Start Up Manual GENERAL CNC Model 40-920 M1 Model 40-924 M1 Model 40-948 M1 Model 40-996 M1

For technical support contact:

General CNC www.generalcnc.ca 1-877-340-8989

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Table of Contents      

Welcome Safe Operation Getting Started Things You Will Need Before You Begin Programming Software Operating Software Overview a) Preview Screen b) View Controls c) Machining Times d) G-Code Operations e) Homing f) Tool Sense g) Model ID and Support Info h) Jogging i) Zero X,Y and Z Axis j) Machine Operation k) Feed Rate l) Tool Change m) Carving/Cutting Mode n) Spindle on/off o) Status Window  Routine Maintenance

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Congratulations! Your decision to purchase a General CNC Router Table was a wise one! General International has been manufacturing quality woodworking equipment for over 60 years. We provide you with state of the art technology, unrivaled technical support and an easy-to-use software package to insure that you get up and cutting in no time at all! The information contained in this start up manual is designed to provide you with a basic understanding of safe machine operation, maintenance and offers troubleshooting tips. Like any new tool in your shop, however, the greatest teaching tool you will use is experience. So if you are having some trouble with a certain aspect of your machines operation or it is not doing what you expected it would, relax, there is likely no problem with your equipment and with some guidance from our on-line resources and an occasional tip from our technical support experts you will move past these challenges and produce a quality of work you never dreamed possible. It is recommended that you take some time to review the information contained in the start up and owner’s before operating you CNC router. This will prepare you well as you move ahead. In addition to bringing your shop into a whole new level of profitability, we have designed the General CNC system to make the experience an enjoyable one. We know that you spend countless hours in your shop so we want it to be a time that is relaxing, rewarding and fun! Welcome to the world of CNC!

Regards,

Your support team at General

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Safe Operation

Warning!! Please read the following safety procedures before operating your CNC router Your CNC router is built to minimize potential danger to the operator, however, like any piece of industrial equipment, safe operation is a must. The following safety procedures should be reviewed and followed prior to operation: 1. While protected by a dust collector shroud the rotating tool is extremely dangerous. NEVER place hands or tools near the rotating tool while the machine is in operation. Failure to adhere to this warning could result in serious injury. Always operate the CNC router with the dust collector shroud attached. 2. The CNC router is equipped with labeling indicating the pinch points, however, with the gantry, head and spindle all moving, there are a number of areas of the machine where there is a danger of serious injury if the operator should place hands or arms in the path of the machine. It is recommended that the operator be a minimum of 39” (or 1 meter) from the front of the machine during operation. 3. Always wear CSA or UL approved eye and ear protection when operating the CNC router. 4. When changing tools (manual tool change machines) always be sure that the power switch on the electronics is switched to the “off” position and the power chord is unplugged. It is the operator’s responsibility to insure that there is no chance for power to be accidentally turned on during a tool change operation. 5. Before operating your CNC router in actual cutting applications, it is recommended that you run a cutting simulation above the work with the spindle turned off. This will help familiarize you with the machine operation. 6. Never operate your CNC router while fatigued, under the influence of alcohol or drugs (prescription or non-prescription) or while distracted by other people or influences. The CNC router requires your undivided attention! 7. Insure that your work piece is securely held down before cutting. The router or spindle can potentially launch the work piece if not properly secured causing severe injury. 8. Emergency stop! Each General CNC router table is equipped with an emergency stop button located at the front of the electronics cabinet. In the event of potential injury or if the operator feels the need to stop the cutting operation for any reason hit the red emergency stop button which will eliminate power to the drive motors.

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Getting Started First let’s make sure you have received everything you need to connect your General CNC router. UNPACK AND INSPECT YOUR MACHINE! After carefully unpacking your CNC router table closely inspect the unit to insure that it has not received any damage in freight. If you discover any visible damage call our technical support line at 1-877-340-8989. WHAT YOU SHOULD RECEIVE (AND WHAT YOU SHOULD NOT!!!) In addition to your machine itself, you should receive one crate containing all the equipment necessary operate your CNC router. Inside this crate you should find:  CNC machine  Collet Wrenches (2)  Collets Qty 1- .50”, Qty 1- .25” (Pro Series also includes Qty 1 -.125”)  Monitor, keyboard and mouse (Pro Series only) 

Here is what you will NOT find:  Cutting tools  Programming Software (you should have already received it, if not contact us immediately)  Monitor, keyboard and mouse (Junior Series only) Note: Make sure that all straps and packing materials are removed from the machine. Move the head and gantry manually before powering the machine to insure there are no straps preventing them from moving freely. GETTING “PLUGGED IN” Before you start you will need to get “plugged in. The following procedure should be followed: 1) Plug you operating computer, electronics cabinet and router/spindle into a 110 volt power supply. If your machine is a Pro Series you can plug the 220 volt cord in. Please note that it is highly recommended that this power supply be dedicated to the machine operation. If you choose to use this power supply to run other electrical appliances or devices you may have electrical surges that may cause signal loss during operation and potentially damage your work. You should have a minimum of 15 amps for 110 volt components and 15 amps for 220 volt spindle (Pro Series) available on this power supply. A power cable with surge protection or a GPF (ground protection fault) outlet is recommended. It is also recommended that you add a UPS line filter to the 110 volt power line to regulate the voltage arriving at the machine. See an example of one below. http://www.thesource.ca/estore/Product.aspx?language=enCA&catalog=Online&category=UPS&product=6118519

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2) Connect a monitor, keyboard and mouse to the front of the of the electronics box. Note! The keyboard and mouse should be USB connection.

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Things You Will Need Before You Begin!!! Before you get your CNC router up and running you should insure you have done the following:  Make sure all connections are securely plugged in as described above  Be sure you have a proper dust collector system. For most CNC applications, you will need about 700 CFM dust collection. General offers a unit that will provide you will all the dust collection you need

http://www.general.ca/site_general/g_produits/dust_collector/10-105.html

You can use an existing dust collector in your shop but do keep in mind that you will need 700 CFM and a 2.5” connection (Junior Series) or a 4” connection (Pro Series). It is recommended that you do not use any dust collection system that has an inlet size smaller than 2.5” or less than 700 CFM. This dust collection system can be purchased through the same General dealer you purchased your CNC machine from.  Be sure to have a selection of cutting tools available. If you have not purchased a set of cutting tools, here is a list of recommended tools and their applications to help get you started: ◦ End Mills: These are used for cutting out component parts and clearing material in roughing tool path operations. Sizes 1/4”, 1/2” and if you plan some larger work 3/4” and 1”. Both up spiral (for clearing) and down spiral (for finish cuts) are recommended. ◦ Fly Cutter: A large diameter fly cutter is used to surface your sacrificial table. Ranging in size from 1 1/4” to 2” this tool is a must for surfacing in a short period of time. ◦ Ball Nose Cutters: If you plan on doing any 3D cutting these tools are a must. Common sizes are 1/8”, 1/4” and 1/2”. ◦ V-Bits: Perfect for doing any engraving, sign or decorative work. Commonly used angles are 90 degree and 60 degree but other angles will create some interesting effects. ◦ Double Spiral End Mill: This tool is specifically used for melamine or other laminates as it will cut both top and bottom surface in a single pass without any chipping.

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ON YOUR MARK, GET SET………. Connect your CNC router to a power supply. We recommend a dedicated power supply with a minimum of 15 amps of service. Power Up the Electronics Box Be sure the red emergency stop button is not engaged and push the green start button. You should hear the motors “bump” when powering up. This is an indication you have power to the motors.

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Programming Software Now the fun begins!!! We have an easy-to-learn software package that is included with your CNC router table as well as tutorials available that will have you producing with your machine very quickly. First, refer to the “Getting Started” page of the General CNC website www.generalcnc.ca/getting_started where you will find some sample projects that will help get you up and running. Next, refer to the General CNC website www.generalcnc.ca/software where you will find a series of tutorials available in both printable PDF and video formats. We recommend that you take the time to create the projects available on the tutorials before venturing out on your own projects. The tutorials are designed to provide you with an overview of the software and will allow you the opportunity to maximize all the tools at your disposal. So what happens when you get stuck! No problem at all. General CNC provides both email and telephone support to help you when you hit a snag. Usually we find that in the first couple of weeks you will encounter the occasional challenge and we are here to help you along the way. You can contact us by visiting the technical support page of our website www.generalcnc.ca/technical_support or phone us toll free from anywhere in Canada or the US at

1-877-340-8989 For fastest response we highly recommend that you use the support ticket found on our technical support page. This allows you to upload pertinent files and we can quickly assess where you are having trouble and get you up and running in the shortest time possible. General tech support will assist you with basic challenges or concerns. We are also proud to offer the secondary support of the software manufacturers who provide secondary support for some of the more challenging problems you may encounter. Here are the email addresses for our software partners.  V-Carve Pro, Photo V-Carve, Cut 3D [email protected]  Cabinet Parts Pro [email protected] We have an entire support team available to help you get the most enjoyment and profit from your General CNC router table.!!! 9 of 26

Operating Software Overview Here is a brief summary of the operating software. With most software configurations the operating program, General CNC, starts up automatically when the system starts up. If not, double click on the icon “General CNC” from the desktop.

Preview Screen The preview screen allows you to see your tool path so you can see that you have imported the correct file. As the cutting operation progresses, you will see the tool path change colour to indicate those areas that have already been machined.

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View Controls Pan – Click on “Pan and you will see the green light to highlight that this function is engaged. Once engaged you will be able to move the preview wherever you choose in the preview window. This can be done by holding the left mouse button and moving the mouse in the direction you choose. Zoom – Click on the “Zoom” icon and, once again, the green light will indicate that this function is engaged. You can zoom in on the part in the preview window by using the roller ball on your mouse or mouse pad. Refresh – This icon returns the preview to the size it was when imported. View – This function will allow you to rotate your part in the view screen so you can look at the cutting operation from different perspectives.

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Machining Times Run Time – This clock will track the cutting operation in real time. Est Machining Time – Before starting your cutting operation you can click the Estimated Machining Time button and the software will scan the entire G-code program and estimate the machine time for this job. Note that it needs to read the entire program so if this is a long cutting operation this may take a few minutes.

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G-Code Operations Load G-code – To load a G-code program to begin the cutting operation. Click on the “Load G-Code” icon. Select the file and you are ready to begin machining your part. Edit G-Code – This icon will open your G-Code in an editing screen. For more details on how to edit G-Code refer to the complete operator’s manual for your CNC machine found on the General CNC website. http://generalcnc.ca/manuals Reset G-Code – To restart a G-code program and run from the beginning click this icon. Close G-Code – If you want to close the G-Code file to load the next file use this function button. G-Code Viewing Screen – The G-code will display in this screen when it is loaded into the program.

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Homing Home All – This icon is used to establish an absolute zero position. Selecting this icon will allow the machine to move to an absolute zero position in the bottom left of the machine. Once the operator selects the “Home All” button the machine will move to top of the Z axis travel (up and down) and the far left of the X axis travel and finally the front of the machine which is the end of the Y axis travel. Once this operation is complete the operator can select the “Display Machine Coord” button and will see that the machine moves to the same X,Y and Z coordinates each time this operation is performed. This position is absolute, in other words, it never changes. This position may be particularly helpful in the event that the operator would want to relocate the tool to a specific location on the table. If the operator chooses to deselect the “Display Machine Coord” button then the program coordinates will, once again, display. These coordinates are relative, in other words, changeable at the operators discretion. If the operator were to zero the X and Y axis at this point this location would be the same for every single cutting operation where he followed this procedure. This would be helpful in relocating the tool location for repetitive parts jobs or in the event of power failure as the operator could recover the position by following this process once again.

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Soft Limits Soft Limits – This feature of the software will establish the machine parameters and will avoid the possibility of the machine head “crashing” into its limits when travelling in any direction. Soft limits should only be engaged after the Hole All function has been performed. When Soft Limits are in place the green light will be on above the Soft Limits button.

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Tool Sense Tool Sense – This icon is used to establish a zero position on the Z axis. Once the operator has established the X and Y zero position he or she may place the tool sensor plate under the tool and select “Tool Sensor”. A warning screen will insure that the plate is under the tool and then it will move until it contacts the Z zero sensing plate. Once it detects the plate it will rise to a position .50” above the part. If your part is designed with the Z zero at the top of the work piece then you should place the sense plate on top of the work. If your part was designed with the Z zero on the top of the table then you should place the sensor plate on top of the table to establish the zero position. Note: When zeroing your axis before cutting you should zero X and Y first AND THEN use the tool sense operation. Once the tool sense has set the Z zero DO NOT zero the Z axis as it is now reading .50” and is, in fact .50” above the work piece.

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Model Identification and Support Information Model Identification – The model number of your machine is conveniently displayed on your operating screen in the event of a tech support call. Customer Support Contact Information – The General CNC technical support phone number, email address or website address are all conveniently displayed so you always know how to reach us. Please note that there is a tech support and troubleshooting page on the website. These are helpful tool to get answers to any questions you might have regarding your CNC router

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Jogging Jog Mode- This icon will allow the operator to select between a continuous jog motion or a step mode. Continuous mode will allow you to move the tool in a continuous fashion by using either the jogging buttons on the screen (shown) or your keyboard (see Key Jog Enable). If Step Jog Mode is selected you can choose what increments you would prefer the movements to be when jogging. For instance, if you would like to move the Z axis .25” then you would hit the Jog Mode button and change to “Step”. Then click on the number screen to the right of the “Step” light. Using your keyboard, type in the number .25 and hit “enter” on your keyboard. This will change the display. Now when you use the “Up” (Z+) or “Down” (Z-) jogging buttons the tool will move accordingly. Key Jog Enable – If Key Jog Enable is selected it will allow you to move your machine in all directions using your keyboard as well as your mouse. Left arrow will move the tool left (X-), right arrow will move the tool right (X+), up arrow will move it away from you (Y+) and down arrow will move it towards you (Y-). The page up key will move the tool upwards (Z+) and page down will move the tool down (Z-). As you jog the tool you will see the coordinates change in the axis display windows so you know what the program coordinates are at all times.

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Zero X,Y and Z Axis Zero X,Y and Z or Zero All – Once the operator has determined what the reference point of his work piece is he must set his program coordinates to match this (bottom left, centre of material, etc). This can be done by jogging the tool to the correct location. Once he or she has located the tool at the reference point the X and Y axis can be zeroed. In the event the machine is equipped with a tool sense plate, this can be used to establish the Z axis. If not the Z axis can be established but jogging as with X and Y and the Zero All Axis button can be utilized.

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Machine Operation Start – Select this icon to run the program and cut the part. Run From Here – This icon will allow the operator to run the part from a predetermined line of code other than the start. Select this icon once you have selected the line of code to start from. Pause – This icon is used to pause the machining operation. Use pause of you want to maintain the machines location and intend to continue the cutting operation. Single Step Mode – This will allow the operator to run the G-code file one line of code at a time. This can be a helpful tool in learning CNC operation without the risk of error. When engaged the light above the Single Step Mode button will turn green. E-Stop – When the software opens the E-Stop will be red. The machine cannot operate until the E-stop is pushed to engage the operating system. The light will change from red to green. In the event you need to stop the machine for any reason the E-stop can be used by simply depressing the button.

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Feed Rate Feed Rate Up/Down – These icons will allow the operator to change the feed rate as the project is cutting. Reset Feed Rate Override – This icon allows the operator to return the feed rate to the speed it was programmed to run at. Feed Rate Slide Bar - There is a green slide bar to the right of the Feed Rate Up/Down buttons that will allow the operator to change the feed rate by simply sliding the bar with your left mouse button. The number displayed above the slide bar indicates the percentage of the original feed rate currently being used. Numeric Feed Rate Display - The numeric feed rate display is located to the right of the slide bar and displays the feed rate in whatever unit the program feed rate is created in (inches per minute, mm per second, etc).

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Tool Change Tool Change Light – When the machine is requesting a tool change the yellow tool change light will eliminate. Tool Change Number – When a tool change is being indicated the tool number will display. This number corresponds with the tool number selected in the design software. NOTE: Once the router/spindle has been shut off and the new tool has been installed in the collet. Turn the router back on and hit the Start button. This moves the g-code to the next command line. Depending on how the program is written this may move the tool into position and start the cutting operation. If not simply hit the Start button again.

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Carving/Cutting Mode Carving Mode: Select carving mode when doing machining operations which consist for many radius cuts or small incremental movements. This mode will smooth the tools performance to insure smooth cutting edges Cutting Mode: This setting can be implemented when cutting straight geometry like cutting out boxes or similar operations. This mode allows for faster cutting speeds without risking cut quality.

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Spindle ON/OFF If your General CNC router comes equipped with automatic spindle on/off from a command in the software (2011 models and newer) than this feature allows you to manual overwrite this function and allows you to turn the spindle on and off at the operators discretion.

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Status Window The status window will provide the operator with any error message during a machine operation. These may include, but not be limited too, soft limit warning, E-stop engaged message, etc.

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Routine Maintenance The General CNC machine requires very little routine maintenance. The following lists the preventative maintenance procedure for your machine: 1. Linear Bearings: General machines use preloaded linear bearings and rails. These bearings are perfect for this type of cutting application and will offer you years of trouble free service. The bearings will never need adjustment but do, from time to time, require lubrication. We recommend lubricating the bearings after every 500 hours of machining. Standard grease gun can be used for the X and Y bearings (20mm), while a needle applicator is required for the Z bearings (15mm). Most standard bearing lubricants will work very well. 2. X and Y Axis Rack and Pinion: The rack and pinion drive system should be lubricated as soon as possible after your machine is set up. White lithium grease works well. The machine should be inspected periodically to insure that these components stay lubricated. If you find that there is a significant build up of debris, wood chips, etc, then the rack should be thoroughly cleaned with mineral spirits and grease reapplied. 3. Z Axis Lead Screw: General recommends that the Z axis lead screw be lubricated with a special ball screw lubricant available from Nook Industries. Here is the link for product description http://www.nookindustries.com/ball/BallLubrication.cfm 4. Spindle: Your Elte Spindle really does not require any specific maintenance, however, over time you may find there is a requirement for service on the internal bearings. This is not a customer serviceable item and should only be re-packed by your local Elte authorized repair facility. If you notice that your spindle head has some “play” in it then this could be an indication that the bearing require service. 5. Frame and Hardware: Once per week the operator should carefully inspect the machine to insure safe operation. One of the recommended procedures is to insure that all hardware is securely tight. Since your CNC router table has a tremendous amount of movement during cutting operations is it possible that, from time to time, some hardware may loosen. This can be affect the quality of your work cause machine failure or serious injury. 6. Wiring Harnesses and Cabling: As is the case with the frame and hardware it is recommended that the operator inspect the wiring and cabling weekly to insure that there are no frayed connections or pinched wiring. Again, this can affect the quality of your work, cause machine failure or serious injury.

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