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Maintenance Manual
How to Perform Maintenance
On LPKF Circuit Board Plotters
Requirements
-
-
LPKF Circuit Board Plotter
BoardMaster Software
2.5 mm Allen wrench (for earlier model machines)
3mm Allen Wrench
4mm Allen Wrench (for large table machines)
Spray Silicone, Teflon or Graphite
Small Brass Wire Brush
Isopropyl Alcohol
3 in 1 oil or equivalent
Plastic Lubricant for lead screw LPKF p/n 102244
(for all models except 95sII, AutoMill, and 101 Hi-P)
or
Universal Lubricant for ball tread assembly LPKF p/n 106976
(for models 95sII, AutoMill, and 101 Hi-P only)
Content
Note: This document is broken up into the following 6 sections of prescribed
maintenance.
I)
II)
III)
IV)
V)
VI)
Lubricating the X-axis lead screw/ball tread assembly and guide bar wipers
Lubricating the Y-axis lead screw/ball tread assembly and guide bar wipers
Lubricating the Z-axis Linear Bearings
Removing, Cleaning, and Lubricating the Working Depth Limiter
Cleaning the Collet Assembly
Replacing the Working Depth Limiter
Requirements ............................................................................................................. 1
Content ....................................................................................................................... 1
Section I: Lubricating The X-Axis (perform every 6 months)...................................... 2
Section II: Lubricating The Y-Axis (perform every 6 months)..................................... 4
Section III: Lubricating the Z-axis Linear Bearings (perform every 3 months) ........... 6
Section IV: Cleaning and Lubricating the Working Depth Limiter (perform every 3
months, or whenever the Working Depth Limiter becomes difficult to
adjust. Also Perform Section V at the same time)................................... 7
Section V: Cleaning the Collet Assembly (perform whenever the Working Depth
Limiter is being cleaned) ........................................................................ 13
Motor Types:............................................................................................................. 13
Section VI: Replacing the Working Depth Limiter (perform every 3 months, or
whenever the Working Depth Limiter becomes difficult to adjust) Also
Perform Section V at the same time! ..................................................... 18
References ............................................................................................................... 18
Author ................................................................................................................... 18
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Section I: Lubricating The X-Axis (perform every 6 months)
1) To lubricate the X-axis lead screw/ball tread assembly, it is first necessary to
remove the controller box. Please perform steps 1-8 from the How to Remove
The Controller Box document. Once removed, you will be able to see the Xaxis lead screw/ball tread assembly.
2) Apply a small amount of the appropriate lubricant (see Requirements) to the
lead screw on each side of the supernut (see figure 1-1) or to the ball tread
assembly (see figure2-1).
Figure 1-1
Lead Screw
Supernut
Figure 2-1
Ball Tread Assembly
3) Due to the tight tolerances of the lead screw and supernut, it is not necessary
to place the lubricant across the entire screw. If you do, the lubricant will build
up and drip onto the table or board surface during operation (see figure 2-2).
Figure 2-2
Only lubricate
aproximately 1 inch on
each side of the supernut.
4) Some machines will have a set of parallel bars under the table that have wiper
pads that traverse with the axis (see figure 2-3). Other machines will have
guide bars with linear bearings (see figure 3-1).
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Figure 2-3
1 wiper pad is shown in this
picture. There is an arrow
pointing to where the second is
located, but it can not be seen in
this picture. There are 2 more
located on the opposite side.
5) If you have wiper pads as shown in figure 2-3, place several drops of 3 in 1 or
equivalent oil on each of the 4 pads.
6) If you have linear bearings as indicated in figure 3-1, place several drops of 3
in 1 or equivalent oil on a rag and wipe it on the guide bars. This will apply a
thin film of oil on the guide bars.
Figure 3-1
These are the guide bars.
Wipe with an oiled rag to apply
a thin coat of lubricant.
7) Replace the controller box by performing steps 9-11 of the How to Remove
The Controller Box document.
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Section II: Lubricating The Y-Axis (perform every 6
months)
1) To lubricate the Y-axis lead screw/ball tread assembly, it is first necessary to
remove the Y-Axis hood. This is done by removing the four 3mm Allen
screws securing the hood (see figure 3-2 and 3-3).
Figure 3-2
Figure 3-3
Remove these four screws to gain
access to the Y-axis lead screw.
Note: Picture shown is from a newer
machine. The cover on some
machines may be black.
2) Apply a small amount of the appropriate lubricant (see Requirements) to the
lead screw on each side of the supernut (see figure 1-1) or to the ball tread
assembly (see figure2-1).
3) Due to the tight tolerances of the lead screw and supernut, it is not necessary
to place the lubricant across the entire screw. If you do, the lubricant will build
up and drip onto the table or board surface during operation (see figure 4-1).
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Figure 4-1
The super nut is located
under this plate.
Place the approriate
lubricant on each side of
the super nut.
4) Some machines will have a set of parallel bars under the Y-axis hood that
have wiper pads that traverse with the axis (see figure 4-2). Other machines
will have guide bars with linear bearings (see figure 5-1).
5) If you have wiper pads as shown in figure 4-2, place several drops of 3 in 1 or
equivalent oil on each of the 4 pads.
Figure 4-2
Here is one of the 4 wiper
pads mentioned in step
11. There are 3 more
pads that cannot be seen
in this picture.
6) If you have linear bearings as indicated in figure 5-1, place several drops of 3
in 1 or equivalent oil on a rag and wipe it on the guide bars. This will apply a
thin film of oil on the guide bars.
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Figure 5-1
These are the guide bars.
Wipe with an oiled rag to apply
a thin coat of lubricant.
7) Replace the Y-axis hood.
Section III: Lubricating the Z-axis Linear Bearings (perform
every 3 months)
1) Place a couple of drops of 3 in 1 or equivalent oil on the Z-axis linear bearings
(see figure 5-2).
Figure 5-2
Micrometer Option
for Z-axis depth
control. LPKF p/n
106279
Place a couple of
drops of 3 in 1 or
equivalent oil in
each linear bearing.
2) Manually push the head assembly up and down several times to distribute the
oil.
3) Plug all the connectors back into the controller box and turn on the power to
the LPKF Milling Machine. The head will come to rest in the exchange
position.
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Section IV: Cleaning and Lubricating the Working Depth
Limiter
(perform every 3 months, or whenever the Working Depth
Limiter becomes difficult to adjust. Also Perform Section V
at the same time)
1) If there is a tool in the collet, remove the tool.
2) Now you must remove the entire motor so you can remove the Depth Limiter.
Please use the pictures below to determine what type of motor you have. (if
you do not see the correct style motor holder for your machine, please skip to
step 6. This motor holder is on most of the older machines and is more
complicated to remove.)
Figure 6-1
You must loosen all 5 of
these screws to move the
motor up and down. The
threeon top the block are
2.5mm, and the two on the
side of the block are 3mm.
91S/HS
92S (after 1997)
92SII
C30
C30/S
M30
&
M30/S
This is the quick change tool bar.
You might have to remove this to
raise the motor enough to allow
the removal of the depth limiter.
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Figure 6-2
95S, 95sII,
101 Hi-P
&
Automill
This collar is set to
factory specifications.
Loosen these two screws to
raise the motor.
Figure 7-1
91S/VS
C60
93S
M60
X60
&
C100/HF
Loosen these two
screws and remove
the 3 pin din connector
to remove the motor
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C20
Figure 7-2
Remove this
Connector.
Loosen these two
quick release levers
and pull the motor
out. The collar on
the motor is set to
factory specifications
3) Loosen the appropriate Allen screws based on the pictures above and remove
the motor so the motor won’t inhibit the removal of the depth limiter.
4) Loosen the following screws to remove the Depth Limiter.
Figure 8-1
Do not adjust
these ball
screws, they
are set at the
factory.
loosen the 3mm allen
screw located here.
Remove the vacuum hose.
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Figure 8-2
Remove the second 3 mm
allen screw located here and
you will be able to remove
the bracket below.
5) Slide the Depth Limiter away from the head. Look for the flat washer shown in
the picture below. If you don’t see it, it could be stuck to the opening the motor
slides through (see figure 8-3) (Now skip to step 8).
Note: If you have the Illuminated Working Depth Limiter installed, the Working
Depth Limiter cannot be completely removed due to wiring. It can be moved to
the side enough to complete the maintenance properly.
Metal Washer
(not present on
all machines.)
Figure 8-3
6) Machines with the following style motor holding device must be removed in a
different fashion (see figures 9-1 and 9-2)
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Figure 9-1
Remove this 7 mm nut.
Remove these two 3 mm
Allen Screws.
Remove this 3 mm allen screw
and you will be able to
remove the bracket below.
Remove this
side of the
vacuum hose.
Look into the Depth Limiter and you
will be able to see 4 2.5 mm allen
screws. Remove these 4 screws. In
order get the allen wrench to each of
these screws, you must spin the Depth
Limiter around taking out one screw at
a time. Once the all the screws are
loose, gently pull up on the motor and
slide the Depth Limiter out.
Figure 9-2
2.5 mm allen screws (4)
7) Now unscrew the knurled wheel from the aluminum housing
(see figure 10-1).
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Figure 10-1
Knurled
wheel
Aluminum
housing
Most style machines
Figure 10-2
OR
Older Machines
Figure 10-3
Knurled Wheel
(Aluminum housing
not shown.)
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8) Clean the threads on both the Knurled Wheel and the Aluminum housing with
a small brass wire brush.
9) Lubricate the threads with silicone, Teflon or graphite. Do not lubricate with
oil. It will act like a magnet to the dust created when milling causing you to
have to clean the Depth Limiter more often, possibly causing it to seize.
10) Screw the Knurled Wheel and the Aluminum housing back together.
11) Ensure the metal washer from figure 8-3 is put back on top of the Knurled
Wheel.
12) Do not put the motor assembly back in yet.
Section V: Cleaning the Collet Assembly (perform
whenever the Working Depth Limiter is being cleaned)
Note: If needed, you can use alcohol as a cleaning agent for the collet.
Warning: Do not lubricate the inside of any collet. This can cause the tool to slip
out of the collet assembly while milling.
1) Take the motor in your hand and determine which motor you have based on
the pictures below.
Motor Types:
•
•
LPKF 91, LPKF 92 (No Picture Available) (13k rpm)
101LC, LPKF 91s, LPKF92s, 91s, 92s (20k rpm)
Figure 11-1
•
C20 (20k rpm)
Figure 11-2
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•
C30, 92sII (30krpm)
Figure 11-3
•
91s/HS, 92s/HS, C30/s (black cap) (30k rpm)
Figure 12-1
•
C30/s (silver cap), M30/s (30k rpm)
Figure 12-2
•
101LC-VS, 91s/VS, 93s (after 1997), C60, H60, M60, X60 (60k rpm)
Figure 12-3
•
93s (prior to 1997) (60k rpm), C100/HF (100k rpm)
Figure 12-4
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•
101 Hi-P, 101 AutoMill, 95s, 95sII (60k rpm)
Figure 12-5
2) For the motor not shown and the motor in figure 11-1, the collet assembly is a
seperable unit. Insert a small brush into the collet to clean it. (Now skip to
section VI, step 54)
Figure 13-1
Insert a small brush into
the collet here.
3) For the motors shown in figure 11-2, 11-3, 12-1, and 12-2, the collet assembly
and the motor are a balanced unit. Do not take them apart. Insert a small
brush into the collet to clean it. (Now skip to section VI, step 1)
4) For the motors in figure 12-3, and 12-4, the collet itself is a
removable/replaceable part.
5) To remove the collet, depress the knob on the top of the motor as if you were
doing a tool change.
6) Turn the knob in the counter clockwise direction until the collet slides out into
your hand.
Figure 13-2
Insert a small brush
into the collet here.
Keyway
7) Insert a small brush into the collet to clean it (see figure 13-2).
8) This collet has a keyway in it (see figure 13-2). In order to place the collet and
the motor assembly back together, the Keyway must be aligned.
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9) With the collet in your hand, gently insert it into the opening in the motor.
10) If it does not slide smoothly all the way in, twist the collet around while
applying little pressure until the keyway in the collet and the keyway in the
motor line up and the collet slides all the way into the motor assembly.
11) Turn the knob in the clockwise direction until the collet retracts into the motor.
12) Pull the knob on the top of the motor up. (Now skip to section VI, step 1)
13) For the motor in figure 12-5, the collet itself is a removable/replaceable part.
Machines that were shipped with this type of motor were also shipped with a
cleaning kit for the motor. The cleaning kit is shown in figure 13-2.
Figure 13-2
1. Tool for cleaning the collet
2. Tool for removing the collet.
3. Lubricant for the end of the spindle.
4. Tool for cleaning the motor
without the collet installed.
14) Make sure that the motor is hooked up to it’s air source (see figure 13-3).
Figure 13-3
Air source, this is the air line
that is hooked up to the top
of the motor. When air is
applied, it opens the collet.
Air source fitting
15) Flip the motor over in your hand so you are looking at the collet and place the
collet-removing tool (tool # 2 in figure 13-2) on the collet (see figure 14-1).
Collet removing tool.
Figure 14-1
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16) With the assistance of another person, you must now depress the green
button on the upper pneumatic block shown in figure 14-2. This will actuate
the collet assembly and allow you to remove the collet.
Depress this button
to actuate the collet.
This valve block might
vary slightly depending
on the model of
machine, but the order
of the valves is the same
on each machine.
Figure 14-2
17) While another person is depressing the green button, turn the collet removing
tool counter clockwise until you can pull the collet from the motor, then release
the green button.
18) Use the cleaning tool (tool # 2 in figure 13-2) to clean the collet
(see figure 15-1).
Figure 15-1
19) Take the motor back in your hand and take the tool labeled # 4 in figure 13-2
and place it into the motor where the collet normally goes (see figure 15-2).
Figure 15-2
20) After moving the tool around to remove any debris, remove the tool.
21) Use the lubricant (# 3 in figure 13-2) and place a very small amount on the end
of the spindle. Do not put any lubricant inside the collet or where the collet
goes (see figure 15-2).
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Place a small
amount of lubricant
here. Do not place
any lubricant inside
the collet or where
the collet goes.
Figure 16-1
22) Put the collet back into the motor.
23) Have someone depress the green button on the upper pneumatic block (see
figure 14-2).
24) Using the collet-removing tool (tool # 2 in figure 13-2), turn the collet clockwise
until tight.
Section VI: Replacing the Working Depth Limiter (perform
every 3 months, or whenever the Working Depth Limiter
becomes difficult to adjust)
Also Perform Section V at the same time!
1) Slide the depth limiter back under the motor block the same way it was taken
out.
2) Replace the bracket and any other Allen screws that were taken off in order to
remove the Working Depth Limiter (see figure 8-2 or 9-1 for the location of the
bracket and what screws need to be replaced or tightened).
3) Replace the vacuum house (see figure 8-1 or 9-1).
4) Try turning the Knurled Wheel to ensure it was reinstalled properly. It should
turn smoothly, but with an audible clicking noise.
5) Put the motor back into the motor holder.
6) Now you must reset your motor height. Please refer to the How To Set The
Motor Height document to perform this procedure.
References
All ProtoMat Manuals
LPKF Laser & Electronics Technical Support
Author
Jeff Bengtson
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