LVL1 - User contributions [en]

Zenbot 1216 CNC

2012-11-30T04:12:32Z

Milutz: First pass of writing some instructions

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=somewhat - in process of setup|contact= Mike Lutz, Chris Pettus or Gerrit|where=In the basement next to the big CNC system}}
== Current status ==
;As of Nov 29 2012: System usable but has no safeties, it is still trivial to cause the machine to destroy itself.

== Operating instructions ==
[[File:Zenbot software flow.gif|thumb|The logical tasks/steps needed to go from an idea to a file that can drive the zenbot]]
As-of-Dec-2012 the equipment can be operated with extreme caution.

:Given the lack of
:* limit switches
:* emergency power off
:* cleaned up software
:There is a high risk that the machine will be damaged if used. If you really want to work with the machine now its '''STRONGLY''' recommended that you have Chris Pettus or Mike Lutz sit with you the first time you try and use the machine.

More instruction will be coming in the future, but the best thing you can do now is pick and learn a 3d CAD package. They are ''shockingly'' hard to use and you should expect spend 8+ hours going through the tutorials in order to drive the system such that all the faces have the surfaces you want and also learning how to use the snap systems to align things in 3d space (all of which will be critical when the file is handed over to the CAM software)

If you happen to be working on OS X, the popular commercial hobbyist-targeted 3d CAD Rhinoceros is freely available while it continues to be in development (see: http://mac.rhino3d.com). I think the primary appeal of Rhino is that it has a very good tutorial (... well, and its free for OS X ... for the moment)

=== Materials tested with zenbot ===
* Machinable wax
** Cuts easily - though not cleanly. Still learning
* RenShape 460
** Cuts easily and cleanly. Only had good experiences with it so far
* Green-blue rigid foam (unsure what it is, was found in scrap box)
** Cuts cleanly and easily, but kicks up static-attracting bits of foam, likely to fowl the mill if not cleaned while cutting
* Some kind of fiber board (found as scrap)
** Sloppy cuts, details tend to break off
* Some kind of clear plexiglass (found as scrap)
** '''BAD''': within a few minutes of cutting, the plastic formed on the blade, completely isolating the cutting surfaces

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif|thumb|none|640px|Wiring diagram for the zenbot]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216 [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle were missing but have been replaced by the smaller belts from faucet repair kit.
** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
*** The info Gerrit received (with regards to the o-rings) didn't match our spindle. Chris P found a match by trial and error
** The smaller o-rings from a DL-15 Single Handle Delta Kitchen Spout Repair Kit seem to be a "good enough" match to the belts that are needed for the spindle. As of Nov 6, 2012, these are the belts on the spindle.
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply
** An HP/Compact server powersupply "ESP115" from the boneyard.
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot.
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|}
{|
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Zenbot Power supply used for Zenbot spindle.JPG|thumb|Powersupply used for spindle motor]]
|[[File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG|thumb|Faucet repair kit. The smaller o-rings (not shown) fit the spindle.]]
|}
{|
|[[File:Zenbot Inch measurement of diameter of bit.jpg|thumb|Size of the bits that will fit in the collet that we have]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Notes from initial equipment build ==

===Log of research (newest to oldest)===

----
[[File:Zenbot Loossing-tightening the collet assembly in spindle.jpg|thumb|The way the collet must be held when unscrewing it switch out the bit (if not held the bit will slam into the base of the CNC and may break)]]
[[File:Zenbot Picture of hex wrench taped to CNC.jpg|thumb|Picture of where a hex wrench that matches the collet/chuck is tapped to the zenbot]]
[[File:Zenbot Bit in collet.jpg|thumb|If the collet is complete unscrewed when changing bits (I suspect this is the safest way to do it]]
[[File:Zenbot Bit partway out of collet.jpg|thumb|When the collet is loose the bit just slides out of it]]
[[File:Zenbot Bit seperate from collet.jpg|thumb|A picture of the collet and the bit seperately]]

Nov 12 Mike L

- Copy of update email -

Virtually all progress in this update (and most from last) is thanks to the continued heroics from '''Chris Pettus'''. He is the unsung hero of this project and will be the reason the machine gets to whatever level of operation that it gets to.

Detail for this week:
:'''Progress made''':
:*Chris P found some < $4 faucet o-rings that are the right size to link the spindle motor to the spindle arm
:**They are installed on the zenbot, have about 30 min of time on them, haven't shown any issue with wear or slippage.
:*Spindle power supply interface case built with integrated fuses
:**currently fussing the spindle at 10 amps, though the power supply really should be able to drive 30 amps safely, we are using the low fuse to better learn what the spindle will really need -- In other words, if anyone tries to cut something really hard (or jams the cutter) the spindle fuse will likely blow.
:**I expect we will increase the fuse as we better understand the spindle (unless we find it never blows)
:*Last meeting, with the help of many other Lvl1'er, the Zenbot was moved down stairs next to the big CNC.
:*Running the spindle at full speed (likely too fast for the wax) Chris P and Mike L did a cut of the first few letters of "LinuxCNC" in machining wax. See the wiki page for full desc or jump here for picture: http://wiki.lvl1.org/File:Zenbot_Clockwise_cut_(first_cut).jpg
:*The spindle motor speed controller has been repaired and tested with a separate motor, not yet integrated back into the zenbot.

:'''Next actions''':
:*Get the speed controller installed between the spindle and its supply (also, perhaps trying to connect the PWM interface to LinuxCNC) - Chris P
:*Measuring spindle speed (at full and different settings of the speed controller - Chris P and Mike L
:*Writing up the software complexities of working with the CNC (Need CAD & CAM before can use LinuxCNC) - Mike L
:*Learning various CAD and CAM packages so-as to create g-code that we can mill with the Zenbot - Mike L, Chris P, and anyone else who is thinking they want to use this system

:'''Future/dream/stuff-it-would-be-nice-if-other-people-would-jump-in-and-tackle''':
:*More bits for the Zenbot
:**We now know that the collet in the zenbot takes 1/8" bits (... and given the collet is high-spec it will likely ONLY take 1/8" bits - it might be able to take 3mm bits, but I wouldn't be surprised if they slip given the collet design
:**The bits for the spindle are both expendable (very breakable and will dull if cutting hard stuf) and kinda pricy (new < 1mm blades seem to be around $35 new).
:**As talked about in the last update, multiple parties have said "get used blade off ebay", and while I'm starting to understand what they are talking about, I'm still not ready to plunge into the used blade world, nor has anyone committed to this work.
:**So I can keep working, I'm going to personally order a few new blades for my personal use and use the experience to better learn about the used market. For anyone else thinking about using the zenbot in the near term, I guess what I'm saying is "for the time being, the zenbot is a 'bring your own bits' device". (I'll add a bit ordering guide to the wiki as I better understand the process)
:*X, Y, Z limit switches
:**Chris P has some switches which may be quite good for this, we are not sure when or if we will get to this though (neither of us are mechanicals, so making readjustable and robust mounting brackets for switches is a bit baffling to us)
:*X, Y homing and measuring the cutter in the Z
:**X & Y homing might be doable with the limit switches depending on what the controller can do. Measuring Z will likely require something new. Chris P has this in mind when he is working with the X,Y,Z controller but no new work has been done on it since last update
:*Integrated vacuum system
:**Gerrit said at last meeting that he might have a vacuum that could be used for this. I have a 15A ac power relay (http://adafruit.com/products/268) that might also be able to be used, but no planning other then ideas of parts have been done.
:*Sacrificial milling surface overlays and/or jigs
:**Chris P, Gerrit and I have all agreed that it would be ''very'' good idea to build some type of sacrificial overlay over the Zenbot milling surface given how easy it is to drive the blade right through the mills surface (the -z limit won't help for this, the spindle is such that the cutting blade would always go through the mills surface before the limit hit)
With that said, no one has picked up the ball on this, and I doubt Chris P or I would any time soon. Help would be welcome, especially if you know what your doing with the big CNC and/or know how useful jigs would be built for specific tasks, like circuit board milling
:*All-in-one enclosure
:**Gerrit has been dreaming of an all-in-one enclosure for the zenbot, with its controls, and the computer system that LinuxCNC runs on packed underneath the zenbot. (something like http://buildyourcnc.com/redSproutCNCComputerSystem.aspx under the zenbot) Chris P has continued to refine/repack the control electronics and this may be relatively straightforward in the furture but no one has taken the ball for this task.

The CNC is nearly at the point where different tracks of work will need to be done for different projects (molds vs. circuit boards).

I'm interested in 3d mold making and to get the ball rolling for that sub-project on the zenbot, I've started a new wiki page about that use: http://wiki.lvl1.org/Copying_Guerrilla_guide_to_cnc-mold-casting
(I've also ordered a board of Renshape 460 - millable plastic for mold making - that I would be up for selling parts off of for anyone else wanting to try 3d part mold making)

I know that a number of other people in the group are interested in cutting circuit boards, thats not really my cup-of-tea (at least not until I have my brain wrapped around the mold making stuff) so I'm hoping some of the other interested parties will jump in, start researching the software/router-bit/jigs that are required to do that work, and building documentation to teach others.

-Mike

----

Nov 8 Mike L

The included bit has been measured and is 1/8", pressumibly this is really the only size the collet can hold (''Might'' be able to hold a 3mm bit but the teeth on the collet were so close, a 3mm might slip)

Numerous pictures were taken of the collet system, later to be use for instruction.
----
[[File:Zenbot Clockwise cut (first cut).jpg|thumb|First (Clockwise, if the spindle is viewed from the top down) cut with the Zenbot since its repair.]]
[[File:Zenbot Counter clockwise cut (second cut).jpg|thumb|Second, counter-clockwise cut (from our examination we feel that clockwise is the correct way to use the bit that came with the machine)]]
Nov 6 Mike L

Through heroic effort of Chris P, all the major drive systems of the CNC are now online (Power found for spindle, drive belts found for spindle, software for X,Y,Z all calibrated)

With the help of Chris C, Nathan and a few others the Zenbot was moved downstairs next to the big CNC.

An initial cut was done in machine wax of the "LinuxCNC" default on LinuxCNC (only the "L", "i", and 1/4 of the "n" fit on the wax)

----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case
a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

File:Zenbot software flow.gif

2012-11-30T03:38:16Z

Milutz: An illustration of the logical steps needed to drive the Zenbot and also some of the software options available to fill in those steps.

An illustration of the logical steps needed to drive the Zenbot and also some of the software options available to fill in those steps.

Zenbot 1216 CNC

2012-11-30T00:30:38Z

Milutz:

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=somewhat - in process of setup|contact= Mike Lutz, Chris Pettus or Gerrit|where=In the basement next to the big CNC system}}
== Current status ==
;As of Nov 29 2012: System usable but has no safeties, it is still trivial to cause the machine to destroy itself.

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif|thumb|none|640px|Wiring diagram for the zenbot]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216 [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle were missing but have been replaced by the smaller belts from faucet repair kit.
** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
*** The info Gerrit received (with regards to the o-rings) didn't match our spindle. Chris P found a match by trial and error
** The smaller o-rings from a DL-15 Single Handle Delta Kitchen Spout Repair Kit seem to be a "good enough" match to the belts that are needed for the spindle. As of Nov 6, 2012, these are the belts on the spindle.
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply
** An HP/Compact server powersupply "ESP115" from the boneyard.
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot.
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|}
{|
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Zenbot Power supply used for Zenbot spindle.JPG|thumb|Powersupply used for spindle motor]]
|[[File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG|thumb|Faucet repair kit. The smaller o-rings (not shown) fit the spindle.]]
|}
{|
|[[File:Zenbot Inch measurement of diameter of bit.jpg|thumb|Size of the bits that will fit in the collet that we have]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Nov-2012 the equipment can be operated with extreme caution. Given the lack of: limit switches, emergency power off, cleaned up software (Its unclear which software to run to control the system) there is a high risk that the machine will be damaged if used.

== Notes from initial equipment build ==

===Log of research (newest to oldest)===

----
[[File:Zenbot Loossing-tightening the collet assembly in spindle.jpg|thumb|The way the collet must be held when unscrewing it switch out the bit (if not held the bit will slam into the base of the CNC and may break)]]
[[File:Zenbot Picture of hex wrench taped to CNC.jpg|thumb|Picture of where a hex wrench that matches the collet/chuck is tapped to the zenbot]]
[[File:Zenbot Bit in collet.jpg|thumb|If the collet is complete unscrewed when changing bits (I suspect this is the safest way to do it]]
[[File:Zenbot Bit partway out of collet.jpg|thumb|When the collet is loose the bit just slides out of it]]
[[File:Zenbot Bit seperate from collet.jpg|thumb|A picture of the collet and the bit seperately]]

Nov 12 Mike L

- Copy of update email -

Virtually all progress in this update (and most from last) is thanks to the continued heroics from '''Chris Pettus'''. He is the unsung hero of this project and will be the reason the machine gets to whatever level of operation that it gets to.

Detail for this week:
:'''Progress made''':
:*Chris P found some < $4 faucet o-rings that are the right size to link the spindle motor to the spindle arm
:**They are installed on the zenbot, have about 30 min of time on them, haven't shown any issue with wear or slippage.
:*Spindle power supply interface case built with integrated fuses
:**currently fussing the spindle at 10 amps, though the power supply really should be able to drive 30 amps safely, we are using the low fuse to better learn what the spindle will really need -- In other words, if anyone tries to cut something really hard (or jams the cutter) the spindle fuse will likely blow.
:**I expect we will increase the fuse as we better understand the spindle (unless we find it never blows)
:*Last meeting, with the help of many other Lvl1'er, the Zenbot was moved down stairs next to the big CNC.
:*Running the spindle at full speed (likely too fast for the wax) Chris P and Mike L did a cut of the first few letters of "LinuxCNC" in machining wax. See the wiki page for full desc or jump here for picture: http://wiki.lvl1.org/File:Zenbot_Clockwise_cut_(first_cut).jpg
:*The spindle motor speed controller has been repaired and tested with a separate motor, not yet integrated back into the zenbot.

:'''Next actions''':
:*Get the speed controller installed between the spindle and its supply (also, perhaps trying to connect the PWM interface to LinuxCNC) - Chris P
:*Measuring spindle speed (at full and different settings of the speed controller - Chris P and Mike L
:*Writing up the software complexities of working with the CNC (Need CAD & CAM before can use LinuxCNC) - Mike L
:*Learning various CAD and CAM packages so-as to create g-code that we can mill with the Zenbot - Mike L, Chris P, and anyone else who is thinking they want to use this system

:'''Future/dream/stuff-it-would-be-nice-if-other-people-would-jump-in-and-tackle''':
:*More bits for the Zenbot
:**We now know that the collet in the zenbot takes 1/8" bits (... and given the collet is high-spec it will likely ONLY take 1/8" bits - it might be able to take 3mm bits, but I wouldn't be surprised if they slip given the collet design
:**The bits for the spindle are both expendable (very breakable and will dull if cutting hard stuf) and kinda pricy (new < 1mm blades seem to be around $35 new).
:**As talked about in the last update, multiple parties have said "get used blade off ebay", and while I'm starting to understand what they are talking about, I'm still not ready to plunge into the used blade world, nor has anyone committed to this work.
:**So I can keep working, I'm going to personally order a few new blades for my personal use and use the experience to better learn about the used market. For anyone else thinking about using the zenbot in the near term, I guess what I'm saying is "for the time being, the zenbot is a 'bring your own bits' device". (I'll add a bit ordering guide to the wiki as I better understand the process)
:*X, Y, Z limit switches
:**Chris P has some switches which may be quite good for this, we are not sure when or if we will get to this though (neither of us are mechanicals, so making readjustable and robust mounting brackets for switches is a bit baffling to us)
:*X, Y homing and measuring the cutter in the Z
:**X & Y homing might be doable with the limit switches depending on what the controller can do. Measuring Z will likely require something new. Chris P has this in mind when he is working with the X,Y,Z controller but no new work has been done on it since last update
:*Integrated vacuum system
:**Gerrit said at last meeting that he might have a vacuum that could be used for this. I have a 15A ac power relay (http://adafruit.com/products/268) that might also be able to be used, but no planning other then ideas of parts have been done.
:*Sacrificial milling surface overlays and/or jigs
:**Chris P, Gerrit and I have all agreed that it would be ''very'' good idea to build some type of sacrificial overlay over the Zenbot milling surface given how easy it is to drive the blade right through the mills surface (the -z limit won't help for this, the spindle is such that the cutting blade would always go through the mills surface before the limit hit)
With that said, no one has picked up the ball on this, and I doubt Chris P or I would any time soon. Help would be welcome, especially if you know what your doing with the big CNC and/or know how useful jigs would be built for specific tasks, like circuit board milling
:*All-in-one enclosure
:**Gerrit has been dreaming of an all-in-one enclosure for the zenbot, with its controls, and the computer system that LinuxCNC runs on packed underneath the zenbot. (something like http://buildyourcnc.com/redSproutCNCComputerSystem.aspx under the zenbot) Chris P has continued to refine/repack the control electronics and this may be relatively straightforward in the furture but no one has taken the ball for this task.

The CNC is nearly at the point where different tracks of work will need to be done for different projects (molds vs. circuit boards).

I'm interested in 3d mold making and to get the ball rolling for that sub-project on the zenbot, I've started a new wiki page about that use: http://wiki.lvl1.org/Copying_Guerrilla_guide_to_cnc-mold-casting
(I've also ordered a board of Renshape 460 - millable plastic for mold making - that I would be up for selling parts off of for anyone else wanting to try 3d part mold making)

I know that a number of other people in the group are interested in cutting circuit boards, thats not really my cup-of-tea (at least not until I have my brain wrapped around the mold making stuff) so I'm hoping some of the other interested parties will jump in, start researching the software/router-bit/jigs that are required to do that work, and building documentation to teach others.

-Mike

----

Nov 8 Mike L

The included bit has been measured and is 1/8", pressumibly this is really the only size the collet can hold (''Might'' be able to hold a 3mm bit but the teeth on the collet were so close, a 3mm might slip)

Numerous pictures were taken of the collet system, later to be use for instruction.
----
[[File:Zenbot Clockwise cut (first cut).jpg|thumb|First (Clockwise, if the spindle is viewed from the top down) cut with the Zenbot since its repair.]]
[[File:Zenbot Counter clockwise cut (second cut).jpg|thumb|Second, counter-clockwise cut (from our examination we feel that clockwise is the correct way to use the bit that came with the machine)]]
Nov 6 Mike L

Through heroic effort of Chris P, all the major drive systems of the CNC are now online (Power found for spindle, drive belts found for spindle, software for X,Y,Z all calibrated)

With the help of Chris C, Nathan and a few others the Zenbot was moved downstairs next to the big CNC.

An initial cut was done in machine wax of the "LinuxCNC" default on LinuxCNC (only the "L", "i", and 1/4 of the "n" fit on the wax)

----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case
a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Zenbot 1216 CNC

2012-11-30T00:27:50Z

Milutz: /* Current status */

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=somewhat - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=In the basement next to the big CNC system}}
== Current status ==
;As of Nov 29 2012: System usable but has no safeties, it is still trivial to cause the machine to destroy itself.

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif|thumb|none|640px|Wiring diagram for the zenbot]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216 [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle were missing but have been replaced by the smaller belts from faucet repair kit.
** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
*** The info Gerrit received (with regards to the o-rings) didn't match our spindle. Chris P found a match by trial and error
** The smaller o-rings from a DL-15 Single Handle Delta Kitchen Spout Repair Kit seem to be a "good enough" match to the belts that are needed for the spindle. As of Nov 6, 2012, these are the belts on the spindle.
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply
** An HP/Compact server powersupply "ESP115" from the boneyard.
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot.
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|}
{|
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Zenbot Power supply used for Zenbot spindle.JPG|thumb|Powersupply used for spindle motor]]
|[[File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG|thumb|Faucet repair kit. The smaller o-rings (not shown) fit the spindle.]]
|}
{|
|[[File:Zenbot Inch measurement of diameter of bit.jpg|thumb|Size of the bits that will fit in the collet that we have]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Nov-2012 the equipment can be operated with extreme caution. Given the lack of: limit switches, emergency power off, cleaned up software (Its unclear which software to run to control the system) there is a high risk that the machine will be damaged if used.

== Notes from initial equipment build ==

===Log of research (newest to oldest)===

----
[[File:Zenbot Loossing-tightening the collet assembly in spindle.jpg|thumb|The way the collet must be held when unscrewing it switch out the bit (if not held the bit will slam into the base of the CNC and may break)]]
[[File:Zenbot Picture of hex wrench taped to CNC.jpg|thumb|Picture of where a hex wrench that matches the collet/chuck is tapped to the zenbot]]
[[File:Zenbot Bit in collet.jpg|thumb|If the collet is complete unscrewed when changing bits (I suspect this is the safest way to do it]]
[[File:Zenbot Bit partway out of collet.jpg|thumb|When the collet is loose the bit just slides out of it]]
[[File:Zenbot Bit seperate from collet.jpg|thumb|A picture of the collet and the bit seperately]]

Nov 12 Mike L

- Copy of update email -

Virtually all progress in this update (and most from last) is thanks to the continued heroics from '''Chris Pettus'''. He is the unsung hero of this project and will be the reason the machine gets to whatever level of operation that it gets to.

Detail for this week:
:'''Progress made''':
:*Chris P found some < $4 faucet o-rings that are the right size to link the spindle motor to the spindle arm
:**They are installed on the zenbot, have about 30 min of time on them, haven't shown any issue with wear or slippage.
:*Spindle power supply interface case built with integrated fuses
:**currently fussing the spindle at 10 amps, though the power supply really should be able to drive 30 amps safely, we are using the low fuse to better learn what the spindle will really need -- In other words, if anyone tries to cut something really hard (or jams the cutter) the spindle fuse will likely blow.
:**I expect we will increase the fuse as we better understand the spindle (unless we find it never blows)
:*Last meeting, with the help of many other Lvl1'er, the Zenbot was moved down stairs next to the big CNC.
:*Running the spindle at full speed (likely too fast for the wax) Chris P and Mike L did a cut of the first few letters of "LinuxCNC" in machining wax. See the wiki page for full desc or jump here for picture: http://wiki.lvl1.org/File:Zenbot_Clockwise_cut_(first_cut).jpg
:*The spindle motor speed controller has been repaired and tested with a separate motor, not yet integrated back into the zenbot.

:'''Next actions''':
:*Get the speed controller installed between the spindle and its supply (also, perhaps trying to connect the PWM interface to LinuxCNC) - Chris P
:*Measuring spindle speed (at full and different settings of the speed controller - Chris P and Mike L
:*Writing up the software complexities of working with the CNC (Need CAD & CAM before can use LinuxCNC) - Mike L
:*Learning various CAD and CAM packages so-as to create g-code that we can mill with the Zenbot - Mike L, Chris P, and anyone else who is thinking they want to use this system

:'''Future/dream/stuff-it-would-be-nice-if-other-people-would-jump-in-and-tackle''':
:*More bits for the Zenbot
:**We now know that the collet in the zenbot takes 1/8" bits (... and given the collet is high-spec it will likely ONLY take 1/8" bits - it might be able to take 3mm bits, but I wouldn't be surprised if they slip given the collet design
:**The bits for the spindle are both expendable (very breakable and will dull if cutting hard stuf) and kinda pricy (new < 1mm blades seem to be around $35 new).
:**As talked about in the last update, multiple parties have said "get used blade off ebay", and while I'm starting to understand what they are talking about, I'm still not ready to plunge into the used blade world, nor has anyone committed to this work.
:**So I can keep working, I'm going to personally order a few new blades for my personal use and use the experience to better learn about the used market. For anyone else thinking about using the zenbot in the near term, I guess what I'm saying is "for the time being, the zenbot is a 'bring your own bits' device". (I'll add a bit ordering guide to the wiki as I better understand the process)
:*X, Y, Z limit switches
:**Chris P has some switches which may be quite good for this, we are not sure when or if we will get to this though (neither of us are mechanicals, so making readjustable and robust mounting brackets for switches is a bit baffling to us)
:*X, Y homing and measuring the cutter in the Z
:**X & Y homing might be doable with the limit switches depending on what the controller can do. Measuring Z will likely require something new. Chris P has this in mind when he is working with the X,Y,Z controller but no new work has been done on it since last update
:*Integrated vacuum system
:**Gerrit said at last meeting that he might have a vacuum that could be used for this. I have a 15A ac power relay (http://adafruit.com/products/268) that might also be able to be used, but no planning other then ideas of parts have been done.
:*Sacrificial milling surface overlays and/or jigs
:**Chris P, Gerrit and I have all agreed that it would be ''very'' good idea to build some type of sacrificial overlay over the Zenbot milling surface given how easy it is to drive the blade right through the mills surface (the -z limit won't help for this, the spindle is such that the cutting blade would always go through the mills surface before the limit hit)
With that said, no one has picked up the ball on this, and I doubt Chris P or I would any time soon. Help would be welcome, especially if you know what your doing with the big CNC and/or know how useful jigs would be built for specific tasks, like circuit board milling
:*All-in-one enclosure
:**Gerrit has been dreaming of an all-in-one enclosure for the zenbot, with its controls, and the computer system that LinuxCNC runs on packed underneath the zenbot. (something like http://buildyourcnc.com/redSproutCNCComputerSystem.aspx under the zenbot) Chris P has continued to refine/repack the control electronics and this may be relatively straightforward in the furture but no one has taken the ball for this task.

The CNC is nearly at the point where different tracks of work will need to be done for different projects (molds vs. circuit boards).

I'm interested in 3d mold making and to get the ball rolling for that sub-project on the zenbot, I've started a new wiki page about that use: http://wiki.lvl1.org/Copying_Guerrilla_guide_to_cnc-mold-casting
(I've also ordered a board of Renshape 460 - millable plastic for mold making - that I would be up for selling parts off of for anyone else wanting to try 3d part mold making)

I know that a number of other people in the group are interested in cutting circuit boards, thats not really my cup-of-tea (at least not until I have my brain wrapped around the mold making stuff) so I'm hoping some of the other interested parties will jump in, start researching the software/router-bit/jigs that are required to do that work, and building documentation to teach others.

-Mike

----

Nov 8 Mike L

The included bit has been measured and is 1/8", pressumibly this is really the only size the collet can hold (''Might'' be able to hold a 3mm bit but the teeth on the collet were so close, a 3mm might slip)

Numerous pictures were taken of the collet system, later to be use for instruction.
----
[[File:Zenbot Clockwise cut (first cut).jpg|thumb|First (Clockwise, if the spindle is viewed from the top down) cut with the Zenbot since its repair.]]
[[File:Zenbot Counter clockwise cut (second cut).jpg|thumb|Second, counter-clockwise cut (from our examination we feel that clockwise is the correct way to use the bit that came with the machine)]]
Nov 6 Mike L

Through heroic effort of Chris P, all the major drive systems of the CNC are now online (Power found for spindle, drive belts found for spindle, software for X,Y,Z all calibrated)

With the help of Chris C, Nathan and a few others the Zenbot was moved downstairs next to the big CNC.

An initial cut was done in machine wax of the "LinuxCNC" default on LinuxCNC (only the "L", "i", and 1/4 of the "n" fit on the wax)

----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case
a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Zenbot 1216 CNC

2012-11-30T00:26:16Z

Milutz: /* Equipment Description */ updated the wiring diagram

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=somewhat - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=In the basement next to the big CNC system}}
== Current status ==
;As of Nov 19 2012:X and Z controllers currently offline, parts on order to fix, expected fix post turkey-day week.

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif|thumb|none|640px|Wiring diagram for the zenbot]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216 [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle were missing but have been replaced by the smaller belts from faucet repair kit.
** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
*** The info Gerrit received (with regards to the o-rings) didn't match our spindle. Chris P found a match by trial and error
** The smaller o-rings from a DL-15 Single Handle Delta Kitchen Spout Repair Kit seem to be a "good enough" match to the belts that are needed for the spindle. As of Nov 6, 2012, these are the belts on the spindle.
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply
** An HP/Compact server powersupply "ESP115" from the boneyard.
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot.
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|}
{|
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Zenbot Power supply used for Zenbot spindle.JPG|thumb|Powersupply used for spindle motor]]
|[[File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG|thumb|Faucet repair kit. The smaller o-rings (not shown) fit the spindle.]]
|}
{|
|[[File:Zenbot Inch measurement of diameter of bit.jpg|thumb|Size of the bits that will fit in the collet that we have]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Nov-2012 the equipment can be operated with extreme caution. Given the lack of: limit switches, emergency power off, cleaned up software (Its unclear which software to run to control the system) there is a high risk that the machine will be damaged if used.

== Notes from initial equipment build ==

===Log of research (newest to oldest)===

----
[[File:Zenbot Loossing-tightening the collet assembly in spindle.jpg|thumb|The way the collet must be held when unscrewing it switch out the bit (if not held the bit will slam into the base of the CNC and may break)]]
[[File:Zenbot Picture of hex wrench taped to CNC.jpg|thumb|Picture of where a hex wrench that matches the collet/chuck is tapped to the zenbot]]
[[File:Zenbot Bit in collet.jpg|thumb|If the collet is complete unscrewed when changing bits (I suspect this is the safest way to do it]]
[[File:Zenbot Bit partway out of collet.jpg|thumb|When the collet is loose the bit just slides out of it]]
[[File:Zenbot Bit seperate from collet.jpg|thumb|A picture of the collet and the bit seperately]]

Nov 12 Mike L

- Copy of update email -

Virtually all progress in this update (and most from last) is thanks to the continued heroics from '''Chris Pettus'''. He is the unsung hero of this project and will be the reason the machine gets to whatever level of operation that it gets to.

Detail for this week:
:'''Progress made''':
:*Chris P found some < $4 faucet o-rings that are the right size to link the spindle motor to the spindle arm
:**They are installed on the zenbot, have about 30 min of time on them, haven't shown any issue with wear or slippage.
:*Spindle power supply interface case built with integrated fuses
:**currently fussing the spindle at 10 amps, though the power supply really should be able to drive 30 amps safely, we are using the low fuse to better learn what the spindle will really need -- In other words, if anyone tries to cut something really hard (or jams the cutter) the spindle fuse will likely blow.
:**I expect we will increase the fuse as we better understand the spindle (unless we find it never blows)
:*Last meeting, with the help of many other Lvl1'er, the Zenbot was moved down stairs next to the big CNC.
:*Running the spindle at full speed (likely too fast for the wax) Chris P and Mike L did a cut of the first few letters of "LinuxCNC" in machining wax. See the wiki page for full desc or jump here for picture: http://wiki.lvl1.org/File:Zenbot_Clockwise_cut_(first_cut).jpg
:*The spindle motor speed controller has been repaired and tested with a separate motor, not yet integrated back into the zenbot.

:'''Next actions''':
:*Get the speed controller installed between the spindle and its supply (also, perhaps trying to connect the PWM interface to LinuxCNC) - Chris P
:*Measuring spindle speed (at full and different settings of the speed controller - Chris P and Mike L
:*Writing up the software complexities of working with the CNC (Need CAD & CAM before can use LinuxCNC) - Mike L
:*Learning various CAD and CAM packages so-as to create g-code that we can mill with the Zenbot - Mike L, Chris P, and anyone else who is thinking they want to use this system

:'''Future/dream/stuff-it-would-be-nice-if-other-people-would-jump-in-and-tackle''':
:*More bits for the Zenbot
:**We now know that the collet in the zenbot takes 1/8" bits (... and given the collet is high-spec it will likely ONLY take 1/8" bits - it might be able to take 3mm bits, but I wouldn't be surprised if they slip given the collet design
:**The bits for the spindle are both expendable (very breakable and will dull if cutting hard stuf) and kinda pricy (new < 1mm blades seem to be around $35 new).
:**As talked about in the last update, multiple parties have said "get used blade off ebay", and while I'm starting to understand what they are talking about, I'm still not ready to plunge into the used blade world, nor has anyone committed to this work.
:**So I can keep working, I'm going to personally order a few new blades for my personal use and use the experience to better learn about the used market. For anyone else thinking about using the zenbot in the near term, I guess what I'm saying is "for the time being, the zenbot is a 'bring your own bits' device". (I'll add a bit ordering guide to the wiki as I better understand the process)
:*X, Y, Z limit switches
:**Chris P has some switches which may be quite good for this, we are not sure when or if we will get to this though (neither of us are mechanicals, so making readjustable and robust mounting brackets for switches is a bit baffling to us)
:*X, Y homing and measuring the cutter in the Z
:**X & Y homing might be doable with the limit switches depending on what the controller can do. Measuring Z will likely require something new. Chris P has this in mind when he is working with the X,Y,Z controller but no new work has been done on it since last update
:*Integrated vacuum system
:**Gerrit said at last meeting that he might have a vacuum that could be used for this. I have a 15A ac power relay (http://adafruit.com/products/268) that might also be able to be used, but no planning other then ideas of parts have been done.
:*Sacrificial milling surface overlays and/or jigs
:**Chris P, Gerrit and I have all agreed that it would be ''very'' good idea to build some type of sacrificial overlay over the Zenbot milling surface given how easy it is to drive the blade right through the mills surface (the -z limit won't help for this, the spindle is such that the cutting blade would always go through the mills surface before the limit hit)
With that said, no one has picked up the ball on this, and I doubt Chris P or I would any time soon. Help would be welcome, especially if you know what your doing with the big CNC and/or know how useful jigs would be built for specific tasks, like circuit board milling
:*All-in-one enclosure
:**Gerrit has been dreaming of an all-in-one enclosure for the zenbot, with its controls, and the computer system that LinuxCNC runs on packed underneath the zenbot. (something like http://buildyourcnc.com/redSproutCNCComputerSystem.aspx under the zenbot) Chris P has continued to refine/repack the control electronics and this may be relatively straightforward in the furture but no one has taken the ball for this task.

The CNC is nearly at the point where different tracks of work will need to be done for different projects (molds vs. circuit boards).

I'm interested in 3d mold making and to get the ball rolling for that sub-project on the zenbot, I've started a new wiki page about that use: http://wiki.lvl1.org/Copying_Guerrilla_guide_to_cnc-mold-casting
(I've also ordered a board of Renshape 460 - millable plastic for mold making - that I would be up for selling parts off of for anyone else wanting to try 3d part mold making)

I know that a number of other people in the group are interested in cutting circuit boards, thats not really my cup-of-tea (at least not until I have my brain wrapped around the mold making stuff) so I'm hoping some of the other interested parties will jump in, start researching the software/router-bit/jigs that are required to do that work, and building documentation to teach others.

-Mike

----

Nov 8 Mike L

The included bit has been measured and is 1/8", pressumibly this is really the only size the collet can hold (''Might'' be able to hold a 3mm bit but the teeth on the collet were so close, a 3mm might slip)

Numerous pictures were taken of the collet system, later to be use for instruction.
----
[[File:Zenbot Clockwise cut (first cut).jpg|thumb|First (Clockwise, if the spindle is viewed from the top down) cut with the Zenbot since its repair.]]
[[File:Zenbot Counter clockwise cut (second cut).jpg|thumb|Second, counter-clockwise cut (from our examination we feel that clockwise is the correct way to use the bit that came with the machine)]]
Nov 6 Mike L

Through heroic effort of Chris P, all the major drive systems of the CNC are now online (Power found for spindle, drive belts found for spindle, software for X,Y,Z all calibrated)

With the help of Chris C, Nathan and a few others the Zenbot was moved downstairs next to the big CNC.

An initial cut was done in machine wax of the "LinuxCNC" default on LinuxCNC (only the "L", "i", and 1/4 of the "n" fit on the wax)

----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case
a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

File:Zenbot parts - oct 24 2012.gif

2012-11-30T00:22:05Z

Milutz: Milutz uploaded a new version of "File:Zenbot parts - oct 24 2012.gif": Updated wiring diagram

This is a crude drawing the the parts that make of the (currently not working) Zenbot 1624

Zenbot 1216 CNC

2012-11-19T22:08:37Z

Milutz: /* Current status */

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=somewhat - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=In the basement next to the big CNC system}}
== Current status ==
;As of Nov 19 2012:X and Z controllers currently offline, parts on order to fix, expected fix post turkey-day week.

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216 [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle were missing but have been replaced by the smaller belts from faucet repair kit.
** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
*** The info Gerrit received (with regards to the o-rings) didn't match our spindle. Chris P found a match by trial and error
** The smaller o-rings from a DL-15 Single Handle Delta Kitchen Spout Repair Kit seem to be a "good enough" match to the belts that are needed for the spindle. As of Nov 6, 2012, these are the belts on the spindle.
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply
** An HP/Compact server powersupply "ESP115" from the boneyard.
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot.
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|}
{|
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Zenbot Power supply used for Zenbot spindle.JPG|thumb|Powersupply used for spindle motor]]
|[[File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG|thumb|Faucet repair kit. The smaller o-rings (not shown) fit the spindle.]]
|}
{|
|[[File:Zenbot Inch measurement of diameter of bit.jpg|thumb|Size of the bits that will fit in the collet that we have]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}
== Operating instructions ==
As-of-Nov-2012 the equipment can be operated with extreme caution. Given the lack of: limit switches, emergency power off, cleaned up software (Its unclear which software to run to control the system) there is a high risk that the machine will be damaged if used.

== Notes from initial equipment build ==

===Log of research (newest to oldest)===

----
[[File:Zenbot Loossing-tightening the collet assembly in spindle.jpg|thumb|The way the collet must be held when unscrewing it switch out the bit (if not held the bit will slam into the base of the CNC and may break)]]
[[File:Zenbot Picture of hex wrench taped to CNC.jpg|thumb|Picture of where a hex wrench that matches the collet/chuck is tapped to the zenbot]]
[[File:Zenbot Bit in collet.jpg|thumb|If the collet is complete unscrewed when changing bits (I suspect this is the safest way to do it]]
[[File:Zenbot Bit partway out of collet.jpg|thumb|When the collet is loose the bit just slides out of it]]
[[File:Zenbot Bit seperate from collet.jpg|thumb|A picture of the collet and the bit seperately]]

Nov 12 Mike L

- Copy of update email -

Virtually all progress in this update (and most from last) is thanks to the continued heroics from '''Chris Pettus'''. He is the unsung hero of this project and will be the reason the machine gets to whatever level of operation that it gets to.

Detail for this week:
:'''Progress made''':
:*Chris P found some < $4 faucet o-rings that are the right size to link the spindle motor to the spindle arm
:**They are installed on the zenbot, have about 30 min of time on them, haven't shown any issue with wear or slippage.
:*Spindle power supply interface case built with integrated fuses
:**currently fussing the spindle at 10 amps, though the power supply really should be able to drive 30 amps safely, we are using the low fuse to better learn what the spindle will really need -- In other words, if anyone tries to cut something really hard (or jams the cutter) the spindle fuse will likely blow.
:**I expect we will increase the fuse as we better understand the spindle (unless we find it never blows)
:*Last meeting, with the help of many other Lvl1'er, the Zenbot was moved down stairs next to the big CNC.
:*Running the spindle at full speed (likely too fast for the wax) Chris P and Mike L did a cut of the first few letters of "LinuxCNC" in machining wax. See the wiki page for full desc or jump here for picture: http://wiki.lvl1.org/File:Zenbot_Clockwise_cut_(first_cut).jpg
:*The spindle motor speed controller has been repaired and tested with a separate motor, not yet integrated back into the zenbot.

:'''Next actions''':
:*Get the speed controller installed between the spindle and its supply (also, perhaps trying to connect the PWM interface to LinuxCNC) - Chris P
:*Measuring spindle speed (at full and different settings of the speed controller - Chris P and Mike L
:*Writing up the software complexities of working with the CNC (Need CAD & CAM before can use LinuxCNC) - Mike L
:*Learning various CAD and CAM packages so-as to create g-code that we can mill with the Zenbot - Mike L, Chris P, and anyone else who is thinking they want to use this system

:'''Future/dream/stuff-it-would-be-nice-if-other-people-would-jump-in-and-tackle''':
:*More bits for the Zenbot
:**We now know that the collet in the zenbot takes 1/8" bits (... and given the collet is high-spec it will likely ONLY take 1/8" bits - it might be able to take 3mm bits, but I wouldn't be surprised if they slip given the collet design
:**The bits for the spindle are both expendable (very breakable and will dull if cutting hard stuf) and kinda pricy (new < 1mm blades seem to be around $35 new).
:**As talked about in the last update, multiple parties have said "get used blade off ebay", and while I'm starting to understand what they are talking about, I'm still not ready to plunge into the used blade world, nor has anyone committed to this work.
:**So I can keep working, I'm going to personally order a few new blades for my personal use and use the experience to better learn about the used market. For anyone else thinking about using the zenbot in the near term, I guess what I'm saying is "for the time being, the zenbot is a 'bring your own bits' device". (I'll add a bit ordering guide to the wiki as I better understand the process)
:*X, Y, Z limit switches
:**Chris P has some switches which may be quite good for this, we are not sure when or if we will get to this though (neither of us are mechanicals, so making readjustable and robust mounting brackets for switches is a bit baffling to us)
:*X, Y homing and measuring the cutter in the Z
:**X & Y homing might be doable with the limit switches depending on what the controller can do. Measuring Z will likely require something new. Chris P has this in mind when he is working with the X,Y,Z controller but no new work has been done on it since last update
:*Integrated vacuum system
:**Gerrit said at last meeting that he might have a vacuum that could be used for this. I have a 15A ac power relay (http://adafruit.com/products/268) that might also be able to be used, but no planning other then ideas of parts have been done.
:*Sacrificial milling surface overlays and/or jigs
:**Chris P, Gerrit and I have all agreed that it would be ''very'' good idea to build some type of sacrificial overlay over the Zenbot milling surface given how easy it is to drive the blade right through the mills surface (the -z limit won't help for this, the spindle is such that the cutting blade would always go through the mills surface before the limit hit)
With that said, no one has picked up the ball on this, and I doubt Chris P or I would any time soon. Help would be welcome, especially if you know what your doing with the big CNC and/or know how useful jigs would be built for specific tasks, like circuit board milling
:*All-in-one enclosure
:**Gerrit has been dreaming of an all-in-one enclosure for the zenbot, with its controls, and the computer system that LinuxCNC runs on packed underneath the zenbot. (something like http://buildyourcnc.com/redSproutCNCComputerSystem.aspx under the zenbot) Chris P has continued to refine/repack the control electronics and this may be relatively straightforward in the furture but no one has taken the ball for this task.

The CNC is nearly at the point where different tracks of work will need to be done for different projects (molds vs. circuit boards).

I'm interested in 3d mold making and to get the ball rolling for that sub-project on the zenbot, I've started a new wiki page about that use: http://wiki.lvl1.org/Copying_Guerrilla_guide_to_cnc-mold-casting
(I've also ordered a board of Renshape 460 - millable plastic for mold making - that I would be up for selling parts off of for anyone else wanting to try 3d part mold making)

I know that a number of other people in the group are interested in cutting circuit boards, thats not really my cup-of-tea (at least not until I have my brain wrapped around the mold making stuff) so I'm hoping some of the other interested parties will jump in, start researching the software/router-bit/jigs that are required to do that work, and building documentation to teach others.

-Mike

----

Nov 8 Mike L

The included bit has been measured and is 1/8", pressumibly this is really the only size the collet can hold (''Might'' be able to hold a 3mm bit but the teeth on the collet were so close, a 3mm might slip)

Numerous pictures were taken of the collet system, later to be use for instruction.
----
[[File:Zenbot Clockwise cut (first cut).jpg|thumb|First (Clockwise, if the spindle is viewed from the top down) cut with the Zenbot since its repair.]]
[[File:Zenbot Counter clockwise cut (second cut).jpg|thumb|Second, counter-clockwise cut (from our examination we feel that clockwise is the correct way to use the bit that came with the machine)]]
Nov 6 Mike L

Through heroic effort of Chris P, all the major drive systems of the CNC are now online (Power found for spindle, drive belts found for spindle, software for X,Y,Z all calibrated)

With the help of Chris C, Nathan and a few others the Zenbot was moved downstairs next to the big CNC.

An initial cut was done in machine wax of the "LinuxCNC" default on LinuxCNC (only the "L", "i", and 1/4 of the "n" fit on the wax)

----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case
a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Copying Guerrilla guide to cnc-mold-casting

2012-11-13T04:18:08Z

Milutz: /* Building up a CNC */

Following are planning notes and a build-log for Mike Lutz's attempt to copy the processes laid out in the [http://lcamtuf.coredump.cx/gcnc/ Guerrilla guide to CNC machining, mold making, and resin casting]

== What got this started ==
Mid october 2012 the [http://lcamtuf.coredump.cx/gcnc/ Guerrilla guide to CNC machining, mold making, and resin casting] became the top link on ycombinator's [http://news.ycombinator.com Hacker News]. Mike stumbled upon it there and [https://groups.google.com/d/msg/lvl1/NV8BNeVABg8/0yGid7w_5dsJ posted a note] to the [https://groups.google.com/d/forum/lvl1 LVL1 list] about it.

That lead to the discovery that the club had an offline [[Zenbot_1216_CNC]], and through large amount of work (of which, much of the work was done by Chris Pettus), the Zenbot was brought online.

Having gone through the zenbot setup process, and feeling as though that gave him some idea of the depth of "rabbit hole" that the Guerrilla guide was presented, Mike decided to continue to copy the steps in the guide and see how far he can get.

== The phases ==
The Guerrilla guide bounces back-and-forth between six primary skills: Building up a CNC, Designing 3d parts (gears) in CAD software, Making G-code with a CAM package, Milling a high spec model from a CNC, Making a Silicone mold, polyurethane casting from the silicon mold.

FYI, a nice guide to all of the options available for the various software needs is at: http://www.probotix.com/cnc_software/
=== Building up a CNC ===
[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|Picture of LVL1's Zenbot 1216]]
The CNC being used for this adventure is a Zenbot 1216 and all of it's details can be found on it's [[zenbot_1216_CNC|equipment page]].

The Zenbot 1216 isn't one of the CNCs that is listed on the Guerrilla guide. While all indications are that it should be able to operate on the order of 1/1000th of an inch, we have yet to do any cuts that would illustrate that resolution, nor is it completely clear what resolution the Guerrilla guide is advocating.

with 1/8th steps (our machines finest mode (driver limited?)) there are 1112 "1/8th steps" per inch. With a modern Zenbot 1216 it looks like the stepper have been improved, they would be 2224 "1/8th steps" per inch, and can now also drive at "1/10th step" (for 2780 per inch).

The closest CNC on the Gurrilla guide (by price and size) is the [https://probotix.com/FireBall_v90_cnc_router_kit/ fireball V90]. This claiming to be able to do 1/8 and 1/16 steps, with "1/8 steps" giving 8000 steps per inch (or 1/16th giving 16000 steps per inch (wow!)) (... strangely they say that is the "X and Y" resolution, it kinda looks like Z might be even higher spec then X and Y but I can't clearly find that.

The Guerrilla guy says he bought a Roland MDX-15 (so presumibly that is the level of machine needed to make the type of parts he shows in his guide). Its kinda hard to understand the [http://www.rolanddg.com/product/3d/3d/mdx-20_15/spec.html specs] for his machine, it says it can do .000984 in/step software, and/or .000246 in/step mechanically. I don't know if high res happens if you enable fractional steps, or if thats as fine as it goes with the fractional steps.

If thats as find as it goes, then his machine gets down to 1016 steps per inch (seems like that might be underselling his (twice as expensive) machine, but if its true, then maybe we are in good shape with our CNC. (... note, at the start of the article he talks about 0.001 mm resolution in all axes, that would be on the order of 25,000 steps per inch)

=== Making 3d designs in CAD software ===

The first big problem is picking which CAD software. I'm trying to find free mac software, that makes things much harder. And, there are now weird option like the HTML5 3dtin.com HTML5 package.

Zenbot 1216 CNC

2012-11-13T02:58:03Z

Milutz: /* Log of research (newest to oldest) */

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=somewhat - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=In the basement next to the big CNC system}}
== Current status ==
;As of Nov 8 2012:Still being setup but has successfully cut machining wax.

Motor controller has been repaired but not re-installed with the system.
limit switches haven't been added, nor have any new bits been ordered.

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216 [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle were missing but have been replaced by the smaller belts from faucet repair kit.
** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
*** The info Gerrit received (with regards to the o-rings) didn't match our spindle. Chris P found a match by trial and error
** The smaller o-rings from a DL-15 Single Handle Delta Kitchen Spout Repair Kit seem to be a "good enough" match to the belts that are needed for the spindle. As of Nov 6, 2012, these are the belts on the spindle.
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply
** An HP/Compact server powersupply "ESP115" from the boneyard.
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot.
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|}
{|
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Zenbot Power supply used for Zenbot spindle.JPG|thumb|Powersupply used for spindle motor]]
|[[File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG|thumb|Faucet repair kit. The smaller o-rings (not shown) fit the spindle.]]
|}
{|
|[[File:Zenbot Inch measurement of diameter of bit.jpg|thumb|Size of the bits that will fit in the collet that we have]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}
== Operating instructions ==
As-of-Nov-2012 the equipment can be operated with extreme caution. Given the lack of: limit switches, emergency power off, cleaned up software (Its unclear which software to run to control the system) there is a high risk that the machine will be damaged if used.

== Notes from initial equipment build ==

===Log of research (newest to oldest)===

----
[[File:Zenbot Loossing-tightening the collet assembly in spindle.jpg|thumb|The way the collet must be held when unscrewing it switch out the bit (if not held the bit will slam into the base of the CNC and may break)]]
[[File:Zenbot Picture of hex wrench taped to CNC.jpg|thumb|Picture of where a hex wrench that matches the collet/chuck is tapped to the zenbot]]
[[File:Zenbot Bit in collet.jpg|thumb|If the collet is complete unscrewed when changing bits (I suspect this is the safest way to do it]]
[[File:Zenbot Bit partway out of collet.jpg|thumb|When the collet is loose the bit just slides out of it]]
[[File:Zenbot Bit seperate from collet.jpg|thumb|A picture of the collet and the bit seperately]]

Nov 12 Mike L

- Copy of update email -

Virtually all progress in this update (and most from last) is thanks to the continued heroics from '''Chris Pettus'''. He is the unsung hero of this project and will be the reason the machine gets to whatever level of operation that it gets to.

Detail for this week:
:'''Progress made''':
:*Chris P found some < $4 faucet o-rings that are the right size to link the spindle motor to the spindle arm
:**They are installed on the zenbot, have about 30 min of time on them, haven't shown any issue with wear or slippage.
:*Spindle power supply interface case built with integrated fuses
:**currently fussing the spindle at 10 amps, though the power supply really should be able to drive 30 amps safely, we are using the low fuse to better learn what the spindle will really need -- In other words, if anyone tries to cut something really hard (or jams the cutter) the spindle fuse will likely blow.
:**I expect we will increase the fuse as we better understand the spindle (unless we find it never blows)
:*Last meeting, with the help of many other Lvl1'er, the Zenbot was moved down stairs next to the big CNC.
:*Running the spindle at full speed (likely too fast for the wax) Chris P and Mike L did a cut of the first few letters of "LinuxCNC" in machining wax. See the wiki page for full desc or jump here for picture: http://wiki.lvl1.org/File:Zenbot_Clockwise_cut_(first_cut).jpg
:*The spindle motor speed controller has been repaired and tested with a separate motor, not yet integrated back into the zenbot.

:'''Next actions''':
:*Get the speed controller installed between the spindle and its supply (also, perhaps trying to connect the PWM interface to LinuxCNC) - Chris P
:*Measuring spindle speed (at full and different settings of the speed controller - Chris P and Mike L
:*Writing up the software complexities of working with the CNC (Need CAD & CAM before can use LinuxCNC) - Mike L
:*Learning various CAD and CAM packages so-as to create g-code that we can mill with the Zenbot - Mike L, Chris P, and anyone else who is thinking they want to use this system

:'''Future/dream/stuff-it-would-be-nice-if-other-people-would-jump-in-and-tackle''':
:*More bits for the Zenbot
:**We now know that the collet in the zenbot takes 1/8" bits (... and given the collet is high-spec it will likely ONLY take 1/8" bits - it might be able to take 3mm bits, but I wouldn't be surprised if they slip given the collet design
:**The bits for the spindle are both expendable (very breakable and will dull if cutting hard stuf) and kinda pricy (new < 1mm blades seem to be around $35 new).
:**As talked about in the last update, multiple parties have said "get used blade off ebay", and while I'm starting to understand what they are talking about, I'm still not ready to plunge into the used blade world, nor has anyone committed to this work.
:**So I can keep working, I'm going to personally order a few new blades for my personal use and use the experience to better learn about the used market. For anyone else thinking about using the zenbot in the near term, I guess what I'm saying is "for the time being, the zenbot is a 'bring your own bits' device". (I'll add a bit ordering guide to the wiki as I better understand the process)
:*X, Y, Z limit switches
:**Chris P has some switches which may be quite good for this, we are not sure when or if we will get to this though (neither of us are mechanicals, so making readjustable and robust mounting brackets for switches is a bit baffling to us)
:*X, Y homing and measuring the cutter in the Z
:**X & Y homing might be doable with the limit switches depending on what the controller can do. Measuring Z will likely require something new. Chris P has this in mind when he is working with the X,Y,Z controller but no new work has been done on it since last update
:*Integrated vacuum system
:**Gerrit said at last meeting that he might have a vacuum that could be used for this. I have a 15A ac power relay (http://adafruit.com/products/268) that might also be able to be used, but no planning other then ideas of parts have been done.
:*Sacrificial milling surface overlays and/or jigs
:**Chris P, Gerrit and I have all agreed that it would be ''very'' good idea to build some type of sacrificial overlay over the Zenbot milling surface given how easy it is to drive the blade right through the mills surface (the -z limit won't help for this, the spindle is such that the cutting blade would always go through the mills surface before the limit hit)
With that said, no one has picked up the ball on this, and I doubt Chris P or I would any time soon. Help would be welcome, especially if you know what your doing with the big CNC and/or know how useful jigs would be built for specific tasks, like circuit board milling
:*All-in-one enclosure
:**Gerrit has been dreaming of an all-in-one enclosure for the zenbot, with its controls, and the computer system that LinuxCNC runs on packed underneath the zenbot. (something like http://buildyourcnc.com/redSproutCNCComputerSystem.aspx under the zenbot) Chris P has continued to refine/repack the control electronics and this may be relatively straightforward in the furture but no one has taken the ball for this task.

The CNC is nearly at the point where different tracks of work will need to be done for different projects (molds vs. circuit boards).

I'm interested in 3d mold making and to get the ball rolling for that sub-project on the zenbot, I've started a new wiki page about that use: http://wiki.lvl1.org/Copying_Guerrilla_guide_to_cnc-mold-casting
(I've also ordered a board of Renshape 460 - millable plastic for mold making - that I would be up for selling parts off of for anyone else wanting to try 3d part mold making)

I know that a number of other people in the group are interested in cutting circuit boards, thats not really my cup-of-tea (at least not until I have my brain wrapped around the mold making stuff) so I'm hoping some of the other interested parties will jump in, start researching the software/router-bit/jigs that are required to do that work, and building documentation to teach others.

-Mike

----

Nov 8 Mike L

The included bit has been measured and is 1/8", pressumibly this is really the only size the collet can hold (''Might'' be able to hold a 3mm bit but the teeth on the collet were so close, a 3mm might slip)

Numerous pictures were taken of the collet system, later to be use for instruction.
----
[[File:Zenbot Clockwise cut (first cut).jpg|thumb|First (Clockwise, if the spindle is viewed from the top down) cut with the Zenbot since its repair.]]
[[File:Zenbot Counter clockwise cut (second cut).jpg|thumb|Second, counter-clockwise cut (from our examination we feel that clockwise is the correct way to use the bit that came with the machine)]]
Nov 6 Mike L

Through heroic effort of Chris P, all the major drive systems of the CNC are now online (Power found for spindle, drive belts found for spindle, software for X,Y,Z all calibrated)

With the help of Chris C, Nathan and a few others the Zenbot was moved downstairs next to the big CNC.

An initial cut was done in machine wax of the "LinuxCNC" default on LinuxCNC (only the "L", "i", and 1/4 of the "n" fit on the wax)

----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case
a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Zenbot 1216 CNC

2012-11-13T02:50:45Z

Milutz: /* Notes from initial equipment build */ Added status update from Nov 12 2012

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=somewhat - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=In the basement next to the big CNC system}}
== Current status ==
;As of Nov 8 2012:Still being setup but has successfully cut machining wax.

Motor controller has been repaired but not re-installed with the system.
limit switches haven't been added, nor have any new bits been ordered.

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216 [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle were missing but have been replaced by the smaller belts from faucet repair kit.
** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
*** The info Gerrit received (with regards to the o-rings) didn't match our spindle. Chris P found a match by trial and error
** The smaller o-rings from a DL-15 Single Handle Delta Kitchen Spout Repair Kit seem to be a "good enough" match to the belts that are needed for the spindle. As of Nov 6, 2012, these are the belts on the spindle.
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply
** An HP/Compact server powersupply "ESP115" from the boneyard.
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot.
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|}
{|
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Zenbot Power supply used for Zenbot spindle.JPG|thumb|Powersupply used for spindle motor]]
|[[File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG|thumb|Faucet repair kit. The smaller o-rings (not shown) fit the spindle.]]
|}
{|
|[[File:Zenbot Inch measurement of diameter of bit.jpg|thumb|Size of the bits that will fit in the collet that we have]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}
== Operating instructions ==
As-of-Nov-2012 the equipment can be operated with extreme caution. Given the lack of: limit switches, emergency power off, cleaned up software (Its unclear which software to run to control the system) there is a high risk that the machine will be damaged if used.

== Notes from initial equipment build ==

===Log of research (newest to oldest)===

----
[[File:Zenbot Loossing-tightening the collet assembly in spindle.jpg|thumb|The way the collet must be held when unscrewing it switch out the bit (if not held the bit will slam into the base of the CNC and may break)]]
[[File:Zenbot Picture of hex wrench taped to CNC.jpg|thumb|Picture of where a hex wrench that matches the collet/chuck is tapped to the zenbot]]
[[File:Zenbot Bit in collet.jpg|thumb|If the collet is complete unscrewed when changing bits (I suspect this is the safest way to do it]]
[[File:Zenbot Bit partway out of collet.jpg|thumb|When the collet is loose the bit just slides out of it]]
[[File:Zenbot Bit seperate from collet.jpg|thumb|A picture of the collet and the bit seperately]]

Nov 12 Mike L

- Copy of update email -

Virtually all progress in this update (and most from last) is thanks to the continued heroics from '''Chris Pettus'''. He is the unsung hero of this project and will be the reason the machine gets to whatever level of operation that it gets to.

Detail for this week:
:'''Progress made''':
:*Chris P found some < $4 faucet o-rings that are the right size to link the spindle motor to the spindle arm
:**They are installed on the zenbot, have about 30 min of time on them, haven't shown any issue with wear or slippage.
:*Spindle power supply interface case built with integrated fuses
:**currently fussing the spindle at 10 amps, though the power supply really should be able to drive 30 amps safely, we are using the low fuse to better learn what the spindle will really need -- In other words, if anyone tries to cut something really hard (or jams the cutter) the spindle fuse will likely blow.
:**I expect we will increase the fuse as we better understand the spindle (unless we find it never blows)
:*Last meeting, with the help of many other Lvl1'er, the Zenbot was moved down stairs next to the big CNC.
:*Running the spindle at full speed (likely too fast for the wax) Chris P and Mike L did a cut of the first few letters of "LinuxCNC" in machining wax. See the wiki page for full desc or jump here for picture: http://wiki.lvl1.org/File:Zenbot_Clockwise_cut_(first_cut).jpg
:*The spindle motor speed controller has been repaired and tested with a separate motor, not yet integrated back into the zenbot.

:'''Next actions''':
:*Get the speed controller installed between the spindle and its supply (also, perhaps trying to connect the PWM interface to LinuxCNC) - Chris P
:*Measuring spindle speed (at full and different settings of the speed controller - Chris P and Mike L
:*Writing up the software complexities of working with the CNC (Need CAD & CAM before can use LinuxCNC) - Mike L
:*Learning various CAD and CAM packages so-as to create g-code that we can mill with the Zenbot - Mike L, Chris P, and anyone else who is thinking they want to use this system

:'''Future/dream/stuff-it-would-be-nice-if-other-people-would-jump-in-and-tackle''':
:*More bits for the Zenbot
:**We now know that the collet in the zenbot takes 1/8" bits (... and given the collet is high-spec it will likely ONLY take 1/8" bits - it might be able to take 3mm bits, but I wouldn't be surprised if they slip given the collet design
:**The bits for the spindle are both expendable (very breakable and will dull if cutting hard stuf) and kinda pricy (new < 1mm blades seem to be around $35 new).
:**As talked about in the last update, multiple parties have said "get used blade off ebay", and while I'm starting to understand what they are talking about, I'm still not ready to plunge into the used blade world, nor has anyone committed to this work.
:**So I can keep working, I'm going to personally order a few new blades for my personal use and use the experience to better learn about the used market. For anyone else thinking about using the zenbot in the near term, I guess what I'm saying is "for the time being, the zenbot is a 'bring your own bits' device". (I'll add a bit ordering guide to the wiki as I better understand the process)
:*X, Y, Z limit switches
:**Chris P has some switches which may be quite good for this, we are not sure when or if we will get to this though (neither of us are mechanicals, so making readjustable and robust mounting brackets for switches is a bit baffling to us)
:*X, Y homing and measuring the cutter in the Z
:**X & Y homing might be doable with the limit switches depending on what the controller can do. Measuring Z will likely require something new. Chris P has this in mind when he is working with the X,Y,Z controller but no new work has been done on it since last update
:*Integrated vacuum system
:**Gerrit said at last meeting that he might have a vacuum that could be used for this. I have a 15A ac power relay (http://adafruit.com/products/268) that might also be able to be used, but no planning other then ideas of parts have been done.
:*Sacrificial milling surface overlays and/or jigs
:**Chris P, Gerrit and I have all agreed that it would be ''very'' good idea to build some type of sacrificial overlay over the Zenbot milling surface given how easy it is to drive the blade right through the mills surface (the -z limit won't help for this, the spindle is such that the cutting blade would always go through the mills surface before the limit hit)
With that said, no one has picked up the ball on this, and I doubt Chris P or I would any time soon. Help would be welcome, especially if you know what your doing with the big CNC and/or know how useful jigs would be built for specific tasks, like circuit board milling
:*All-in-one enclosure
:**Gerrit has been dreaming of an all-in-one enclosure for the zenbot, with its controls, and the computer system that LinuxCNC runs on packed underneath the zenbot. (something like http://buildyourcnc.com/redSproutCNCComputerSystem.aspx under the zenbot) Chris P has continued to refine/repack the control electronics and this may be relatively straightforward in the furture but no one has taken the ball for this task.

The CNC is nearly at the point where different tracks of work will need to be done for different projects (molds vs. circuit boards).

I'm interested in 3d mold making and to get the ball rolling for that sub-project on the zenbot, I've started a new wiki page about that use: http://wiki.lvl1.org/Copying_Guerrilla_guide_to_cnc-mold-casting
(I've also ordered a board of Renshape 460 - millable plastic for mold making - that I would be up for selling parts off of for anyone else wanting to try 3d part mold making)

I know that a number of other people in the group are interested in cutting circuit boards, thats not really my cup-of-tea (at least not until I have my brain wrapped around the mold making stuff) so I'm hoping some of the other interested parties will jump in, start researching the software/router-bit/jigs that are required to do that work, and building documentation to teach others.

-Mike

----

Nov 8 Mike L

The included bit has been measured and is 1/8", pressumibly this is really the only size the collet can hold (''Might'' be able to hold a 3mm bit but the teeth on the collet were so close, a 3mm might slip)

Numerous pictures were taken of the collet system, later to be use for instruction.
----
[[File:Zenbot Clockwise cut (first cut).jpg|thumb|First (Clockwise, if the spindle is viewed from the top down) cut with the Zenbot since its repair.]]
[[File:Zenbot Counter clockwise cut (second cut).jpg|thumb|Second, counter-clockwise cut (from our examination we feel that clockwise is the correct way to use the bit that came with the machine)]]
Nov 6 Mike L

Through heroic effort of Chris P, all the major drive systems of the CNC are now online (Power found for spindle, drive belts found for spindle, software for X,Y,Z all calibrated)

With the help of Chris C, Nathan and a few others the Zenbot was moved downstairs next to the big CNC.

An initial cut was done in machine wax of the "LinuxCNC" default on LinuxCNC (only the "L", "i", and 1/4 of the "n" fit on the wax)

----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case a dedicated
video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Copying Guerrilla guide to cnc-mold-casting

2012-11-12T23:56:25Z

Milutz: /* Building up a CNC */

Following are planning notes and a build-log for Mike Lutz's attempt to copy the processes laid out in the [http://lcamtuf.coredump.cx/gcnc/ Guerrilla guide to CNC machining, mold making, and resin casting]

== What got this started ==
Mid october 2012 the [http://lcamtuf.coredump.cx/gcnc/ Guerrilla guide to CNC machining, mold making, and resin casting] became the top link on ycombinator's [http://news.ycombinator.com Hacker News]. Mike stumbled upon it there and [https://groups.google.com/d/msg/lvl1/NV8BNeVABg8/0yGid7w_5dsJ posted a note] to the [https://groups.google.com/d/forum/lvl1 LVL1 list] about it.

That lead to the discovery that the club had an offline [[Zenbot_1216_CNC]], and through large amount of work (of which, much of the work was done by Chris Pettus), the Zenbot was brought online.

Having gone through the zenbot setup process, and feeling as though that gave him some idea of the depth of "rabbit hole" that the Guerrilla guide was presented, Mike decided to continue to copy the steps in the guide and see how far he can get.

== The phases ==
The Guerrilla guide bounces back-and-forth between six primary skills: Building up a CNC, Designing 3d parts (gears) in CAD software, Making G-code with a CAM package, Milling a high spec model from a CNC, Making a Silicone mold, polyurethane casting from the silicon mold.

FYI, a nice guide to all of the options available for the various software needs is at: http://www.probotix.com/cnc_software/
=== Building up a CNC ===
[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|Picture of LVL1's Zenbot 1216]]
The CNC being used for this adventure is a Zenbot 1216 and all of it's details can be found on it's [[zenbot_1216_CNC|equipment page]].

The Zenbot 1216 isn't one of the CNCs that is listed on the Guerrilla guide. While all indications are that it should be able to operate on the order of 1/1000th of an inch, we have yet to do any cuts that would illustrate that resolution, nor is it completely clear what resolution the Guerrilla guide is advocating.

with 1/8th steps (our machines finest mode (driver limited?)) there are 1112 1/8th steps per inch. With a modern Zenbot 1216 it looks like the stepper have been improved, they would be 2224 1/8th steps per inch, and can now also drive 1/10th steps (for 2780 per inch).

The closest CNC on the Gurrilla guide (by price and size) is the fireball V90. This claiming to be able to do 1/8 and 1/16 steps, with 1/8 giving 8000 steps (or 1/16th giving 16000 steps (wow!)) (... strangely they say that is the "X and Y" resolution, it kinda looks like Z might be even higher spec then X and Y but I can't clearly find that.

The Guerrilla guy says he bought a Roland MDX-15 (so presumibly that is the level of machine needed to make the type of parts he shows in his guide). Its kinda hard to understand the [http://www.rolanddg.com/product/3d/3d/mdx-20_15/spec.html specs] for his machine, it says it can do .000984 in/step software, and/or .000246 in/step mechanically. I don't know if high res happens if you enable fractional steps, or if thats as fine as it goes with the fractional steps.

If thats as find as it goes, then his machine gets down to 1016 steps per inch (seems like that might be underselling his (twice as expensive) machine, but if its true, then maybe we are in good shape with our CNC. (... note, at the start of the article he talks about 0.001 mm resolution in all axes, that would be on the order of 25,000 steps per inch)

=== Making 3d designs in CAD software ===

The first big problem is picking which CAD software. I'm trying to find free mac software, that makes things much harder. And, there are now weird option like the HTML5 3dtin.com HTML5 package.

Zenbot 1216 CNC

2012-11-12T21:19:56Z

Milutz: /* Log of research (newest to oldest) */ Fixed a misplaced '[' on an image

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=somewhat - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=In the basement next to the big CNC system}}
== Current status ==
;As of Nov 8 2012:Still being setup but has successfully cut machining wax.

Motor controller has been repaired but not re-installed with the system.
limit switches haven't been added, nor have any new bits been ordered.

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216 [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle were missing but have been replaced by the smaller belts from faucet repair kit.
** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
*** The info Gerrit received (with regards to the o-rings) didn't match our spindle. Chris P found a match by trial and error
** The smaller o-rings from a DL-15 Single Handle Delta Kitchen Spout Repair Kit seem to be a "good enough" match to the belts that are needed for the spindle. As of Nov 6, 2012, these are the belts on the spindle.
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply
** An HP/Compact server powersupply "ESP115" from the boneyard.
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot.
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|}
{|
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Zenbot Power supply used for Zenbot spindle.JPG|thumb|Powersupply used for spindle motor]]
|[[File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG|thumb|Faucet repair kit. The smaller o-rings (not shown) fit the spindle.]]
|}
{|
|[[File:Zenbot Inch measurement of diameter of bit.jpg|thumb|Size of the bits that will fit in the collet that we have]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}
== Operating instructions ==
As-of-Nov-2012 the equipment can be operated with extreme caution. Given the lack of: limit switches, emergency power off, cleaned up software (Its unclear which software to run to control the system) there is a high risk that the machine will be damaged if used.

== Notes from initial equipment build ==

===Log of research (newest to oldest)===
----

[[File:Zenbot Loossing-tightening the collet assembly in spindle.jpg|thumb|The way the collet must be held when unscrewing it switch out the bit (if not held the bit will slam into the base of the CNC and may break)]]
[[File:Zenbot Picture of hex wrench taped to CNC.jpg|thumb|Picture of where a hex wrench that matches the collet/chuck is tapped to the zenbot]]
[[File:Zenbot Bit in collet.jpg|thumb|If the collet is complete unscrewed when changing bits (I suspect this is the safest way to do it]]
[[File:Zenbot Bit partway out of collet.jpg|thumb|When the collet is loose the bit just slides out of it]]
[[File:Zenbot Bit seperate from collet.jpg|thumb|A picture of the collet and the bit seperately]]

Nov 8 Mike L

The included bit has been measured and is 1/8", pressumibly this is really the only size the collet can hold (''Might'' be able to hold a 3mm bit but the teeth on the collet were so close, a 3mm might slip)

Numerous pictures were taken of the collet system, later to be use for instruction.
----
[[File:Zenbot Clockwise cut (first cut).jpg|thumb|First (Clockwise, if the spindle is viewed from the top down) cut with the Zenbot since its repair.]]
[[File:Zenbot Counter clockwise cut (second cut).jpg|thumb|Second, counter-clockwise cut (from our examination we feel that clockwise is the correct way to use the bit that came with the machine)]]
Nov 6 Mike L

Through heroic effort of Chris P, all the major drive systems of the CNC are now online (Power found for spindle, drive belts found for spindle, software for X,Y,Z all calibrated)

With the help of Chris C, Nathan and a few others the Zenbot was moved downstairs next to the big CNC.

An initial cut was done in machine wax of the "LinuxCNC" default on LinuxCNC (only the "L", "i", and 1/4 of the "n" fit on the wax)

----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case a dedicated
video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Copying Guerrilla guide to cnc-mold-casting

2012-11-11T20:46:54Z

Milutz: Added a whole bunch of text, the first writing of the first few "phase" sections

Following are planning notes and a build-log for Mike Lutz's attempt to copy the processes laid out in the [http://lcamtuf.coredump.cx/gcnc/ Guerrilla guide to CNC machining, mold making, and resin casting]

== What got this started ==
Mid october 2012 the [http://lcamtuf.coredump.cx/gcnc/ Guerrilla guide to CNC machining, mold making, and resin casting] became the top link on ycombinator's [http://news.ycombinator.com Hacker News]. Mike stumbled upon it there and [https://groups.google.com/d/msg/lvl1/NV8BNeVABg8/0yGid7w_5dsJ posted a note] to the [https://groups.google.com/d/forum/lvl1 LVL1 list] about it.

That lead to the discovery that the club had an offline [[Zenbot_1216_CNC]], and through large amount of work (of which, much of the work was done by Chris Pettus), the Zenbot was brought online.

Having gone through the zenbot setup process, and feeling as though that gave him some idea of the depth of "rabbit hole" that the Guerrilla guide was presented, Mike decided to continue to copy the steps in the guide and see how far he can get.

== The phases ==
The Guerrilla guide bounces back-and-forth between six primary skills: Building up a CNC, Designing 3d parts (gears) in CAD software, Making G-code with a CAM package, Milling a high spec model from a CNC, Making a Silicone mold, polyurethane casting from the silicon mold.

FYI, a nice guide to all of the options available for the various software needs is at: http://www.probotix.com/cnc_software/
=== Building up a CNC ===
[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|Picture of LVL1's Zenbot 1216]]
The CNC being used for this adventure is a Zenbot 1216 and all of it's details can be found on it's [[zenbot_1216_CNC|equipment page]].

The Zenbot 1216 isn't one of the CNCs that is listed on the Guerrilla guide. While all indications are that it should be able to operate on the order of 1/1000th of an inch, we have yet to do any cuts that would illustrate that resolution, nor is it completely clear what resolution the Guerrilla guide is advocating.

with 1/8th steps (our machines finest mode (driver limited?)) there are 1112 1/8th steps per inch. With a modern Zenbot 1216 it looks like the stepper have been improved, they would be 2224 1/8th steps per inch, and can now also drive 1/10th steps (for 2780 per inch).

The closest CNC on the Gurrilla guide (by price and size) is the fireball V90. This claiming to be able to do 1/8 and 1/16" steps, with 1/8 giving 8000 steps (or 1/16th giving 16000 steps (wow!)) (... strangely they say that is the "X and Y" resolution, it kinda looks like Z might be even higher spec then X and Y but I can't clearly find that.

The Guerrilla guy says he bought a Roland MDX-15 (so presumibly that is the level of machine needed to make the type of parts he shows in his guide). Its kinda hard to understand the [http://www.rolanddg.com/product/3d/3d/mdx-20_15/spec.html specs] for his machine, it says it can do .000984 in/step software, and/or .000246 in/step mechanically. I don't know if high res happens if you enable fractional steps, or if thats as fine as it goes with the fractional steps.

If thats as find as it goes, then his machine gets down to 1016 steps per inch (seems like that might be underselling his (twice as expensive) machine, but if its true, then maybe we are in good shape with our CNC. (... note, at the start of the article he talks about 0.001 mm resolution in all axes, that would be on the order of 25,000 steps per inch)

=== Making 3d designs in CAD software ===

The first big problem is picking which CAD software. I'm trying to find free mac software, that makes things much harder. And, there are now weird option like the HTML5 3dtin.com HTML5 package.

Copying Guerrilla guide to cnc-mold-casting

2012-11-11T18:28:31Z

Milutz: Created page with "Following are planning notes and a build-log for Mike Lutz's attempt to copy the processes laid out in the [http://lcamtuf.coredump.cx/gcnc/ Guerrilla guide to CNC machining, ..."

Main Page

2012-11-11T17:44:34Z

Milutz: /* What's Happening? */

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File:Zenbot Clockwise cut (first cut).jpg

2012-11-09T21:30:13Z

Milutz: Milutz uploaded a new version of "File:Zenbot Clockwise cut (first cut).jpg"

File:Zenbot Clockwise cut (first cut).jpg

2012-11-09T21:24:40Z

Milutz: Milutz uploaded a new version of "File:Zenbot Clockwise cut (first cut).jpg"

File:Zenbot Counter clockwise cut (second cut).jpg

2012-11-09T21:12:46Z

Milutz: Milutz uploaded a new version of "File:Zenbot Counter clockwise cut (second cut).jpg"

Zenbot 1216 CNC

2012-11-09T20:50:19Z

Milutz: Major update of both notes for nov 6-9 and also updating all of the page to reflect that the machine is somewhat working

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=somewhat - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=In the basement next to the big CNC system}}
== Current status ==
;As of Nov 8 2012:Still being setup but has successfully cut machining wax.

Motor controller has been repaired but not re-installed with the system.
limit switches haven't been added, nor have any new bits been ordered.

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216 [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle were missing but have been replaced by the smaller belts from faucet repair kit.
** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
*** The info Gerrit received (with regards to the o-rings) didn't match our spindle. Chris P found a match by trial and error
** The smaller o-rings from a DL-15 Single Handle Delta Kitchen Spout Repair Kit seem to be a "good enough" match to the belts that are needed for the spindle. As of Nov 6, 2012, these are the belts on the spindle.
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply
** An HP/Compact server powersupply "ESP115" from the boneyard.
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot.
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|}
{|
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Zenbot Power supply used for Zenbot spindle.JPG|thumb|Powersupply used for spindle motor]]
|[[File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG|thumb|Faucet repair kit. The smaller o-rings (not shown) fit the spindle.]]
|}
{|
|[[File:Zenbot Inch measurement of diameter of bit.jpg|thumb|Size of the bits that will fit in the collet that we have]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}
== Operating instructions ==
As-of-Nov-2012 the equipment can be operated with extreme caution. Given the lack of: limit switches, emergency power off, cleaned up software (Its unclear which software to run to control the system) there is a high risk that the machine will be damaged if used.

== Notes from initial equipment build ==

===Log of research (newest to oldest)===
----
[[File:Zenbot Loossing-tightening the collet assembly in spindle.jpg |thumb|The way the collet must be held when unscrewing it switch out the bit (if not held the bit will slam into the base of the CNC and may break)]]
[File:Zenbot Picture of hex wrench taped to CNC.jpg[|thumb|Picture of where a hex wrench that matches the collet/chuck is tapped to the zenbot]]
[[File:Zenbot Bit in collet.jpg|thumb|If the collet is complete unscrewed when changing bits (I suspect this is the safest way to do it]]
[[File:Zenbot Bit partway out of collet.jpg|thumb|When the collet is loose the bit just slides out of it]]
[[File:Zenbot Bit seperate from collet.jpg|thumb|A picture of the collet and the bit seperately]]

Nov 8 Mike L

The included bit has been measured and is 1/8", pressumibly this is really the only size the collet can hold (''Might'' be able to hold a 3mm bit but the teeth on the collet were so close, a 3mm might slip)

Numerous pictures were taken of the collet system, later to be use for instruction.
----
[[File:Zenbot Clockwise cut (first cut).jpg|thumb|First (Clockwise, if the spindle is viewed from the top down) cut with the Zenbot since its repair.]]
[[File:Zenbot Counter clockwise cut (second cut).jpg|thumb|Second, counter-clockwise cut (from our examination we feel that clockwise is the correct way to use the bit that came with the machine)]]
Nov 6 Mike L

Through heroic effort of Chris P, all the major drive systems of the CNC are now online (Power found for spindle, drive belts found for spindle, software for X,Y,Z all calibrated)

With the help of Chris C, Nathan and a few others the Zenbot was moved downstairs next to the big CNC.

An initial cut was done in machine wax of the "LinuxCNC" default on LinuxCNC (only the "L", "i", and 1/4 of the "n" fit on the wax)

----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case a dedicated
video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

File:Zenbot Bit partway out of collet.jpg

2012-11-09T20:47:22Z

Milutz:

File:Zenbot Bit seperate from collet.jpg

2012-11-09T20:47:20Z

Milutz:

File:Zenbot Bit in collet.jpg

2012-11-09T20:45:02Z

Milutz:

File:Zenbot Picture of hex wrench taped to CNC.jpg

2012-11-09T20:41:53Z

Milutz: Milutz uploaded a new version of "File:Zenbot Picture of hex wrench taped to CNC.jpg"

File:Zenbot Picture of hex wrench taped to CNC.jpg

2012-11-09T20:39:09Z

Milutz:

File:Zenbot Loossing-tightening the collet assembly in spindle.jpg

2012-11-09T20:01:28Z

Milutz:

File:Zenbot Power supply used for Zenbot spindle.JPG

2012-11-09T19:46:31Z

Milutz:

File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG

2012-11-09T19:27:44Z

Milutz: Milutz uploaded a new version of "File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG"

File:Zenbot Delta kitchen Spout repair kit for spindle drive belts.JPG

2012-11-09T19:27:07Z

Milutz:

File:Zenbot Inch measurement of diameter of bit.jpg

2012-11-09T15:19:53Z

Milutz:

File:Zenbot Counter clockwise cut (second cut).jpg

2012-11-09T15:17:14Z

Milutz:

File:Zenbot Clockwise cut (first cut).jpg

2012-11-09T15:12:34Z

Milutz:

11/06/2012

2012-11-07T00:22:58Z

Milutz: /* Equipment and Supplies Wanted */

= Agenda =

== First time Visitor Info ==
*Waivers of Liability - Please sign if you have not already
*Our website / calendar is http://www.lvl1.org
*You can find all of our Meeting Minutes at http://wiki.lvl1.org
*Sign up for our Google Group discussion list at https://groups.google.com/forum/?fromgroups#!forum/lvl1

== Equipment and Supplies Wanted ==
*(Gerrit) <del>AC to DC PSU for CNC spindle (20-30 amps @ 12v)</del> (Mike L and Chris P have this covered)
*(Brad) [[Req-Furby|Furby]] (one or more)
*(Gerrit) [[Req-Roomba|Roomba]] parts for building the cleaning robot army.
*(Jon C) High Pressure 250psi large tanks
*(Matt) [[Req-Geiger-Counter|Geiger Counter]]
*(Joe P) 3D model of Wilford Brimley's head

== Space Upgrades ==
* ??

== Space Downgrade ==
* Search for LVL1 missing handtools, last chance before we reorder stuff that's missing

== Regular Meetups ==
*[[Louisville Soundbuilders|Sound Builders]] (fortnightly Mondays, next 11/12 8pm)
*LVL1 Open Meeting & Making every (Tuesday 8pm)
*[[Rocketeers|The Rocketeers]] (Wed 8pm)
*Muddytech Computer training (upstairs Thurs 6pm) Looking for students
*[[Game Dev|Game Dev Group]] (Sat 12pm)
*Mozilla Community Meeting (11/8 7pm-8pm)
*KYOSS Monthly Meeting (2nd Wed of the Month 11/14 6:30pm)

== Upcoming Workshops and Events ==
* Makership Deadline 11/6 8pm (already expired!)
* Louisville Transportation Camp (11/7 6pm-8pm)
** http://louisvilletransportationcamp2-estw.eventbrite.com/
** Status of Open Data / Realtime GPS data from TARC
** Opportunities for civic transportation hacking
* What's Next series at the library: Biomedical Engineering (11/15 7pm)
** Dr. Stuart Williams discusses the latest in biomedical engineering
** http://www.lfpl.org/next.html

== 5 Minute Maintenance and Cleaning ==
* List on the whiteboard

== Project Roll Call ==

Zenbot 1216 CNC

2012-11-06T05:21:38Z

Milutz: /* Log of research (newest to oldest) */

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=no - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=desk very close to the north door on the ground floor}}
== Current status ==
;As of Nov 4 2012:Still being setup.

X,Y,Z is tested and software configured such that its close to real measurements.

Spindle control is blown, parts on order to fix (expected on the order of 1 week)

One set of belts received (based off of recommendation from wolfgang eng) but still not the right size/material. Close enough that an array of sizes on order, one pair of which should work correctly

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216, hasn't been absolutely confirmed (Unsure if zenbot stamps model numbers on their products) [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle are '''MISSING'''.
*** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply - '''MISSING'''
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot is believed to be ready to go. There is some debate whether the EMC2 configure is complete. The people with Zenbot have said they have a (non-guaranteed) config that a customer made for EMC2 but thus far they haven't posted or emailed it to us
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|}
{|
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Oct-2012 the equipment shouldn't be operated

== Notes from initial equipment build ==

===Log of research (newest to oldest)===
----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Sacrificial milling surface overlays and/or jigs - surfaces that would screw in the zenbot surface to increasing the distance the mill would have to improperly travel before it started destroying the Zenbots primary surface. Best made on-mass, likely using the big CNC in the basement. A subset should also be created for specialized use of the mill (alignment pegs for circuit board milling, etc)
:**No work done, no one offering to do the work
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Zenbot 1216 CNC

2012-11-05T20:30:05Z

Milutz: /* Log of research (newest to oldest) */

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=no - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=desk very close to the north door on the ground floor}}
== Current status ==
;As of Nov 4 2012:Still being setup.

X,Y,Z is tested and software configured such that its close to real measurements.

Spindle control is blown, parts on order to fix (expected on the order of 1 week)

One set of belts received (based off of recommendation from wolfgang eng) but still not the right size/material. Close enough that an array of sizes on order, one pair of which should work correctly

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216, hasn't been absolutely confirmed (Unsure if zenbot stamps model numbers on their products) [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle are '''MISSING'''.
*** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply - '''MISSING'''
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot is believed to be ready to go. There is some debate whether the EMC2 configure is complete. The people with Zenbot have said they have a (non-guaranteed) config that a customer made for EMC2 but thus far they haven't posted or emailed it to us
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|}
{|
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Oct-2012 the equipment shouldn't be operated

== Notes from initial equipment build ==

===Log of research (newest to oldest)===
----
Nov 5 Mike L

Copy of status update email:

:'''Progress made''':
:*The x and y stepper control wires were switched and the Axis config rewritten for X,Y,Z such that motion is true to Zenbot docs and is also much closer to real-world measurement (Was > 730% off, now estimated at < 1% of real world) - Chris P
:*Belts for the spindle are on order - delivery unclear, worst case expected before Nov 16th - Mike L
:*Motor controller blown - replacement motor control IC expected yet this week - Chris P

:'''Next actions''':
:*Directly test spindle motor make sure its isn't the cause of the trouble with the controller - Mike L & Chris P
:*(as parts come in)
:**Install/test belts connecting the spindle motor to the spindle rotor. - Mike L
:**Repair/troubleshoot spindle motor controller. - Chris P
:*Run a test milling using soft material (machinable wax) - Mike L
:*Run test milling to better lock-in the real-world vs. software measurement accuracy. - Chris P & Mike L

:'''Unaddressed needs''':
:*More spindle bits - have been told to "carefully" order off of ebay
:**Gerrit may pick this up, but if anyone else out there wants to take charge of getting and calibrating rough and fine milling bits off of ebay let me know.

:'''Future/dream stuff''':
:*Add limit switches to X,Y,Z -- important to prolong the life of the machine
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*Add homing switches for X,Y,Z -- required to allow high resolution milling and/or double sided alignment for circuit board cutting
:**Chris P has switches on order - still lots of planning to figure out how to install and use
:*All-in-one enclosure -- Desire of Gerrit
:**One of Gerrit's ideas - no significant planning or sourcing has been done to make this happen
:*Vacuum system -- Desire of Gerrit
:**Another desired feature Gerrit would like to see - no significant planning or sourcing has been done to make this happen

:An aside:
:
:For the last two weeks I've been working-on, writing-up and PM'ing anything I've found on the Zenbot because I'm highly amused by it and I've had a small block of extra time. I've been taking the communication approach you've seen (all info on wiki plus occasional email updates) because I expect I may suddenly run out of time and/or others may choose to work on the machine, and I both want to enable the project to continue with or without me and avoid people repeating others work.
:
:With that said, I'm not under any illusion that I have sole (or even any) exclusivity to the machine and I apologize if anyone has taken my communication to mean I am claiming dominion over it.
:
:I've had one person walk up to me, wanting me to take a different approach to the way I was proceeding with the machine, when I explained that I wanted to continue in the course I had planned (after all this is hobby work for me, I want to do it as I see fit) they were quite unhappy me. It didn't occur to me at the time, but what I needed to say to them was, "while I'm not going to do what you want, if you want to do that, go ahead, but it would be cool if you would add to the notes on the wiki so we all know what the current state is", instead I think my past communications may have lead them to think had dominion over the machine and I was forbidding them from trying what they wanted. That was definitely not what I meant to do.

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Main Page

2012-11-05T05:14:32Z

Milutz: /* Our Space */ Fixed link for laser cutter. Was a direct http style link in a form that the wiki doesn't seem to support any more, changed to a wiki (double brace) style link

__NOTOC__
{| cellpadding="5" style="border:1px; background-color:#f9f9f9; solid #B0B0B0; padding:3px; width:100%; margin-bottom:2px;"
!width="49%"|
!width="49%"|
|-valign="top";|
| colspan="2" |
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|-
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===New to LVL1.org?===
This is our fast and loose wiki site. It's the quickest way for all those involved with LVL1 to add and update information. For news, announcements and blogs check out our main page [http://www.lvl1.org http://www.lvl1.org]!

=== Join in the LVL1 discussions. ===

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=== What's Happening? ===
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Zenbot 1216 CNC

2012-11-05T01:22:37Z

Milutz: whole page update with status as-of nov 4 2012

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=none found on device so far|model=1216|arrived=???|doesitwork=no - in process of setup|contact=Gerrit, Mike Lutz, or Chris Pettus|where=desk very close to the north door on the ground floor}}
== Current status ==
;As of Nov 4 2012:Still being setup.

X,Y,Z is tested and software configured such that its close to real measurements.

Spindle control is blown, parts on order to fix (expected on the order of 1 week)

One set of belts received (based off of recommendation from wolfgang eng) but still not the right size/material. Close enough that an array of sizes on order, one pair of which should work correctly

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216, hasn't been absolutely confirmed (Unsure if zenbot stamps model numbers on their products) [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle are '''MISSING'''.
*** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply - '''MISSING'''
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot is believed to be ready to go. There is some debate whether the EMC2 configure is complete. The people with Zenbot have said they have a (non-guaranteed) config that a customer made for EMC2 but thus far they haven't posted or emailed it to us
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|}
{|
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Oct-2012 the equipment shouldn't be operated

== Notes from initial equipment build ==

===Log of research (newest to oldest)===

----
Nov 4 Mike L

Moved the page now that the model is clear - its a 1216

:The reason is that 12" by 16" is the x/y travel of the head, but the measurement of the baseboard of the CNC is roughly 16 by 24 (causing many of us to think it is zenbot 1624). If you look on the [http://www.zenbotcnc.com zenbot] product page, the specs for the 1216 is:
:
:* Travels: X-12”, Y-16”, Z-4”
:*Table size: 23” x 16.5”
:*Footprint: 28” x 24”
:*Motors: 4 wire bipolar 285 ounce/in Nema-23
:
: Which matches the machine the space has.
----
Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Equipment

2012-11-05T00:39:08Z

Milutz: /* Tools */ relinked zenbot to its new name (because I had the model wrong)

This page is meant to be a master list for all of the equipment at LVL1. Add a wiki page link here and follow it to fill out the details. QR Code images and general information are generated with a simple MediaWiki template. Cut, paste and edit the following code into a new wiki page

<code><nowiki>
{{Template:Equipment
|owner=Owner of Loaner of equipment
|serial=Serial Number
|model=Make/Model of equipment
|arrived=When this thing first showed up
|doesitwork=Does this work or not
|contact=person to contact
|where=where is it
}}
</nowiki></code>

=== LVL1 Equipment Catalog ===
{{columns-start}}

== Safety ==
* [[Fire Extinguisher]]
* [[First Aid Kit]]

== Communications ==
* [[HF Transceiver]]
* [[Satelite Modem]]
* [[Icom IC-229H 2M Transceiver]]
* [[Astron RS-20A]]
* [[KeyLessEntry]]

== Electronics Equipment ==
* [[Tektronix 2432 Digital Oscilloscope]]
* [[BK Dual Time Base Oscillosope]]
* [[Fluke Digital Multimeter 8000A]]
* [[Leader DC Tracking Power Supply]]
* [[Heathkit Sine-Square Audio Generator]]
* [[Sencore Capacitor Inductor Analyzer]]
* [[Bel MERIT All-In-One Instrument]]
* [[HD Tesla High Voltage Coils]]
* [[Jacob's Ladder with Enclosure]]
* [[Heathkit Oscilloscope]]
* [[Fluke 37 Multimeter]]
* [[MPJA Soldering Station]]
* [[Hitachi Oscilloscope]]

== Printing ==
* [[Clive Badger|Makerbot Replicator - Clive Badger]]
* [[Johnny 5|Makerbot Replicator - Johnny 5]]
* [[HP 2600n Color LaserJet]]
* [[Purple Cows Laminator]]
* [[GBC Personal Laminator]]
* [[Brother Label Maker]]
* [[Veruca Gloop|Makerbot - Veruca Gloop]]

== Audio / Video ==
* [[Onkyo AV Receiver]]
* [[KLH Audio Speakers]]
* [[Peavey Audition 30 Amplifier]]
* [[Boss Digital Reverb Pedal]]
* [[Boss Digital Delay Pedal]]
* [[Boss Dr. Rhythm Machine]]
* [[Crown CE1000 Amp]]
* [[Carvin 1584 Speaker]]
* [[Zoom Handy Recorder H2]]
* [[Harmony Electric Guitar]]
* [[Playmate Electric Guitar]]
* [[Philips Magnavox Smart Series CRT TV]]
* [[Marshall MG Series 15CD Amplifier]]
* [[Gibson Epiphone Electric Guitar]]
* [[Western Safety Megaphone]]
* [[Kinect]]
* [[Video Visualizer]]
* [[InfocusProjector]]
* [[Oculus LVL1]]
* [[Oculus LVL1 Nikon]]

== Kitchen ==
* [[Melitta Coffee Maker]]
* [[Kitchen Fridge]]
* [[Kenmore Microwave]]
* [[Kegerator]]
* [[Enhanced Toaster Pastry]]

== Misc ==
* [[Mr. White PC]]
* [[Guard dog]]
* [[Toms Vending Machine]]
* [[iRobot Roomba Robotic Vacuum]]
* [[Radio Teletype Machine]]
* [[Hyundai Monitor]]
* [[Toy Helicopter]]
* [[Beehive Light Show]]
* [[Star Wars Force Trainer]]
* [[Robo-Pony]]
* [[Make T-Shirts]]
* [[Peanut Butter Snickers Storage Unit]]
* [[Traffic Light]]

{{column}}

== Tools ==
* [[Craftsmen Work Light]]
* [[Craftsmen Cordless Drill]]
* [[Milwaukee Sawzall]]
* [[Full Spectrum Laser]]
* [[CNC Machine]] - drafting table size, 1/64 of an inch precision, kit made CNC
* [[Zenbot 1216 CNC]] - tabletop soft-material-only high precision CNC system
* [[Drill Press]]
* [[Dremel 300]]
* [[Drill bit set]]
* [[Gray Tool Kit]]
* [[Tool Cart]]
* [[GE Hotplate]]
* [[Dremel Drill Press]]
* [[iFixit 54 Piece Bit Driver Kit]]
* [[iFixit 26 Piece Bit Driver Kit]]
* [[52 Piece Racheting Wrench Kit]]
* [[32 Piece Screwdriver Kit]]
* [[Rigid WetDry Vac]]
* [[Craftsman 10 inch Tablesaw]]
* [[Craftsman 13 inch Scrollsaw]]
* [[Belt Sander]]
* [[DeWalt Compound Miter Saw]]
* [[Buffalo Wood Lathe]]
* [[Multi-Mig Welder]]
* [[Toolkraft Drill Press]]
* [[Hitachi Cordless Driver Drill]]
* [[Sewing machine]]
* [[Vacuum pump]]
* [[Heavy Duty Bandsaw]]
* [[Hitachi Hammer Drill]]
* [[Ryobi Mini Power Saw]]
* [[Ryobi Power Drill]]
* [[Ryobi Sawzaw]]
* [[Ryobi Battery Charger]]
* [[Ryobi Battery (x1)]]
* [[Black & Decker 14.4V Cordless Saw]]
* [[Black & Decker 14.4 Cordless Drill #1]]
* [[Black & Decker 14.4 Cordless Drill #2]]
* [[Black & Decker 14.4 Batteries (x3)]]
* [[Black & Decker Battery Charger]]
* [[Dewalt Battery Charger]]
* [[Black & Decker Corded Drill]]
* [[Husky Pneumatic Socket Wrench ]]
* [[Husky Pneumatic Hammer ]]
* [[Husky Pneumatic Impact Wrench ]]
* [[Husky Pneumatic Rotary Tool]]
* [[Husky Pneumatic Paint Sprayer ]]
* [[Powermate Pneumatic Nail Gun]]
* [[Pneumatic Tire Pressure Gauge and Hose]]
* [[Rotozip Rotary Tool]]
* [[Dremel 200 Series]]
* [[Dremel MultiPro]]
* [[Dremel Flex Shaft Extender]]
* [[Dremel Multi Purpose/Bench Press Stand ]]
* [[ColdHeat Battery Powered Soldering Iron]]
* [[Sperry LAN TRACKER]]
* [[Kobalt 3.6V Lithium Drill]]
* [[Ryobi 4V Lithium Drill]]
* [[Unknown Lithium Drill]]
* [[4.8V Cordless Screwdriver]]
* [[Compression Tool Kit]]
* [[Conduit Pipe Cutters (x2)]]
* [[TaskForce Corded Skill Saw]]
* [[SKIL Dual Axis Rotary Laser Level]]
* [[Masonry/Boring/Forester Bit Kits]]
* [[RJ11/RJ45 Terminating Tool]]
* [[Ideal 10/100 Terminating Punch]]
* [[CenTech Fiberglass Wiring Rods]]
* [[JET Dust Collection System ]]
* [[120 Volt 100 Amp Welder ]]
* [[Corona Machine ]]
* [[Virtual CD Drive]]

{{columns-end}}

== Large multiple QR sheets for mass printing ==

[[Equipment/QRCodes|Master List of QR Codes]]

[[Big Soldering Station Sticker Sheet]]

Talk:Zenbot 1624

2012-11-05T00:35:55Z

Milutz: Milutz moved page Talk:Zenbot 1624 to Talk:Zenbot 1216 CNC: Detective work has proven that the zenbot is a 1216 not a 1624

#REDIRECT [[Talk:Zenbot 1216 CNC]]

Talk:Zenbot 1216 CNC

2012-11-05T00:35:55Z

Milutz: Milutz moved page Talk:Zenbot 1624 to Talk:Zenbot 1216 CNC: Detective work has proven that the zenbot is a 1216 not a 1624

Zenbot 1624

2012-11-05T00:35:55Z

Milutz: Milutz moved page Zenbot 1624 to Zenbot 1216 CNC: Detective work has proven that the zenbot is a 1216 not a 1624

#REDIRECT [[Zenbot 1216 CNC]]

Zenbot 1216 CNC

2012-11-05T00:35:53Z

Milutz: Milutz moved page Zenbot 1624 to Zenbot 1216 CNC: Detective work has proven that the zenbot is a 1216 not a 1624

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=??|model=1216?|arrived=???|doesitwork=no|contact=Gerrit|where=front room east wall on floor}}
== Current status ==
As of Oct 24 2012 LVL1 hasn't ever been able to cut anything with this CNC. Effectively its still in the initial setup phase.

Gerrit and Mike L have been researching with the goal of getting it working. (The X,Y, & Z have previously been tested, the spindle is hasn't every been brought online)

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1216, hasn't been absolutely confirmed (Unsure if zenbot stamps model numbers on their products) [http://www.zenbotcnc.com/all-products/zenbot-1216-cnc-router zenbot 1216 product page] [http://www.zenbotcnc.com/assets/user-manuals/1216%20.9.pdf Zenbot 1216 manual]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle are '''MISSING'''.
*** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply - '''MISSING'''
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot is believed to be ready to go. There is some debate whether the EMC2 configure is complete. The people with Zenbot have said they have a (non-guaranteed) config that a customer made for EMC2 but thus far they haven't posted or emailed it to us
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|}
{|
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Oct-2012 the equipment shouldn't be operated

== Notes from initial equipment build ==

===Log of research (newest to oldest)===

Nov 3 Chris P

The manual for the Zenbot 1216 states that "the drive pulley diameter on this machine is .458 inches. The circumference of the drive pulley is 1.439. This means that the motor rotates .695 turns per inch (1/1.439). The stepper motors on this machine are .9 degree per step motor, which means that there are 400 steps per revolution. Now you just need to know the micro-step settings on your drivers. The formula for calculating the steps per inch is .695 x 400 x micro-steps/step. For a 1/8 micro-step driver, the formula would be .695 x 400 x 8 = 2224 steps per inch."

The stepper motors on the Zenbot 1216 at the LVL1 space are labeled as 1.8 degree per step. The steppers have 200 steps per revolution. The DIP switches on the driver are configured for 1/8 micro-steps. Using the same formula 0.695 x 200 x 8 = 1112 steps per inch.

<pre>
Settings for LinuxCNC:
Driver Type = Other
Step Time = 10000 (unsure, using the recommended value)
Step Space = 10000 (unsure, using the recommended value)
Direction Hold = 200000 (unsure, using the recommended value)
Direction Setup = 200000 (unsure, using the recommended value)
First Parport = 0x378
Base Period Maximum Jitter = 10816 (Measured with latency test, could be higher in which case a dedicated video card should be installed. Current PC has a low profile PCI-E slot).

Parallel Port
Pin 1 = unused (inverted)
Pin 2 = X Step
Pin 3 = X Direction
Pin 4 = Y Step
Pin 5 = Y Direction
Pin 6 = Z Step
Pin 7 = Z Direction
Pin 8 = Spindle CW (future)
Pin 9 = Spindle CCW (future)
Pin 14 = Spindle PWM (future, inverted)
Pin 16 = unused
Pin 17 = unused (inverted)
Pin 10 = unused
Pin 11 = unused
Pin 12 = unused
Pin 13 = unused
Pin 15 = unused

X Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 12

Y Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = 0 to 16

Z Axis
Motor Steps Per Revolution = 200
Driver Microstepping = 8
Pulley Ratio = 1:1
Leadscrew Pitch = -0.694927 (negative causes axis to move in opposite direction)
Maximum Velocity = 3.33 (using the recommended 200 inches per minute from Zenbot manual)
Maximum Acceleration = 40 (using the recommended 40 inches/sec/sec from Zenbot manual)
Home Location = 0
Table Travel = -4 to 0

Spindle (future, using guessed numbers now)
PWM Rate = 5000 Hz (MD30B can do up to 10000 Hz)
Speed 1 = 100
Speed 2 = 800
PWM 1 = 0.2
PWM 2 = 0.8
</pre>

The MD30B spindle motor driver was damaged during initial test of power supply, parts are ordered/shipped for repair.

----

[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Zenbot 1216 CNC

2012-10-29T22:42:38Z

Milutz: /* Log of research (newest to oldest) */

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=??|model=1624?|arrived=???|doesitwork=no|contact=Gerrit|where=front room east wall on floor}}
== Current status ==
As of Oct 24 2012 LVL1 hasn't ever been able to cut anything with this CNC. Effectively its still in the initial setup phase.

Gerrit and Mike L have been researching with the goal of getting it working. (The X,Y, & Z have previously been tested, the spindle is hasn't every been brought online)

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1624, hasn't been absolutely confirmed (Unsure if zenbot stamps model numbers on their products) [http://www.zenbotcnc.com/all-products/zenbot-1624-cnc-router zenbot 1624 product page]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle are '''MISSING'''.
*** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply - '''MISSING'''
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot is believed to be ready to go. There is some debate whether the EMC2 configure is complete. The people with Zenbot have said they have a (non-guaranteed) config that a customer made for EMC2 but thus far they haven't posted or emailed it to us
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|}
{|
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Oct-2012 the equipment shouldn't be operated

== Notes from initial equipment build ==

===Log of research (newest to oldest)===
[[File:Zenbot spindle Motor info.jpg|thumb|Close-up of the printing on the Zenbot's spindle motor]]
Oct 29 Mike L

Info found on motor:

<pre>12 VDC MOTOR
Mabuchi # RS-555VD.
12Vdc, 750mA (no-load).
Operates over 8-18 Vdc range.
38.5mm diameter x 65mm long.
3.17mm (1/8") diameter shaft. Solder lug / 0.18" qc terminals.
CAT# DCM-354
$3.50 each
</pre>

From http://www.scribd.com/doc/66758727/42/DC-MOTORS page 79

In order to get something going on the belts, I ordered:

<pre>Products
------------------------------------------------------
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $8.00
Cut-Length 5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.78
Cut-Length 5.5
2 x 3/16" (4.8mm) Orange 83A O-ring Belt = $7.86
Cut-Length 5.3125
2 x 5/32" (4mm) Clear 83A O-ring Belt = $7.10
Cut-Length 5.25
------------------------------------------------------
</pre>

from Ebelting.com
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

File:Zenbot spindle Motor info.jpg

2012-10-29T22:36:12Z

Milutz:

Zenbot 1216 CNC

2012-10-29T05:52:51Z

Milutz: /* Log of research (newest to oldest) */ First pass at belt length

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=??|model=1624?|arrived=???|doesitwork=no|contact=Gerrit|where=front room east wall on floor}}
== Current status ==
As of Oct 24 2012 LVL1 hasn't ever been able to cut anything with this CNC. Effectively its still in the initial setup phase.

Gerrit and Mike L have been researching with the goal of getting it working. (The X,Y, & Z have previously been tested, the spindle is hasn't every been brought online)

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1624, hasn't been absolutely confirmed (Unsure if zenbot stamps model numbers on their products) [http://www.zenbotcnc.com/all-products/zenbot-1624-cnc-router zenbot 1624 product page]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle are '''MISSING'''.
*** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply - '''MISSING'''
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot is believed to be ready to go. There is some debate whether the EMC2 configure is complete. The people with Zenbot have said they have a (non-guaranteed) config that a customer made for EMC2 but thus far they haven't posted or emailed it to us
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|}
{|
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Oct-2012 the equipment shouldn't be operated

== Notes from initial equipment build ==

===Log of research (newest to oldest)===
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at http://durabelt.com/beltlengthcalculator.php. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Zenbot 1216 CNC

2012-10-29T05:51:12Z

Milutz: /* Log of research (newest to oldest) */

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=??|model=1624?|arrived=???|doesitwork=no|contact=Gerrit|where=front room east wall on floor}}
== Current status ==
As of Oct 24 2012 LVL1 hasn't ever been able to cut anything with this CNC. Effectively its still in the initial setup phase.

Gerrit and Mike L have been researching with the goal of getting it working. (The X,Y, & Z have previously been tested, the spindle is hasn't every been brought online)

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1624, hasn't been absolutely confirmed (Unsure if zenbot stamps model numbers on their products) [http://www.zenbotcnc.com/all-products/zenbot-1624-cnc-router zenbot 1624 product page]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle are '''MISSING'''.
*** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply - '''MISSING'''
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot is believed to be ready to go. There is some debate whether the EMC2 configure is complete. The people with Zenbot have said they have a (non-guaranteed) config that a customer made for EMC2 but thus far they haven't posted or emailed it to us
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|}
{|
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Oct-2012 the equipment shouldn't be operated

== Notes from initial equipment build ==

===Log of research (newest to oldest)===
----
Oct 28 Mike L

Working to figure out which belt to acquire.

The durabelt people have a calculator for spec'ing out a belt at [http://durabelt.com/beltlengthcalculator.php]. Method three seems the most promising given the measurements Chris and I took.

After two pages of trying to work out the math, I came up with a length of 146.35mm (5.76181") for the unstretched length, durabelts calculator gave me the same thing (if I said 0 percentage stretch.

Still not sure if I have this right though. The belt vender sells belts in 1/16" increments.
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Zenbot 1216 CNC

2012-10-28T22:54:49Z

Milutz: /* Log of research (newest to oldest) */ Added information about belt manufacture that Chris found

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=??|model=1624?|arrived=???|doesitwork=no|contact=Gerrit|where=front room east wall on floor}}
== Current status ==
As of Oct 24 2012 LVL1 hasn't ever been able to cut anything with this CNC. Effectively its still in the initial setup phase.

Gerrit and Mike L have been researching with the goal of getting it working. (The X,Y, & Z have previously been tested, the spindle is hasn't every been brought online)

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1624, hasn't been absolutely confirmed (Unsure if zenbot stamps model numbers on their products) [http://www.zenbotcnc.com/all-products/zenbot-1624-cnc-router zenbot 1624 product page]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle are '''MISSING'''.
*** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply - '''MISSING'''
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot is believed to be ready to go. There is some debate whether the EMC2 configure is complete. The people with Zenbot have said they have a (non-guaranteed) config that a customer made for EMC2 but thus far they haven't posted or emailed it to us
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|}
{|
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Oct-2012 the equipment shouldn't be operated

== Notes from initial equipment build ==

===Log of research (newest to oldest)===
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

Chris found a "O ring style belt" custom belt maker. dura-belt durabelt.com is the manufacture, but they don't sell retail. ebelting.com is one of the retails for them.

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

Talk:Zenbot 1216 CNC

2012-10-28T22:53:32Z

Milutz: Moving info to main page

Zenbot 1216 CNC

2012-10-28T20:58:45Z

Milutz: /* Log of research (newest to oldest) */ Added pictures of spindle belt groves

{{Template:Equipment|owner=LVL1 (donation from chorgy)|serial=??|model=1624?|arrived=???|doesitwork=no|contact=Gerrit|where=front room east wall on floor}}
== Current status ==
As of Oct 24 2012 LVL1 hasn't ever been able to cut anything with this CNC. Effectively its still in the initial setup phase.

Gerrit and Mike L have been researching with the goal of getting it working. (The X,Y, & Z have previously been tested, the spindle is hasn't every been brought online)

== Equipment Description ==
Parts that make up this system:

[[File:Zenbot_parts_-_oct_24_2012.gif]]
* Zenbot itself (Includes the body, armatures, and the x, y, and z motors and actuation hardware (belts))
** Believed to be a Zenbot 1624, hasn't been absolutely confirmed (Unsure if zenbot stamps model numbers on their products) [http://www.zenbotcnc.com/all-products/zenbot-1624-cnc-router zenbot 1624 product page]
* X, Y, Z motor controller
** Believed to be a Mechatronics 3-axis CNC micro-stepper motor driver [http://www.easy-cnc.com/3axisdriver.html mechtronics 3-axis]
* Power brick for X, Y, Z controller
** Labeled "PA3290U-2ACA SEB 100P2-15.0". Input 100-240v 2.5A 50/60Hz. Output 19V at 6.3A. Center of connector is plus, outer shield is minus.
* Spindle (the routing part) - Believed to be a Wolfgang Engineering ... um ... spindle? (they don't seem to have any model info on the spindle or historical information on the website)
** [http://www.wolfgangengineering.com Wolfgang engineering website]
** The belts needed to couple the motor to the spindle are '''MISSING'''.
*** Gerrit has talked with Wolfgang about this and he may have enough info to order the belts as parts (They may effectively be big O-rings)
* Spindle motor controller
** Cytron Technologies [http://cytron.com.my/viewProduct.php?pcode=MD30B&name=Enhanced%2030%20Amp%20DC%20Motor%20Driver MD30B]
* Spindle power supply - '''MISSING'''
** Documentation for the MD30B controller says that it wants between 10 and 30Vdc with with a peak (output) of 30A (at 12Vdc?). Current product from wolfgangengineering has 200W 12Vdc motor, so 30A peek seems possible.
* Computer running EMC2 CNC control software and that has a parallel port
** Thin dell desktop sitting with the zenbot is believed to be ready to go. There is some debate whether the EMC2 configure is complete. The people with Zenbot have said they have a (non-guaranteed) config that a customer made for EMC2 but thus far they haven't posted or emailed it to us
* Bits
** There is one bit with the Zenbot, but to be of use more will have to be acquired. There seems to be agreement that the best way is to buy of Ebay, more digging will be needed to understand what to buy and how to re-cert/re-measure it in order to make it usable with the machine.
=== Pictures ===
[[File:Full Zenbot system.jpg|thumb|none|640px|Picture of the heap of parts and pieces that make up the Zenbot]]
{|
|[[File:From of X,Y,Z controller.jpg|thumb|Front of the X,Y,Z controller]]
|[[File:Back of X,Y,Z controller.jpg|thumb|Back of the X,Y,Z controller]]
|[[File:Zenbot Spindle motor controller.jpg|thumb|The spindle motor controller board]]
|[[File:Zenbot X,Y,Z power supply.jpg|thumb|upright=0.56|The power supply that has a plug matching the X,Y,Z controller]]
|}
{|
|[[File:Spindle with motor model visable.jpg|thumb|Spindle assembly with motor model visable]]
|[[File:Quality picture of spindle as was mounted when equipment was worked with oct 2012.jpg|thumb|upright|Spindle as it was mounted when Zenbot was first worked on by Mike Lutz]]
|[[File:Distance between motor standoff holes, wolfgang spindle (zenbot).jpg|thumb|measurement between the holes for the motor mount on the spindle (should be common with DC remote control car motors)]]
|}

== Operating instructions ==
As-of-Oct-2012 the equipment shouldn't be operated

== Notes from initial equipment build ==

===Log of research (newest to oldest)===
----
Oct 26 2012 - Mike L
[[File:Diameter of belt grove on motor side of spindle (zenbot).jpg|thumb|Diameter of belt grove on motor side]]
[[File:Diameter of belt grove on spindle side (zenbot).jpg|thumb|Diameter of belt grove on spindle]]
[[File:Distance spindle grove to motor grove (zenbot).jpg|thumb|Distance grove to grove]]

Zenbot has been moved to a desk in the front (broadway facing door) room.

It is missing one of the rubber feet (that might have been added aftermarket). May be easiest to just replace all four - the three that are still on are clearly "stick on" type. There is no special size or shape required.

PC originally wouldn't boot. Chris P. futzed with the ram in the machine (added/removed/cleaned-with-eraser) and the machine became willing to boot.

Once machine was booting the EMC2/linuxcnc?/axis-software was willing to run, and upon turning on the X,Y,Z controller, the software would drive the armature.

The machine is sitting with its orignal QR code facing out, this seem to be a good way point it so-as to have the x driver-motor pointing out at the user as it slides left to right '''BUT''' the config on the machine currently has both x and y configured for the machine rotated 180 degrees. I'm working to understand the config, with the expectation that I'm going to reverse both the x and the y (the z is fine)

Also critically important, all the axis are '''WAY''' out of scale. Moving the head 1.4 inches in the controlling software really moves the head very rapidly 10 inches in real space. Given the machine only has 10-20 inches of travel on x and y this makes a really easy to crash the head into the end of the rails its mounted on. Given the machine has no sensors for the end of the rails, if the software commands it there it will simply slam the head into the rails and grind the motors trying to keep moving on. (specifically moving 10" in real space read 1.3892" on the software, moving the head 10" on the y axis in real space read as 1.3762" on the software, z wasn't measured)

To the right are pictures of measurements of the spindle belt groves, with the goal of computing what size belt we need to acquire

--

Chris Pettus did some googling and found another zenbot user using a Wolfgang spindle and powering it with a computer power supply:
https://plus.google.com/103014027224354212001/posts/9EELxYozG4W
----
Oct 25 2012 - Mike L

In a back-and-forth with Chorgy he said: "The spindle I ran using a generic 13v regulated bench top that I bought from radio shack for like $30-$40."
Which I'm somewhat unclear if he donated but regardless is not in the pile of equipment with the Zenbot.

Chorgy also added that he really can't see the motor drawing more then 20A 12v dc max (.. through the motor controller board) and so he though a computer power supply would work.

----
[[File:QR_code_on_zenbot_as_of_Oct_2012.JPG|thumb|upright=0.56|QR code label on the side of the Zenbot]]
Oct 24 2012 - Mike L

Warped photo of the QR code that attached to the Zenbot

----
Oct 23 2012 - Mike L

Following up on what I found out about the zenbot:
*Chris connected me to Gerrit, he is the writer of the note (that I sent earlier) on the zenbot and seems to be on top of what needs to be done to get it going. (I.E. he does "have the ball")
*Current status
**Believed capable of high precision operation other then a non-operating spindle (the router part) because of multiple missing parts, and likely incompletely configured control software.
*Parts needed to get the zenbot operating:
**Power supply for the spindle motor
***either found by chorgy or an expense of $75-150
**Belts for spindle
***Gerrit had an exchange with Wolfgang Eng (maker of the spindle part) and thinks he may have enough info to order from a parts house (price currently unknown, though expected to be low)
**More bits (there is one with the zenbot now)
***Both Gerrit and chorgy agree that ebay is the way to go. Gerrit's comment was that the reason that ebay bits are so cheap is because they are partly used and have become slightly out of dimensional spec. With effort, the bits can be re-measure there-by enabling them to be used at full precision.
**Config for EMC2? (x,y,z stepper motor control software)
***The current assumption is that the EMC2 on the linux box doesn't have a fully configured config for the zenbot. Gerrit has contacted the zenbot and they have said they will send him a (customer supplied) EMC2 config, though they haven't yet so he is planning on bugging them again.
***Brian W posted that he had x,y,z working a few months back, Brian if you think the config is complete then please reply so Gerrit doesn't have to keep hassling the zenbot folks

If the zenbot gets up and running, there are number of improvement that Gerrit is already thinking about ("stops" to calibrate the arms - likely requiring a different controller, enclosure for the control systems, vacuum system, etc..)

The consensus seems to be that machine is in good shape, and should really be capable of high accuracy milling if the parts/config are done and the machine is treated gently.

I have some extra time over the next few weeks and I'm going to try and help Gerrit move things forward, I suspect that may not be enough to get the system operational, but if nothing else I'll make sure to document what happens.
----
Pre Oct 20 2012

Had written notes from Gerrit:
[[File:Gerrit's Zenbot1624 Notes.jpg|thumb|center|600px|Gerrit's handwritten notes on the zenbot]]

File:Distance spindle grove to motor grove (zenbot).jpg

2012-10-28T20:54:17Z

Milutz:

File:Diameter of belt grove on spindle side (zenbot).jpg

2012-10-28T20:53:25Z

Milutz: