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General Router with M2521 Board
Installation Checklist
These machine installation procedures should be followed in order by a MultiCam Technician, and the
router should be fully functional at the end of the installation. Three asterisks (***) indicate optional steps
that may not be applicable to all routers.
Receiving Preparation
See Pre-Installation Documents.
1. Machine unpacked & inventoried (suggest 6. Ethernet communication cable run
customer take digital pictures)
2. Shipping damage claimed & replacement 7. Air pressure to machine ***
parts ordered if any
3. Machine & vacuum in final location w/proper 8. Dust collection provided ***
space requirements
4. Leveling feet on 9. Computer provided
5. Proper electrical to disconnect switch from 10. Tooling, spoilboard, & material for
disconnect box on machine & vacuum training
Gantry Installation
1. Unload controller off table top. 5. Slightly hand-tighten gantry bolts.
2. Rotate gantry perpendicular to table over X 6. Attach E-chain front & rear brackets.
rails.
3. Lower gantry to just above X castings and 7. Verify smooth motion on X.
start gantry bolts.
4. Lower gantry all the way down onto castings. 8. Install XA & XB limit switches if
removed.
Mechanical Installation: PHASE I
Perform Part A Tasks before Part B Tasks.
Part A
1. Level table (as low as possible). 3. Remove all axis covers.
2. Verify X proximity switch clearance 4. Re-adjust belts if necessary.
(approximately 1mm or 0.040”).
Part B
1. Mount X-axis motor assemblies. 3. Install ATC (if applicable) ***
2. Install pendant and pendant holder. 4. Mount spindle and connect wiring.
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Electrical Installation
Make sure voltage settings are correct before continuing!
1. Flip all breakers OFF. 8. Return Fuse 126/128 to original state.
2. Pull out 126/128 fuse block. 9. Power up – Verify 24V output from 24V
power supply (348/358).
3. Check for loose/disconnected wires (including 10. Power down, reconnect internal I/O
gantry head and M2521 board). plug to board, and turn on all circuit
breakers.
4. Check AC voltage at the power switch. 11. Power up – Verify 24V output from
24V power supply (348/358) again.
5. Tap Transformer (to 220Vac). See schematics. 12. Verify 5V at M2521 board by ensuring
the bad power LED is not lit.
6. Remove internal I/O connection plug from the 13. Check AC/DC voltage (ex: 24Vdc
M2521 board. power supply, capacitor, isolation
transformer, etc). See schematics and
chart below.
7. Power up, measure 126 & 138 for proper
220Vac +/- 2%, and then power down.
Voltage Chart
Incoming at Switch Stepper power 65Vdc
____________ ____________
(L1,L2,L3) (168/178)
Transformed Power Servo power 75Vdc
____________ ____________
(128/138) (168/178)
Servo power 315Vdc±20
24Vdc (348/358) ____________ ____________
(294/2A4)
Mechanical Installation: PHASE II
Slightly loosen gantry bolts - Loosen both sides of the X-axis (moving gantry only).
Hard Home - This will enable the spindle. If machine will not find limits, then see Help Docs.
Verify Resolutions - See Help Docs for more information on how to check resolution.
Verify Table Parameters - Jog the full distance in X-, Y-, and Z-axes. Make sure that the gantry, head,
or spindle does not make physical contact with the end stops.
Square Table - Use Square Macro or MOVE command to square the table until 4 corners are marked.
Measure the 2 diagonal points. Both diagonal points should be the same. The bigger the perfect rectangle
or square, the more accurate.
Tighten Gantry Bolts - Tighten both sides of the X-axis (moving gantry only).
Sweep Spindle Head - Sweep the spindle head to make sure the spindle head is perpendicular to the table
top.
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Suite4 Machine Software Installation
Reboot Machine – Check for red letter errors.
Verify MODBUS programming – Find Home. Check for Inverter Params scrolling up the screen.
Capture NVRAM – Check the factory Flash settings before making any modifications. Save to
Customer and Tech Computer.
Check Init and Firmware Version – Type v & press Enter. Capture the screen or write down the
information. Update if necessary.
Interface Board ____________ Init File Version Loader ____________
Controller Board Revision ____________ Init File Version STD ____________
Firmware Version (MCIF) ____________ MD4 Version ____________
Help Files – Manuals, Routing Guide, and Help JobNameServer – Confirm Operations.
Docs
JobReporter – Confirm Operations. JobEditor – Confirm operations.
Mechanical Installation: PHASE III for Rotary ATC only
Warning: All ATCs must be double-checked for alignment. Factory ATC settings are only good until the
ATC is removed from the gantry for shipment. Some minor changes will probably be necessary.
Recommendation: Remove all rust protectant from tool holders.
1. Carousel Alignment #1 Go to MENU / ATC / LOAD TOOLS and visually check the general
alignment and location of the spindle chuck with the tool cradle’s
position.
2. Carousel Alignment #2 Start a Set Surface function with an empty carousel and visually check
the alignment of the carousel with the spindle chuck. Verify the Z, Y,
and R height alignments. After the spindle has attempted to pick up the
tool from the empty cradle, the keypad will prompt “Tool NOT
Loaded.” Insert the tool holder manually by pressing Shift and Five to
open the chuck, place the tool holder inside the chuck, and wait for the
chuck to close.
* If the alignment looks way off, then go to #5.
3. Put Tool Away Use the ATC menu to put the tool away. This will verify if the position
of the carousel is calibrated or aligned correctly. Use a critical eye. All
tool changes should be perfect.
4. Surface Tools Surface 1, 3, and 5. Visually verify that the Tool Lift Height is
sufficient to clear the spindle from the top of the tool holders as they
spin into location.
* If all tool changes are perfect, then go to #7.
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5. Adjust Mechanically Surface any Tool. Press Pause right as the spindle is doing the Tool
Blow-off portion of the tool pick-up. The spindle should be directly
above the tool holder at this point. Loosen appropriate mounting bolts
to physically adjust ATC into perfect alignment with the center line of
the spindle. Remember that the cradles can be slightly moved into
location as well.
* If alignment is still required, go to #6.
6. Run ATC Macro for Manually change the Y and R coordinates. The Y and R coordinates
Adjustment must be changed together in order to align perfectly.
- If Y is not perfect, then Jog into the correct location and note the Y
coordinate on the keypad. Then change location 71 to the new
number. Reboot, hard home, and re-verify Y and R as before.
- If Rotation is not perfect, then Jog or move to Y location 71's
coordinates and then execute ATC macro again while in current
position. Jog down in Z so that the spindle draw bar is directly over
the tool holder. Rotate and move in Y to obtain perfect alignment to
center of spindle line. Save coordinates even though Z is in the wrong
location. Reboot from keypad. Change location 72 back to the
original setting. Reboot, hard home, and re-verify Y and R as before.
7. ATC Self Test Macro Recommend 50 repetitions to verify the correct alignment of loading
and unloading tools. May want to have the customer sign off that this
process was successful.
Mechanical Installation: PHASE III for Linear ATC only
Warning: All ATCs must be double-checked for alignment. Factory ATC settings are only good until the
ATC is removed from the gantry for shipment. Some minor changes will probably be necessary.
Recommendation: Remove all rust protectant from tool holders.
1. General Alignment Start a Set Surface function with an empty linear tool changer and
visually check the alignment of the changer with the spindle chuck.
Verify the X, Y, and Z height alignments. After the spindle has
attempted to pick up the tool from the empty changer, the keypad will
prompt “Tool NOT Loaded.” Insert the tool holder manually by
pressing Shift and Five to open the chuck, place the tool holder inside
the chuck, and wait for the chuck to close.
* If the alignment looks way off, then go to #5.
2. Put Tool Away Use the ATC menu to put the tool away. This will verify if the position
of the changer is calibrated or aligned correctly. Use a critical eye. All
tool changes should be perfect.
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3. Surface Tools Surface all tools. Visually verify that the Tool Lift Height is sufficient
to clear the spindle from the top of the tool holders.
Repeat Steps 1-3 for all tool locations.
* If all tool changes are perfect, then run Self Test macro.
4. Run ATC Macro for Execute the M2521 ATC tool macro (MH_atc_tool.uc) and use the
Adjustment Tool Locations sub-menu to align each cradle.
• Press Set Max Depth to open and close the spindle
chuck.
• Press Cancel to skip a tool cradle number.
5. ATC Self Test Macro Execute the Self Test macro (TC_test.uc) Recommend 50 repetitions
to verify the correct alignment for loading and unloading tools. May
want to have the customer sign off that this process was successful.
Mechanical Installation: PHASE IV
Option Installation
Dust Collector – Adjust the air flow. Engraver
Bar Code 2D Rapid Shape
MultiVision – See MultiVision Setup doc. Knife – See Knife Setup doc.
Run a test file to verify machine operation.
Mill the table surface - Suggest milling off 0.02” (0.50mm) from both sides of the spoilboard since
the shipment can sometimes make the top not perfectly flat as it had been at the factory. Mill off only what
it takes to have the mill bit touch in all areas of the spoilboard so that Z depths will be identical over the
entire table.
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