during an instructor-led workshop.

== My First Plasma Cut ==
Your first plasma cut begins at the end of the typical workflow. The focus here is to understand the machine itself: how to setup and operate the plasma cutter.

# Download [https://vector-space.org/wiki/images/5/58/My_first_plasma_cut.ngc my_first_plasma_cut.ngc] by right clicking the link and selecting Save Link As.
# Release the E-stop on the gantry.
# Begin filling the water table using the switch below the plasma cutter to turn on the pump.
# Launch the Dynatorch application.
# Allow the machine to home, and ensure that nothing stands in the way of the gantry and torch heading toward you.
# After the machine is homed, set your workpiece on the plasma table. Your workpiece needs to be a 16GA sheet of plain carbon steel for these instructions to be accurate.
# Set the speed and arc voltage parameters by clicking Cut Chart button at the center left of the screen. Then use the dropdowns to select Carbon Steel, 40 Amp. Then click Apply and you'll see these settings applied to the setpoints at the top of the screen.
# Ensure that the nozzle inside of the torch is rated for 40 Amps by unscrewing the grey part of the torch and separating the components until finding the engraving on the nozzle. If it is not correct, replace it with a 40 Amp nozzle. Re-assemble the torch and screw this assembly back onto the machine tight enough that the plasma cutter recognizes the re-installation and makes an audible click, but not so tight as to rotate the torch and damage the wires. Do NOT use a wrench or any tool other than your hand for this process.
# Using the control interface at the top right of the Dynatorch software, drive the torch to the bottom left corner of the workpiece.
# Zero the X and Y axes by clicking the associated buttons at the top left of the screen.
# Once the water table is filled, turn off the water pump.
# Turn on the plasma cutting power source (big box to the right of the computer). Turn the dial to 40 Amps.
# Prepare the software for a practice run by disabling the plasma arc. This is done by clicking the lightning bolt at the top center of the screen so that it becomes grey. Now click the start button at the center right of the screen. This will start the plasma torch moving without actually cutting. Observe the movement to ensure that it matches your expectations.
# Once happy with the practice run, click stop. This disables the X and Y motors, so re-enable those motors by clicking All Motors On at the top left of the screen. Then ensure that the gcode is reset to the very beginning by clicking the Reset button at the center right of the screen.
# Put on your safety glasses. Enable the plasma by clicking the lightning bolt. Then begin the operation by clicking Start.
# Drain the water table and cleanup your work.

== My Second Plasma Cut ==
[[File:My second plasma cut-ss.png|thumb|SheetCAM Simulation]]
Your second plasma cut begins a step further from the end, the focus of which is to understand how to generate gcode.

# Download [https://vector-space.org/wiki/images/d/d7/My_second_plasma_cut.job my_second_plasma_cut.job].
# Launch the SheetCAM application from a desktop in the computer lab.
# Open my_second_plasma_cut.job by click File->Open Job.
# Ensure that your machine options are correct by clicking Settings->Machine Options. Click the PostProcessor tab and ensure that Dynatorch is selected as the postprocessor.
# The toolpaths have already been set in this file, but you should still review them to ensure that they make sense and to set your expectations for what will happen when the gcode is executed at the plasma cutter.
## Double click each of the two operations listed at the bottom left of the screen.
## Note the speed set for each operation, the layer that the operation is applied to, the lead-in and lead-out methods, and the offset selected.
# Now simulate the gcode by clicking Simulate, an aqua colored drill bit icon at the top center of the icon list.
# Generate the gcode by clicking File-> Run Post Processor.
# Once the gcode is ready, you are ready to repeat the process you learned in your first plasma cut.

== My Third Plasma Cut ==
[[File:My third plasma cut-ss.png|thumb|SheetCAM Toolpath Creation]]
Now we'll take another step back and create your own toolpaths.

# Download [[:File:My third plasma cut.svg|my_third_plasma_cut.svg]].
# Launch the SheetCAM application from a desktop in the computer lab.
# Import the SVG file by File -> Import Drawing. Ensure that the file type filter at the bottom right has SVG files selected.
## Set drawing position to bottom left.
## Set scaling to 1.
## Click OK
# Create a plasma cutting tool by clicking Tools -> New Jet Cutting Tool.
## Name it plasma.
## Select Plasma from the Type dropdown list.
## Set the feedrate to 90 ipm.
## Leave the remaining fields at their defaults and click OK.
# Create a plasma cutting operation by clicking Operation -> Plasma Cut.
## Set Contour method to No Offset.
## Set Layer to black.
## Set Feedrate to 90 ipm.
## Set Lead in and Lead out to Arc with Length of 0.1 inch.
## Click OK.
# Repeat this process for the red layer, changing the Contour method to an Outside Offset.
# Save your work as a SheetCAM job file. File-> Save Job As.
# Continue with what you learned in from your Second Plasma Cut.

== My Fourth Plasma Cut ==
If we were to take another step back, I'm afraid we'd step into an infinite number of tutorials, for after the creation of a drawing, we'd need to branch off into the fundamentals of art and computer science, which will ultimately take us all the way back to Euclid's Geometry. And while we encourage you to take these steps, we must end our tutorials here.
= TROUBLESHOOTING =

* Torch does not arc
** Check that the ground cable is properly attached to the table or workpiece
* Torch arcs but cuts out quickly
** Check that the workpiece is level relative to the torch, meaning that the gap is consistent across the entire workpiece
** Check and if necessary, replace the torch consumables
* The back side of the cut is not clean
** Adjust the power and speed

== Dynatorch Troubleshooting ==
{| class="wikitable"
|+
!Problem
!Solution
|-
|Torch move to Arc Start Height will exceed the range limit of motion of the Torch...
|When the torch moves down to sense your workpiece, it's running into resistance before actually reaching the workpeice and concluding that it must have hit the piece. The next step is for the torch to move upwards, but it's already so high up that it doesn't have enough room for the move.
The first thing you should do is clean the z-axis ways of debris that could cause this excess resistance.
The second step is to increase the downforce factor when searching for the plate.
|-
|
|
|-
|
|
|}

== '''GENERAL PLASMA CUTTING TROUBLESHOOTING''' ==

{|
!width="25%"| PROBLEM
!width="25%"| POTENTIAL CAUSES
!width="50%"| SOLUTIONS
|-
| Excessive cut edge angularity (bevel).
| Plasma torch nozzle is worn.
| The most common cause for increased edge angularity is a worn nozzle. Remove your plasma torch from the torch mount and inspect the nozzle orifice for wear. Replace as necessary.
|-
|
| Moisture in the compressed supply air.
| Moisture in the supply air can result in decreased cut quality which can produce undesired edge bevel. Make sure that you have a water separator in line with your supply air going to the plasma cutter. Also ensure that this water separator is functioning properly and is not full.
|-
|
| Torch is not perpendicular to cut surface.
| Inspect that your torch is mounted properly in the torch mount and that the torch is aligned perpendicular to the workpiece surface. Re-align the torch carriage as necessary in accordance with the Assembly Manual provided.
|-
|
| Travel speed is too fast.
| An increased travel speed will not allow the plasma jet to cut fully down through the workpiece while moving. This causes the plasma column to lag behind while cutting which can produce excessive edge bevel. Slow your travel speed down in increments of 10IPM until the desired cut quality is achieved.
|-
|
| Plasma torch nozzle diameter is too large.
| Most plasma cutters have a range of nozzles that are rated for amperage. Typically the higher amperage nozzles will have a larger nozzle orifice diameter. This larger orifice can produce more edge angularity because the plasma jet is not as tightly focused when using a smaller nozzle size. We recommend lowering your amperage and selected a smaller fine cut nozzle if possible for your project to produce better edge angularity.
|-
|
| Incorrect cutting amperage.
| Incorrect cutting amperage can product either positive or negative edge bevel. Adjust your arc amperage in 3A increments until the desired cut quality is achieved.
|-
|
| Workpiece is warped.
| A warped workpiece can result in irregular cut angularity due to the fact that the torch is no longer perpendicular to the workpiece. Inspect your workpiece and clamp as necessary. If you are experiencing warpage while cutting on thinner material, we recommending cutting with a water table to eliminate this thermal distortion.
|-
|
| Improper cut height.
| Cut height can have an affect on edge angularity which can produce either a positive or negative edge bevel angle. Adjust the cut height either up or down in 0.030" to reduce edge angularity.
|-
| Excessive backside dross (slag).
| Slow travel speed.
| Backside dross can occur when cutting if the travel speed used is too slow. Try increasing your travel speed by 5 IPM increments until the amount of dross is reduced.
|-
|
| Cut height is too low.
| If the cut height is too low, this can cause more backside dross to form. Try increasing the cut height in 0.030” increments until the back side dross is reduced.
|-
|
| Cutting amperage is too high.
| If the cutting amperage is too high, this can cause an increase in the amount of backside dross. Try reducing the cutting amps in increments of 3A until the amount of dross is reduced.
|-
|
| Large nozzle orifice diameter.
| A larger nozzle orifice can result in an increased presence of backside dross. Consult your plasma cutter manufacturer for the availability of smaller nozzle sizes that are compatible with your cutting torch.
|-
| Excessive topside dross (spatter).
| Cut height is too high.
| Top spatter or top dross can occur when the plasma stream first pierces the work piece and the molten metal adheres to the top surface of the material. It is typically much less common than back side dross and it can be easily removed by chipping away from the work piece. If you are experiencing a high incidence of top dross, it is possible that your chosen cut height is too high and should be reduced.
|-
|
| Pierce delay is too short.
| If the pierce delay is too short, it does not allow the plasma arc enough time to correctly pierce the material completely before motion begins. Try increase the pierce delay in 0.1 second intervals until top dross is eliminated.
|-
|
| Amperage is too low.
| If the amperage is too low, the plasma cutter does not have enough power to quickly pierce the material. Try increasing the cutting amperage in intervals of 3A.
|-
| Cut holes are excessively tapered.
| Travel speed is too fast.
| When cutting holes, the plasma cutter is constantly changing direction which can make it difficult to achieve a full speed cut in smaller holes. If you are experiencing holes that measure larger on the top surface than the bottom, it may be necessary to cut these holes out at a slower travel speed. We recommend programming a second layer in SheetCAM for your part and putting holes in the second layer at half of the desired travel speed.
|-
|
| Excessive edge angularity on part.
| Holes typically have higher edge angularity than straight edges. If you are already experiencing high edge angularity on the rest of your part, this will make holes even worse. Please refer to the above section on edge angularity for more troubleshooting tips.
|-
| Workpiece experiences a large amount of distortion when cutting.
| Thermal gradients established in workpiece during cutting.
| The plasma cutting processes uses a high temperature plasma arc to melt and cut through the workpiece. As a result, the workpiece will heat up locally which can establish a thermal gradient in the part. This gradient can lead to distortion which will effectively warp you workpiece. Typically with material that is 3/16" and thicker, distortion is not as much of an issue because the plate is strong enough to resist this warping. On thinner plate and sheet metal, distortion can be an issue which can make detailed cutting impossible without distorting the workpiece. 
 
Fortunately, some cooling methods can be used that completely eliminates this distortion when cutting. A water table is simply a tray filled with water that surrounds the slat bed of a gantry-style CNC plasma machine. The tray is filled with water to below the top surface of the slat bed so that the action of plasma cutting causes water in the tray to splash back up onto the backside of the part being cut. This allows for part cooling, reduces cutting noise, decreases part warpage, reduces arc flash, and reduces smoke and cutting dust. A water table can be purchased for the CrossFireTM machine from Langmuir Systems or it can be made by following our guide in the Projects page. If you are not able to purchase a water table, we have had an equal amount of success by using a standard spray water bottle and continuously spraying the plasma arc with the water bottle during cutting to cool the part.
|-
| Cut does not penetrate completely through workpiece.
| Amperage is too low.
| If the plasma cutter amperage is too low, it will not have enough power to completely penetrate the material. Try increasing the amperage in 3A intervals until a clean and complete cut edge is achieved. Consult your plasma cutter manufacturer for proper amperage settings for your machine.
|-
|
| Travel speed is too fast.
| If the travel speed is too fast, the plasma arc will lag behind and will not be able to complete several the material. We recommend slowing down the travel speed in 10 IPM increments until a satisfactory cut edge is achieved.
|-
|
| Supply air pressure too low.
| If the supply air is too low, it will not have enough power to completely sever the material and will result in a poor cut edge. Consult your manufacture for the correct supply air pressure settings and make sure that your air compressor has enough capacity to keep up when cutting.
|-
|
| Cut height is too high.
| If the cut height is too high, the plasma arc may not penetrate completely through the material. Try lowering the cut high in 0.030" increments until a complete severance cut is achieved.
|-
| Consumables are wearing out more quickly than expected.
| Nozzle orifice is clogged or dirty.
| The daily buildup of dirt and grime on the nozzle can clog the orifice which greatly affects the swirling of the plasma arc. This can lead to decreased lifetime for both the nozzle and electrode. Make sure that the plasma nozzle remains clean before each use.
|-
|
| Supply air pressure is incorrect.
| If air pressure is too high, this can greatly reduce the lifetime of the electrode. Conversely, if air pressure is too low the nozzle orifice will wear which can affect cut quality. Consult your plasma cutter manufacturer for ideal air pressure settings for your specific plasma cutter model.
|-
|
| Cut height is not set correctly.
| When the plasma cutter initiates the arc, it can take several moments to completely pierce the material depending on the thickness of the material. During this pierce, molten metal is ejected from the topside of the material which can be blown back onto the nozzle orifice. As a result, it is important to use a cut height that is not too low to avoid this blow back of material which can damage the nozzle orifice over time. Conversely, if the cut height is too high the arc will not transfer which will degrade the lifetime of the electrode. Consult your plasma cutter manufacturer for the correct cutting height parameters for your given project.
|-
|
| Supply air is not dry.
| The plasma cutting arc is especially sensitive to moisture. Air compressors take humidified air from the atmosphere which always contains some amount of water. Make sure that you either have a water separator on your plasma cutter or that you have a water separator in line with your air compressor before the air is delivered to your plasma cutter. Moisturized air can greatly decrease the lifetime of your consumables and can negatively affect cut quality.
|-
|
| Incorrect cutting parameters.
| Every plasma cutter is different. We encourage you to contact your plasma cutter manufacturer to get a complete list of proper cutting parameters to use with your machine to optimize the lifetime of your consumables.
|-
| Unequal (uni-directional) edge angularity.
| The workpiece is warped.
| If a workpiece is warped, it can cause a unidirectional edge bevel because the plasma arc is not perpendicular to the material surface. Inspect the material for flatness and use clamping as necessary.
|-
|
| The torch is not mounted perpendicular to the slat bed surface.
| Inspect that your torch is mounted properly in the torch mount and that the torch is aligned perpendicular to the workpiece surface. Re-align the torch carriage as necessary in accordance with the Assembly Manual provided.
|-
|
| Slag accumulation on slat bed creating an unequal cut surface.
| The table surface is established by the top surface of the slat bed which can become chewed up after repetitive cutting and slag accumulation. We recommend removing the slag accumulation from the slat bed to re-establish the original bed surface. If the slats are too worn, it may be necessary to purchase a new slat pack.
|-
|
| The gantry tube is misaligned.
| If all other solutions fail, it is possible that the gantry tube is not level to the surface created by the slat bed. Please consult the Assembly Manual for the correct procedure for aligning the gantry tube.
|-
| Irregular cut geometry along one axis.
| Incorrect stepper motor settings in Mach3.
| If the motor tuning settings are changed accidently in Mach3, it can affect the 'gear ratio' for a given axis. If this happens, you will need to re-load the specific Mach3 configuration file for the CrossFireTM machine. Please consult the Assembly Manual for instructions on how to configure Mach 3 for your machine.
|-
|
| One lead screw coupler is loose.
| Inspect that two couplers used on each end of the lead screw to ensure that a tight fit is achieved. Re-tighten as necessary.
|-
|
| Lead nut is worn or damaged.
| Inspect the lead nut to ensure that the threads are not damaged and that the spring tensioning mechanism is functioning properly. Replace lead nuts as necessary.
|-
|
| Loose fastener between the lead screw coupler and roller bearing.
| Inspect the fastener at the end of the lead screw coupler where it clamps to the bearing. Tighten as necessary.
|-
|
| Lead nut fasteners are loose.
| Inspect the fasteners that attach the lead nuts to the lead nut mounts. Tighten as necessary.
|-
| Part dimensions are oversized/undersized compared to design.
| Kerf width setting is too large.
| If the kerf width setting for your programmed tool in SheetCAM is too large, the dimensions of all outside offset part geometry will be undersized (all inside offset geometry will be oversized). We recommend making a test cut at the known parameters in a straight line and using a tape measure or caliper to measure the actual kerf width.
|-
|
| Kerf width setting is too small.
| If the kerf width setting for your programmed tool in SheetCAM is too small, the dimensions of all outside offset part geometry will be oversized (all inside offset geometry will be undersized). We recommend making a test cut at the known parameters in a straight line and using a tape measure or caliper to measure the actual kerf width.
|-
| Divots' created in cut edge at starts/stops.
| Missing or under-sized cut lead-in.
| Lead-ins are used when CNC plasma cutting in order to make smooth cuts when piercing a material. A lead-in is used at the start of a cut so that the plasma arc can be pierced in an area of the part that is slightly away from the actual geometry of the part. After making the pierce, the plasma torch moves along the lead-in path (usual an arc) and makes a smooth cut around the part geometry. Without a lead-in, a rough cut or 'divot' will result where the plasma torch first made the initial pierce since it pauses here for a given amount of time when piercing.
|-
|
| Excessive gap between part and slat surface.
| Sometime 'divots' in the cut edge can result when a cut is finished and the part starts to drop out before the cut is completely finished. This usually happens when the drop is small enough so that it is unsupported by the slat bed when the cut is complete. To avoid this, make sure that the drop is supported when the cut is complete.
|}

'''END OF THE PROCEDURE'''

File:Dynatorch.jpg

2026-07-02T10:41:16Z

Aspontarelli:

CNC Plasma Cutter

Panel-saw

2026-05-13T17:53:10Z

Aspontarelli: /* PROCEDURE */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Panel Saw

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-12, Rev. 0
|width="33%"|
'''Date'''

5/13/2026
|}

= GENERAL =
This is a Putsch Meniconi Univer Panel Saw, great for ripping and cross-cutting sheets of plywood up to 5 x 10'.
[[File:Panel-saw.jpg|thumb|Univer Panel Saw]]

= SAFETY =

= REFERENCE =
* Univer Manual: [[Media:Panel-Saw-user-manual.pdf| Panel Saw user manual.pdf]]

= PROCEDURE =

=== Cross Cuts ===

# Depress the foot pedal to lock the gantry in place
# Orient the saw blade vertically
# Start the saw at the highest point and cut downward

=== Rip Cuts ===

# Lift the foot pedal
# Orient the saw horizontally
# Set the height of the blade and lock it in place with the lock knob.
# Start the saw at the left and cut to the right

'''END OF THE PROCEDURE'''

Panel-saw

2026-05-13T17:49:57Z

Aspontarelli: /* GENERAL */

File:Panel-saw.jpg

2026-05-13T17:49:44Z

Aspontarelli:

Univer Panel Saw

Panel-saw

2026-05-13T17:48:30Z

Aspontarelli: /* REFERENCE */

Panel-saw

2026-05-13T17:48:09Z

Aspontarelli: /* REFERENCE */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Panel Saw

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-12, Rev. 0
|width="33%"|
'''Date'''

5/13/2026
|}

= GENERAL =
This is a Putsch Meniconi Univer Panel Saw, great for ripping and cross-cutting sheets of plywood up to 5 x 10'.

= SAFETY =

= REFERENCE =
* Univer Manual: [[Media:Panel-Saw-user-manual.pdf| Panel-Saw-user-manual.pdf]]
* Univer Manual: [[Media:Panel Saw user manual.pdf| Panel Saw user manual.pdf]]
Panel-Saw-user-manual.pdf

= PROCEDURE =

'''END OF THE PROCEDURE'''

Panel-saw

2026-05-13T17:47:51Z

Aspontarelli: /* REFERENCE */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Panel Saw

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-12, Rev. 0
|width="33%"|
'''Date'''

5/13/2026
|}

= GENERAL =
This is a Putsch Meniconi Univer Panel Saw, great for ripping and cross-cutting sheets of plywood up to 5 x 10'.

= SAFETY =

= REFERENCE =
* Univer Manual: [[Media:Panel Saw user manual.pdf| Panel-Saw-user-manual.pdf]]
* Univer Manual: [[Media:Panel Saw user manual.pdf| Panel Saw user_manual.pdf]]
Panel-Saw-user-manual.pdf

= PROCEDURE =

'''END OF THE PROCEDURE'''

Panel-saw

2026-05-13T17:47:38Z

Aspontarelli: /* REFERENCE */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Panel Saw

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-12, Rev. 0
|width="33%"|
'''Date'''

5/13/2026
|}

= GENERAL =
This is a Putsch Meniconi Univer Panel Saw, great for ripping and cross-cutting sheets of plywood up to 5 x 10'.

= SAFETY =

= REFERENCE =
* Univer Manual: [[Media:Panel Saw user manual.pdf| Panel-Saw-user-manual.pdf]]
* Univer Manual: [[Media:Panel Saw user manual.pdf| Panel_Saw_user_manual.pdf]]
Panel-Saw-user-manual.pdf

= PROCEDURE =

'''END OF THE PROCEDURE'''

File:Panel Saw user manual.pdf

2026-05-13T17:46:45Z

Aspontarelli: Univer panel saw user manual

== Summary ==
Univer panel saw user manual

Panel-saw

2026-05-13T17:45:31Z

Aspontarelli: /* REFERENCE */

Panel-saw

2026-05-13T17:43:55Z

Aspontarelli: /* REFERENCE */

File:Panel-Saw-user-manual.pdf

2026-05-13T17:43:44Z

Aspontarelli: user manual for the univer panel saw

== Summary ==
user manual for the univer panel saw

Panel-saw

2026-05-13T17:42:56Z

Aspontarelli: /* GENERAL */

Panel-saw

2026-05-13T17:40:41Z

Aspontarelli: Created page with "{| |width="33%"| '''Shop Area:''' Woodshop '''Tool:''' Panel Saw '''Requires in-person training:''' Yes |width="33%"| '''Procedure Number''' UG 110-12, Rev. 0 |width="33%"| '''Date''' 5/13/2026 |} = GENERAL = = SAFETY = = REFERENCE = = PROCEDURE = '''..."

Tool-User-Guides

2026-05-13T17:40:03Z

Aspontarelli: /* Woodshop (110) */

== Woodshop (110) ==

[[Band Saw User Guide|Band Saw User Guide]]

[[thickness-planer-user-guide|Thickness Planer User Guide]]

[[Table Saw User Guide]]

[[miter-saw-user-guide|Miter Saw User Guide]]

[[jointer-user-guide|Jointer User Guide]]

[[drill-press-user-guide|Drill Press User Guide]]

[[wood_lathe_user_guide|Wood Lathe User Guide]]

[[cnc-router-user-guide|CNC Router User Guide]]

[[scroll-saw-user-guide|Scroll Saw User Guide]]

[[drum-sander|Wide Belt Sander User Guide]]

[[edge-sander|Edge Sander User Guide]]

[[panel-saw|Panel Saw User Guide]]

== Rapid Prototyping (120) ==

[[3d-printer-user-guide|FDM 3D Printer User Guide]]

[[resin-printer-user-guide|Resin Printer User Guide]]

[[laser-cutter-user-guide|CO2 Laser Cutter User Guide]]

[[Fiber-Laser-user-guide|Fiber Laser User Guide]]

[[vinyl_cutter_user_guide|Vinyl Cutter User Guide]]

[[heat-press-user-guide|Heat Press User Guide]]

== Metal Shop (130) ==

[[Blacksmithing User Guide]]

[[Stick Welding User Guide]]

[[MIG Welding User Guide]]

[[TIG Welding User Guide]]

[[Plasma Cutter (handheld) User Guide]]

[[CNC Plasma Cutter User Guide]]

[[Milling Bridgeport User Guide]]

[[Tormach CNC Milling Machine User Guide]]

[[Ovens and Kilns]]

[[Shear Brake Roll Forming User Guide]]

[[Pipe and Tube Bender User Guide]]

[[Hydraulic Press User Guide]]

[[Hardinge Lathe User Guide|Metal Lathe User Guide]]

[[Cold Saw User Guide]]

[[metal_bandsaw_user_guide|Vertical Bandsaw User Guide]]

[[horizontal_bandsaw_user_guide|Horizontal Bandsaw User Guide]]

[[Klutch Heavy Duty English Wheel Kit User Guide]]

[[Roll Bender]]

[[Blast Cabinet User Guide]]

[[Parts Washer User Guide]]

== Textiles (140) ==

[[brother-industrial-sewing-machine-user-guide|Brother Industrial Sewing Machine User Guide]]

[[viking_sewing-machine-user-guide|Viking Sewing Machine User Guide]]

[[Serger User Guide|Serger User Guide]]

[[screen-printing-user-guide|Screen Printing User Guide]]

[[brother-pr655-embroidery-machine|Brother PR655 Embroidery Machine]]

== Computer Lab (150) ==

[[inkscape_user_guide|Inkscape User Guide]]

[[freecad_user_guide|FreeCAD User Guide]]

== Electronics (160) ==

[[oscilloscope-user-guide|Oscilloscope User Guide]]

[[battery-welder-user-guide|Battery Spot Welder User Guide]]

== Photography (170) ==

[[analog-photography-user-guide|Analog Photography User Guide]]

[[digital-photography-user-guide|Digital Photography User Guide]]

== Printmaking (180) ==
[[Chandler & Price Letterpress]]

[[Screen Printing]]

Industrial Paper Cutter

[[large-format-printer|Large Format Printer User Guide]]

[[ceramic-decal-printer|Ceramic Decal Printer User Guide]]

== Ceramics (190) ==
[[kiln-user-guide|Kiln User Guide]]

[[Ceramics Shop Policies & Procedures]]

[[decal-printer-user-guide|Decal Printer User Guide]]

== Stained Glass (200) ==
[[Stained Glass Shop Policies + Procedures]]

Main Page

2026-05-12T20:32:58Z

Aspontarelli:

==[[design_files|Design Files]]==
==[[Forms|Forms]]==
==[[Policies|Policies]]==
==[[Tool-User-Guides|Tool User Guides]]==
==[[Tool_Trainer_Checklists|Tool Trainer Checklists]]==

==[[Tool_Maintenance_Guides|Tool Maintenance Guides]]==
==[[Membership_Resources|Membership Resources]]==

== Getting started ==
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Manual:Configuration_settings Configuration settings list]
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Manual:FAQ MediaWiki FAQ]
* [https://lists.wikimedia.org/mailman/listinfo/mediawiki-announce MediaWiki release mailing list]
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Localisation#Translation_resources Localise MediaWiki for your language]
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Manual:Combating_spam Learn how to combat spam on your wiki]

Main Page

2026-05-12T20:32:47Z

Aspontarelli:

==[[design_files|Design Files]]==
==[[Forms|Forms]]==
==[[Policies|Policies]]==
==[[Tool-User-Guides|Tool User Guides]]==
==[[Tool_Trainer_Checklists|Tool Trainer Checklists]]==

==[[Tool_Maintenance_Guides|Tool Maintenance Guides]]==
==[[Membership_Resources|Membership Resources]]==
[https://vector-space.org/wiki/Membership_Resources?veaction=edit Membership Resources]
== Getting started ==
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Manual:Configuration_settings Configuration settings list]
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Manual:FAQ MediaWiki FAQ]
* [https://lists.wikimedia.org/mailman/listinfo/mediawiki-announce MediaWiki release mailing list]
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Localisation#Translation_resources Localise MediaWiki for your language]
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Manual:Combating_spam Learn how to combat spam on your wiki]

Main Page

2026-05-12T20:32:18Z

Aspontarelli:

==[[design_files|Design Files]]==
==[[Forms|Forms]]==
==[[Policies|Policies]]==
==[[Tool-User-Guides|Tool User Guides]]==
==[[Tool_Trainer_Checklists|Tool Trainer Checklists]]==

==[[Tool_Maintenance_Guides|Tool Maintenance Guides]]==
==[[https://vector-space.org/wiki/Membership_Resources|Membership Resources]]==
[https://vector-space.org/wiki/Membership_Resources?veaction=edit Membership Resources]
== Getting started ==
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Manual:Configuration_settings Configuration settings list]
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Manual:FAQ MediaWiki FAQ]
* [https://lists.wikimedia.org/mailman/listinfo/mediawiki-announce MediaWiki release mailing list]
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Localisation#Translation_resources Localise MediaWiki for your language]
* [https://www.mediawiki.org/wiki/Special:MyLanguage/Manual:Combating_spam Learn how to combat spam on your wiki]

Band saw maintenance and specifications

2026-04-28T14:45:53Z

Aspontarelli: /* Rikon */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Band Saw
|width="33%"|
'''Procedure Number'''

MT 110-01, Rev. 1
|width="33%"|
'''Date'''

1/21/2021
|}

= General =

There are two woodworking Band Saws:

* Rotary International Bridgewood PBS 440: 16 inch vertical bandsaw

* Rikon 10-326: 14 inch vertical bandsaw

[[File:Bandsaws.png]]

= Reference =

* Link to YouTube videos https://www.youtube.com/watch?v=paXdjslgPgU
* https://www.rikontools.com/manuals/10-326.pdf
* Rikon Operator's Manual: https://www.rikontools.com/wp-content/uploads/10-326M6.pdf

= Maintenance =

'''Cleaning:''' If you've adjusted the tracking properly but the blade will not stay centered inside the slot, it probably means the wheel needs cleaning. Depending on what you've been cutting -- pine is a likely suspect -- sawdust mixes with resin and clings to the blade. As it travels around in a circle, the sticky sawdust packs onto the wheel, causing a buildup. The buildup causes the blade to wander back and forth inside the slot. Remove the blade and use a putty knife to scrape off any packed sawdust, dirt or grime from the wheel until it's clean. Wipe off the blade and install it, turn on the saw, and readjust the tracking.

'''Blade:''' Check blade tracking, blade tension, and condition of band wheels.

* '''Daily:''' Inspect blade, blade wipers, blade guides, sawing fluid condition and ratio, hydraulic system oil level, and chip removal system.
* '''Weekly: '''Check maximum and minimum band speed range and calibrate if necessary.
* '''Quarterly:''' Clean sawing fluid reservoir and screen.
* '''Biannually:''' Change hydraulic fluid filters, clean hydraulic fluid reservoir magnetic plug, lubricate saw column pivot point, and inspect and adjust blade guides. Check band wheel bearings, band guides, drives, belts, and vises.
* '''Annually:''' Drain hydraulic fluid tank and clean fluid strainer and filter. Replace hydraulic fluid and transmission oil.
* '''Dull Blade:''' If you've tightened the blade sufficiently and the blade still wanders, you might have a dull blade. Test the sharpness of the blade by cutting into a piece of scrap wood. If you have to use excessive force to push the wood through the blade, or you see wisps of smoke coming from the wood or the blade, it's probably dull. If the teeth are burnt with dark tips, the blade needs changing. The blade should be replaced if the ends of the teeth are bent or blunted.

'''Blade Tracks'''

* Ensure blade tracks are true and ride correctly in the blade guides.
* '''Blade Tracking:''' Turn on the saw and observe the blade as it travels down through the slot in the top of the table. The blade should be centered in the slot. If the blade is too far forward or too far back, or even rubs at the front or back, it means the tracking is off and needs adjusting

'''Blade Tension'''

* Check the accuracy of the blade tension using a tension gage. The correct spacing between the back edge of the blade and the flange of the wheel should be approximately 132’’, though it may vary according to different manufacturers’ instructions. Adjust if necessary.
* '''Tension:''' draw a line across a piece of scrap wood. Attempt to cut along the line. If you have trouble following the line or the blade wanders back and forth across the line, your blade might be too loose. The blade should flex no more than 1/4 inch when you push it sideways.

'''Band Wheels, Band Wheel/Bearings'''

* Assess the band wheels for surface and flange wear.
* Remove any chips that could fill the grooves and impede band wheels from turning freely.
* Replace when surfaces or flanges are worn, cracked, or chipped.
* Check the maximum and minimum band speed with a tachometer; the reading should match the gauge.
* Check band wheel bearings for unusual wheel movement and replace as needed.

'''Blade Guides'''

* Clean chips from blade guides and wipers daily.
* Do not use blade guides that are chipped or cracked.
* For maximum support, move the guide arm as close as possible to the workpiece.
* Ensure the guide holds the blade with the correct pressure.
* Check that band guides are perpendicular to material vice and adjust if necessary.
* If cuts become incorrect or crooked, or blade fails prematurely, adjust the guide alignment.

'''Lubricant/Sawing Fluid'''

* Check sawing fluid or lubricants daily. Keep the level to the machine’s specifications.
* Ensure the fluid flows freely through all fluid nozzles.
* Only use lubricant or sawing fluid that is clean and mixed properly. Test the ratio using a refractometer in addition to visual inspection.
* When replacing the fluid, start with water and carefully add the correct quantity lubricating fluid as per the manufacturer’s instructions.

'''Hydraulic System'''

* Monitor hydraulic fluid levels. Low oil level may cause air in the lines and impede the hydraulic system.
* Watch for sediment in the bottom of the reservoir, as it could block the line and filter.
* Check oil level daily.

'''Drive System'''

* Inspect all areas with bearings for oil leaks.
* Check transmission level and replace any defective seals.
* Check drive wheel of gear-driven machines for excess play, which indicates worn gears.
* Check pulleys for proper alignment, tension and wear. Adjust if possible or replace if damaged.
* Check drive belt and chip brush belt for cracks, wear and stretching.

'''Vises'''

* Clean chips from vise jaws.
* Check for wear and correct alignment on both stationary and moveable vises.

'''Chip Removal System'''

* Inspect to ensure the auger or conveyor system works properly and removes all chips.
* Check that screens are not allowing chips into the sawing fluid/lubricant tank.
* Check the chip brush. It should keep chips from re-entering the cut.

= List of Specifications =

== Rikon ==

Motor ............................................................................................. 1.75 HP, TEFC

Motor Speed (no load)......................................................................... 1,720 RPM

Volts ................................................................................................... 115 / 230 V

Amps, Hertz, Phase .............................................................. 14 / 7 A, 60 Hz, 1Ph

Blade Length ................................................................................111” (2,819 mm)

Blade Width ..................................................................3/16” - 3/4” (4.78 - 19 mm)

Blade Speed ........................................ 1,445 / 2,950 ft/min (440.5 / 899.2 m/min)

Table Size (W x D) ............................................ 21-1/2” x 15-3/4” (546 x 400 mm)

Table Tilt ................................................................................... Left -70 , Right 45°

Miter Gauge T-Slots (2) ......................................................................... 3/4” x 3/8”

Maximum Cutting Width (throat) ................................................ 13-5/8” (346 mm)

Maximum Cutting Depth (height) ..................................................... 13” (330 mm)

Table Height ........................................................................... 40-3/8” (1,026 mm)

Fence Height ..................................................................................... 6” (152 mm)

Fence Length ............................................................................ 18-3/4’” (476 mm)

Dust Ports (1) ..................................................................... 4” Diameter (100 mm)

Base Size (LxWxH) ....................... 24” x 17-5/16” x 1-3/16” (610 x 440 x 30 mm)

Overall Height ......................................................................... 74-1/2” (1,892 mm)

Overall Width x Depth.................................... 34-1/4” x 25-13/16” (870 x 656mm)

Net Weight ................................................................................... 285 lbs (129 kg)

Guide Bearings: 6202-2RS

Drive belt: super awesome proprietary belt geometry that couldn't possibly be replicated by a generic and abundant offering.

== Bridgewood PBS 440 ==
* Blade Length: 145"
* Blade Width: 1" for resaw
* Blade TPI: 2 or 3
* Guide Bearing Size: 6200-2RS x 10

The guide bearings on this machine need frequent replacement, about every 6 months.

== Maintenance Log ==

=== 5/15/24: ===

# Rikon Bandsaw won't turn on.
# Checked switch by pressing on and measuring non-contact voltage at motor wires. Voltage present. Assuming bad start capacitor. Ordered Start (50 uF) and Run (150uF) capacitors.
# Installed capacitors, still not working.
# Measured hot to neutral voltage: ~0V. Hot to Gnd: 122V. Neutral to Gnd: 122V. Something is wrong.
# Disassemble switch and measure for continuity. Top contacts work, bottom contacts do not.
# Opened up switch to find that bottom contacts were melted.
# Ordered new switch.
# The switch shouldn't be wired this way when motor is wired for 120V operation. Do not switch the neutral for this very reason, just tie the neutrals together.
'''5/17/24:'''

# Wired new switch for Rikon. Joined all neutrals together, bypassing the switch.
# Replaced 10 bearings on Bridgewood with 6200-2RS, SKF brand. The bearings removed were a combination of shielded and sealed. Almost all of the shielded bearings were seized, whereas none of the sealed ones were. Clearly need to use sealed bearings.

'''END OF THE PROCEDURE'''

Cnc-router-user-guide

2026-04-22T13:01:25Z

Aspontarelli: /* Workflow */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-08, Rev. 1
|width="33%"|
'''Date'''

1/20/2021
|}

= GENERAL =

We have two CNC routers:
* Phoenix - a 4x4', heavy duty machine running LinuxCNC
* AXYZ 4008 - a 4x8', heavy duty machine running LinuxCNC

[[File:Shapeoko 2 – CNC Router.png]]

= SAFETY =

* Safety glasses to be worn when making a cut.
* Ear protection recommended.
* Before operating, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Non-slip footwear or anti-skid floor strips are recommended.
* Do not wear gloves.
* Do not leave workstation until cut is complete.

= REFERENCE =

*[[:File:Sheet CAM Manual_R3.pdf|Ken's SheetCAM Manual]]
* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

* [[:File:Zen_of_CNC.pdf|Router Advice - Zen of CNC]]
*[[:File:MAKE CHIPS NOT DUST.pdf|Why chips are important - About Chip Load]]

* [[:File:CNConsrud routing guide.pdf|Technical information on router tooling]]
* ShopBot guide to feeds and speeds: https://static1.squarespace.com/static/59efc96d90badec50a4afa15/t/5a21f4b6e2c483bcf39a2c84/1512174775486/FeedsandSpeeds.pdf
*[[:File:MAKE A BOX.pdf|Cheat Sheet to make a simple box with lid]]
*[[:File:Make A Simple Tray.pdf|Cheat sheet for making a simple router tray]]
*[[:File:MAKE A ROUND BOTTOM TRAYR1.pdf|Cheat sheet for making a round bottom router tray]]
*[[:File:F engrave Cheat Sheet.pdf|Cheat sheet for programming a V-carve in F-engrave.]]
*[[:File:WORK HOLDING STRATEGIES.pdf|Work Holding Strategies]]
*Onsrund guide to calculating feeds and speeds: https://www.youtube.com/watch?v=JPvBzaA3GY0

== Feed and Speed Reference ==

=== Aluminum Workpiece Feeds and Speeds ===
While the CNC routers are typically used for cutting wood and plastic, the Phoenix router is capable of cutting aluminum as well. Use of a 50% dilution of isopropyl alcohol in the lube cube is critical for success, as is the use of single flute endmills and shallow depths of cut.

The following settings have been used with success in cutting 6061.

1/4" O-flute carbide endmill, 16,000 RPM, 50 ipm, 0.03in DOC

= PROCEDURE =

== General Controls and Configuration==
The Phoenix and AXYZ CNC routers can both be controlled using their respective gamepad controllers. The button configuration is shown below.

[[File:Controller movelist.png]]

== Workflow ==
[[File:CNC router max depth.png|thumb|Maximum through cuts < 0.025"]]
There are many ways to complete this workflow, but included in this section are descriptions of how to make a successful cut with two different sets of software. The first is the most simple, the second more challenging but more powerful.

=== Inkscape -> SheetCAM -> LinuxCNC ===

One method of getting from idea to CNC routed part is to create your CAD design in Inkscape, then use SheetCAM to generate the tool paths. If carving a 2D design like a sign, this is the quickest and simplest method. Below is the general outline of this approach.

# Import drawing into SheetCAM (svg or dxf)
# Check machine options (Options -> Machine)
## Postprocessor -> LinuxCNC
## Postprocessor -> output units
# Set job options (Options -> Job Options)
## Set material dimensions
## Set origin
# Assign contours to layers
# Create tools to be used
# Create operations that assign tools to layers
## Set feeds and speeds (flip to other side for help)
# Visualize the job with Mode -> Simulation
# Create gcode: File -> Run Post Processor
# Transfer gcode file to cncrouter computer using USB stick or /vsfs01/share directory
# Open gcode file from LinuxCNC
# Insert tool in CNC router
# Clamp down workpiece (Always use a spoil board!)
# Turn on CNC router by rotating E-stop button clockwise
# Home machine by clicking Home All in LinuxCNC or by pressing Start + Select at the same time
# Move tool to origin and set the x, y, and z coordinates to zero by click Touch Off in LinuxCNC or by pressing Select + Direction Pad
# Confirm that tool won’t collide with hold-downs by manually jogging machine around the path
# Turn on dust collector
# Run operation
# Turn off dust collector and tidy up

=== FreeCAD -> LinuxCNC ===

Another method of using the CNC router is to use a program like FreeCAD to generate your 2D or 3D model, then also doing the CAM within FreeCAD. The benefit to this approach is that everything is done in a single program, and that the program is significantly more powerful and capable of handling 3D designs.

==== Vacuum Table ====
[[File:Vacuum table-labeled.jpg|thumb|Vacuum table with labels]]
The AXYZ router has a vacuum table plumbed into five distinct sections. The photo below shows the vacuum chamber arrangement and the valves associated with each.

# Place your workpiece as best you can over a complete chamber. For example if your workpiece is 24x48", it will fit perfectly over a single chamber, and should not be placed on the intersection of four chambers.
# Cover the rest of the table surface with impermeable cover sheets.
# Open as few valves as necessary to hold your workpiece. The pressure gauge indicates pressure in inHg and kPA. 1 inHg is about 0.5 psi, so 10inHg holding a 24x24in piece would exert 2,880 pounds of force. A very rough rule of thumb is to target at least 1,000 pounds.

=== Machine Operation ===

# Release E-stop and Enable Power
# Home All
# Load tool (G61)
# (for AXYZ router: Turn on vacuum)
# Touch tool probe
# Zero X and Y axes
# Cycle Start
# Press E-stop when finish
# Clean

= TROUBLESHOOTING =

== General Issues ==
Turn the machine on, so that the motors energize, but don't tell it to move. Do not turn the spindle on. Try to wiggle the spindle left and right by hand. Can you move it? If you can, watch carefully to see what moves with it. Does the belt move but the pulley doesn't turn? You have a loose belt. Does the pulley turn too? You have a loose pulley set screw. Does the entire gantry move with respect to the stationary rails? You have loose V-wheels or eccentric spacers. And so on. Repeat for back and forth movement, and up and down too, if that's also causing problems.

== Machine won't start ==
The console window will show the command being sent and a confirmation of "ok". However, the active state goes to "Queue" and never returns to "Idle.

* Auto cycle start has been turned off - Note that turning off auto cycle start requires that one begin the machine manually.
* Previous operation was quit from the Communication / Control program w/o disconnecting. Restart the computer system.
* USB port has gone into low-power mode. Energy-savings features can interfere w/ sending data to the Arduino. Do not let the controlling machine go into low power mode,
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine jogs, but won't respond to downloaded file ==
The machine will respond to single commands, but will not accept a downloaded file and will endlessly repeat some statement to the console.

* Grbl software installation corrupt. Reflash Grbl.
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine won't hold position ==
Set Grbl setting for "step idle delay" in milliseconds to 255 (suggested default). It will always energize the motors to a hold position. If set to some other value, motors will be turned off after the specified time.

== Toolpath Differs from Expected ==
If the machine's behavior doesn't match what is simulated.

* '''software bug''' - Grbl is very reliable, so unlikely to be in the firmware.
** Carbide Motion 4 ought to give an error message on any G-Code which it can't properly send on to the machine, and Carbide Create ought not make any code which doesn't work properly
* '''file problem''' - an example of this would be setting safety / retract height too high, using the wrong post-processor, or enabling a feature such as XY datum in Vectric Vcarve.
* '''machine misconfiguration / user error''' - this can be a lot of things, occasionally overlapping with the above, for example setting safety / retract height and the Z-axis zero so that when the machine lifts to safety height it bumps against and loses steps against the top stop, so that the Z-axis height isn't correct.
* '''mechanical machine setup''' - these ought to be covered by the machine Operating Checklist --- frequent things to check:
** Check pulley set screws
** Check V wheels / eccentric nuts
** Belt tension, the Z-axis belt in particular needs to be guitar string tight (but careful not to bend the motor shaft).
** Electronics - it's possible for a wire or connector to break or for a lost connection or excessive current generated by the stepper motors or a stray static spark to damage the stepper driver or controller.

== Radius of corners is different ==
Stairstepped diagonals, jagged circles/curves, loud squealing or 'ker-chunka' thuds, gantry chattering, mis-aligned edges. A useful troubleshooting technique for this is to listen to the machine:

* If it sounds awful = loose wire (or the stepper driver going into thermal shutdown).
* If it sounds normal = loose set screw (or other mechanical issue such as loose belts).

== File worked previously, doesn't work now ==
Reaching limits of machine.

* Either overheating or reaching acceleration limits.
* Steppers may be entering thermal shutdown, add active cooling.
* Machine is operating at the limits of its acceleration. Slow down feed speeds and max acceleration in GRBL.
* Endmill no longer sharp, spindle not working properly (rotating in wrong direction). If the machine is not able to properly cut, then it will not be able to move along the desired path, since it will not be clear.
* A spindle which is not working properly may put out EMI which will interfere w/ the movement of the stepper motors. Brushes on a router are a consumable part and must be replaced periodically.

== Steppers are missing steps ==

* Drivers overheating - Position the fan so that in blows across both the top and bottom of the drivers. Airflow does the most, followed by a heatsink on top of the chip. Note that this may also be caused by setting the current too high.
* Steppers being run too fast - GRBL has a maximum speed that it can drive stepper motors at. Because the X and Y axis are belt driven while the Z is threaded rod drive, it is very easy to set the x/y Default Feed speed faster than the Z axis can be signaled. Cut your default feed and test.
* Feed rate too fast - The harder the material being cut, the more torque the steppers have to resist. If you're feeding too fast, this can overcome the holding torque of your motors.
* Axis binding - Check that all of your v-wheels rotate freely when bolted and tightened, as some of the tolerance problems in the v-wheel components can be bad enough to cause the bearings to bind and the v-wheel to be stiff. If you're not using a drive shaft or dual Y axis steppers and your v-wheels or rails are adjusted incorrectly, the Y axis can bind and overwhelm the rated torque on your steppers. Also check that you've tensioned the eccentric spacers correctly. The v-wheels should be firmly planted but should not be so tight that there is any deflection/bowing in the plate, and should be easy to slide along the rails.
* Axis stalling - If you're using a drive shaft it is possible to have one pulley slip while the other will continue to drive the machine. Any instance of slippage should be investigated by checking the set screws on the pulleys.
* Electrical brownout - The power supply does draw a fair bit of power for the stepper motors, minimize other power drawing sources.
* Electrical interference - The spindle and motors put out quite a bit of electrical interference. This may cause random or irregular deviations in the movement of the machine. Shield the wires.
* Loose Idler - Odd distortions, all tending towards a particular direction may be caused by an idler pulley being loose.

== Deviations in slots when cutting ==
The bit is pulled along creating random path deviations which get worse as one gets deeper into a slot.

* Spindle is more powerful than the machine can manage. Spindle not kept up with the balance of the machine, the machine flexing along the Z-axis may flex and allow the bit to rub up against the edge of a slot where the cutting action will then pull the machine further along. Make the X-axis more rigid.

== Deviations in shapes when cutting ==
The machine lags behind at changes of direction, distorting shapes and creating flat edge at the extrema of rounded forms.

* Backlash/Insufficient belt tension - If your belts are too lose, the machine will shift w/ the cutting forces, distorting shapes. Machines w/ threaded rod will have similar difficulties if nuts do not have anti-backlash features.

== Z-axis cuts more deeply than expected ==
The bit is pulled along going deeper into the material than it should.

* Acceleration / movement too fast. The Z-axis is limited in its acceleration and top speed by the torque of the motor. If it is able to move down okay, but will not move up reliably, then the acceleration or movement may be too fast or high. Some G-code senders have an option to limit the Z-axis speed.
* Spindle is loose in its mounts, Z-axis plunge rate too fast causing the machine to go deeper. Always check to ensure the spindle is secure. Always be cautious with Z-axis plunge rates, especially when using CAM tools which lack spiral or ramp Z-axis moves.
* Z-axis motor is over-heating, causing the machine to fail to move up on negative moves (it's more difficult to lift the spindle than to lower it) causing it to cumulatively go deeper. Adjust the current, consider adding heat sinks and/or a fan to cool the stepper drivers.
* End mill loose in collet --- this can also cause other path deviations as the needed cutting forces are increased beyond the machine's capabilities. Tighten collet.

== Z-axis cuts at odd angles when cutting thin stock ==
The bit is pulling the material up or twisting it as it cuts.

* Switch to a down-cutting spiral bit --- check and ensure the bit is sharp.
* Lines are not straight, circles not round, dog bone pattern at corners, cut quality poor - DC spindle wired to run backwards.
** A damaged or dull end mill.
** Milling direction may be wrong.
* Repeating curve/wobble - Bad bearing or V-wheel

== Material Stock Melting or Burning ==
Smoke, fire, material build-up on tooling, poor cut edges (plastic) or burn marks (wood).

* RPM too high / Feed rate too low The surface of your tooling is moving too fast relative to the material. This leads to 'dwell', where the tooling rubs against the material to create a significant amount of heat.
** Increase your feed rate (higher mm/minute). Increasing your feed rate decreases the speed difference between the edge of your tooling and the material, reducing friction. GRBL has some limitations on feed, especially in smaller parts and curves, so this is not always possible.
** Slow your spindle (lower RPM)'''.''' If your router or dremel has variable speeds, turn it down. This, however, usually reduces the available torque, which can in turn lead to stalling your spindle during the cut.

== Persistent Ridges ==
Endmill is either bent or deflecting.

== Bit Chatter ==
Loud chattering, jagged cut edges, snapped tooling. Feed rates too high or loose frame.

* Slow the feed - If your tooling is trying to bite too much material, it will be under much higher stresses, pushing away or into the material much more than usual. Slowing down your feed rate can reduce this.
* Tighten the frame - Especially if you did not use loctite when assembling, bolts can work loose over time (or never having been tightened sufficiently), greatly reducing the rigidity of the frame - this rigidity is what a CNC uses to move the tool where it is supposed to be. Tightening everything up will help this.
* Another possibility is the spindle carriage plate is running off the bottom of the rail, esp. w/ the new style plate.

== Machine Chatters/Vibrates ==
Chattering, buzzing. Tighten wheels.

'''END OF THE PROCEDURE'''

Mig welding maintenance and specifications

2026-04-20T12:41:14Z

Aspontarelli: /* Specifications */

{|
|width="33%"|
'''Shop Area:''' Metal Shop

'''Tool:''' MIG Welder

'''Requires in-person training:''' Yes
|width="33%"|
'''Procedure Number'''

MT 130-03, Rev. 1
|width="33%"|
'''Date'''

4/1/2025
|}

= General =

The Millermatic 211 is both a stick welder and a MIG welder, see sister Stick Welding Guide UG 130-02 and Maintenance Guide MT 130-02

Lincoln 350MP

= Reference =

* https://www.millerwelds.com/files/owners-manuals/o239988d_mil.pdf
* User Manual: https://ch-delivery.lincolnelectric.com/api/public/content/4ffe51e45277469283cb461945f9c93c?v=d2f21cfc

= Maintenance =

= Specifications =

[[File:Stick Welding Specs.png]]

'''Lincoln 350MP:'''

Magnum PRO Curve 300 Gun uses Bernard consumables

Nozzle: NT-3800C

Contact tip: TT-035

Gas diffuser: D-1
'''END OF THE PROCEDURE'''

Mig welding maintenance and specifications

2026-04-19T12:54:07Z

Aspontarelli: /* Specifications */

Drill press maintenance and specifications

2026-02-17T16:53:25Z

Aspontarelli: /* GENERAL */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Drill Press

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

MT 110-06, Rev. 1
|width="33%"|
'''Date'''

1/25/2021
|}

= GENERAL =

PM2800B Drill Press

= REFERENCE =

* Manual (https://cdme.osu.edu/sites/default/files/uploads/clausing_20_in._drill_presses_variable_speed_drive_models.pdf)
* https://powermatic.com/media/akeneo_connector/asset_files/1/7/1792800b_man_en_34b5.pdf

= Maintenance =
* Oil quill bearings with ISO 68, monthly.
* Grease feed shaft, monthly.
* Oil table lift shaft and rack with ISO 68, monthly.

= List of Specifications =
Spindle taper: MT2
'''END OF PROCEDURE'''

Cnc-router-user-guide

2026-02-06T11:48:41Z

Aspontarelli: /* REFERENCE */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-08, Rev. 1
|width="33%"|
'''Date'''

1/20/2021
|}

= GENERAL =

We have two CNC routers:
* Phoenix - a 4x4', heavy duty machine running LinuxCNC
* AXYZ 4008 - a 4x8', heavy duty machine running LinuxCNC

[[File:Shapeoko 2 – CNC Router.png]]

= SAFETY =

* Safety glasses to be worn when making a cut.
* Ear protection recommended.
* Before operating, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Non-slip footwear or anti-skid floor strips are recommended.
* Do not wear gloves.
* Do not leave workstation until cut is complete.

= REFERENCE =

*[[:File:Sheet CAM Manual_R3.pdf|Ken's SheetCAM Manual]]
* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

* [[:File:Zen_of_CNC.pdf|Router Advice - Zen of CNC]]
*[[:File:MAKE CHIPS NOT DUST.pdf|Why chips are important - About Chip Load]]

* [[:File:CNConsrud routing guide.pdf|Technical information on router tooling]]
* ShopBot guide to feeds and speeds: https://static1.squarespace.com/static/59efc96d90badec50a4afa15/t/5a21f4b6e2c483bcf39a2c84/1512174775486/FeedsandSpeeds.pdf
*[[:File:MAKE A BOX.pdf|Cheat Sheet to make a simple box with lid]]
*[[:File:Make A Simple Tray.pdf|Cheat sheet for making a simple router tray]]
*[[:File:MAKE A ROUND BOTTOM TRAYR1.pdf|Cheat sheet for making a round bottom router tray]]
*[[:File:F engrave Cheat Sheet.pdf|Cheat sheet for programming a V-carve in F-engrave.]]
*[[:File:WORK HOLDING STRATEGIES.pdf|Work Holding Strategies]]
*Onsrund guide to calculating feeds and speeds: https://www.youtube.com/watch?v=JPvBzaA3GY0

== Feed and Speed Reference ==

=== Aluminum Workpiece Feeds and Speeds ===
While the CNC routers are typically used for cutting wood and plastic, the Phoenix router is capable of cutting aluminum as well. Use of a 50% dilution of isopropyl alcohol in the lube cube is critical for success, as is the use of single flute endmills and shallow depths of cut.

The following settings have been used with success in cutting 6061.

1/4" O-flute carbide endmill, 16,000 RPM, 50 ipm, 0.03in DOC

= PROCEDURE =

== General Controls and Configuration==
The Phoenix and AXYZ CNC routers can both be controlled using their respective gamepad controllers. The button configuration is shown below.

[[File:Controller movelist.png]]

== Workflow ==
[[File:CNC router max depth.png|thumb|Maximum through cuts < 0.025"]]
There are many ways to complete this workflow, but included in this section are descriptions of how to make a successful cut with two different sets of software. The first is the most simple, the second more challenging but more powerful.

=== Inkscape -> SheetCAM -> LinuxCNC ===

One method of getting from idea to CNC routed part is to create your CAD design in Inkscape, then use SheetCAM to generate the tool paths. If carving a 2D design like a sign, this is the quickest and simplest method. Below is the general outline of this approach.

# Import drawing into SheetCAM (svg or dxf)
# Check machine options (Options -> Machine)
## Postprocessor -> LinuxCNC
## Postprocessor -> output units
# Set job options (Options -> Job Options)
## Set material dimensions
## Set origin
# Assign contours to layers
# Create tools to be used
# Create operations that assign tools to layers
## Set feeds and speeds (flip to other side for help)
# Visualize the job with Mode -> Simulation
# Create gcode: File -> Run Post Processor
# Transfer gcode file to cncrouter computer using USB stick or /vsfs01/share directory
# Open gcode file from LinuxCNC
# Insert tool in CNC router
# Clamp down workpiece (Always use a spoil board!)
# Turn on CNC router by rotating E-stop button clockwise
# Home machine by clicking Home All in LinuxCNC or by pressing Start + Select at the same time
# Move tool to origin and set the x, y, and z coordinates to zero by click Touch Off in LinuxCNC or by pressing Select + Direction Pad
# Confirm that tool won’t collide with hold-downs by manually jogging machine around the path
# Turn on dust collector
# Run operation
# Turn off dust collector and tidy up

=== FreeCAD -> LinuxCNC ===

Another method of using the CNC router is to use a program like FreeCAD to generate your 2D or 3D model, then also doing the CAM within FreeCAD. The benefit to this approach is that everything is done in a single program, and that the program is significantly more powerful and capable of handling 3D designs.

==== Vacuum Table ====
[[File:Vacuum table-labeled.jpg|thumb|Vacuum table with labels]]
The AXYZ router has a vacuum table plumbed into five distinct sections. The photo below shows the vacuum chamber arrangement and the valves associated with each.

# Place your workpiece as best you can over a complete chamber. For example if your workpiece is 24x48", it will fit perfectly over a single chamber, and should not be placed on the intersection of four chambers.
# Cover the rest of the table surface with impermeable cover sheets.
# Open as few valves as necessary to hold your workpiece. The pressure gauge indicates pressure in inHg and kPA. 1 inHg is about 0.5 psi, so 10inHg holding a 24x24in piece would exert 2,880 pounds of force. A very rough rule of thumb is to target at least 1,000 pounds.

= TROUBLESHOOTING =

== General Issues ==
Turn the machine on, so that the motors energize, but don't tell it to move. Do not turn the spindle on. Try to wiggle the spindle left and right by hand. Can you move it? If you can, watch carefully to see what moves with it. Does the belt move but the pulley doesn't turn? You have a loose belt. Does the pulley turn too? You have a loose pulley set screw. Does the entire gantry move with respect to the stationary rails? You have loose V-wheels or eccentric spacers. And so on. Repeat for back and forth movement, and up and down too, if that's also causing problems.

== Machine won't start ==
The console window will show the command being sent and a confirmation of "ok". However, the active state goes to "Queue" and never returns to "Idle.

* Auto cycle start has been turned off - Note that turning off auto cycle start requires that one begin the machine manually.
* Previous operation was quit from the Communication / Control program w/o disconnecting. Restart the computer system.
* USB port has gone into low-power mode. Energy-savings features can interfere w/ sending data to the Arduino. Do not let the controlling machine go into low power mode,
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine jogs, but won't respond to downloaded file ==
The machine will respond to single commands, but will not accept a downloaded file and will endlessly repeat some statement to the console.

* Grbl software installation corrupt. Reflash Grbl.
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine won't hold position ==
Set Grbl setting for "step idle delay" in milliseconds to 255 (suggested default). It will always energize the motors to a hold position. If set to some other value, motors will be turned off after the specified time.

== Toolpath Differs from Expected ==
If the machine's behavior doesn't match what is simulated.

* '''software bug''' - Grbl is very reliable, so unlikely to be in the firmware.
** Carbide Motion 4 ought to give an error message on any G-Code which it can't properly send on to the machine, and Carbide Create ought not make any code which doesn't work properly
* '''file problem''' - an example of this would be setting safety / retract height too high, using the wrong post-processor, or enabling a feature such as XY datum in Vectric Vcarve.
* '''machine misconfiguration / user error''' - this can be a lot of things, occasionally overlapping with the above, for example setting safety / retract height and the Z-axis zero so that when the machine lifts to safety height it bumps against and loses steps against the top stop, so that the Z-axis height isn't correct.
* '''mechanical machine setup''' - these ought to be covered by the machine Operating Checklist --- frequent things to check:
** Check pulley set screws
** Check V wheels / eccentric nuts
** Belt tension, the Z-axis belt in particular needs to be guitar string tight (but careful not to bend the motor shaft).
** Electronics - it's possible for a wire or connector to break or for a lost connection or excessive current generated by the stepper motors or a stray static spark to damage the stepper driver or controller.

== Radius of corners is different ==
Stairstepped diagonals, jagged circles/curves, loud squealing or 'ker-chunka' thuds, gantry chattering, mis-aligned edges. A useful troubleshooting technique for this is to listen to the machine:

* If it sounds awful = loose wire (or the stepper driver going into thermal shutdown).
* If it sounds normal = loose set screw (or other mechanical issue such as loose belts).

== File worked previously, doesn't work now ==
Reaching limits of machine.

* Either overheating or reaching acceleration limits.
* Steppers may be entering thermal shutdown, add active cooling.
* Machine is operating at the limits of its acceleration. Slow down feed speeds and max acceleration in GRBL.
* Endmill no longer sharp, spindle not working properly (rotating in wrong direction). If the machine is not able to properly cut, then it will not be able to move along the desired path, since it will not be clear.
* A spindle which is not working properly may put out EMI which will interfere w/ the movement of the stepper motors. Brushes on a router are a consumable part and must be replaced periodically.

== Steppers are missing steps ==

* Drivers overheating - Position the fan so that in blows across both the top and bottom of the drivers. Airflow does the most, followed by a heatsink on top of the chip. Note that this may also be caused by setting the current too high.
* Steppers being run too fast - GRBL has a maximum speed that it can drive stepper motors at. Because the X and Y axis are belt driven while the Z is threaded rod drive, it is very easy to set the x/y Default Feed speed faster than the Z axis can be signaled. Cut your default feed and test.
* Feed rate too fast - The harder the material being cut, the more torque the steppers have to resist. If you're feeding too fast, this can overcome the holding torque of your motors.
* Axis binding - Check that all of your v-wheels rotate freely when bolted and tightened, as some of the tolerance problems in the v-wheel components can be bad enough to cause the bearings to bind and the v-wheel to be stiff. If you're not using a drive shaft or dual Y axis steppers and your v-wheels or rails are adjusted incorrectly, the Y axis can bind and overwhelm the rated torque on your steppers. Also check that you've tensioned the eccentric spacers correctly. The v-wheels should be firmly planted but should not be so tight that there is any deflection/bowing in the plate, and should be easy to slide along the rails.
* Axis stalling - If you're using a drive shaft it is possible to have one pulley slip while the other will continue to drive the machine. Any instance of slippage should be investigated by checking the set screws on the pulleys.
* Electrical brownout - The power supply does draw a fair bit of power for the stepper motors, minimize other power drawing sources.
* Electrical interference - The spindle and motors put out quite a bit of electrical interference. This may cause random or irregular deviations in the movement of the machine. Shield the wires.
* Loose Idler - Odd distortions, all tending towards a particular direction may be caused by an idler pulley being loose.

== Deviations in slots when cutting ==
The bit is pulled along creating random path deviations which get worse as one gets deeper into a slot.

* Spindle is more powerful than the machine can manage. Spindle not kept up with the balance of the machine, the machine flexing along the Z-axis may flex and allow the bit to rub up against the edge of a slot where the cutting action will then pull the machine further along. Make the X-axis more rigid.

== Deviations in shapes when cutting ==
The machine lags behind at changes of direction, distorting shapes and creating flat edge at the extrema of rounded forms.

* Backlash/Insufficient belt tension - If your belts are too lose, the machine will shift w/ the cutting forces, distorting shapes. Machines w/ threaded rod will have similar difficulties if nuts do not have anti-backlash features.

== Z-axis cuts more deeply than expected ==
The bit is pulled along going deeper into the material than it should.

* Acceleration / movement too fast. The Z-axis is limited in its acceleration and top speed by the torque of the motor. If it is able to move down okay, but will not move up reliably, then the acceleration or movement may be too fast or high. Some G-code senders have an option to limit the Z-axis speed.
* Spindle is loose in its mounts, Z-axis plunge rate too fast causing the machine to go deeper. Always check to ensure the spindle is secure. Always be cautious with Z-axis plunge rates, especially when using CAM tools which lack spiral or ramp Z-axis moves.
* Z-axis motor is over-heating, causing the machine to fail to move up on negative moves (it's more difficult to lift the spindle than to lower it) causing it to cumulatively go deeper. Adjust the current, consider adding heat sinks and/or a fan to cool the stepper drivers.
* End mill loose in collet --- this can also cause other path deviations as the needed cutting forces are increased beyond the machine's capabilities. Tighten collet.

== Z-axis cuts at odd angles when cutting thin stock ==
The bit is pulling the material up or twisting it as it cuts.

* Switch to a down-cutting spiral bit --- check and ensure the bit is sharp.
* Lines are not straight, circles not round, dog bone pattern at corners, cut quality poor - DC spindle wired to run backwards.
** A damaged or dull end mill.
** Milling direction may be wrong.
* Repeating curve/wobble - Bad bearing or V-wheel

== Material Stock Melting or Burning ==
Smoke, fire, material build-up on tooling, poor cut edges (plastic) or burn marks (wood).

* RPM too high / Feed rate too low The surface of your tooling is moving too fast relative to the material. This leads to 'dwell', where the tooling rubs against the material to create a significant amount of heat.
** Increase your feed rate (higher mm/minute). Increasing your feed rate decreases the speed difference between the edge of your tooling and the material, reducing friction. GRBL has some limitations on feed, especially in smaller parts and curves, so this is not always possible.
** Slow your spindle (lower RPM)'''.''' If your router or dremel has variable speeds, turn it down. This, however, usually reduces the available torque, which can in turn lead to stalling your spindle during the cut.

== Persistent Ridges ==
Endmill is either bent or deflecting.

== Bit Chatter ==
Loud chattering, jagged cut edges, snapped tooling. Feed rates too high or loose frame.

* Slow the feed - If your tooling is trying to bite too much material, it will be under much higher stresses, pushing away or into the material much more than usual. Slowing down your feed rate can reduce this.
* Tighten the frame - Especially if you did not use loctite when assembling, bolts can work loose over time (or never having been tightened sufficiently), greatly reducing the rigidity of the frame - this rigidity is what a CNC uses to move the tool where it is supposed to be. Tightening everything up will help this.
* Another possibility is the spindle carriage plate is running off the bottom of the rail, esp. w/ the new style plate.

== Machine Chatters/Vibrates ==
Chattering, buzzing. Tighten wheels.

'''END OF THE PROCEDURE'''

Cnc-router-user-guide

2026-02-01T14:55:03Z

Aspontarelli: /* Workflow */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-08, Rev. 1
|width="33%"|
'''Date'''

1/20/2021
|}

= GENERAL =

We have two CNC routers:
* Phoenix - a 4x4', heavy duty machine running LinuxCNC
* AXYZ 4008 - a 4x8', heavy duty machine running LinuxCNC

[[File:Shapeoko 2 – CNC Router.png]]

= SAFETY =

* Safety glasses to be worn when making a cut.
* Ear protection recommended.
* Before operating, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Non-slip footwear or anti-skid floor strips are recommended.
* Do not wear gloves.
* Do not leave workstation until cut is complete.

= REFERENCE =

*[[:File:Sheet CAM Manual_R3.pdf|Ken's SheetCAM Manual]]
* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

* [[:File:Zen_of_CNC.pdf|Router Advice - Zen of CNC]]
*[[:File:MAKE CHIPS NOT DUST.pdf|Why chips are important - About Chip Load]]

* [[:File:CNConsrud routing guide.pdf|Technical information on router tooling]]
* ShopBot guide to feeds and speeds: https://static1.squarespace.com/static/59efc96d90badec50a4afa15/t/5a21f4b6e2c483bcf39a2c84/1512174775486/FeedsandSpeeds.pdf
*[[:File:MAKE A BOX.pdf|Cheat Sheet to make a simple box with lid]]
*[[:File:Make A Simple Tray.pdf|Cheat sheet for making a simple router tray]]
*[[:File:MAKE A ROUND BOTTOM TRAYR1.pdf|Cheat sheet for making a round bottom router tray]]
*[[:File:F engrave Cheat Sheet.pdf|Cheat sheet for programming a V-carve in F-engrave.]]
*[[:File:WORK HOLDING STRATEGIES.pdf|Work Holding Strategies]]

== Feed and Speed Reference ==

=== Aluminum Workpiece Feeds and Speeds ===
While the CNC routers are typically used for cutting wood and plastic, the Phoenix router is capable of cutting aluminum as well. Use of a 50% dilution of isopropyl alcohol in the lube cube is critical for success, as is the use of single flute endmills and shallow depths of cut.

The following settings have been used with success in cutting 6061.

1/4" O-flute carbide endmill, 16,000 RPM, 50 ipm, 0.03in DOC

= PROCEDURE =

== General Controls and Configuration==
The Phoenix and AXYZ CNC routers can both be controlled using their respective gamepad controllers. The button configuration is shown below.

[[File:Controller movelist.png]]

== Workflow ==
[[File:CNC router max depth.png|thumb|Maximum through cuts < 0.025"]]
There are many ways to complete this workflow, but included in this section are descriptions of how to make a successful cut with two different sets of software. The first is the most simple, the second more challenging but more powerful.

=== Inkscape -> SheetCAM -> LinuxCNC ===

One method of getting from idea to CNC routed part is to create your CAD design in Inkscape, then use SheetCAM to generate the tool paths. If carving a 2D design like a sign, this is the quickest and simplest method. Below is the general outline of this approach.

# Import drawing into SheetCAM (svg or dxf)
# Check machine options (Options -> Machine)
## Postprocessor -> LinuxCNC
## Postprocessor -> output units
# Set job options (Options -> Job Options)
## Set material dimensions
## Set origin
# Assign contours to layers
# Create tools to be used
# Create operations that assign tools to layers
## Set feeds and speeds (flip to other side for help)
# Visualize the job with Mode -> Simulation
# Create gcode: File -> Run Post Processor
# Transfer gcode file to cncrouter computer using USB stick or /vsfs01/share directory
# Open gcode file from LinuxCNC
# Insert tool in CNC router
# Clamp down workpiece (Always use a spoil board!)
# Turn on CNC router by rotating E-stop button clockwise
# Home machine by clicking Home All in LinuxCNC or by pressing Start + Select at the same time
# Move tool to origin and set the x, y, and z coordinates to zero by click Touch Off in LinuxCNC or by pressing Select + Direction Pad
# Confirm that tool won’t collide with hold-downs by manually jogging machine around the path
# Turn on dust collector
# Run operation
# Turn off dust collector and tidy up

=== FreeCAD -> LinuxCNC ===

Another method of using the CNC router is to use a program like FreeCAD to generate your 2D or 3D model, then also doing the CAM within FreeCAD. The benefit to this approach is that everything is done in a single program, and that the program is significantly more powerful and capable of handling 3D designs.

==== Vacuum Table ====
[[File:Vacuum table-labeled.jpg|thumb|Vacuum table with labels]]
The AXYZ router has a vacuum table plumbed into five distinct sections. The photo below shows the vacuum chamber arrangement and the valves associated with each.

# Place your workpiece as best you can over a complete chamber. For example if your workpiece is 24x48", it will fit perfectly over a single chamber, and should not be placed on the intersection of four chambers.
# Cover the rest of the table surface with impermeable cover sheets.
# Open as few valves as necessary to hold your workpiece. The pressure gauge indicates pressure in inHg and kPA. 1 inHg is about 0.5 psi, so 10inHg holding a 24x24in piece would exert 2,880 pounds of force. A very rough rule of thumb is to target at least 1,000 pounds.

= TROUBLESHOOTING =

== General Issues ==
Turn the machine on, so that the motors energize, but don't tell it to move. Do not turn the spindle on. Try to wiggle the spindle left and right by hand. Can you move it? If you can, watch carefully to see what moves with it. Does the belt move but the pulley doesn't turn? You have a loose belt. Does the pulley turn too? You have a loose pulley set screw. Does the entire gantry move with respect to the stationary rails? You have loose V-wheels or eccentric spacers. And so on. Repeat for back and forth movement, and up and down too, if that's also causing problems.

== Machine won't start ==
The console window will show the command being sent and a confirmation of "ok". However, the active state goes to "Queue" and never returns to "Idle.

* Auto cycle start has been turned off - Note that turning off auto cycle start requires that one begin the machine manually.
* Previous operation was quit from the Communication / Control program w/o disconnecting. Restart the computer system.
* USB port has gone into low-power mode. Energy-savings features can interfere w/ sending data to the Arduino. Do not let the controlling machine go into low power mode,
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine jogs, but won't respond to downloaded file ==
The machine will respond to single commands, but will not accept a downloaded file and will endlessly repeat some statement to the console.

* Grbl software installation corrupt. Reflash Grbl.
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine won't hold position ==
Set Grbl setting for "step idle delay" in milliseconds to 255 (suggested default). It will always energize the motors to a hold position. If set to some other value, motors will be turned off after the specified time.

== Toolpath Differs from Expected ==
If the machine's behavior doesn't match what is simulated.

* '''software bug''' - Grbl is very reliable, so unlikely to be in the firmware.
** Carbide Motion 4 ought to give an error message on any G-Code which it can't properly send on to the machine, and Carbide Create ought not make any code which doesn't work properly
* '''file problem''' - an example of this would be setting safety / retract height too high, using the wrong post-processor, or enabling a feature such as XY datum in Vectric Vcarve.
* '''machine misconfiguration / user error''' - this can be a lot of things, occasionally overlapping with the above, for example setting safety / retract height and the Z-axis zero so that when the machine lifts to safety height it bumps against and loses steps against the top stop, so that the Z-axis height isn't correct.
* '''mechanical machine setup''' - these ought to be covered by the machine Operating Checklist --- frequent things to check:
** Check pulley set screws
** Check V wheels / eccentric nuts
** Belt tension, the Z-axis belt in particular needs to be guitar string tight (but careful not to bend the motor shaft).
** Electronics - it's possible for a wire or connector to break or for a lost connection or excessive current generated by the stepper motors or a stray static spark to damage the stepper driver or controller.

== Radius of corners is different ==
Stairstepped diagonals, jagged circles/curves, loud squealing or 'ker-chunka' thuds, gantry chattering, mis-aligned edges. A useful troubleshooting technique for this is to listen to the machine:

* If it sounds awful = loose wire (or the stepper driver going into thermal shutdown).
* If it sounds normal = loose set screw (or other mechanical issue such as loose belts).

== File worked previously, doesn't work now ==
Reaching limits of machine.

* Either overheating or reaching acceleration limits.
* Steppers may be entering thermal shutdown, add active cooling.
* Machine is operating at the limits of its acceleration. Slow down feed speeds and max acceleration in GRBL.
* Endmill no longer sharp, spindle not working properly (rotating in wrong direction). If the machine is not able to properly cut, then it will not be able to move along the desired path, since it will not be clear.
* A spindle which is not working properly may put out EMI which will interfere w/ the movement of the stepper motors. Brushes on a router are a consumable part and must be replaced periodically.

== Steppers are missing steps ==

* Drivers overheating - Position the fan so that in blows across both the top and bottom of the drivers. Airflow does the most, followed by a heatsink on top of the chip. Note that this may also be caused by setting the current too high.
* Steppers being run too fast - GRBL has a maximum speed that it can drive stepper motors at. Because the X and Y axis are belt driven while the Z is threaded rod drive, it is very easy to set the x/y Default Feed speed faster than the Z axis can be signaled. Cut your default feed and test.
* Feed rate too fast - The harder the material being cut, the more torque the steppers have to resist. If you're feeding too fast, this can overcome the holding torque of your motors.
* Axis binding - Check that all of your v-wheels rotate freely when bolted and tightened, as some of the tolerance problems in the v-wheel components can be bad enough to cause the bearings to bind and the v-wheel to be stiff. If you're not using a drive shaft or dual Y axis steppers and your v-wheels or rails are adjusted incorrectly, the Y axis can bind and overwhelm the rated torque on your steppers. Also check that you've tensioned the eccentric spacers correctly. The v-wheels should be firmly planted but should not be so tight that there is any deflection/bowing in the plate, and should be easy to slide along the rails.
* Axis stalling - If you're using a drive shaft it is possible to have one pulley slip while the other will continue to drive the machine. Any instance of slippage should be investigated by checking the set screws on the pulleys.
* Electrical brownout - The power supply does draw a fair bit of power for the stepper motors, minimize other power drawing sources.
* Electrical interference - The spindle and motors put out quite a bit of electrical interference. This may cause random or irregular deviations in the movement of the machine. Shield the wires.
* Loose Idler - Odd distortions, all tending towards a particular direction may be caused by an idler pulley being loose.

== Deviations in slots when cutting ==
The bit is pulled along creating random path deviations which get worse as one gets deeper into a slot.

* Spindle is more powerful than the machine can manage. Spindle not kept up with the balance of the machine, the machine flexing along the Z-axis may flex and allow the bit to rub up against the edge of a slot where the cutting action will then pull the machine further along. Make the X-axis more rigid.

== Deviations in shapes when cutting ==
The machine lags behind at changes of direction, distorting shapes and creating flat edge at the extrema of rounded forms.

* Backlash/Insufficient belt tension - If your belts are too lose, the machine will shift w/ the cutting forces, distorting shapes. Machines w/ threaded rod will have similar difficulties if nuts do not have anti-backlash features.

== Z-axis cuts more deeply than expected ==
The bit is pulled along going deeper into the material than it should.

* Acceleration / movement too fast. The Z-axis is limited in its acceleration and top speed by the torque of the motor. If it is able to move down okay, but will not move up reliably, then the acceleration or movement may be too fast or high. Some G-code senders have an option to limit the Z-axis speed.
* Spindle is loose in its mounts, Z-axis plunge rate too fast causing the machine to go deeper. Always check to ensure the spindle is secure. Always be cautious with Z-axis plunge rates, especially when using CAM tools which lack spiral or ramp Z-axis moves.
* Z-axis motor is over-heating, causing the machine to fail to move up on negative moves (it's more difficult to lift the spindle than to lower it) causing it to cumulatively go deeper. Adjust the current, consider adding heat sinks and/or a fan to cool the stepper drivers.
* End mill loose in collet --- this can also cause other path deviations as the needed cutting forces are increased beyond the machine's capabilities. Tighten collet.

== Z-axis cuts at odd angles when cutting thin stock ==
The bit is pulling the material up or twisting it as it cuts.

* Switch to a down-cutting spiral bit --- check and ensure the bit is sharp.
* Lines are not straight, circles not round, dog bone pattern at corners, cut quality poor - DC spindle wired to run backwards.
** A damaged or dull end mill.
** Milling direction may be wrong.
* Repeating curve/wobble - Bad bearing or V-wheel

== Material Stock Melting or Burning ==
Smoke, fire, material build-up on tooling, poor cut edges (plastic) or burn marks (wood).

* RPM too high / Feed rate too low The surface of your tooling is moving too fast relative to the material. This leads to 'dwell', where the tooling rubs against the material to create a significant amount of heat.
** Increase your feed rate (higher mm/minute). Increasing your feed rate decreases the speed difference between the edge of your tooling and the material, reducing friction. GRBL has some limitations on feed, especially in smaller parts and curves, so this is not always possible.
** Slow your spindle (lower RPM)'''.''' If your router or dremel has variable speeds, turn it down. This, however, usually reduces the available torque, which can in turn lead to stalling your spindle during the cut.

== Persistent Ridges ==
Endmill is either bent or deflecting.

== Bit Chatter ==
Loud chattering, jagged cut edges, snapped tooling. Feed rates too high or loose frame.

* Slow the feed - If your tooling is trying to bite too much material, it will be under much higher stresses, pushing away or into the material much more than usual. Slowing down your feed rate can reduce this.
* Tighten the frame - Especially if you did not use loctite when assembling, bolts can work loose over time (or never having been tightened sufficiently), greatly reducing the rigidity of the frame - this rigidity is what a CNC uses to move the tool where it is supposed to be. Tightening everything up will help this.
* Another possibility is the spindle carriage plate is running off the bottom of the rail, esp. w/ the new style plate.

== Machine Chatters/Vibrates ==
Chattering, buzzing. Tighten wheels.

'''END OF THE PROCEDURE'''

File:CNC router max depth.png

2026-02-01T14:54:29Z

Aspontarelli:

drawing of through cut expectation

Cnc router maintenance and specifications

2026-01-05T13:24:26Z

Aspontarelli: /* Phoenix CNC Router */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

MT 110-08, Rev. 1
|width="33%"|
'''Date'''

1/26/2021
|}

= GENERAL =

Specifications for the Phoenix-GS5 and the AXYZ 4008 CNC routers.

= REFERENCE =

* E-stop configuration, https://www.youtube.com/watch?v=hVkNtq4C1F8
* Vacuum pump manual, https://usermanual.wiki/m/6172b69756810f1a013746a37ab528c1ca07c989d01f18765ef5a459c483cbe0.pdf

= Maintenance =

See Links

* Link to YouTube videos - https://www.bing.com/videos/search?q=Shapeoko+2+%e2%80%93+CNC&view=detail&mid=91AB54FF364A496A01E491AB54FF364A496A01E4&FORM=VIRE

* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

=== AXYZ MDF Cover Replacement ===
The AXYZ vacuum table is covered by 3/4" MDF. In order to cover the full 5'x8' table surface, two sheets of MDF are required. We have designed a hold down system such that the two sheets of MDF are identical to one another and are made using a single CAM operation.
[[File:Mdf cover CAM.ngc|thumb]]

= List of Specifications =

== Phoenix CNC Router ==
* KL-2200 Spindle: 3 phase, 2220 Watt (3HP), 400 hz
* [//store.mesanet.com/index.php?route=product/product&product_id=124&search=7i85 MESA-7i85 encoder] with [//store.mesanet.com/index.php?route=product/product&product_id=123&search=7i84 MESA-7i84 daughtercard]
* X and Y motors: [//www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&ved=2ahUKEwjK5On80cPqAhW8knIEHShaCuYQFjACegQIBxAB&url=https%3A%2F%2Fdocs.rs-online.com%2F3ef3%2F0900766b80211175.pdf&usg=AOvVaw3QwEoog3jLHVgvXjFKsXDp MEI M644] gantry servo motors
* X and Y drivers: Leadshine DCS810
* Z motor: stepper
* Z driver: DM556T
* HY VFD, 240V
* [//store.mesanet.com/index.php?route=product/product&product_id=55&search=5i25 Mesa-5i25] superport PCI card

=== Bed Dimensions ===
X-axis: -0.175 to 47.5"

Y-axis: -0.25 to 47.5"

== AXYZ CNC Router ==

=== Perske D68167 Spindle ===
7.7 HP spindle

OZ12/EOC12 collets

=== PVL 270B Vacuum Pump ===
* 5.3 qt of DICREA 100 oil. Change every 500 hours

=== X2C Inverter ===
* manual, https://www.mikrocontroller.net/attachment/223502/vacon-x2c-series-user-s-manual.pdf

=== 7i76e MESA controller ===

=== Stepper drivers ===

There are 4 total stepper drivers. One for the Y-axis, two for the X-axis, and one for the Z-axis.

The Y and Z axes are controlled by PACSCI 6410 drivers.
https://www.electromate.com/pub/media/assets/catalog-library/pdfs/kollmorgen/Kollmorgen_6410_6415_Stepper_Drive_Catalog.pdf

DIP switch positions, described on pg C-10 of manual.
* Z1: DUUUUDDD
* X1: DUUUUDDD
* X2: DUUUUDDD
* Y1: DUDUUDDD

The X axis is controlled by two Gecko GR214V drivers.
https://www.geckodrive.com/gr214v-bulletproof-high-resolution-stepper-drive.html

The mismatch exists because one of the X-axis PACSCI drivers died and we replaced it with a more modern driver. These newer Gecko drivers are better in every way, and should eventually replace the remaining PACSCI drivers.

=== PST341-3A Stepper Motors ===
X-motors: AXYZ PST341-3A Stepping motor. Voltage 1.45V, 5.0 Amps, 1.8 Deg.

=== Z-axis ===
Stepper Motor:
Stepper Driver:
Drive pulley:
Driven Pulley:
Leadscrew:
Linear Bearings: AAD4K, 1622-81x-10, X=4

'''END OF PROCEDURE'''

Cnc-router-user-guide

2026-01-04T19:56:47Z

Aspontarelli: /* Aluminum Workpiece Feeds and Speeds */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-08, Rev. 1
|width="33%"|
'''Date'''

1/20/2021
|}

= GENERAL =

We have two CNC routers:
* Phoenix - a 4x4', heavy duty machine running LinuxCNC
* AXYZ 4008 - a 4x8', heavy duty machine running LinuxCNC

[[File:Shapeoko 2 – CNC Router.png]]

= SAFETY =

* Safety glasses to be worn when making a cut.
* Ear protection recommended.
* Before operating, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Non-slip footwear or anti-skid floor strips are recommended.
* Do not wear gloves.
* Do not leave workstation until cut is complete.

= REFERENCE =

*[[:File:Sheet CAM Manual_R3.pdf|Ken's SheetCAM Manual]]
* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

* [[:File:Zen_of_CNC.pdf|Router Advice - Zen of CNC]]
*[[:File:MAKE CHIPS NOT DUST.pdf|Why chips are important - About Chip Load]]

* [[:File:CNConsrud routing guide.pdf|Technical information on router tooling]]
* ShopBot guide to feeds and speeds: https://static1.squarespace.com/static/59efc96d90badec50a4afa15/t/5a21f4b6e2c483bcf39a2c84/1512174775486/FeedsandSpeeds.pdf
*[[:File:MAKE A BOX.pdf|Cheat Sheet to make a simple box with lid]]
*[[:File:Make A Simple Tray.pdf|Cheat sheet for making a simple router tray]]
*[[:File:MAKE A ROUND BOTTOM TRAYR1.pdf|Cheat sheet for making a round bottom router tray]]
*[[:File:F engrave Cheat Sheet.pdf|Cheat sheet for programming a V-carve in F-engrave.]]
*[[:File:WORK HOLDING STRATEGIES.pdf|Work Holding Strategies]]

== Feed and Speed Reference ==

=== Aluminum Workpiece Feeds and Speeds ===
While the CNC routers are typically used for cutting wood and plastic, the Phoenix router is capable of cutting aluminum as well. Use of a 50% dilution of isopropyl alcohol in the lube cube is critical for success, as is the use of single flute endmills and shallow depths of cut.

The following settings have been used with success in cutting 6061.

1/4" O-flute carbide endmill, 16,000 RPM, 50 ipm, 0.03in DOC

= PROCEDURE =

== General Controls and Configuration==
The Phoenix and AXYZ CNC routers can both be controlled using their respective gamepad controllers. The button configuration is shown below.

[[File:Controller movelist.png]]

== Workflow ==

There are many ways to complete this workflow, but included in this section are descriptions of how to make a successful cut with two different sets of software. The first is the most simple, the second more challenging but more powerful.

=== Inkscape -> SheetCAM -> LinuxCNC ===

One method of getting from idea to CNC routed part is to create your CAD design in Inkscape, then use SheetCAM to generate the tool paths. If carving a 2D design like a sign, this is the quickest and simplest method. Below is the general outline of this approach.

# Import drawing into SheetCAM (svg or dxf)
# Check machine options (Options -> Machine)
## Postprocessor -> LinuxCNC
## Postprocessor -> output units
# Set job options (Options -> Job Options)
## Set material dimensions
## Set origin
# Assign contours to layers
# Create tools to be used
# Create operations that assign tools to layers
## Set feeds and speeds (flip to other side for help)
# Visualize the job with Mode -> Simulation
# Create gcode: File -> Run Post Processor
# Transfer gcode file to cncrouter computer using USB stick or /vsfs01/share directory
# Open gcode file from LinuxCNC
# Insert tool in CNC router
# Clamp down workpiece (Always use a spoil board!)
# Turn on CNC router by rotating E-stop button clockwise
# Home machine by clicking Home All in LinuxCNC or by pressing Start + Select at the same time
# Move tool to origin and set the x, y, and z coordinates to zero by click Touch Off in LinuxCNC or by pressing Select + Direction Pad
# Confirm that tool won’t collide with hold-downs by manually jogging machine around the path
# Turn on dust collector
# Run operation
# Turn off dust collector and tidy up

=== FreeCAD -> LinuxCNC ===

Another method of using the CNC router is to use a program like FreeCAD to generate your 2D or 3D model, then also doing the CAM within FreeCAD. The benefit to this approach is that everything is done in a single program, and that the program is significantly more powerful and capable of handling 3D designs.

==== Vacuum Table ====
[[File:Vacuum table-labeled.jpg|thumb|Vacuum table with labels]]
The AXYZ router has a vacuum table plumbed into five distinct sections. The photo below shows the vacuum chamber arrangement and the valves associated with each.

# Place your workpiece as best you can over a complete chamber. For example if your workpiece is 24x48", it will fit perfectly over a single chamber, and should not be placed on the intersection of four chambers.
# Cover the rest of the table surface with impermeable cover sheets.
# Open as few valves as necessary to hold your workpiece. The pressure gauge indicates pressure in inHg and kPA. 1 inHg is about 0.5 psi, so 10inHg holding a 24x24in piece would exert 2,880 pounds of force. A very rough rule of thumb is to target at least 1,000 pounds.

= TROUBLESHOOTING =

== General Issues ==
Turn the machine on, so that the motors energize, but don't tell it to move. Do not turn the spindle on. Try to wiggle the spindle left and right by hand. Can you move it? If you can, watch carefully to see what moves with it. Does the belt move but the pulley doesn't turn? You have a loose belt. Does the pulley turn too? You have a loose pulley set screw. Does the entire gantry move with respect to the stationary rails? You have loose V-wheels or eccentric spacers. And so on. Repeat for back and forth movement, and up and down too, if that's also causing problems.

== Machine won't start ==
The console window will show the command being sent and a confirmation of "ok". However, the active state goes to "Queue" and never returns to "Idle.

* Auto cycle start has been turned off - Note that turning off auto cycle start requires that one begin the machine manually.
* Previous operation was quit from the Communication / Control program w/o disconnecting. Restart the computer system.
* USB port has gone into low-power mode. Energy-savings features can interfere w/ sending data to the Arduino. Do not let the controlling machine go into low power mode,
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine jogs, but won't respond to downloaded file ==
The machine will respond to single commands, but will not accept a downloaded file and will endlessly repeat some statement to the console.

* Grbl software installation corrupt. Reflash Grbl.
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine won't hold position ==
Set Grbl setting for "step idle delay" in milliseconds to 255 (suggested default). It will always energize the motors to a hold position. If set to some other value, motors will be turned off after the specified time.

== Toolpath Differs from Expected ==
If the machine's behavior doesn't match what is simulated.

* '''software bug''' - Grbl is very reliable, so unlikely to be in the firmware.
** Carbide Motion 4 ought to give an error message on any G-Code which it can't properly send on to the machine, and Carbide Create ought not make any code which doesn't work properly
* '''file problem''' - an example of this would be setting safety / retract height too high, using the wrong post-processor, or enabling a feature such as XY datum in Vectric Vcarve.
* '''machine misconfiguration / user error''' - this can be a lot of things, occasionally overlapping with the above, for example setting safety / retract height and the Z-axis zero so that when the machine lifts to safety height it bumps against and loses steps against the top stop, so that the Z-axis height isn't correct.
* '''mechanical machine setup''' - these ought to be covered by the machine Operating Checklist --- frequent things to check:
** Check pulley set screws
** Check V wheels / eccentric nuts
** Belt tension, the Z-axis belt in particular needs to be guitar string tight (but careful not to bend the motor shaft).
** Electronics - it's possible for a wire or connector to break or for a lost connection or excessive current generated by the stepper motors or a stray static spark to damage the stepper driver or controller.

== Radius of corners is different ==
Stairstepped diagonals, jagged circles/curves, loud squealing or 'ker-chunka' thuds, gantry chattering, mis-aligned edges. A useful troubleshooting technique for this is to listen to the machine:

* If it sounds awful = loose wire (or the stepper driver going into thermal shutdown).
* If it sounds normal = loose set screw (or other mechanical issue such as loose belts).

== File worked previously, doesn't work now ==
Reaching limits of machine.

* Either overheating or reaching acceleration limits.
* Steppers may be entering thermal shutdown, add active cooling.
* Machine is operating at the limits of its acceleration. Slow down feed speeds and max acceleration in GRBL.
* Endmill no longer sharp, spindle not working properly (rotating in wrong direction). If the machine is not able to properly cut, then it will not be able to move along the desired path, since it will not be clear.
* A spindle which is not working properly may put out EMI which will interfere w/ the movement of the stepper motors. Brushes on a router are a consumable part and must be replaced periodically.

== Steppers are missing steps ==

* Drivers overheating - Position the fan so that in blows across both the top and bottom of the drivers. Airflow does the most, followed by a heatsink on top of the chip. Note that this may also be caused by setting the current too high.
* Steppers being run too fast - GRBL has a maximum speed that it can drive stepper motors at. Because the X and Y axis are belt driven while the Z is threaded rod drive, it is very easy to set the x/y Default Feed speed faster than the Z axis can be signaled. Cut your default feed and test.
* Feed rate too fast - The harder the material being cut, the more torque the steppers have to resist. If you're feeding too fast, this can overcome the holding torque of your motors.
* Axis binding - Check that all of your v-wheels rotate freely when bolted and tightened, as some of the tolerance problems in the v-wheel components can be bad enough to cause the bearings to bind and the v-wheel to be stiff. If you're not using a drive shaft or dual Y axis steppers and your v-wheels or rails are adjusted incorrectly, the Y axis can bind and overwhelm the rated torque on your steppers. Also check that you've tensioned the eccentric spacers correctly. The v-wheels should be firmly planted but should not be so tight that there is any deflection/bowing in the plate, and should be easy to slide along the rails.
* Axis stalling - If you're using a drive shaft it is possible to have one pulley slip while the other will continue to drive the machine. Any instance of slippage should be investigated by checking the set screws on the pulleys.
* Electrical brownout - The power supply does draw a fair bit of power for the stepper motors, minimize other power drawing sources.
* Electrical interference - The spindle and motors put out quite a bit of electrical interference. This may cause random or irregular deviations in the movement of the machine. Shield the wires.
* Loose Idler - Odd distortions, all tending towards a particular direction may be caused by an idler pulley being loose.

== Deviations in slots when cutting ==
The bit is pulled along creating random path deviations which get worse as one gets deeper into a slot.

* Spindle is more powerful than the machine can manage. Spindle not kept up with the balance of the machine, the machine flexing along the Z-axis may flex and allow the bit to rub up against the edge of a slot where the cutting action will then pull the machine further along. Make the X-axis more rigid.

== Deviations in shapes when cutting ==
The machine lags behind at changes of direction, distorting shapes and creating flat edge at the extrema of rounded forms.

* Backlash/Insufficient belt tension - If your belts are too lose, the machine will shift w/ the cutting forces, distorting shapes. Machines w/ threaded rod will have similar difficulties if nuts do not have anti-backlash features.

== Z-axis cuts more deeply than expected ==
The bit is pulled along going deeper into the material than it should.

* Acceleration / movement too fast. The Z-axis is limited in its acceleration and top speed by the torque of the motor. If it is able to move down okay, but will not move up reliably, then the acceleration or movement may be too fast or high. Some G-code senders have an option to limit the Z-axis speed.
* Spindle is loose in its mounts, Z-axis plunge rate too fast causing the machine to go deeper. Always check to ensure the spindle is secure. Always be cautious with Z-axis plunge rates, especially when using CAM tools which lack spiral or ramp Z-axis moves.
* Z-axis motor is over-heating, causing the machine to fail to move up on negative moves (it's more difficult to lift the spindle than to lower it) causing it to cumulatively go deeper. Adjust the current, consider adding heat sinks and/or a fan to cool the stepper drivers.
* End mill loose in collet --- this can also cause other path deviations as the needed cutting forces are increased beyond the machine's capabilities. Tighten collet.

== Z-axis cuts at odd angles when cutting thin stock ==
The bit is pulling the material up or twisting it as it cuts.

* Switch to a down-cutting spiral bit --- check and ensure the bit is sharp.
* Lines are not straight, circles not round, dog bone pattern at corners, cut quality poor - DC spindle wired to run backwards.
** A damaged or dull end mill.
** Milling direction may be wrong.
* Repeating curve/wobble - Bad bearing or V-wheel

== Material Stock Melting or Burning ==
Smoke, fire, material build-up on tooling, poor cut edges (plastic) or burn marks (wood).

* RPM too high / Feed rate too low The surface of your tooling is moving too fast relative to the material. This leads to 'dwell', where the tooling rubs against the material to create a significant amount of heat.
** Increase your feed rate (higher mm/minute). Increasing your feed rate decreases the speed difference between the edge of your tooling and the material, reducing friction. GRBL has some limitations on feed, especially in smaller parts and curves, so this is not always possible.
** Slow your spindle (lower RPM)'''.''' If your router or dremel has variable speeds, turn it down. This, however, usually reduces the available torque, which can in turn lead to stalling your spindle during the cut.

== Persistent Ridges ==
Endmill is either bent or deflecting.

== Bit Chatter ==
Loud chattering, jagged cut edges, snapped tooling. Feed rates too high or loose frame.

* Slow the feed - If your tooling is trying to bite too much material, it will be under much higher stresses, pushing away or into the material much more than usual. Slowing down your feed rate can reduce this.
* Tighten the frame - Especially if you did not use loctite when assembling, bolts can work loose over time (or never having been tightened sufficiently), greatly reducing the rigidity of the frame - this rigidity is what a CNC uses to move the tool where it is supposed to be. Tightening everything up will help this.
* Another possibility is the spindle carriage plate is running off the bottom of the rail, esp. w/ the new style plate.

== Machine Chatters/Vibrates ==
Chattering, buzzing. Tighten wheels.

'''END OF THE PROCEDURE'''

Cnc router maintenance and specifications

2026-01-04T17:01:38Z

Aspontarelli: /* Phoenix CNC Router */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

MT 110-08, Rev. 1
|width="33%"|
'''Date'''

1/26/2021
|}

= GENERAL =

Specifications for the Phoenix-GS5 and the AXYZ 4008 CNC routers.

= REFERENCE =

* E-stop configuration, https://www.youtube.com/watch?v=hVkNtq4C1F8
* Vacuum pump manual, https://usermanual.wiki/m/6172b69756810f1a013746a37ab528c1ca07c989d01f18765ef5a459c483cbe0.pdf

= Maintenance =

See Links

* Link to YouTube videos - https://www.bing.com/videos/search?q=Shapeoko+2+%e2%80%93+CNC&view=detail&mid=91AB54FF364A496A01E491AB54FF364A496A01E4&FORM=VIRE

* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

=== AXYZ MDF Cover Replacement ===
The AXYZ vacuum table is covered by 3/4" MDF. In order to cover the full 5'x8' table surface, two sheets of MDF are required. We have designed a hold down system such that the two sheets of MDF are identical to one another and are made using a single CAM operation.
[[File:Mdf cover CAM.ngc|thumb]]

= List of Specifications =

== Phoenix CNC Router ==
* KL-2200 Spindle: 3 phase, 2220 Watt (3HP), 400 hz
* [//store.mesanet.com/index.php?route=product/product&product_id=124&search=7i85 MESA-7i85 encoder] with [//store.mesanet.com/index.php?route=product/product&product_id=123&search=7i84 MESA-7i84 daughtercard]
* X and Y motors: [//www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&ved=2ahUKEwjK5On80cPqAhW8knIEHShaCuYQFjACegQIBxAB&url=https%3A%2F%2Fdocs.rs-online.com%2F3ef3%2F0900766b80211175.pdf&usg=AOvVaw3QwEoog3jLHVgvXjFKsXDp MEI M644] gantry servo motors
* X and Y drivers: Leadshine DCS810
* Z motor: stepper
* Z driver: generic microstepper
* HY VFD, 240V
* [//store.mesanet.com/index.php?route=product/product&product_id=55&search=5i25 Mesa-5i25] superport PCI card

=== Bed Dimensions ===
X-axis: -0.175 to 47.5"

Y-axis: -0.25 to 47.5"

== AXYZ CNC Router ==

=== Perske D68167 Spindle ===
7.7 HP spindle

OZ12/EOC12 collets

=== PVL 270B Vacuum Pump ===
* 5.3 qt of DICREA 100 oil. Change every 500 hours

=== X2C Inverter ===
* manual, https://www.mikrocontroller.net/attachment/223502/vacon-x2c-series-user-s-manual.pdf

=== 7i76e MESA controller ===

=== Stepper drivers ===

There are 4 total stepper drivers. One for the Y-axis, two for the X-axis, and one for the Z-axis.

The Y and Z axes are controlled by PACSCI 6410 drivers.
https://www.electromate.com/pub/media/assets/catalog-library/pdfs/kollmorgen/Kollmorgen_6410_6415_Stepper_Drive_Catalog.pdf

DIP switch positions, described on pg C-10 of manual.
* Z1: DUUUUDDD
* X1: DUUUUDDD
* X2: DUUUUDDD
* Y1: DUDUUDDD

The X axis is controlled by two Gecko GR214V drivers.
https://www.geckodrive.com/gr214v-bulletproof-high-resolution-stepper-drive.html

The mismatch exists because one of the X-axis PACSCI drivers died and we replaced it with a more modern driver. These newer Gecko drivers are better in every way, and should eventually replace the remaining PACSCI drivers.

=== PST341-3A Stepper Motors ===
X-motors: AXYZ PST341-3A Stepping motor. Voltage 1.45V, 5.0 Amps, 1.8 Deg.

=== Z-axis ===
Stepper Motor:
Stepper Driver:
Drive pulley:
Driven Pulley:
Leadscrew:
Linear Bearings: AAD4K, 1622-81x-10, X=4

'''END OF PROCEDURE'''

Cnc-router-user-guide

2026-01-04T13:47:50Z

Aspontarelli: /* Aluminum Workpiece Feeds and Speeds */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-08, Rev. 1
|width="33%"|
'''Date'''

1/20/2021
|}

= GENERAL =

We have two CNC routers:
* Phoenix - a 4x4', heavy duty machine running LinuxCNC
* AXYZ 4008 - a 4x8', heavy duty machine running LinuxCNC

[[File:Shapeoko 2 – CNC Router.png]]

= SAFETY =

* Safety glasses to be worn when making a cut.
* Ear protection recommended.
* Before operating, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Non-slip footwear or anti-skid floor strips are recommended.
* Do not wear gloves.
* Do not leave workstation until cut is complete.

= REFERENCE =

*[[:File:Sheet CAM Manual_R3.pdf|Ken's SheetCAM Manual]]
* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

* [[:File:Zen_of_CNC.pdf|Router Advice - Zen of CNC]]
*[[:File:MAKE CHIPS NOT DUST.pdf|Why chips are important - About Chip Load]]

* [[:File:CNConsrud routing guide.pdf|Technical information on router tooling]]
* ShopBot guide to feeds and speeds: https://static1.squarespace.com/static/59efc96d90badec50a4afa15/t/5a21f4b6e2c483bcf39a2c84/1512174775486/FeedsandSpeeds.pdf
*[[:File:MAKE A BOX.pdf|Cheat Sheet to make a simple box with lid]]
*[[:File:Make A Simple Tray.pdf|Cheat sheet for making a simple router tray]]
*[[:File:MAKE A ROUND BOTTOM TRAYR1.pdf|Cheat sheet for making a round bottom router tray]]
*[[:File:F engrave Cheat Sheet.pdf|Cheat sheet for programming a V-carve in F-engrave.]]
*[[:File:WORK HOLDING STRATEGIES.pdf|Work Holding Strategies]]

== Feed and Speed Reference ==

=== Aluminum Workpiece Feeds and Speeds ===
While the CNC routers are typically used for cutting wood and plastic, the Phoenix router is capable of cutting aluminum as well. Use of a 50% dilution of isopropyl alcohol in the lube cube is critical for success, as is the use of single flute endmills and shallow depths of cut.

The following settings have been used with success in cutting 6061.

1/4" O-flute carbide endmill, 16,000 RPM, 40 ipm, 0.03in DOC

= PROCEDURE =

== General Controls and Configuration==
The Phoenix and AXYZ CNC routers can both be controlled using their respective gamepad controllers. The button configuration is shown below.

[[File:Controller movelist.png]]

== Workflow ==

There are many ways to complete this workflow, but included in this section are descriptions of how to make a successful cut with two different sets of software. The first is the most simple, the second more challenging but more powerful.

=== Inkscape -> SheetCAM -> LinuxCNC ===

One method of getting from idea to CNC routed part is to create your CAD design in Inkscape, then use SheetCAM to generate the tool paths. If carving a 2D design like a sign, this is the quickest and simplest method. Below is the general outline of this approach.

# Import drawing into SheetCAM (svg or dxf)
# Check machine options (Options -> Machine)
## Postprocessor -> LinuxCNC
## Postprocessor -> output units
# Set job options (Options -> Job Options)
## Set material dimensions
## Set origin
# Assign contours to layers
# Create tools to be used
# Create operations that assign tools to layers
## Set feeds and speeds (flip to other side for help)
# Visualize the job with Mode -> Simulation
# Create gcode: File -> Run Post Processor
# Transfer gcode file to cncrouter computer using USB stick or /vsfs01/share directory
# Open gcode file from LinuxCNC
# Insert tool in CNC router
# Clamp down workpiece (Always use a spoil board!)
# Turn on CNC router by rotating E-stop button clockwise
# Home machine by clicking Home All in LinuxCNC or by pressing Start + Select at the same time
# Move tool to origin and set the x, y, and z coordinates to zero by click Touch Off in LinuxCNC or by pressing Select + Direction Pad
# Confirm that tool won’t collide with hold-downs by manually jogging machine around the path
# Turn on dust collector
# Run operation
# Turn off dust collector and tidy up

=== FreeCAD -> LinuxCNC ===

Another method of using the CNC router is to use a program like FreeCAD to generate your 2D or 3D model, then also doing the CAM within FreeCAD. The benefit to this approach is that everything is done in a single program, and that the program is significantly more powerful and capable of handling 3D designs.

==== Vacuum Table ====
[[File:Vacuum table-labeled.jpg|thumb|Vacuum table with labels]]
The AXYZ router has a vacuum table plumbed into five distinct sections. The photo below shows the vacuum chamber arrangement and the valves associated with each.

# Place your workpiece as best you can over a complete chamber. For example if your workpiece is 24x48", it will fit perfectly over a single chamber, and should not be placed on the intersection of four chambers.
# Cover the rest of the table surface with impermeable cover sheets.
# Open as few valves as necessary to hold your workpiece. The pressure gauge indicates pressure in inHg and kPA. 1 inHg is about 0.5 psi, so 10inHg holding a 24x24in piece would exert 2,880 pounds of force. A very rough rule of thumb is to target at least 1,000 pounds.

= TROUBLESHOOTING =

== General Issues ==
Turn the machine on, so that the motors energize, but don't tell it to move. Do not turn the spindle on. Try to wiggle the spindle left and right by hand. Can you move it? If you can, watch carefully to see what moves with it. Does the belt move but the pulley doesn't turn? You have a loose belt. Does the pulley turn too? You have a loose pulley set screw. Does the entire gantry move with respect to the stationary rails? You have loose V-wheels or eccentric spacers. And so on. Repeat for back and forth movement, and up and down too, if that's also causing problems.

== Machine won't start ==
The console window will show the command being sent and a confirmation of "ok". However, the active state goes to "Queue" and never returns to "Idle.

* Auto cycle start has been turned off - Note that turning off auto cycle start requires that one begin the machine manually.
* Previous operation was quit from the Communication / Control program w/o disconnecting. Restart the computer system.
* USB port has gone into low-power mode. Energy-savings features can interfere w/ sending data to the Arduino. Do not let the controlling machine go into low power mode,
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine jogs, but won't respond to downloaded file ==
The machine will respond to single commands, but will not accept a downloaded file and will endlessly repeat some statement to the console.

* Grbl software installation corrupt. Reflash Grbl.
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine won't hold position ==
Set Grbl setting for "step idle delay" in milliseconds to 255 (suggested default). It will always energize the motors to a hold position. If set to some other value, motors will be turned off after the specified time.

== Toolpath Differs from Expected ==
If the machine's behavior doesn't match what is simulated.

* '''software bug''' - Grbl is very reliable, so unlikely to be in the firmware.
** Carbide Motion 4 ought to give an error message on any G-Code which it can't properly send on to the machine, and Carbide Create ought not make any code which doesn't work properly
* '''file problem''' - an example of this would be setting safety / retract height too high, using the wrong post-processor, or enabling a feature such as XY datum in Vectric Vcarve.
* '''machine misconfiguration / user error''' - this can be a lot of things, occasionally overlapping with the above, for example setting safety / retract height and the Z-axis zero so that when the machine lifts to safety height it bumps against and loses steps against the top stop, so that the Z-axis height isn't correct.
* '''mechanical machine setup''' - these ought to be covered by the machine Operating Checklist --- frequent things to check:
** Check pulley set screws
** Check V wheels / eccentric nuts
** Belt tension, the Z-axis belt in particular needs to be guitar string tight (but careful not to bend the motor shaft).
** Electronics - it's possible for a wire or connector to break or for a lost connection or excessive current generated by the stepper motors or a stray static spark to damage the stepper driver or controller.

== Radius of corners is different ==
Stairstepped diagonals, jagged circles/curves, loud squealing or 'ker-chunka' thuds, gantry chattering, mis-aligned edges. A useful troubleshooting technique for this is to listen to the machine:

* If it sounds awful = loose wire (or the stepper driver going into thermal shutdown).
* If it sounds normal = loose set screw (or other mechanical issue such as loose belts).

== File worked previously, doesn't work now ==
Reaching limits of machine.

* Either overheating or reaching acceleration limits.
* Steppers may be entering thermal shutdown, add active cooling.
* Machine is operating at the limits of its acceleration. Slow down feed speeds and max acceleration in GRBL.
* Endmill no longer sharp, spindle not working properly (rotating in wrong direction). If the machine is not able to properly cut, then it will not be able to move along the desired path, since it will not be clear.
* A spindle which is not working properly may put out EMI which will interfere w/ the movement of the stepper motors. Brushes on a router are a consumable part and must be replaced periodically.

== Steppers are missing steps ==

* Drivers overheating - Position the fan so that in blows across both the top and bottom of the drivers. Airflow does the most, followed by a heatsink on top of the chip. Note that this may also be caused by setting the current too high.
* Steppers being run too fast - GRBL has a maximum speed that it can drive stepper motors at. Because the X and Y axis are belt driven while the Z is threaded rod drive, it is very easy to set the x/y Default Feed speed faster than the Z axis can be signaled. Cut your default feed and test.
* Feed rate too fast - The harder the material being cut, the more torque the steppers have to resist. If you're feeding too fast, this can overcome the holding torque of your motors.
* Axis binding - Check that all of your v-wheels rotate freely when bolted and tightened, as some of the tolerance problems in the v-wheel components can be bad enough to cause the bearings to bind and the v-wheel to be stiff. If you're not using a drive shaft or dual Y axis steppers and your v-wheels or rails are adjusted incorrectly, the Y axis can bind and overwhelm the rated torque on your steppers. Also check that you've tensioned the eccentric spacers correctly. The v-wheels should be firmly planted but should not be so tight that there is any deflection/bowing in the plate, and should be easy to slide along the rails.
* Axis stalling - If you're using a drive shaft it is possible to have one pulley slip while the other will continue to drive the machine. Any instance of slippage should be investigated by checking the set screws on the pulleys.
* Electrical brownout - The power supply does draw a fair bit of power for the stepper motors, minimize other power drawing sources.
* Electrical interference - The spindle and motors put out quite a bit of electrical interference. This may cause random or irregular deviations in the movement of the machine. Shield the wires.
* Loose Idler - Odd distortions, all tending towards a particular direction may be caused by an idler pulley being loose.

== Deviations in slots when cutting ==
The bit is pulled along creating random path deviations which get worse as one gets deeper into a slot.

* Spindle is more powerful than the machine can manage. Spindle not kept up with the balance of the machine, the machine flexing along the Z-axis may flex and allow the bit to rub up against the edge of a slot where the cutting action will then pull the machine further along. Make the X-axis more rigid.

== Deviations in shapes when cutting ==
The machine lags behind at changes of direction, distorting shapes and creating flat edge at the extrema of rounded forms.

* Backlash/Insufficient belt tension - If your belts are too lose, the machine will shift w/ the cutting forces, distorting shapes. Machines w/ threaded rod will have similar difficulties if nuts do not have anti-backlash features.

== Z-axis cuts more deeply than expected ==
The bit is pulled along going deeper into the material than it should.

* Acceleration / movement too fast. The Z-axis is limited in its acceleration and top speed by the torque of the motor. If it is able to move down okay, but will not move up reliably, then the acceleration or movement may be too fast or high. Some G-code senders have an option to limit the Z-axis speed.
* Spindle is loose in its mounts, Z-axis plunge rate too fast causing the machine to go deeper. Always check to ensure the spindle is secure. Always be cautious with Z-axis plunge rates, especially when using CAM tools which lack spiral or ramp Z-axis moves.
* Z-axis motor is over-heating, causing the machine to fail to move up on negative moves (it's more difficult to lift the spindle than to lower it) causing it to cumulatively go deeper. Adjust the current, consider adding heat sinks and/or a fan to cool the stepper drivers.
* End mill loose in collet --- this can also cause other path deviations as the needed cutting forces are increased beyond the machine's capabilities. Tighten collet.

== Z-axis cuts at odd angles when cutting thin stock ==
The bit is pulling the material up or twisting it as it cuts.

* Switch to a down-cutting spiral bit --- check and ensure the bit is sharp.
* Lines are not straight, circles not round, dog bone pattern at corners, cut quality poor - DC spindle wired to run backwards.
** A damaged or dull end mill.
** Milling direction may be wrong.
* Repeating curve/wobble - Bad bearing or V-wheel

== Material Stock Melting or Burning ==
Smoke, fire, material build-up on tooling, poor cut edges (plastic) or burn marks (wood).

* RPM too high / Feed rate too low The surface of your tooling is moving too fast relative to the material. This leads to 'dwell', where the tooling rubs against the material to create a significant amount of heat.
** Increase your feed rate (higher mm/minute). Increasing your feed rate decreases the speed difference between the edge of your tooling and the material, reducing friction. GRBL has some limitations on feed, especially in smaller parts and curves, so this is not always possible.
** Slow your spindle (lower RPM)'''.''' If your router or dremel has variable speeds, turn it down. This, however, usually reduces the available torque, which can in turn lead to stalling your spindle during the cut.

== Persistent Ridges ==
Endmill is either bent or deflecting.

== Bit Chatter ==
Loud chattering, jagged cut edges, snapped tooling. Feed rates too high or loose frame.

* Slow the feed - If your tooling is trying to bite too much material, it will be under much higher stresses, pushing away or into the material much more than usual. Slowing down your feed rate can reduce this.
* Tighten the frame - Especially if you did not use loctite when assembling, bolts can work loose over time (or never having been tightened sufficiently), greatly reducing the rigidity of the frame - this rigidity is what a CNC uses to move the tool where it is supposed to be. Tightening everything up will help this.
* Another possibility is the spindle carriage plate is running off the bottom of the rail, esp. w/ the new style plate.

== Machine Chatters/Vibrates ==
Chattering, buzzing. Tighten wheels.

'''END OF THE PROCEDURE'''

Cnc-router-user-guide

2026-01-03T20:38:44Z

Aspontarelli: /* Aluminum Workpiece Feeds and Speeds */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-08, Rev. 1
|width="33%"|
'''Date'''

1/20/2021
|}

= GENERAL =

We have two CNC routers:
* Phoenix - a 4x4', heavy duty machine running LinuxCNC
* AXYZ 4008 - a 4x8', heavy duty machine running LinuxCNC

[[File:Shapeoko 2 – CNC Router.png]]

= SAFETY =

* Safety glasses to be worn when making a cut.
* Ear protection recommended.
* Before operating, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Non-slip footwear or anti-skid floor strips are recommended.
* Do not wear gloves.
* Do not leave workstation until cut is complete.

= REFERENCE =

*[[:File:Sheet CAM Manual_R3.pdf|Ken's SheetCAM Manual]]
* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

* [[:File:Zen_of_CNC.pdf|Router Advice - Zen of CNC]]
*[[:File:MAKE CHIPS NOT DUST.pdf|Why chips are important - About Chip Load]]

* [[:File:CNConsrud routing guide.pdf|Technical information on router tooling]]
* ShopBot guide to feeds and speeds: https://static1.squarespace.com/static/59efc96d90badec50a4afa15/t/5a21f4b6e2c483bcf39a2c84/1512174775486/FeedsandSpeeds.pdf
*[[:File:MAKE A BOX.pdf|Cheat Sheet to make a simple box with lid]]
*[[:File:Make A Simple Tray.pdf|Cheat sheet for making a simple router tray]]
*[[:File:MAKE A ROUND BOTTOM TRAYR1.pdf|Cheat sheet for making a round bottom router tray]]
*[[:File:F engrave Cheat Sheet.pdf|Cheat sheet for programming a V-carve in F-engrave.]]
*[[:File:WORK HOLDING STRATEGIES.pdf|Work Holding Strategies]]

== Feed and Speed Reference ==

=== Aluminum Workpiece Feeds and Speeds ===
While the CNC routers are typically used for cutting wood and plastic, the Phoenix router is capable of cutting aluminum as well. Use of a 50% dilution of isopropyl alcohol in the lube cube is critical for success, as is the use of single flute endmills.

The following settings have been used with success in cutting 6061.

1/4" O-flute carbide endmill, 16,000 RPM, 40 ipm, 0.03in DOC

= PROCEDURE =

== General Controls and Configuration==
The Phoenix and AXYZ CNC routers can both be controlled using their respective gamepad controllers. The button configuration is shown below.

[[File:Controller movelist.png]]

== Workflow ==

There are many ways to complete this workflow, but included in this section are descriptions of how to make a successful cut with two different sets of software. The first is the most simple, the second more challenging but more powerful.

=== Inkscape -> SheetCAM -> LinuxCNC ===

One method of getting from idea to CNC routed part is to create your CAD design in Inkscape, then use SheetCAM to generate the tool paths. If carving a 2D design like a sign, this is the quickest and simplest method. Below is the general outline of this approach.

# Import drawing into SheetCAM (svg or dxf)
# Check machine options (Options -> Machine)
## Postprocessor -> LinuxCNC
## Postprocessor -> output units
# Set job options (Options -> Job Options)
## Set material dimensions
## Set origin
# Assign contours to layers
# Create tools to be used
# Create operations that assign tools to layers
## Set feeds and speeds (flip to other side for help)
# Visualize the job with Mode -> Simulation
# Create gcode: File -> Run Post Processor
# Transfer gcode file to cncrouter computer using USB stick or /vsfs01/share directory
# Open gcode file from LinuxCNC
# Insert tool in CNC router
# Clamp down workpiece (Always use a spoil board!)
# Turn on CNC router by rotating E-stop button clockwise
# Home machine by clicking Home All in LinuxCNC or by pressing Start + Select at the same time
# Move tool to origin and set the x, y, and z coordinates to zero by click Touch Off in LinuxCNC or by pressing Select + Direction Pad
# Confirm that tool won’t collide with hold-downs by manually jogging machine around the path
# Turn on dust collector
# Run operation
# Turn off dust collector and tidy up

=== FreeCAD -> LinuxCNC ===

Another method of using the CNC router is to use a program like FreeCAD to generate your 2D or 3D model, then also doing the CAM within FreeCAD. The benefit to this approach is that everything is done in a single program, and that the program is significantly more powerful and capable of handling 3D designs.

==== Vacuum Table ====
[[File:Vacuum table-labeled.jpg|thumb|Vacuum table with labels]]
The AXYZ router has a vacuum table plumbed into five distinct sections. The photo below shows the vacuum chamber arrangement and the valves associated with each.

# Place your workpiece as best you can over a complete chamber. For example if your workpiece is 24x48", it will fit perfectly over a single chamber, and should not be placed on the intersection of four chambers.
# Cover the rest of the table surface with impermeable cover sheets.
# Open as few valves as necessary to hold your workpiece. The pressure gauge indicates pressure in inHg and kPA. 1 inHg is about 0.5 psi, so 10inHg holding a 24x24in piece would exert 2,880 pounds of force. A very rough rule of thumb is to target at least 1,000 pounds.

= TROUBLESHOOTING =

== General Issues ==
Turn the machine on, so that the motors energize, but don't tell it to move. Do not turn the spindle on. Try to wiggle the spindle left and right by hand. Can you move it? If you can, watch carefully to see what moves with it. Does the belt move but the pulley doesn't turn? You have a loose belt. Does the pulley turn too? You have a loose pulley set screw. Does the entire gantry move with respect to the stationary rails? You have loose V-wheels or eccentric spacers. And so on. Repeat for back and forth movement, and up and down too, if that's also causing problems.

== Machine won't start ==
The console window will show the command being sent and a confirmation of "ok". However, the active state goes to "Queue" and never returns to "Idle.

* Auto cycle start has been turned off - Note that turning off auto cycle start requires that one begin the machine manually.
* Previous operation was quit from the Communication / Control program w/o disconnecting. Restart the computer system.
* USB port has gone into low-power mode. Energy-savings features can interfere w/ sending data to the Arduino. Do not let the controlling machine go into low power mode,
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine jogs, but won't respond to downloaded file ==
The machine will respond to single commands, but will not accept a downloaded file and will endlessly repeat some statement to the console.

* Grbl software installation corrupt. Reflash Grbl.
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine won't hold position ==
Set Grbl setting for "step idle delay" in milliseconds to 255 (suggested default). It will always energize the motors to a hold position. If set to some other value, motors will be turned off after the specified time.

== Toolpath Differs from Expected ==
If the machine's behavior doesn't match what is simulated.

* '''software bug''' - Grbl is very reliable, so unlikely to be in the firmware.
** Carbide Motion 4 ought to give an error message on any G-Code which it can't properly send on to the machine, and Carbide Create ought not make any code which doesn't work properly
* '''file problem''' - an example of this would be setting safety / retract height too high, using the wrong post-processor, or enabling a feature such as XY datum in Vectric Vcarve.
* '''machine misconfiguration / user error''' - this can be a lot of things, occasionally overlapping with the above, for example setting safety / retract height and the Z-axis zero so that when the machine lifts to safety height it bumps against and loses steps against the top stop, so that the Z-axis height isn't correct.
* '''mechanical machine setup''' - these ought to be covered by the machine Operating Checklist --- frequent things to check:
** Check pulley set screws
** Check V wheels / eccentric nuts
** Belt tension, the Z-axis belt in particular needs to be guitar string tight (but careful not to bend the motor shaft).
** Electronics - it's possible for a wire or connector to break or for a lost connection or excessive current generated by the stepper motors or a stray static spark to damage the stepper driver or controller.

== Radius of corners is different ==
Stairstepped diagonals, jagged circles/curves, loud squealing or 'ker-chunka' thuds, gantry chattering, mis-aligned edges. A useful troubleshooting technique for this is to listen to the machine:

* If it sounds awful = loose wire (or the stepper driver going into thermal shutdown).
* If it sounds normal = loose set screw (or other mechanical issue such as loose belts).

== File worked previously, doesn't work now ==
Reaching limits of machine.

* Either overheating or reaching acceleration limits.
* Steppers may be entering thermal shutdown, add active cooling.
* Machine is operating at the limits of its acceleration. Slow down feed speeds and max acceleration in GRBL.
* Endmill no longer sharp, spindle not working properly (rotating in wrong direction). If the machine is not able to properly cut, then it will not be able to move along the desired path, since it will not be clear.
* A spindle which is not working properly may put out EMI which will interfere w/ the movement of the stepper motors. Brushes on a router are a consumable part and must be replaced periodically.

== Steppers are missing steps ==

* Drivers overheating - Position the fan so that in blows across both the top and bottom of the drivers. Airflow does the most, followed by a heatsink on top of the chip. Note that this may also be caused by setting the current too high.
* Steppers being run too fast - GRBL has a maximum speed that it can drive stepper motors at. Because the X and Y axis are belt driven while the Z is threaded rod drive, it is very easy to set the x/y Default Feed speed faster than the Z axis can be signaled. Cut your default feed and test.
* Feed rate too fast - The harder the material being cut, the more torque the steppers have to resist. If you're feeding too fast, this can overcome the holding torque of your motors.
* Axis binding - Check that all of your v-wheels rotate freely when bolted and tightened, as some of the tolerance problems in the v-wheel components can be bad enough to cause the bearings to bind and the v-wheel to be stiff. If you're not using a drive shaft or dual Y axis steppers and your v-wheels or rails are adjusted incorrectly, the Y axis can bind and overwhelm the rated torque on your steppers. Also check that you've tensioned the eccentric spacers correctly. The v-wheels should be firmly planted but should not be so tight that there is any deflection/bowing in the plate, and should be easy to slide along the rails.
* Axis stalling - If you're using a drive shaft it is possible to have one pulley slip while the other will continue to drive the machine. Any instance of slippage should be investigated by checking the set screws on the pulleys.
* Electrical brownout - The power supply does draw a fair bit of power for the stepper motors, minimize other power drawing sources.
* Electrical interference - The spindle and motors put out quite a bit of electrical interference. This may cause random or irregular deviations in the movement of the machine. Shield the wires.
* Loose Idler - Odd distortions, all tending towards a particular direction may be caused by an idler pulley being loose.

== Deviations in slots when cutting ==
The bit is pulled along creating random path deviations which get worse as one gets deeper into a slot.

* Spindle is more powerful than the machine can manage. Spindle not kept up with the balance of the machine, the machine flexing along the Z-axis may flex and allow the bit to rub up against the edge of a slot where the cutting action will then pull the machine further along. Make the X-axis more rigid.

== Deviations in shapes when cutting ==
The machine lags behind at changes of direction, distorting shapes and creating flat edge at the extrema of rounded forms.

* Backlash/Insufficient belt tension - If your belts are too lose, the machine will shift w/ the cutting forces, distorting shapes. Machines w/ threaded rod will have similar difficulties if nuts do not have anti-backlash features.

== Z-axis cuts more deeply than expected ==
The bit is pulled along going deeper into the material than it should.

* Acceleration / movement too fast. The Z-axis is limited in its acceleration and top speed by the torque of the motor. If it is able to move down okay, but will not move up reliably, then the acceleration or movement may be too fast or high. Some G-code senders have an option to limit the Z-axis speed.
* Spindle is loose in its mounts, Z-axis plunge rate too fast causing the machine to go deeper. Always check to ensure the spindle is secure. Always be cautious with Z-axis plunge rates, especially when using CAM tools which lack spiral or ramp Z-axis moves.
* Z-axis motor is over-heating, causing the machine to fail to move up on negative moves (it's more difficult to lift the spindle than to lower it) causing it to cumulatively go deeper. Adjust the current, consider adding heat sinks and/or a fan to cool the stepper drivers.
* End mill loose in collet --- this can also cause other path deviations as the needed cutting forces are increased beyond the machine's capabilities. Tighten collet.

== Z-axis cuts at odd angles when cutting thin stock ==
The bit is pulling the material up or twisting it as it cuts.

* Switch to a down-cutting spiral bit --- check and ensure the bit is sharp.
* Lines are not straight, circles not round, dog bone pattern at corners, cut quality poor - DC spindle wired to run backwards.
** A damaged or dull end mill.
** Milling direction may be wrong.
* Repeating curve/wobble - Bad bearing or V-wheel

== Material Stock Melting or Burning ==
Smoke, fire, material build-up on tooling, poor cut edges (plastic) or burn marks (wood).

* RPM too high / Feed rate too low The surface of your tooling is moving too fast relative to the material. This leads to 'dwell', where the tooling rubs against the material to create a significant amount of heat.
** Increase your feed rate (higher mm/minute). Increasing your feed rate decreases the speed difference between the edge of your tooling and the material, reducing friction. GRBL has some limitations on feed, especially in smaller parts and curves, so this is not always possible.
** Slow your spindle (lower RPM)'''.''' If your router or dremel has variable speeds, turn it down. This, however, usually reduces the available torque, which can in turn lead to stalling your spindle during the cut.

== Persistent Ridges ==
Endmill is either bent or deflecting.

== Bit Chatter ==
Loud chattering, jagged cut edges, snapped tooling. Feed rates too high or loose frame.

* Slow the feed - If your tooling is trying to bite too much material, it will be under much higher stresses, pushing away or into the material much more than usual. Slowing down your feed rate can reduce this.
* Tighten the frame - Especially if you did not use loctite when assembling, bolts can work loose over time (or never having been tightened sufficiently), greatly reducing the rigidity of the frame - this rigidity is what a CNC uses to move the tool where it is supposed to be. Tightening everything up will help this.
* Another possibility is the spindle carriage plate is running off the bottom of the rail, esp. w/ the new style plate.

== Machine Chatters/Vibrates ==
Chattering, buzzing. Tighten wheels.

'''END OF THE PROCEDURE'''

Cnc-router-user-guide

2026-01-03T20:37:58Z

Aspontarelli: /* REFERENCE */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-08, Rev. 1
|width="33%"|
'''Date'''

1/20/2021
|}

= GENERAL =

We have two CNC routers:
* Phoenix - a 4x4', heavy duty machine running LinuxCNC
* AXYZ 4008 - a 4x8', heavy duty machine running LinuxCNC

[[File:Shapeoko 2 – CNC Router.png]]

= SAFETY =

* Safety glasses to be worn when making a cut.
* Ear protection recommended.
* Before operating, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Non-slip footwear or anti-skid floor strips are recommended.
* Do not wear gloves.
* Do not leave workstation until cut is complete.

= REFERENCE =

*[[:File:Sheet CAM Manual_R3.pdf|Ken's SheetCAM Manual]]
* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

* [[:File:Zen_of_CNC.pdf|Router Advice - Zen of CNC]]
*[[:File:MAKE CHIPS NOT DUST.pdf|Why chips are important - About Chip Load]]

* [[:File:CNConsrud routing guide.pdf|Technical information on router tooling]]
* ShopBot guide to feeds and speeds: https://static1.squarespace.com/static/59efc96d90badec50a4afa15/t/5a21f4b6e2c483bcf39a2c84/1512174775486/FeedsandSpeeds.pdf
*[[:File:MAKE A BOX.pdf|Cheat Sheet to make a simple box with lid]]
*[[:File:Make A Simple Tray.pdf|Cheat sheet for making a simple router tray]]
*[[:File:MAKE A ROUND BOTTOM TRAYR1.pdf|Cheat sheet for making a round bottom router tray]]
*[[:File:F engrave Cheat Sheet.pdf|Cheat sheet for programming a V-carve in F-engrave.]]
*[[:File:WORK HOLDING STRATEGIES.pdf|Work Holding Strategies]]

== Feed and Speed Reference ==

=== Aluminum Workpiece Feeds and Speeds ===
While the CNC routers are typically used for cutting wood and plastic, the Phoenix router is capable of cutting aluminum as well. Use of a 50% dilution of isopropyl alcohol in the lube cube is critical for successingle s, as is the use of single flute endmills.

The following settings have been used with success in cutting 6061.

1/4" O-flute carbide endmill, 16,000 RPM, 40 ipm, 0.03in DOC

= PROCEDURE =

== General Controls and Configuration==
The Phoenix and AXYZ CNC routers can both be controlled using their respective gamepad controllers. The button configuration is shown below.

[[File:Controller movelist.png]]

== Workflow ==

There are many ways to complete this workflow, but included in this section are descriptions of how to make a successful cut with two different sets of software. The first is the most simple, the second more challenging but more powerful.

=== Inkscape -> SheetCAM -> LinuxCNC ===

One method of getting from idea to CNC routed part is to create your CAD design in Inkscape, then use SheetCAM to generate the tool paths. If carving a 2D design like a sign, this is the quickest and simplest method. Below is the general outline of this approach.

# Import drawing into SheetCAM (svg or dxf)
# Check machine options (Options -> Machine)
## Postprocessor -> LinuxCNC
## Postprocessor -> output units
# Set job options (Options -> Job Options)
## Set material dimensions
## Set origin
# Assign contours to layers
# Create tools to be used
# Create operations that assign tools to layers
## Set feeds and speeds (flip to other side for help)
# Visualize the job with Mode -> Simulation
# Create gcode: File -> Run Post Processor
# Transfer gcode file to cncrouter computer using USB stick or /vsfs01/share directory
# Open gcode file from LinuxCNC
# Insert tool in CNC router
# Clamp down workpiece (Always use a spoil board!)
# Turn on CNC router by rotating E-stop button clockwise
# Home machine by clicking Home All in LinuxCNC or by pressing Start + Select at the same time
# Move tool to origin and set the x, y, and z coordinates to zero by click Touch Off in LinuxCNC or by pressing Select + Direction Pad
# Confirm that tool won’t collide with hold-downs by manually jogging machine around the path
# Turn on dust collector
# Run operation
# Turn off dust collector and tidy up

=== FreeCAD -> LinuxCNC ===

Another method of using the CNC router is to use a program like FreeCAD to generate your 2D or 3D model, then also doing the CAM within FreeCAD. The benefit to this approach is that everything is done in a single program, and that the program is significantly more powerful and capable of handling 3D designs.

==== Vacuum Table ====
[[File:Vacuum table-labeled.jpg|thumb|Vacuum table with labels]]
The AXYZ router has a vacuum table plumbed into five distinct sections. The photo below shows the vacuum chamber arrangement and the valves associated with each.

# Place your workpiece as best you can over a complete chamber. For example if your workpiece is 24x48", it will fit perfectly over a single chamber, and should not be placed on the intersection of four chambers.
# Cover the rest of the table surface with impermeable cover sheets.
# Open as few valves as necessary to hold your workpiece. The pressure gauge indicates pressure in inHg and kPA. 1 inHg is about 0.5 psi, so 10inHg holding a 24x24in piece would exert 2,880 pounds of force. A very rough rule of thumb is to target at least 1,000 pounds.

= TROUBLESHOOTING =

== General Issues ==
Turn the machine on, so that the motors energize, but don't tell it to move. Do not turn the spindle on. Try to wiggle the spindle left and right by hand. Can you move it? If you can, watch carefully to see what moves with it. Does the belt move but the pulley doesn't turn? You have a loose belt. Does the pulley turn too? You have a loose pulley set screw. Does the entire gantry move with respect to the stationary rails? You have loose V-wheels or eccentric spacers. And so on. Repeat for back and forth movement, and up and down too, if that's also causing problems.

== Machine won't start ==
The console window will show the command being sent and a confirmation of "ok". However, the active state goes to "Queue" and never returns to "Idle.

* Auto cycle start has been turned off - Note that turning off auto cycle start requires that one begin the machine manually.
* Previous operation was quit from the Communication / Control program w/o disconnecting. Restart the computer system.
* USB port has gone into low-power mode. Energy-savings features can interfere w/ sending data to the Arduino. Do not let the controlling machine go into low power mode,
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine jogs, but won't respond to downloaded file ==
The machine will respond to single commands, but will not accept a downloaded file and will endlessly repeat some statement to the console.

* Grbl software installation corrupt. Reflash Grbl.
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine won't hold position ==
Set Grbl setting for "step idle delay" in milliseconds to 255 (suggested default). It will always energize the motors to a hold position. If set to some other value, motors will be turned off after the specified time.

== Toolpath Differs from Expected ==
If the machine's behavior doesn't match what is simulated.

* '''software bug''' - Grbl is very reliable, so unlikely to be in the firmware.
** Carbide Motion 4 ought to give an error message on any G-Code which it can't properly send on to the machine, and Carbide Create ought not make any code which doesn't work properly
* '''file problem''' - an example of this would be setting safety / retract height too high, using the wrong post-processor, or enabling a feature such as XY datum in Vectric Vcarve.
* '''machine misconfiguration / user error''' - this can be a lot of things, occasionally overlapping with the above, for example setting safety / retract height and the Z-axis zero so that when the machine lifts to safety height it bumps against and loses steps against the top stop, so that the Z-axis height isn't correct.
* '''mechanical machine setup''' - these ought to be covered by the machine Operating Checklist --- frequent things to check:
** Check pulley set screws
** Check V wheels / eccentric nuts
** Belt tension, the Z-axis belt in particular needs to be guitar string tight (but careful not to bend the motor shaft).
** Electronics - it's possible for a wire or connector to break or for a lost connection or excessive current generated by the stepper motors or a stray static spark to damage the stepper driver or controller.

== Radius of corners is different ==
Stairstepped diagonals, jagged circles/curves, loud squealing or 'ker-chunka' thuds, gantry chattering, mis-aligned edges. A useful troubleshooting technique for this is to listen to the machine:

* If it sounds awful = loose wire (or the stepper driver going into thermal shutdown).
* If it sounds normal = loose set screw (or other mechanical issue such as loose belts).

== File worked previously, doesn't work now ==
Reaching limits of machine.

* Either overheating or reaching acceleration limits.
* Steppers may be entering thermal shutdown, add active cooling.
* Machine is operating at the limits of its acceleration. Slow down feed speeds and max acceleration in GRBL.
* Endmill no longer sharp, spindle not working properly (rotating in wrong direction). If the machine is not able to properly cut, then it will not be able to move along the desired path, since it will not be clear.
* A spindle which is not working properly may put out EMI which will interfere w/ the movement of the stepper motors. Brushes on a router are a consumable part and must be replaced periodically.

== Steppers are missing steps ==

* Drivers overheating - Position the fan so that in blows across both the top and bottom of the drivers. Airflow does the most, followed by a heatsink on top of the chip. Note that this may also be caused by setting the current too high.
* Steppers being run too fast - GRBL has a maximum speed that it can drive stepper motors at. Because the X and Y axis are belt driven while the Z is threaded rod drive, it is very easy to set the x/y Default Feed speed faster than the Z axis can be signaled. Cut your default feed and test.
* Feed rate too fast - The harder the material being cut, the more torque the steppers have to resist. If you're feeding too fast, this can overcome the holding torque of your motors.
* Axis binding - Check that all of your v-wheels rotate freely when bolted and tightened, as some of the tolerance problems in the v-wheel components can be bad enough to cause the bearings to bind and the v-wheel to be stiff. If you're not using a drive shaft or dual Y axis steppers and your v-wheels or rails are adjusted incorrectly, the Y axis can bind and overwhelm the rated torque on your steppers. Also check that you've tensioned the eccentric spacers correctly. The v-wheels should be firmly planted but should not be so tight that there is any deflection/bowing in the plate, and should be easy to slide along the rails.
* Axis stalling - If you're using a drive shaft it is possible to have one pulley slip while the other will continue to drive the machine. Any instance of slippage should be investigated by checking the set screws on the pulleys.
* Electrical brownout - The power supply does draw a fair bit of power for the stepper motors, minimize other power drawing sources.
* Electrical interference - The spindle and motors put out quite a bit of electrical interference. This may cause random or irregular deviations in the movement of the machine. Shield the wires.
* Loose Idler - Odd distortions, all tending towards a particular direction may be caused by an idler pulley being loose.

== Deviations in slots when cutting ==
The bit is pulled along creating random path deviations which get worse as one gets deeper into a slot.

* Spindle is more powerful than the machine can manage. Spindle not kept up with the balance of the machine, the machine flexing along the Z-axis may flex and allow the bit to rub up against the edge of a slot where the cutting action will then pull the machine further along. Make the X-axis more rigid.

== Deviations in shapes when cutting ==
The machine lags behind at changes of direction, distorting shapes and creating flat edge at the extrema of rounded forms.

* Backlash/Insufficient belt tension - If your belts are too lose, the machine will shift w/ the cutting forces, distorting shapes. Machines w/ threaded rod will have similar difficulties if nuts do not have anti-backlash features.

== Z-axis cuts more deeply than expected ==
The bit is pulled along going deeper into the material than it should.

* Acceleration / movement too fast. The Z-axis is limited in its acceleration and top speed by the torque of the motor. If it is able to move down okay, but will not move up reliably, then the acceleration or movement may be too fast or high. Some G-code senders have an option to limit the Z-axis speed.
* Spindle is loose in its mounts, Z-axis plunge rate too fast causing the machine to go deeper. Always check to ensure the spindle is secure. Always be cautious with Z-axis plunge rates, especially when using CAM tools which lack spiral or ramp Z-axis moves.
* Z-axis motor is over-heating, causing the machine to fail to move up on negative moves (it's more difficult to lift the spindle than to lower it) causing it to cumulatively go deeper. Adjust the current, consider adding heat sinks and/or a fan to cool the stepper drivers.
* End mill loose in collet --- this can also cause other path deviations as the needed cutting forces are increased beyond the machine's capabilities. Tighten collet.

== Z-axis cuts at odd angles when cutting thin stock ==
The bit is pulling the material up or twisting it as it cuts.

* Switch to a down-cutting spiral bit --- check and ensure the bit is sharp.
* Lines are not straight, circles not round, dog bone pattern at corners, cut quality poor - DC spindle wired to run backwards.
** A damaged or dull end mill.
** Milling direction may be wrong.
* Repeating curve/wobble - Bad bearing or V-wheel

== Material Stock Melting or Burning ==
Smoke, fire, material build-up on tooling, poor cut edges (plastic) or burn marks (wood).

* RPM too high / Feed rate too low The surface of your tooling is moving too fast relative to the material. This leads to 'dwell', where the tooling rubs against the material to create a significant amount of heat.
** Increase your feed rate (higher mm/minute). Increasing your feed rate decreases the speed difference between the edge of your tooling and the material, reducing friction. GRBL has some limitations on feed, especially in smaller parts and curves, so this is not always possible.
** Slow your spindle (lower RPM)'''.''' If your router or dremel has variable speeds, turn it down. This, however, usually reduces the available torque, which can in turn lead to stalling your spindle during the cut.

== Persistent Ridges ==
Endmill is either bent or deflecting.

== Bit Chatter ==
Loud chattering, jagged cut edges, snapped tooling. Feed rates too high or loose frame.

* Slow the feed - If your tooling is trying to bite too much material, it will be under much higher stresses, pushing away or into the material much more than usual. Slowing down your feed rate can reduce this.
* Tighten the frame - Especially if you did not use loctite when assembling, bolts can work loose over time (or never having been tightened sufficiently), greatly reducing the rigidity of the frame - this rigidity is what a CNC uses to move the tool where it is supposed to be. Tightening everything up will help this.
* Another possibility is the spindle carriage plate is running off the bottom of the rail, esp. w/ the new style plate.

== Machine Chatters/Vibrates ==
Chattering, buzzing. Tighten wheels.

'''END OF THE PROCEDURE'''

Cnc-router-user-guide

2026-01-03T20:37:34Z

Aspontarelli: /* REFERENCE */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' CNC Router

'''Requires in-person training:''' Yes 
|width="33%"|
'''Procedure Number'''

UG 110-08, Rev. 1
|width="33%"|
'''Date'''

1/20/2021
|}

= GENERAL =

We have two CNC routers:
* Phoenix - a 4x4', heavy duty machine running LinuxCNC
* AXYZ 4008 - a 4x8', heavy duty machine running LinuxCNC

[[File:Shapeoko 2 – CNC Router.png]]

= SAFETY =

* Safety glasses to be worn when making a cut.
* Ear protection recommended.
* Before operating, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Non-slip footwear or anti-skid floor strips are recommended.
* Do not wear gloves.
* Do not leave workstation until cut is complete.

= REFERENCE =

*[[:File:Sheet CAM Manual_R3.pdf|Ken's SheetCAM Manual]]
* SheetCAM tutorials - https://arclightcnc.com/sheetcam-tutorials/

* [[:File:Zen_of_CNC.pdf|Router Advice - Zen of CNC]]
*[[:File:MAKE CHIPS NOT DUST.pdf|Why chips are important - About Chip Load]]

* [[:File:CNConsrud routing guide.pdf|Technical information on router tooling]]
* ShopBot guide to feeds and speeds: https://static1.squarespace.com/static/59efc96d90badec50a4afa15/t/5a21f4b6e2c483bcf39a2c84/1512174775486/FeedsandSpeeds.pdf
*[[:File:MAKE A BOX.pdf|Cheat Sheet to make a simple box with lid]]
*[[:File:Make A Simple Tray.pdf|Cheat sheet for making a simple router tray]]
*[[:File:MAKE A ROUND BOTTOM TRAYR1.pdf|Cheat sheet for making a round bottom router tray]]
*[[:File:F engrave Cheat Sheet.pdf|Cheat sheet for programming a V-carve in F-engrave.]]
*[[:File:WORK HOLDING STRATEGIES.pdf|Work Holding Strategies]]

==== Feed and Speed Reference ====

===== Aluminum Workpiece Feeds and Speeds =====
While the CNC routers are typically used for cutting wood and plastic, the Phoenix router is capable of cutting aluminum as well. Use of a 50% dilution of isopropyl alcohol in the lube cube is critical for success, as is the use of single flute endmills.

The following settings have been used with success in cutting 6061.

1/4" O-flute carbide endmill, 16,000 RPM, 40 ipm, 0.03in DOC

= PROCEDURE =

== General Controls and Configuration==
The Phoenix and AXYZ CNC routers can both be controlled using their respective gamepad controllers. The button configuration is shown below.

[[File:Controller movelist.png]]

== Workflow ==

There are many ways to complete this workflow, but included in this section are descriptions of how to make a successful cut with two different sets of software. The first is the most simple, the second more challenging but more powerful.

=== Inkscape -> SheetCAM -> LinuxCNC ===

One method of getting from idea to CNC routed part is to create your CAD design in Inkscape, then use SheetCAM to generate the tool paths. If carving a 2D design like a sign, this is the quickest and simplest method. Below is the general outline of this approach.

# Import drawing into SheetCAM (svg or dxf)
# Check machine options (Options -> Machine)
## Postprocessor -> LinuxCNC
## Postprocessor -> output units
# Set job options (Options -> Job Options)
## Set material dimensions
## Set origin
# Assign contours to layers
# Create tools to be used
# Create operations that assign tools to layers
## Set feeds and speeds (flip to other side for help)
# Visualize the job with Mode -> Simulation
# Create gcode: File -> Run Post Processor
# Transfer gcode file to cncrouter computer using USB stick or /vsfs01/share directory
# Open gcode file from LinuxCNC
# Insert tool in CNC router
# Clamp down workpiece (Always use a spoil board!)
# Turn on CNC router by rotating E-stop button clockwise
# Home machine by clicking Home All in LinuxCNC or by pressing Start + Select at the same time
# Move tool to origin and set the x, y, and z coordinates to zero by click Touch Off in LinuxCNC or by pressing Select + Direction Pad
# Confirm that tool won’t collide with hold-downs by manually jogging machine around the path
# Turn on dust collector
# Run operation
# Turn off dust collector and tidy up

=== FreeCAD -> LinuxCNC ===

Another method of using the CNC router is to use a program like FreeCAD to generate your 2D or 3D model, then also doing the CAM within FreeCAD. The benefit to this approach is that everything is done in a single program, and that the program is significantly more powerful and capable of handling 3D designs.

==== Vacuum Table ====
[[File:Vacuum table-labeled.jpg|thumb|Vacuum table with labels]]
The AXYZ router has a vacuum table plumbed into five distinct sections. The photo below shows the vacuum chamber arrangement and the valves associated with each.

# Place your workpiece as best you can over a complete chamber. For example if your workpiece is 24x48", it will fit perfectly over a single chamber, and should not be placed on the intersection of four chambers.
# Cover the rest of the table surface with impermeable cover sheets.
# Open as few valves as necessary to hold your workpiece. The pressure gauge indicates pressure in inHg and kPA. 1 inHg is about 0.5 psi, so 10inHg holding a 24x24in piece would exert 2,880 pounds of force. A very rough rule of thumb is to target at least 1,000 pounds.

= TROUBLESHOOTING =

== General Issues ==
Turn the machine on, so that the motors energize, but don't tell it to move. Do not turn the spindle on. Try to wiggle the spindle left and right by hand. Can you move it? If you can, watch carefully to see what moves with it. Does the belt move but the pulley doesn't turn? You have a loose belt. Does the pulley turn too? You have a loose pulley set screw. Does the entire gantry move with respect to the stationary rails? You have loose V-wheels or eccentric spacers. And so on. Repeat for back and forth movement, and up and down too, if that's also causing problems.

== Machine won't start ==
The console window will show the command being sent and a confirmation of "ok". However, the active state goes to "Queue" and never returns to "Idle.

* Auto cycle start has been turned off - Note that turning off auto cycle start requires that one begin the machine manually.
* Previous operation was quit from the Communication / Control program w/o disconnecting. Restart the computer system.
* USB port has gone into low-power mode. Energy-savings features can interfere w/ sending data to the Arduino. Do not let the controlling machine go into low power mode,
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine jogs, but won't respond to downloaded file ==
The machine will respond to single commands, but will not accept a downloaded file and will endlessly repeat some statement to the console.

* Grbl software installation corrupt. Reflash Grbl.
* Corrupt Grbl settings. It is possible for a power interruption or other issue to result in invalid data being stored, making it impossible for Grbl, which has minimal error checking, to process any commands.

== Machine won't hold position ==
Set Grbl setting for "step idle delay" in milliseconds to 255 (suggested default). It will always energize the motors to a hold position. If set to some other value, motors will be turned off after the specified time.

== Toolpath Differs from Expected ==
If the machine's behavior doesn't match what is simulated.

* '''software bug''' - Grbl is very reliable, so unlikely to be in the firmware.
** Carbide Motion 4 ought to give an error message on any G-Code which it can't properly send on to the machine, and Carbide Create ought not make any code which doesn't work properly
* '''file problem''' - an example of this would be setting safety / retract height too high, using the wrong post-processor, or enabling a feature such as XY datum in Vectric Vcarve.
* '''machine misconfiguration / user error''' - this can be a lot of things, occasionally overlapping with the above, for example setting safety / retract height and the Z-axis zero so that when the machine lifts to safety height it bumps against and loses steps against the top stop, so that the Z-axis height isn't correct.
* '''mechanical machine setup''' - these ought to be covered by the machine Operating Checklist --- frequent things to check:
** Check pulley set screws
** Check V wheels / eccentric nuts
** Belt tension, the Z-axis belt in particular needs to be guitar string tight (but careful not to bend the motor shaft).
** Electronics - it's possible for a wire or connector to break or for a lost connection or excessive current generated by the stepper motors or a stray static spark to damage the stepper driver or controller.

== Radius of corners is different ==
Stairstepped diagonals, jagged circles/curves, loud squealing or 'ker-chunka' thuds, gantry chattering, mis-aligned edges. A useful troubleshooting technique for this is to listen to the machine:

* If it sounds awful = loose wire (or the stepper driver going into thermal shutdown).
* If it sounds normal = loose set screw (or other mechanical issue such as loose belts).

== File worked previously, doesn't work now ==
Reaching limits of machine.

* Either overheating or reaching acceleration limits.
* Steppers may be entering thermal shutdown, add active cooling.
* Machine is operating at the limits of its acceleration. Slow down feed speeds and max acceleration in GRBL.
* Endmill no longer sharp, spindle not working properly (rotating in wrong direction). If the machine is not able to properly cut, then it will not be able to move along the desired path, since it will not be clear.
* A spindle which is not working properly may put out EMI which will interfere w/ the movement of the stepper motors. Brushes on a router are a consumable part and must be replaced periodically.

== Steppers are missing steps ==

* Drivers overheating - Position the fan so that in blows across both the top and bottom of the drivers. Airflow does the most, followed by a heatsink on top of the chip. Note that this may also be caused by setting the current too high.
* Steppers being run too fast - GRBL has a maximum speed that it can drive stepper motors at. Because the X and Y axis are belt driven while the Z is threaded rod drive, it is very easy to set the x/y Default Feed speed faster than the Z axis can be signaled. Cut your default feed and test.
* Feed rate too fast - The harder the material being cut, the more torque the steppers have to resist. If you're feeding too fast, this can overcome the holding torque of your motors.
* Axis binding - Check that all of your v-wheels rotate freely when bolted and tightened, as some of the tolerance problems in the v-wheel components can be bad enough to cause the bearings to bind and the v-wheel to be stiff. If you're not using a drive shaft or dual Y axis steppers and your v-wheels or rails are adjusted incorrectly, the Y axis can bind and overwhelm the rated torque on your steppers. Also check that you've tensioned the eccentric spacers correctly. The v-wheels should be firmly planted but should not be so tight that there is any deflection/bowing in the plate, and should be easy to slide along the rails.
* Axis stalling - If you're using a drive shaft it is possible to have one pulley slip while the other will continue to drive the machine. Any instance of slippage should be investigated by checking the set screws on the pulleys.
* Electrical brownout - The power supply does draw a fair bit of power for the stepper motors, minimize other power drawing sources.
* Electrical interference - The spindle and motors put out quite a bit of electrical interference. This may cause random or irregular deviations in the movement of the machine. Shield the wires.
* Loose Idler - Odd distortions, all tending towards a particular direction may be caused by an idler pulley being loose.

== Deviations in slots when cutting ==
The bit is pulled along creating random path deviations which get worse as one gets deeper into a slot.

* Spindle is more powerful than the machine can manage. Spindle not kept up with the balance of the machine, the machine flexing along the Z-axis may flex and allow the bit to rub up against the edge of a slot where the cutting action will then pull the machine further along. Make the X-axis more rigid.

== Deviations in shapes when cutting ==
The machine lags behind at changes of direction, distorting shapes and creating flat edge at the extrema of rounded forms.

* Backlash/Insufficient belt tension - If your belts are too lose, the machine will shift w/ the cutting forces, distorting shapes. Machines w/ threaded rod will have similar difficulties if nuts do not have anti-backlash features.

== Z-axis cuts more deeply than expected ==
The bit is pulled along going deeper into the material than it should.

* Acceleration / movement too fast. The Z-axis is limited in its acceleration and top speed by the torque of the motor. If it is able to move down okay, but will not move up reliably, then the acceleration or movement may be too fast or high. Some G-code senders have an option to limit the Z-axis speed.
* Spindle is loose in its mounts, Z-axis plunge rate too fast causing the machine to go deeper. Always check to ensure the spindle is secure. Always be cautious with Z-axis plunge rates, especially when using CAM tools which lack spiral or ramp Z-axis moves.
* Z-axis motor is over-heating, causing the machine to fail to move up on negative moves (it's more difficult to lift the spindle than to lower it) causing it to cumulatively go deeper. Adjust the current, consider adding heat sinks and/or a fan to cool the stepper drivers.
* End mill loose in collet --- this can also cause other path deviations as the needed cutting forces are increased beyond the machine's capabilities. Tighten collet.

== Z-axis cuts at odd angles when cutting thin stock ==
The bit is pulling the material up or twisting it as it cuts.

* Switch to a down-cutting spiral bit --- check and ensure the bit is sharp.
* Lines are not straight, circles not round, dog bone pattern at corners, cut quality poor - DC spindle wired to run backwards.
** A damaged or dull end mill.
** Milling direction may be wrong.
* Repeating curve/wobble - Bad bearing or V-wheel

== Material Stock Melting or Burning ==
Smoke, fire, material build-up on tooling, poor cut edges (plastic) or burn marks (wood).

* RPM too high / Feed rate too low The surface of your tooling is moving too fast relative to the material. This leads to 'dwell', where the tooling rubs against the material to create a significant amount of heat.
** Increase your feed rate (higher mm/minute). Increasing your feed rate decreases the speed difference between the edge of your tooling and the material, reducing friction. GRBL has some limitations on feed, especially in smaller parts and curves, so this is not always possible.
** Slow your spindle (lower RPM)'''.''' If your router or dremel has variable speeds, turn it down. This, however, usually reduces the available torque, which can in turn lead to stalling your spindle during the cut.

== Persistent Ridges ==
Endmill is either bent or deflecting.

== Bit Chatter ==
Loud chattering, jagged cut edges, snapped tooling. Feed rates too high or loose frame.

* Slow the feed - If your tooling is trying to bite too much material, it will be under much higher stresses, pushing away or into the material much more than usual. Slowing down your feed rate can reduce this.
* Tighten the frame - Especially if you did not use loctite when assembling, bolts can work loose over time (or never having been tightened sufficiently), greatly reducing the rigidity of the frame - this rigidity is what a CNC uses to move the tool where it is supposed to be. Tightening everything up will help this.
* Another possibility is the spindle carriage plate is running off the bottom of the rail, esp. w/ the new style plate.

== Machine Chatters/Vibrates ==
Chattering, buzzing. Tighten wheels.

'''END OF THE PROCEDURE'''

Band saw maintenance and specifications

2025-10-16T16:53:50Z

Aspontarelli: /* Rikon */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Band Saw
|width="33%"|
'''Procedure Number'''

MT 110-01, Rev. 1
|width="33%"|
'''Date'''

1/21/2021
|}

= General =

There are two woodworking Band Saws:

* Rotary International Bridgewood PBS 440: 16 inch vertical bandsaw

* Rikon 10-326: 14 inch vertical bandsaw

[[File:Bandsaws.png]]

= Reference =

* Link to YouTube videos https://www.youtube.com/watch?v=paXdjslgPgU
* https://www.rikontools.com/manuals/10-326.pdf
* Rikon Operator's Manual: https://www.rikontools.com/wp-content/uploads/10-326M6.pdf

= Maintenance =

'''Cleaning:''' If you've adjusted the tracking properly but the blade will not stay centered inside the slot, it probably means the wheel needs cleaning. Depending on what you've been cutting -- pine is a likely suspect -- sawdust mixes with resin and clings to the blade. As it travels around in a circle, the sticky sawdust packs onto the wheel, causing a buildup. The buildup causes the blade to wander back and forth inside the slot. Remove the blade and use a putty knife to scrape off any packed sawdust, dirt or grime from the wheel until it's clean. Wipe off the blade and install it, turn on the saw, and readjust the tracking.

'''Blade:''' Check blade tracking, blade tension, and condition of band wheels.

* '''Daily:''' Inspect blade, blade wipers, blade guides, sawing fluid condition and ratio, hydraulic system oil level, and chip removal system.
* '''Weekly: '''Check maximum and minimum band speed range and calibrate if necessary.
* '''Quarterly:''' Clean sawing fluid reservoir and screen.
* '''Biannually:''' Change hydraulic fluid filters, clean hydraulic fluid reservoir magnetic plug, lubricate saw column pivot point, and inspect and adjust blade guides. Check band wheel bearings, band guides, drives, belts, and vises.
* '''Annually:''' Drain hydraulic fluid tank and clean fluid strainer and filter. Replace hydraulic fluid and transmission oil.
* '''Dull Blade:''' If you've tightened the blade sufficiently and the blade still wanders, you might have a dull blade. Test the sharpness of the blade by cutting into a piece of scrap wood. If you have to use excessive force to push the wood through the blade, or you see wisps of smoke coming from the wood or the blade, it's probably dull. If the teeth are burnt with dark tips, the blade needs changing. The blade should be replaced if the ends of the teeth are bent or blunted.

'''Blade Tracks'''

* Ensure blade tracks are true and ride correctly in the blade guides.
* '''Blade Tracking:''' Turn on the saw and observe the blade as it travels down through the slot in the top of the table. The blade should be centered in the slot. If the blade is too far forward or too far back, or even rubs at the front or back, it means the tracking is off and needs adjusting

'''Blade Tension'''

* Check the accuracy of the blade tension using a tension gage. The correct spacing between the back edge of the blade and the flange of the wheel should be approximately 132’’, though it may vary according to different manufacturers’ instructions. Adjust if necessary.
* '''Tension:''' draw a line across a piece of scrap wood. Attempt to cut along the line. If you have trouble following the line or the blade wanders back and forth across the line, your blade might be too loose. The blade should flex no more than 1/4 inch when you push it sideways.

'''Band Wheels, Band Wheel/Bearings'''

* Assess the band wheels for surface and flange wear.
* Remove any chips that could fill the grooves and impede band wheels from turning freely.
* Replace when surfaces or flanges are worn, cracked, or chipped.
* Check the maximum and minimum band speed with a tachometer; the reading should match the gauge.
* Check band wheel bearings for unusual wheel movement and replace as needed.

'''Blade Guides'''

* Clean chips from blade guides and wipers daily.
* Do not use blade guides that are chipped or cracked.
* For maximum support, move the guide arm as close as possible to the workpiece.
* Ensure the guide holds the blade with the correct pressure.
* Check that band guides are perpendicular to material vice and adjust if necessary.
* If cuts become incorrect or crooked, or blade fails prematurely, adjust the guide alignment.

'''Lubricant/Sawing Fluid'''

* Check sawing fluid or lubricants daily. Keep the level to the machine’s specifications.
* Ensure the fluid flows freely through all fluid nozzles.
* Only use lubricant or sawing fluid that is clean and mixed properly. Test the ratio using a refractometer in addition to visual inspection.
* When replacing the fluid, start with water and carefully add the correct quantity lubricating fluid as per the manufacturer’s instructions.

'''Hydraulic System'''

* Monitor hydraulic fluid levels. Low oil level may cause air in the lines and impede the hydraulic system.
* Watch for sediment in the bottom of the reservoir, as it could block the line and filter.
* Check oil level daily.

'''Drive System'''

* Inspect all areas with bearings for oil leaks.
* Check transmission level and replace any defective seals.
* Check drive wheel of gear-driven machines for excess play, which indicates worn gears.
* Check pulleys for proper alignment, tension and wear. Adjust if possible or replace if damaged.
* Check drive belt and chip brush belt for cracks, wear and stretching.

'''Vises'''

* Clean chips from vise jaws.
* Check for wear and correct alignment on both stationary and moveable vises.

'''Chip Removal System'''

* Inspect to ensure the auger or conveyor system works properly and removes all chips.
* Check that screens are not allowing chips into the sawing fluid/lubricant tank.
* Check the chip brush. It should keep chips from re-entering the cut.

= List of Specifications =

== Rikon ==

Motor ............................................................................................. 1.75 HP, TEFC

Motor Speed (no load)......................................................................... 1,720 RPM

Volts ................................................................................................... 115 / 230 V

Amps, Hertz, Phase .............................................................. 14 / 7 A, 60 Hz, 1Ph

Blade Length ................................................................................111” (2,819 mm)

Blade Width ..................................................................3/16” - 3/4” (4.78 - 19 mm)

Blade Speed ........................................ 1,445 / 2,950 ft/min (440.5 / 899.2 m/min)

Table Size (W x D) ............................................ 21-1/2” x 15-3/4” (546 x 400 mm)

Table Tilt ................................................................................... Left -70 , Right 45°

Miter Gauge T-Slots (2) ......................................................................... 3/4” x 3/8”

Maximum Cutting Width (throat) ................................................ 13-5/8” (346 mm)

Maximum Cutting Depth (height) ..................................................... 13” (330 mm)

Table Height ........................................................................... 40-3/8” (1,026 mm)

Fence Height ..................................................................................... 6” (152 mm)

Fence Length ............................................................................ 18-3/4’” (476 mm)

Dust Ports (1) ..................................................................... 4” Diameter (100 mm)

Base Size (LxWxH) ....................... 24” x 17-5/16” x 1-3/16” (610 x 440 x 30 mm)

Overall Height ......................................................................... 74-1/2” (1,892 mm)

Overall Width x Depth.................................... 34-1/4” x 25-13/16” (870 x 656mm)

Net Weight ................................................................................... 285 lbs (129 kg)

Guide Bearings: 6202-2RS

== Bridgewood PBS 440 ==
* Blade Length: 145"
* Blade Width: 1" for resaw
* Blade TPI: 2 or 3
* Guide Bearing Size: 6200-2RS x 10

The guide bearings on this machine need frequent replacement, about every 6 months.

== Maintenance Log ==

=== 5/15/24: ===

# Rikon Bandsaw won't turn on.
# Checked switch by pressing on and measuring non-contact voltage at motor wires. Voltage present. Assuming bad start capacitor. Ordered Start (50 uF) and Run (150uF) capacitors.
# Installed capacitors, still not working.
# Measured hot to neutral voltage: ~0V. Hot to Gnd: 122V. Neutral to Gnd: 122V. Something is wrong.
# Disassemble switch and measure for continuity. Top contacts work, bottom contacts do not.
# Opened up switch to find that bottom contacts were melted.
# Ordered new switch.
# The switch shouldn't be wired this way when motor is wired for 120V operation. Do not switch the neutral for this very reason, just tie the neutrals together.
'''5/17/24:'''

# Wired new switch for Rikon. Joined all neutrals together, bypassing the switch.
# Replaced 10 bearings on Bridgewood with 6200-2RS, SKF brand. The bearings removed were a combination of shielded and sealed. Almost all of the shielded bearings were seized, whereas none of the sealed ones were. Clearly need to use sealed bearings.

'''END OF THE PROCEDURE'''

Diamond bandsaw maintenance and specifications

2025-09-30T13:11:38Z

Aspontarelli: Created page with "Blade: MD3718. 37in x 0.125in"

Blade: MD3718. 37in x 0.125in

Tool Maintenance Guides

2025-09-30T13:11:10Z

Aspontarelli: /* Stained Glass */

= Woodshop (110) =

[[band_saw_maintenance_and_specifications|Band Saw Maintenance and Specifications]]

[[thickness_planer_maintenance_and_specifications|Thickness Planer Maintenance and Specifications]]

[[table_saw_maintenance_and_specifications|Table Saw Maintenance and Specifications]]

[[miter_saw_maintenance_and_specifications|Miter Saw Maintenance and Specifications]]

[[jointer_maintenance_and_specifications|Jointer Maintenance and Specifications]]

[[drill_press_maintenance_and_specifications|Drill Press Maintenance and Specifications]]

[[lathe_maintenance_and_specifications|Lathe Maintenance and Specifications]]

[[cnc_router_maintenance_and_specifications|CNC Router Maintenance and Specifications]]

[[scroll_saw_maintenance_and_specifications|Scroll Saw Maintenance and Specifications]]

[[drum sander_maintenance_and_specifications|Wide Belt Sander Maintenance and Specifications]]

[[air_compressor|Air Compressor Maintenance and Specifications]]

[[edge_sander_maintenance_and_specifications|Edge Sander Maintenance and Specifications]]

[[vertical_belt_sander_maintenance_and_specifications|Vertical Belt Sander Maintenance and Specifications]]

= Rapid Prototyping (120) =

[[3d_printer_maintenance_and_specifications|3D Printer Maintenance and Specifications]]

[[co2_laser_cutter_maintenance_and_specifications|CO2 Laser Cutter Maintenance and Specifications]]

[[Fiber Laser Maintenance and Specifications]]

[[vinyl_cutter_maintenance_and_specifications|Vinyl Cutter Maintenance and Specifications]]

[[heat_press_maintenance_and_specifications|Heat Press Maintenance and Specifications]]

= Metal Shop (130) =

[[blacksmithing_maintenance_and_specifications|Blacksmithing Maintenance and Specifications]]

[[stick_welding_maintenance_and_specifications|Stick Welding Maintenance and Specifications]]

[[mig_welding_maintenance_and_specifications|MIG Welding Maintenance and Specifications]]

[[tig_welding_maintenance_and_specifications|TIG Welding Maintenance and Specifications]]

[[plasma_cutter_maintenance_and_specifications|Plasma Cutter (handheld) Maintenance and Specifications]]

[[cnc_plasma_maintenance_and_specifications|CNC Plasma Cutter Maintenance and Specifications]]

[[milling_bridgeport_maintenance_and_specifications|Milling Bridgeport Maintenance and Specifications]]

[[tormach_cnc_milling_machine_maintenance_and_specifications|Tormach CNC Milling Machine Maintenance and Specifications]]

[[eztrak_cnc_milling_machine_maintenance_and_specifications|EZTrak CNC Milling Machine Maintenance and Specifications]]

[[ovens_and_kilns_maintenance_and_specifications|Ovens and Kilns Maintenance and Specifications]]

[[shearing_brake_forming_roll_forming_maintenance_and_specifications|Shearing - Brake Forming - Roll Forming Maintenance and Specifications]]

[[pipe_and_tube_bender_maintenance_and_specifications|Pipe and Tube Bender Maintenance and Specifications]]

[[hydraulic_press_maintenance_and_specifications|Hydraulic Press Maintenance and Specifications]]

[[hardinge_lathe_maintenance_and_specifications|Hardinge Lathe Maintenance and Specifications]]

[[cold_saw_maintenance_and_specifications|Cold Saw Maintenance and Specifications]]

[[vertical_bandsaw_maintenance_and_specifications|Vertical Bandsaw Maintenance and Specifications]]

[[horizontal_bandsaw_maintenance_and_specifications|Horizontal Bandsaw Maintenance and Specifications]]

[[english_wheel_maintenance_and_specifications|English Wheel Maintenance and Specifications]]

[[sand_blaster_maintenance_and_specifications|Sandblaster Maintenance and Specifications]]

[[Parts Washer Maintenance and Specifications]]

[[horizontal_milling_machine_maintenance_and_specifications|Horizontal Milling Machine Maintenance and Specifications]]

= Textiles (140) =

[[brother_industrial_sewing_machine_maintenance_and_specifications|Brother Industrial Sewing Machine Maintenance and Specifications]]

[[viking_sewing_machine_maintenance_and_specifications|Viking Sewing Machine Maintenance and Specifications]]

[[serger_maintenance_and_specifications|Serger Maintenance and Specifications]]

[[brother_pr655_embroidery_machine_maintenance_and_specifications|Brother PR655 Embroider Machine Maintenance and Specifications]]

= Computer Lab (150) =

[[inkscape_maintenance_and_specifications|Inkscape Maintenance and Specifications]]

[[freecad_maintenance_and_specifications|FreeCAD Maintenance and Specifications]]

= Electronics (160) =

= Ceramics =
[[pottery_wheel_maintenance_and_specifications|Pottery Wheel Maintenance and Specifications]]

= Stained Glass =
[[glass_grinder_maintenance_and_specifications| Glass Grinder Maintenance and Specifications]]

[[diamond_bandsaw_maintenance_and_specifications| Diamond Bandsaw Maintenance and Specifications]]

Tool Maintenance Guides

2025-09-30T13:11:06Z

Aspontarelli: /* Stained Glass */

Tool Maintenance Guides

2025-09-30T13:10:46Z

Aspontarelli: /* Stained Glass */

Band saw maintenance and specifications

2025-09-22T16:45:26Z

Aspontarelli: /* Reference */

{|
|width="33%"|
'''Shop Area:''' Woodshop

'''Tool:''' Band Saw
|width="33%"|
'''Procedure Number'''

MT 110-01, Rev. 1
|width="33%"|
'''Date'''

1/21/2021
|}

= General =

There are two woodworking Band Saws:

* Rotary International Bridgewood PBS 440: 16 inch vertical bandsaw

* Rikon 10-326: 14 inch vertical bandsaw

[[File:Bandsaws.png]]

= Reference =

* Link to YouTube videos https://www.youtube.com/watch?v=paXdjslgPgU
* https://www.rikontools.com/manuals/10-326.pdf
* Rikon Operator's Manual: https://www.rikontools.com/wp-content/uploads/10-326M6.pdf

= Maintenance =

'''Cleaning:''' If you've adjusted the tracking properly but the blade will not stay centered inside the slot, it probably means the wheel needs cleaning. Depending on what you've been cutting -- pine is a likely suspect -- sawdust mixes with resin and clings to the blade. As it travels around in a circle, the sticky sawdust packs onto the wheel, causing a buildup. The buildup causes the blade to wander back and forth inside the slot. Remove the blade and use a putty knife to scrape off any packed sawdust, dirt or grime from the wheel until it's clean. Wipe off the blade and install it, turn on the saw, and readjust the tracking.

'''Blade:''' Check blade tracking, blade tension, and condition of band wheels.

* '''Daily:''' Inspect blade, blade wipers, blade guides, sawing fluid condition and ratio, hydraulic system oil level, and chip removal system.
* '''Weekly: '''Check maximum and minimum band speed range and calibrate if necessary.
* '''Quarterly:''' Clean sawing fluid reservoir and screen.
* '''Biannually:''' Change hydraulic fluid filters, clean hydraulic fluid reservoir magnetic plug, lubricate saw column pivot point, and inspect and adjust blade guides. Check band wheel bearings, band guides, drives, belts, and vises.
* '''Annually:''' Drain hydraulic fluid tank and clean fluid strainer and filter. Replace hydraulic fluid and transmission oil.
* '''Dull Blade:''' If you've tightened the blade sufficiently and the blade still wanders, you might have a dull blade. Test the sharpness of the blade by cutting into a piece of scrap wood. If you have to use excessive force to push the wood through the blade, or you see wisps of smoke coming from the wood or the blade, it's probably dull. If the teeth are burnt with dark tips, the blade needs changing. The blade should be replaced if the ends of the teeth are bent or blunted.

'''Blade Tracks'''

* Ensure blade tracks are true and ride correctly in the blade guides.
* '''Blade Tracking:''' Turn on the saw and observe the blade as it travels down through the slot in the top of the table. The blade should be centered in the slot. If the blade is too far forward or too far back, or even rubs at the front or back, it means the tracking is off and needs adjusting

'''Blade Tension'''

* Check the accuracy of the blade tension using a tension gage. The correct spacing between the back edge of the blade and the flange of the wheel should be approximately 132’’, though it may vary according to different manufacturers’ instructions. Adjust if necessary.
* '''Tension:''' draw a line across a piece of scrap wood. Attempt to cut along the line. If you have trouble following the line or the blade wanders back and forth across the line, your blade might be too loose. The blade should flex no more than 1/4 inch when you push it sideways.

'''Band Wheels, Band Wheel/Bearings'''

* Assess the band wheels for surface and flange wear.
* Remove any chips that could fill the grooves and impede band wheels from turning freely.
* Replace when surfaces or flanges are worn, cracked, or chipped.
* Check the maximum and minimum band speed with a tachometer; the reading should match the gauge.
* Check band wheel bearings for unusual wheel movement and replace as needed.

'''Blade Guides'''

* Clean chips from blade guides and wipers daily.
* Do not use blade guides that are chipped or cracked.
* For maximum support, move the guide arm as close as possible to the workpiece.
* Ensure the guide holds the blade with the correct pressure.
* Check that band guides are perpendicular to material vice and adjust if necessary.
* If cuts become incorrect or crooked, or blade fails prematurely, adjust the guide alignment.

'''Lubricant/Sawing Fluid'''

* Check sawing fluid or lubricants daily. Keep the level to the machine’s specifications.
* Ensure the fluid flows freely through all fluid nozzles.
* Only use lubricant or sawing fluid that is clean and mixed properly. Test the ratio using a refractometer in addition to visual inspection.
* When replacing the fluid, start with water and carefully add the correct quantity lubricating fluid as per the manufacturer’s instructions.

'''Hydraulic System'''

* Monitor hydraulic fluid levels. Low oil level may cause air in the lines and impede the hydraulic system.
* Watch for sediment in the bottom of the reservoir, as it could block the line and filter.
* Check oil level daily.

'''Drive System'''

* Inspect all areas with bearings for oil leaks.
* Check transmission level and replace any defective seals.
* Check drive wheel of gear-driven machines for excess play, which indicates worn gears.
* Check pulleys for proper alignment, tension and wear. Adjust if possible or replace if damaged.
* Check drive belt and chip brush belt for cracks, wear and stretching.

'''Vises'''

* Clean chips from vise jaws.
* Check for wear and correct alignment on both stationary and moveable vises.

'''Chip Removal System'''

* Inspect to ensure the auger or conveyor system works properly and removes all chips.
* Check that screens are not allowing chips into the sawing fluid/lubricant tank.
* Check the chip brush. It should keep chips from re-entering the cut.

= List of Specifications =

== Rikon ==

Motor ............................................................................................. 1.75 HP, TEFC

Motor Speed (no load)......................................................................... 1,720 RPM

Volts ................................................................................................... 115 / 230 V

Amps, Hertz, Phase .............................................................. 14 / 7 A, 60 Hz, 1Ph

Blade Length ................................................................................111” (2,819 mm)

Blade Width ..................................................................3/16” - 3/4” (4.78 - 19 mm)

Blade Speed ........................................ 1,445 / 2,950 ft/min (440.5 / 899.2 m/min)

Table Size (W x D) ............................................ 21-1/2” x 15-3/4” (546 x 400 mm)

Table Tilt ................................................................................... Left -70 , Right 45°

Miter Gauge T-Slots (2) ......................................................................... 3/4” x 3/8”

Maximum Cutting Width (throat) ................................................ 13-5/8” (346 mm)

Maximum Cutting Depth (height) ..................................................... 13” (330 mm)

Table Height ........................................................................... 40-3/8” (1,026 mm)

Fence Height ..................................................................................... 6” (152 mm)

Fence Length ............................................................................ 18-3/4’” (476 mm)

Dust Ports (1) ..................................................................... 4” Diameter (100 mm)

Base Size (LxWxH) ....................... 24” x 17-5/16” x 1-3/16” (610 x 440 x 30 mm)

Overall Height ......................................................................... 74-1/2” (1,892 mm)

Overall Width x Depth.................................... 34-1/4” x 25-13/16” (870 x 656mm)

Net Weight ................................................................................... 285 lbs (129 kg)

== Bridgewood PBS 440 ==
* Blade Length: 145"
* Blade Width: 1" for resaw
* Blade TPI: 2 or 3
* Guide Bearing Size: 6200-2RS x 10

The guide bearings on this machine need frequent replacement, about every 6 months.

== Maintenance Log ==

=== 5/15/24: ===

# Rikon Bandsaw won't turn on.
# Checked switch by pressing on and measuring non-contact voltage at motor wires. Voltage present. Assuming bad start capacitor. Ordered Start (50 uF) and Run (150uF) capacitors.
# Installed capacitors, still not working.
# Measured hot to neutral voltage: ~0V. Hot to Gnd: 122V. Neutral to Gnd: 122V. Something is wrong.
# Disassemble switch and measure for continuity. Top contacts work, bottom contacts do not.
# Opened up switch to find that bottom contacts were melted.
# Ordered new switch.
# The switch shouldn't be wired this way when motor is wired for 120V operation. Do not switch the neutral for this very reason, just tie the neutrals together.
'''5/17/24:'''

# Wired new switch for Rikon. Joined all neutrals together, bypassing the switch.
# Replaced 10 bearings on Bridgewood with 6200-2RS, SKF brand. The bearings removed were a combination of shielded and sealed. Almost all of the shielded bearings were seized, whereas none of the sealed ones were. Clearly need to use sealed bearings.

'''END OF THE PROCEDURE'''