Direction, Commitment, Follow Through

SUPER X3 CNC MILL

Manual
Revision 1A
These pages are provided as a service and informational source. INFORMATION IS PROVIDED ON THE ASSUMPTION THAT THE RECEIVER OF SUCH INFORMATION IS COMPETENT TO PERFORM SAID TASK (INCLUDING, BUT NOT LIMITED TO OPERATION AND/OR REPAIR OF POWER EQUIPMENT), FOR WHICH THE INFORMATION IS PROVIDED, AND THAT PERSON IS KNOWLEDGEABLE AND MINDFUL OF THE PROPER SAFETY PRECAUTIONS. SYIL AMERICA INC., NOR OUR SUPPLIERS MAKE ANY CLAIMS ABOUT THE SUITABILITY OR FITNESS OF THE INFORMATION CONTAINED IN THIS MANUAL FOR A PARTICULAR PURPOSE. ALL INFORMATION, INCLUDING GRAPHICS, TEXT, AND ELECRONIC MAIL IS PROVIDED STRICTLY ON AN "AS IS" BASIS, WITHOUT ANY EXPRESS OR IMPLIED WARRANTY, GUARANTEE, ASSURANCE OF QUALITY, CONFORMITY OF SPECIFICATIONS, RELIABILITY, FUNCTIONALITY, OR SUITABILITY. IN NO EVENT SHALL SYIL AMERICA INC., NOR OUR SUPPLIERS BE HELD LIABLE, WHETHER IN CONTRACT OR TORT, TO ANY PARTY FOR ANY DIRECT, INDIRECT, PUNITIVE, OR CONSEQUENTIAL (INCLUDING, BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION), ARISING OUT OF ANY ERRORS, TYPOGRAPHICAL OR OTHERWISE, INACCURACIES, OMISSIONS, OR DELAYS ARISING OUT OF OR PERTAINING TO THE USE, RELIANCE ON, OR INABILITY TO USE ANY TYPE OF INFORMATION, PART, OR GOOD, EVEN IF NOTIFIED IN ADVANCE ABOUT THE POSSIBILITY OF SUCH ACTION

Syil America
1887 North Bayshore Drive Coos Bay, OR 94720 (541) 266-0635 (541) 267-0909 Fax http://www.syilamerica.com

Initial Setup
Tools needed: Tin snips, or tool suitable for cutting metal straps Claw hammer Philips Screwdriver 17 mm end wrench or socket Hoist, lift, or friends with big muscles When you receive your Super X3, it is preferred to place it in an area that is clear around the crate. Once you remove the straps, the crate can be disassembled. Start from the top by prying with the claw hammer. After the top is removed and placed away from your working area, the sides can be removed by lightly tapping on the inside with the hammer. Underneath the lower skid, there are 4 retainer bolts that hold the mill down. You will need your 17mm end wrench or socket to loosen and remove these bolts. The power supplies, drivers, fan, and PCB boards are located in the black casing to the side. All connections have been made at the factory except two. However, with jarring of transportation, it is possible to loosen other connections. Visually check all connectors in the case and make sure there are not loose. The two remaining connectors are the Emergency Stop and power. Emergency stop connection is made on the PCB board labeled E-Stop. Only one power connection is required. It is a white four pin connector that connects inside the rear housing. If you do not easily see the mating power connector, it will make it easier to remove the upper inspection plate. This is located at the top of the body. After connecting power and E-Stop, you can mount the component casing onto the back of the mill. Re-use the 6 screws removed from the lower case plate. The unit is heavy. An engine hoist (cherry picker), if available, is the easiest way of moving these. If not, 2 of your biggest friends will suffice. The working platform of the Super X3 needs to be stout. The heavier the construction the happier you will be with the performance. Noise, smoothness, and safety are all enhanced by a working structure that is sturdy. *Note on electrical connections: The unit has a 1300 watt motor and 600 watts of available power for its driver/stepper system. Make sure your breaker that the Super X3 CNC mill is connected to has at least 15 amps available.

Table of Contents

Syil CNC Conversion

Introduction We at Syil have a passion for seeing something come from nothing. We also share of love of manufacturing. We wanted to share this love with the rest of the world. Historically, manufacturing in the U.S. was associated with 15,000lb machines that required lifts to move and trained operators monitoring 24/7. These colossal machines, outfitted with high grade ball screws, G-code controlled spindles, and huge motors, run 24/7 because of the need to pay for themselves. Moving these machines not only presents a problem, but the power requirements for such a beast can hinder many shops capacity. These machines cost as much as a house, and demand about the same in maintenance. Where does that leave the rest of us? A characteristic, small production shop is filled with manual machines dating back to when my great grandfather first ate solid foods. Granted, these machines are true American legends, worthy of much praise. They still fall short on keeping up with competition. To compound the problem even more: U.S. politics and what have you, has blessed us with all the protections conceivable. We are well protected, even from ourselves. While this may seem brilliant on the surface, it comes at a price. Labor is costly. What is the byproduct? You have a shop with 4 people running all the machinery with what used to have 16. Computer numerical control is a godsend to manufacturing. It is part of the answer. However, it is out of reach for most shops. It would also be somewhat unwise to indenture the business, just to pay for the Zeus sized VMCs. Some people have kindled that creative spirit and converted their manual machines over to CNC. Some work well. Some, not so much. So we at Syil have tried to come up with a balance. Giving all those great advantages of the more expensive CNC mills to the rest of us. Using some of the best components and some ingenuity, we are proud to offer the first product of our venture together, the Super X3 CNC machine. Finally: consistency in quality, and affordability for the rest of us.

A note on accuracy: We have extensively tested our machines with the following results. Although there may be some variation between machines, we try for consistency in every product. These are some of our findings: Spindle run out: .001 .001 *Locking the spindle on the front panel will get you much better results X Travel Y Travel Z Travel Backlash Repeatability 14.4.04 6.3.08 8.1.07 .004 .0004

Ballscrews:

5 T.P.I. Stainless steel Rolled type Double nut

The ballscrews included on the Syil products are made from high quality Italian stainless steel. They will provide a lifetime of precision with very light maintenance. Maintenance:

Every year or 100 hours of operation:

Spray a light film of light weight #2 oil (WD-40, etc.) on the screws and run them from throw to throw.

Access to the ball screws can be viewed as a challenge, but is really quite easy. It can be done by the average person. Z axis: Remove the controller assembly Remove the black casing cover from the back of the mill X axis Remove left end plate Remove motor dust cover Remove bolts from right end plate Slide table off from the left Y axis Remove bed Remove rear y axis dust cover *Note: Do not run the screw completely out of the nut. If you do, you will have the experience of a hundred ball bearings fall and run about the floor. Then the fun task of re-inserting them. 5

Parallel Interface PCB:

4 Axis support 4 Axis limit / home support Direct support for all common PC controller software (Mach, KCAM, Etc.) Support for spindle control (DC power, AC power, frequency conversion) Photocoupled input/output protection Emergency stop 2 Aux inputs/outputs (Coolant, Probe, Tool height, etc.)

Technical: Power: DC 13-18V, AC 12-16V (50-60Hz) Current at idle: 9mA Current at full: 100mA Output drive voltage: 5V Output current: ~2mA Input signals: Pull-up resistors

Pin Name

Input/Output

Parallel interface pin number

Description

X axis direction X axis pulse X axis limit Y axis direction Y axis pulse Y axis limit Z axis direction Z axis pulse Z axis limit A axis direction A axis pulse A axis limit Spindle direction Spindle pulse Aux 1 Aux 2 E Stop Digitizing Probe

OUT OUT IN OUT OUT IN OUT OUT OUT IN OUT IN OUT OUT OUT OUT IN IN

2 16 15 14 5 13 17 6 12 4 3 11 8 9 7 1 10 11

X axis stepper direction control X axis stepper drive X axis origin point detection Y axis stepper direction control Y axis stepper drive Y axis origin detection Z axis stepper direction control Z axis stepper drive Z axis origin point detection A axis stepper direction control A axis stepper drive A axis origin point detection Spindle direction control Spindle speed control Configure software to assign usage Configure software to assign usage Emergency stop switch correct configure this pin if you are using a tool adjuster, digitizing probe

Stepper Driver:

Features
Power supply from DC 32V to 60V. Auto half-current functionthat means the output current of the driver will automatically decline to half if the stepper pulse pause over than 0.3s. Forced shut down of output current by the E-Stop. Driving current can be adjusted from 1.0A to 4.3A. Phase origin and malfunction protection indicator. All input / output are isolated by photocouplers. 2, 4, 5, 10, 20, 25, 50, 100 microstep subdivisions are selectable. Over-heat protection is integrated. When the driver over-heats, it will shut down the output current. And when the temperature returns to normal level, it will reset automatically. H bridge structure driver circuits just like a servo system are applied in the driver. This creates performance of this stepper drive system very close to servo systems. Protection functions----When the power supply is lower than 30V, or the temperature of the shell is over than 80 the driver will shut down automatically and the fault LED will light.

Each case is capable of housing 4 drivers. They are powered by a 600 watt power supply.

Auto Half Current Set

This driver contains an auto half current function. The output current of the driver will automatically decline to half, if the stepper pulse pause goes over 0.3s. When the next pulse comes, the current will recover to the original value. This function can depress the thermal value both of the driver and stepper motor. When the drive current is in half state, the moment of force will come down. If this situation is not wanted, it can be disabled.
Auto Half Current Function Enable Disable s1 OFF ON

NOTE: The auto half current function is a real-time function. So user can set it while the driver is working.

Drive Current Adjustment:

The driving current can be adjusted from 1.0A to 4.3A. The current will go down with clockwise rotation of the pots resistor; and the current will go up when rotated counterclockwise. Half of the total movement on the pot = 2.6A. Adjust your drive current to approximation. Steppers will generate more heat while they are not moving due to the holding torque. If your stepper is extremely hot (160 degrees or more) after 5 minutes, Then reduce the current by turning counter-clockwise slightly.

ATTENTION: Do not adjust the current value too high. High current will increase the holding torque of the stepper motor, but it will bring increase the stepper temperature. Possibly causing a thermal problem. Please adjust the drive current to the stepper motors specifications.

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Spindle Control Board

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