BobsCNC Evolution 4, Assembly Instructions Manual

Page 1: ...Evolution 4 Assembly Instructions Rev 1 9 Upgrade Kit Converts the Evolution 4 CNC Router into an Evolution 5 CNC Router ...

Page 2: ...tep by Step Instructions 7 X Frame Extension Assembly 12 Wood Components 12 Hardware 13 Illustrated Step by Step Instructions 14 Final Assembly 21 Illustrated Step by Step Instructions 21 T Slot Spoilboard 39 Wood Components 39 Required Hardware 39 Illustrated Step by Step Instructions 40 Updating Firmware 49 Evolution 4 Extension Firmware Value Change 49 Appendix 130 1283 50 Evolution 4 Firmware ...

Page 3: ...2 EVOLUTION 4 Upgrade Specifications The Assembled Footprint Length 58 7 1490 mm Width 39 994 mm Height 20 9 530 mm Assembled Weight 48 lbs Cutting Area X 50 5 1283 mm Y 24 610 mm Z 3 3 85 mm ...

Page 4: ...ow this instruction WARNING Indicates the possible damage to the machine its components the work piece or injury that can result from failure to follow this warning DANGER Indicates a serious risk of bodily harm injury and death This is a serious warning and should not be ignored Any work must be carried out with extreme caution TIPs Contains helpful information shortcuts and hints to simplify ass...

Page 5: ...ngs bracelets watches necklaces before using the machine Wear snug fitting clothing and or roll up long sleeves to prevent snagging Use appropriate personal protective equipment PPE when operating machine including safety glasses and hearing protection Keep hands hair and clothing away from the moving parts of the machine Do not operate the machine when under the influence of alcohol or prescripti...

Page 6: ...Metric Sockets and SAE Wrenches Set of Metric and SAE Allen Wrenches Assembly Recommendations Use a large flat clean work surface for assembling your EVOLUTION All Screws unless noted should be installed snug then rotated 1 2 turns Apply LOCTITE to all M4 X 16 mm Machine Screw that are used to secure plywood pieces except for the 4 screws that clamp the router in step 10 of the final assembly Ligh...

Page 7: ...uts are never used to secure components that have T Slots They are only used to mount components where the Nut is not held in a T Slot CAUTION This kit contains numerous small components that pose a choking risk for small children and pets Keep kit pieces in a secure location out of the reach or small children and pets ...

Page 8: ...7 Removing Components Illustrated Step by Step Instructions Before you can upgrade your Evolution 4 you will need to remove several components Step 1 Remove and discard Spoilboard ...

Page 9: ...8 Step 2 Remove and discard Belts by first loosening the Belt Tensioner Be sure to keep the Belt Retainers ...

Page 10: ...9 Step 3 Remove front Frame End Support and discard Step 4 Remove both sides of the front Frame Corner Supports and set aside They will be reinstalled with the new Evolution 5 End Support ...

Page 11: ...move both sides of the Frame Corner Braces and set aside to be used in the Front Assembly Step 6 Clip and remove the Zip Ties that secure the USB Cable and Power Cords to the Wire Harness Supports Save these parts ...

Page 12: ...11 Step 7 Slide Gantry Assembly off the Rails and carefully set it aside Step 8 Remove the four X Rails and discard The X frame will form the Rear Assembly ...

Page 13: ...bly Wood Components Part Description Qty Photo X1 Rail Support 6 X4 Frame Mid Support 4 EX4 Extension Frame Mid Support 1 EX5 Extension Frame Side Support 2 X6 Frame End Support 2 X7 Wire Harness Support 2 EX12 Coupling Plate 2 ...

Page 14: ...13 Hardware Part Description Qty Photo H14 M4 x 16 Machine Screw 74 H15 M4 Nut 58 H47 M4 Locknut 16 H56 GT2 Belts 2 H82 Stress Proof Steel X Rail 4 ...

Page 15: ...nd rear Assembly To build the Front Assembly Align the tabs of the Rail Supports X1 into the slots in the Extension Frame Side Support EX5 Secure with three M4 x 16 Machine Screws and Nuts for each Rail Support as shown Repeat for both Frame Side Supports Front Right Side Left Side ...

Page 16: ...x 16 Machine Screws and Nuts as shown Repeat to complete the second Frame Side Assembly Step 3 Align the tabs of the four Frame Corner Braces previously removed into upper slots of the Frame Side Assembly on the outside and secure with two M4 x 16 Machine Screws and Nuts as shown Repeat on the remaining Frame Side Assembly Right Side Left Side ...

Page 17: ...16 Completed Front Side Assemblies ...

Page 18: ...17 Step 4 Align the slots in one of the Frame Side Assemblies with the tabs in the Frame Mid Support X4 as shown and secure with two M4 x 16 Screws and Nuts Inside View Outside View ...

Page 19: ...18 Step 5 Repeat the process until three Frame Mid Supports have been installed and secured Step 6 Repeat this procedure to install the remaining Side Support Assembly ...

Page 20: ...19 Step 7 Align the slots in the X6 Frame End Support with the tabs in the Front X Frame Assembly and secure each side with six M4 x 16 Screws and Nuts Completed Front X Frame Assembly ...

Page 21: ...e Wire Harness Support X7 with the slots and secure with two M4 x 16 Machine Screws and Nuts for each end as shown Align and mount the Frame Mid Support X4 to the Mid Frame Assembly X4 EX4 Repeat to install the remaining Wire Harness Support X7 Completed Mid Frame Assembly ...

Page 22: ...ssembly Illustrated Step by Step Instructions Step 1 Align the tabs of the Mid Frame Assembly into the slots of the Coupling Plate EX12 one for each Side of the Mid Frame Assembly and press them together as shown ...

Page 23: ...22 Step 2 Align the mounting holes of the Coupling Plates EX12 with the holes in the Front X Frame Assembly The ends of the Front X Frame Assembly will fit between the Coupling Plates ...

Page 24: ...23 Step 3 Insert the tabs of the Frame Mid Support X4 into the slots of the Front X Frame Assembly and secure with four M4 x 16 Machine Screws and Locking Nuts for each side as shown ...

Page 25: ...e unused mounting holes of the Coupling Plate with the holes in the Rear X Frame Assembly The ends of the Rear X Frame Assembly will fit between the Coupling Plates Secure each side with four M4 X 16 Screws and Lock Nuts ...

Page 26: ...25 IMPORTANT NOTE Before tightening the Lock Nuts hold a straight edge across the top each side Make sure the top edges of the entire X Frame Assembly are flat when tightening Completed Frame Assembly ...

Page 27: ...end while moving through each support Note rotating the rod gently will ease installation Step 6 Carefully reinstall the Gantry Assembly In the photos below the Gantry is resting on a piece of scrap to help hold the bearings up before installing the new Rails ...

Page 28: ... and the Rail Supports Lift one side of the Gantry to allow the Rail to pass beneath the upper bearing Step 8 Carefully install the lower Rails through the X Frame Assembly and the Rail Supports threading the rail to pass over the lower bearing Repeat to install Rails on other side ...

Page 29: ...e the SG20U Bearing against the Rail on the Left Side use a 13mm wrench or socket to rotate the Eccentric Adjustment Spacer clockwise To raise the Bearing on the Right Side rotate the Eccentric Adjustment Spacer counterclockwise Clockwise Counterclockwise ...

Page 30: ...t lower Bearing The Bearing should only move if the Gantry moves Once the Bearings are snug against the Rail tighten the Locknut with a 10mm wrench and Phillips Head screwdriver as shown NOTE There are access holes located at the bottom of the Sides of the X Frame to help you tighten the Bearings ...

Page 31: ...T2 Belts 10a Cut two of the GT2 Belts to a length of 60 7 8 inches 10b Insert one end of the Belt into the Short Belt Retainer previously removed 10c Next thread the free end of the GT2 Belt through the Rail Stop previously removed ...

Page 32: ...ssembly into the bottom slot at the back of the X Frame Assembly NOTE Using a Zip Tie snug the belt in the Retainer Make sure the square lock of the Zip Tie is located on the top of the Belt Retainer Right Side Rear View Zip Tie Be sure to insert in the lower slot at the rear of the machine ...

Page 33: ...f the square access hole in the X Frame This opening provides the access you need to loop the Belt around the Idler and Flange Bearings We suggest that you watch the short video demonstrating how to correctly route and install the Belts around the Flange and Idler Bearings https youtu be SAz9UjGeOa0 ...

Page 34: ...on the belt are facing outboard The following photos illustrate the proper path for routing the Belt The photos were taken before the Gantry was installed on the X Frame for Illustration purposes only The Gantry Assembly must be installed on the X Frame Assembly before attempting to install the Belts TIP T ...

Page 35: ...34 10g Loop the Belt over the Belt Pulley so that the Belt teeth engage the teeth of Pulley 10h Repeat to install the other X Belt Finished Belt Routing viewed through the access port ...

Page 36: ...ne Screws through the Belt Adjustment Plate previously removed and secure with a M6 Nut 11b Add one M6 Nut to each Machine Screw as shown 11c Insert the Long Belt Retainer previously removed through the Belt Adjusting Plate into the Rail Stop previously removed as shown ...

Page 37: ...e upper slot of the X Assembly as shown 11e Insert the end of the Belt into the Belt Retainer Be sure to seat the Belt completely in the Retainer as shown and secure with a Zip Tie Zip Tie At the front of the machine be sure to insert in the upper slot ...

Page 38: ...e Nut closest to the Belt Adjusting Plate is tight Using a 10mm wrench hold the adjustment Nut and turn the machine screw to tighten the Belt Be sure to adjust both Screws the same amount until the Belt is tight Repeat these steps to tighten the X2 Belt ...

Page 39: ...38 Step 13 Secure the USB Cable to the underside of the Wire Harness with Zip Ties as shown Step 14 Secure the Power Cords to the underside of the Wire Harness with Zip Ties as shown ...

Page 40: ...rt Description Qty Photo SB1 Fastening Strip 11 SB3 T Slot Small Board 2 SB4 T Slot Large Board 8 SB7 Spacer Strips set 9 Required Hardware Part Description Qty Photo H9 1 25 Woodscrews 110 H14 M4 X 16 Machine Screws 44 H80 M4 Square Nuts 44 ...

Page 41: ...ve 1 x 2 furring strips Illustrated Step by Step Instructions Step 1 NOTE For newer kits skip this Step and Step 2 For the old version use a new Fastening Strip SB1 as a template to mark the location of mounting holes The holes should be centered 5 16 from the top edge of the Frame Mid and End Supports Use new components as a reference Drill with a 1 8 bit TIP T ...

Page 42: ...as battens that you can screw into to secure your spoilboard Align the pieces so that their top edge is approx 1 16 inch below the top edge of the Frame Supports as shown Attach the one 17 inch pieces at end between the Corner Supports and attach with 3 4 wood screws not included Space and attach the 28 inch pieces for the interior Frame Supports ...

Page 43: ...nto each of the T Slots in the SB1 Fastening Strip Step 4 Lay a T Slot Small Board SB3 on the X Frame Assembly with the cut mark facing up The position of the predrilled holes circled below in the strip will indicate the side on which the Fastening Strips SB1 will be mounted ...

Page 44: ...secure with four M4 x 16 Screws Make sure the Fastening Strip is mounted on the inside of the X Frame Front Before tightening make sure the Fastening Strips are mounted so that the X Frame Supports are approximately 1 16 proud This will allow the T Slot Boards to fastened flush against each of the frame supports ...

Page 45: ...44 Step 6 Repeat to install the next fastening strip until all eleven strips are installed ...

Page 46: ...The simplest way to do this is to measure diagonally from one corner of the cutting area to the other If the measurements are exactly the same the X Frame is square If not gently rack the Frame until the measurements are equal Step 8 Join two Spacer Strips SB7 together using the scarf joint ends ...

Page 47: ...the bottom notch of the T Slot Board Step 10 Repeat using T Slot Large Board SB4 making sure the notch is fully seated on top of the Spacer Strip Repeat the procedure to install the remaining Spacer Strips and T Slot Boards The remaining T Slot Small Board SB3 is installed to the right side Make sure the T Slot Boards and Spacer Strips are lying flat on the X Frame Assembly Cross Members ...

Page 48: ...face of the T Slot Boards NOTE Make sure the T Slot Small Boards are tight against each side Then using the 1 inch Wood Screws secure the Spoilboard to the X Frame Assembly We recommend counter sinking the cabinet screws approx 3 16 below the surface of the T Slot Boards Insert the first wood screw in the middle hole of the MDF then insert the remaining wood screws working from the center to the f...

Page 49: ...48 Finished View ...

Page 50: ...rmware Value Change Connect the CNC to the USB and connect to UGS Platform Type in 130 1283 in the command textbox of the console window of UGS and press the enter key This will change the soft limit for the X axis to the new value of 1283mm 50 5 ...

Page 51: ...port mask 00000011 11 0 01 junction deviation mm 12 0 002 arc tolerance mm 13 0 report inches bool 20 1 soft limits bool 21 0 hard limits bool 22 1 homing cycle bool 23 3 homing dir invert mask 00000011 24 250 homing feed mm min 25 2000 homing seek mm min 26 250 homing debounce msec 27 5 homing pull off mm 30 1000 Maximum spindle speed RPM 31 0 Minimum spindle speed RPM 32 0 Laser mode enable bool...

Page 52: ...rate mm min 120 500 X axis acceleration mm sec 2 121 500 Y axis acceleration mm sec 2 122 500 Z axis acceleration mm sec 2 130 1283 X axis maximum travel millimeters 131 610 Y axis maximum travel millimeters 132 85 Z axis maximum travel millimeters ...