CNC MILLING MACHINE

PRO-SERIES - USER MANUAL

www.mekanika.io
 MAINTENANCE

GENERAL INFORMATION

Prior to commissioning the Mekanika Pro CNC Milling Machine, it has to be ensured that the machine is in a
technically perfect and well-maintained condition. Always ensure that the machine is not powered if you want
to perform adjustment or maintenance works. For this purpose, disconnect the power plug.

Sharp-edged cutting tools must also be dismounted prior any maintenance work to avoid a risk of injury.

Remove workpieces you have clamped onto the machine table, including the clamping system.

Only use high quality tools during your maintenance work.

Lubrication of Ball Screws and linear rails

A linear system has to be sufficiently lubricated in order to work properly and to avoid excessive wear or over-
heating. The required lubrication interval is determined by the environmental conditions. Generally, lubrication
is required every 100 to 200 operating hours. A guideline for the lubrication interval is approx. 1 cm³ lubrication
per ball screw nut. We recommend using lithium-based greases, which perform well in high-load applications
and have good stability against oxidation.

RECOMMENDED MAINTENANCE WORK

The Mekanika Pro CNC machine is, to a good extent, maintenance-free. Handle your CNC system with
care in order to ensure a long service life. Regular maintenance has a substantial impact on the service life of
your machine. Frequently clean the CNC system with a cloth.

Ball screws and linear guides are to be regularly checked, cleansed of dirt and lubricated if necessary.

Clean the electronics area, including screen, keyboard and mouse from dust and impurities.

Regularly clean the fan filter of the control unit. A clogged filter might result in overheating inside the box, po-
tentially leading to permanent damage to the electronic components.

SPARE PARTS

All parts of the machine and of the control box can be purchased individually as spare parts.

Please contact us directly about this.

When ordering spare parts, please provided the information on the machine model, size and part number avail-
able in accordance with the building instructions.

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 TRANSPORTATION & STORAGE TABLE OF CONTENT

TRANSPORT GENERAL INFORMATION 4

Contact for Customer Information 4
If you want to transport the machine, please pay special attention to its dimensions. You might need additional Notice 4
people for transportation. Never lift heavy loads above people! Meaning of Terms Used 4
Avoid a unilateral load of the machine frame!
GENERAL INSTRUCTIONS 5
Foreword 5
General Safety Warnings for the Use of Machines 5
PACKAGING Protective Measures 8
Personal Protective Equipment 9
If you do not want to reuse the packaging material of the machine and its components, please separate it Emergency Stop Button 9
according to the disposal conditions on site and take it to a collection centre for recycling or dispose of it. Residual Risk 9
Check-list for Safety When Using the Machine 10
Safety Symbols 10
STORAGE
MACHINE DESCRIPTION 11
If the machine or its components is not used for a longer period of time, please observe the following points Workplace 12
regarding storage: Intended Use of the Machine 12

• Only store the machine and the components in closed rooms. ASSEMBLY & SYSTEM SETUP 13
• Protect the machine and the components against humidity, wetness, cold, heat and direct sun radiation. Environmental Conditions 13
Machine Positioning 13
• Store the machine and its components dust-free and cover it if necessary. Machine Assembly 13
• The storage place must not be subjected to vibrations. Machine References 14
Recommended Workplace Layout 15

OPERATION 16
Commissioning and Safe Operation 16
Machine Work Surface 16
Clamping the Workpiece 16
Operation of the CNC System 16

TECHNICAL DATA 17
Dimensions and Weight 17
Technical Specifications 17

TRANSPORTATION AND STORAGE 18

Transport 18
Packaging 18
Storage 18

MAINTENANCE 19
General information 19
Recommended Maintenance Work 19
Spare Parts 19

18 3
 GENERAL INFORMATION TECHNICAL DATA

CONTACT FOR CUSTOMER INFORMATION DIMENSIONS & WEIGHT

Mekanika SRL
55, Quai Fernand Demets Model Footprint Height Weight
1070 Anderlecht
Belgium PRO-S 850 x 850mm 650mm 55 kg
E-mail: [email protected]
PRO-M 850 x 1250mm 650mm 62 kg
If you encounter any issue or have any question regarding your machine, contact us and we’ll get back to you
within 24 hours. PRO-L 1250 x 1250mm 650mm 69 kg

NOTICE
TECHNICAL SPECIFICATIONS
All instructions, warranties and other collateral documents are subject to change at the sole discretion of
Mekanika SRL.

Please visit www.mekanika.io on your product page to access up-to-date informations and documents. Working Area 630 x 630mm | 630 x 1030mm | 1030 x 1030mm

Z Clearance Height 105mm (without spoilerboard)

Z Travel Distance 115mm

MEANING OF TERMS USED
Linear Guides HBR20 linear rails with carriages
The following terms are used throughout this operating manual to indicate various levels of potential harm
when operating this machine. The safety symbols, and their explanations, deserve your careful attention and Drive system 16mm Ball screws
understanding.
Accuracy 0,01mm - 0,05mm, with a repeatability of 0,01mm
The safety warnings themselves do not eliminate any danger. The instructions or warnings they give are not Maximal Travel Speed 10.000mm/min
substitutes for proper accident prevention measures.
Motors (X, Y1, Y2, Z) 4 High-torque Nema23 stepper motors
NOTICE
Procedures which, if not properly followed, create a possibility of physical property damage and a little or no Limit switches 6 NC PNP inductive sensors
possibility of injury.
Structure High quality aluminium profiles and digitally manufactured steel plates
CAUTION
Procedures which, if not properly followed, create a probability of physical property damage and a possibility Controller & Software PlanetCNC software installed and pre-configured on a Raspberry Pi 4B
of serious injury.
Interface 7” LCD Touchscreen & bluetooth keypad
WARNING Spindle AMB 1400 FME-P DI (software controlled spindle)
Procedures which, if not properly followed, create a probability of property damage, collateral damage, serious
injury or death or create a high probability of superficial injury.

Read the entire operating manual in order to become familiar with the features of the machine and how to
operate them. Failure to operate the machine correctly can result in damage to the machine, personal property
and cause serious injury, electric shock and/or fire.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE.

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 OPERATION GENERAL INSTRUCTIONS

COMMISSIONING AND SAFE OPERATION FOREWORD

The machine and all connected components have to be wired correctly and be in perfect condition. These operating instructions explain how the Mekanika Pro CNC Milling Machine works and inform you about
the correct handling of the machine.
The operator must have completely read and understood the entire documentation of the relevant machine
model and its corresponding instructions. Furthermore, he must have been trained in operating the machine as Please read these operating instructions as well as all accompanying documents in their entirety before
well as its accessories and has to be familiar with the use of a CNC Milling Machine and CNC software in general. commissioning of the system.

The workplace needs to be compliant with the applicable regulations and provisions of the respective industry. It is imperative to adhere to the safety instructions listed in these operating instructions at all times.

The operator must use a dust shoe to prevent access to the cutting tool and be protected from ejection of chips Should any doubts or the need for further information arise, do not hesitate to contact us prior to the use of the
while machining. machine.

All axes feature inductive sensors to provide end stop according to ISO 13854 “Safety of machinery - Minimum
gaps to avoid crushing of parts of the human body“, in order to avoid hand or finger crushes.

GENERAL SAFETY WARNINGS FOR THE USE OF MACHINES

MACHINE WORK SURFACE

There is no spoilerboard included in our kit. At first, a simple MDF wood panel is enough to get a grasp on CNC All persons who operate the machine must have read and fully understood
machining. When being more experienced, we suggest building a threaded insert grid on a surfaced spoiler- NOTICE all relevant safety and operating instructions. Misunderstanding may re-
board. If you intend to machine hard material and use a lubrication system on the machine, we suggest you sult in personal injury.
purchase an aluminium T-slot profiles worktable, as MDF will swell in contact with water.
Dress properly. Do not wear loose clothing or jewellery. Pin your hair above
CAUTION your shoulders so that it cannot get caught in the linear guides or moving
CLAMPING THE WORKPIECE parts.

The workpiece must be secured directly on the machine table using clamping devices.
Stay alert, watch what you are doing and use common sense when operat-
ing a machine. Do not use a machine while you are tired and/or under the
If you want to mill through the material and produce cut-outs, we recommend the use of suitable material as CAUTION

PERSONAL SAFETY
influence of drugs, alcohol or medication. A moment of inattention while
spoilerboard. It is placed under the workpiece and protects the machine table from potential damage.
operating a machine may result in serious personal injury.
The workpiece should be sufficiently clamped in order to prevent it from unintentional shifting during process-
ing. Use personal protective equipment. Always wear eye protection. Protec-
CAUTION tive equipment, such as a suitable dust mask or ear protection, reduces
Never hold the workpiece with your hands during the operating process. There is a high risk of serious injury! the risk of injuries.

This tool is controlled by a computer. During operation, it cannot be con-

CAUTION trolled directly. Lack of caution or expertise as well as program errors can
OPERATION OF THE CNC SYSTEM lead to unexpected movements.

Do not touch the motors as they can heat up significantly during opera-
The entire CNC system is controlled and operated via a Raspberry Pi. CAUTION
tion.
The operator must have completely read and understood the entire documentation of the CNC control software
before commissioning the CNC system. Never place any parts of the tool or accessories in your mouth as this can
CAUTION
lead to serious injuries.
For further questions regarding the applied control software, please contact the respective software manufac-
turer at https://planet-cnc.com/

16 5
 NOTICE
Keep work area clean and well lit. Cluttered or dark areas are prone to ac- RECOMMENDED WORKPLACE LAYOUT
cidents.

Operate the machine only in interior spaces on a solid, horizontal table or

WORK AREA SAFETY

NOTICE
workbench. MAINTENANCE &
SETUP AREA

Keep children and bystanders at a distance while operating a power tool.

CAUTION
Distractions can cause you to lose control and can result in accidents.

Do not operate the machine in explosive atmospheres, such as in the

CAUTION presence of flammable liquids, gases or dust. Machines can create sparks
which may ignite the dust or fumes.

MAINTENANCE &

MAINTENANCE &
SETUP AREA

SETUP AREA
Do not expose the machine to moisture. The machine is only suitable for
NOTICE
indoor use.
ELECTRICAL
SAFETY

Machine plugs must match the outlet. Never modify the plug in any way.
Be careful if you use adapter plugs with a grounded machine. Unmodi-
WARNING
fied plugs and matching outlets will reduce the risk of electric defects and
malfunctions

Do not leave a running tool unattended, turn power off. Only when tool
NOTICE
comes to a complete stop and is disconnected from the mains it is safe.

Use the machine and accessories in accordance with these instructions,

taking into account the working conditions and the work to be performed.
NOTICE

0,5 meter
Use of the machine for operations different from those intended could re-
MATERIAL
sult in a hazardous situation with high probability of superficial injury. OPERATING
USE OF THE MACHINE

LOADING
AREA
AREA

Never use dull or damaged end mills. Sharp end mills must be handled
NOTICE with care. Damaged end mills can snap during use. Dull end mills require

1 meter
more force to cut the tool, possibly causing the end mill to break.

The speed and feed of the end mill when carving, routing or cutting is very
NOTICE important. Always observe the speed and feed for the particular end mill
recommended.

Do not allow familiarity gained from frequent use of your rotary tool to be-
NOTICE come commonplace. Always remember that a careless fraction of a second
is sufficient to inflict severe injury.

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MACHINE REFERENCES Clean the spindle’s air vents every four hours by using compressed air.
NOTICE Excessive accumulation of chips and dust inside the motor housing may
cause electrical failures.

AXES TERMINOLOGY Do not reach in the area of the rotating tool. The proximity of the rotating
CAUTION
tool to your hand may not always be obvious.

X-AXIS Never try to reach the limit sensors while the machine is moving, it could
CAUTION
lead to the crushing of your hand or fingers.

Z-AXIS
Do not alter or misuse the tool. Any alteration or modification is a misuse
CAUTION
and may result in serious personal injury.

Disconnect the plug from the power source before you make any adjust-

USE OF THE MACHINE

CAUTION ments, change accessories, or store the tool. Such preventive safety meas-
ures reduce the risk of starting the power tool accidentally.

Store the machine out of the reach of children and do not allow persons
CAUTION unfamiliar with these instructions to operate the machine. Machines are
Y-AXIS dangerous in the hands of untrained users.

If the workpiece or end mill gets jammed, immediately press the emergen-
cy stop button. Wait for all moving parts to stop and turn off the spindle
CAUTION
with the power switch, then free the jammed material. Do not try to do this
CONTROL BOX with the spindle turned on.

EMERGENCY STOP Do not touch the end mill or collet after use. After usage they are too hot to
CAUTION
MOTORS be touched with bare hands.
ENCLOSURE INPUTS
FAN & DUST X Y1 Z Y2
FILTER USB
POWER SUPPLY
Before starting any machining operation, always have the workpiece se-
curely clamped. Never attempt to hold the workpiece with your hands or
CAUTION
using any accessories. These tools can jam easily in the material, and can
kickback, causing loss of control resulting in serious injury.

Properly maintain the tools you use. Check for misalignment or binding of

CARE OF THE TOOLS

moving parts, breakage of parts and any other conditions that may affect
NOTICE
the machine’s operation. If damaged, have the machine repaired before
use. Many accidents are caused by poorly maintained machines.

ETHERNET
HDMI
Have your machine serviced by a qualified repair person using only identi-
X Y1 Z Y2 SPINDLE CONTROL (DI/VFD) NOTICE
cal replacement parts.
LIMIT
SWITCHES PROBE Z

14 7
 ASSEMBLY & SYSTEM SETUP
Depending on the application field of the machine (private or commer-
CAUTION cial), observe the applicable occupational safety and health, safety and
accident prevention and environmental regulations.
ADDITIONNAL SAFETY MEASURES

ENVIRONMENTAL CONDITIONS
Some dust created while machining certain types of material can
contain chemicals known to cause cancer, birth defects or other re- The machine is solely suitable for the operation in dry, interior spaces.
productive harm. Always inform yourself on the material you have
at hand before machining it. Some examples of these chemicals are: Keep the environmental temperature of the machine dust-free. High dust exposure can cause damages to the
lead from non-ferrous metals with lead content, carbonate from car- system.
bon fibre, arsenic and chromium from chemically-treated lumber.
WARNING The humidity should be within normal limits for humidity indoors (40 to 60 %). Protect the machine against
Your risk from exposures to these varies, depending on how often you per- wetness and humidity.
form this type of work. To reduce your exposure to these chemicals: work
in a well ventilated area, and work with approved safety equipment, such The ideal environmental temperature for the system lies between 18°C to 25°C, respectively from
as those dust masks that are specially designed to filter out microscopic 64°F to 77°F.
particles.
Particularly protect the electronics against overheating by avoiding direct sun radiation or indirect heating up
nearby a radiator.

MACHINE POSITIONING
PROTECTIVE MEASURES
Place the machine on a suitable table or on a machine stand. In order to provide a comfortable working height,
we recommend a working height of approx. 840 mm. For a torsion-free stand, the surface of the machine stand
The Mekanika Pro CNC Machine has been designed for advanced users and is only to be operated by technically needs to be solid and even. The machine is to be secured in a way that it cannot shift or fall down.
skilled adults.
All movable parts of the machine must be able to operate collision-free.
The machine is only to be used in a technically perfect condition, which is to be ensured by the user prior to
each operation. The routing of the tool´s cables, such as with the milling motor, has to be effected in a way that the cable cannot
be clamped between the guide ways of the machine. For this purpose, use the cable chains we have set up for
The emergency switch as well as, if applicable, additional safety devices, always need to be easily accessible and the different axis.
fully functional.
The machine has to be easily accessible and operable. Especially the emergency switch has to be easily acces-
The use of air and water lubrication systems is allowed. Please take into consideration that if you are using an sible at all times.
MDF spoilerboard (machine worktable), the MDF panel will swell and be damaged by the water.
Take care to ensure a sufficient illumination of the machine`s location and the workplace surrounding the ma-
chine.

The control unit and the machine interface (screen & keypad) have to be placed in the vicinity of the machine in
order to have both in clear view at all time.

MACHINE ASSEMBLY

Please follow carefully our attached mounting guide and datasheet in order to properly mount your Mekanika
Pro CNC Milling Machine.

If you have any questions, please do not hesitate to contact us!

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WORKPLACE PERSONAL PROTECTIVE EQUIPMENT

The workplace needs to provide enough space around the machine in order to work comfortably and to allow When working with the machine, the operator has to wear at least the following personal protective equipment
the machine to fully use its traveling paths. Additionally, a safe distance to possibly nearby positioned machines and has to be compliant with the below-mentioned safety aspects:
is to be maintained.
• Safety glasses to protect the eyes against flying chips and other projections.
The location of the machine as well as the workplace surrounding the machine has to be sufficiently illuminated. • Ear protection to protect the ears against noise.
• Safety shoes to protect the feet against falling objects.
The control box and the interface items have to be placed in the vicinity of the machine in order to have both • No wearing of clothes which can get caught in the machine, such as ties, scarves, wide sleeves. Roll up
in clear view. sleeves to prevent caught in moving parts. Additionally, jewellery, watches, rings and especially long neck-
laces and rings are to be dispensed with.
• Shoulder-length or longer hair must be secured with a hairnet or a hat in order to prevent it from getting
caught in the linear guides and / or rotating tools.
INTENDED USE OF THE MACHINE
Prior to all adjustments to the machine, such as to the spindle and to the control unit, its control or system-guid-
The Mekanika Pro CNC Milling Machine is constructed for a permanent and regular application for profession- ed tools have to be disconnected from the power source.
als. Due to the machine stiffness, a variety of different materials, such as wood and non-ferrous metals, can be
processed. Never hold the workpiece with your hands. It is mandatory to secure the workpiece on the worktable. Otherwise,
there exists a high risk of injuries!
The plausible and reasonable scope of uses include:

• Manual movement mode, using a digital “jog” to move the machine along its 3 axes independently.
• Automatic “Homing” procedure, operated by the user by clicking a digital button. This procedure moves the EMERGENCY STOP BUTTON
machine sequentially on each of its axes in the following order: Z, X, Y, until it encounters the limit switches.
• Automatic “Square Gantry” procedure, activated by the user by clicking a digital button. This procedure The emergency stop is located in a separate housing and is securely connected with the machine. In order to
moves the machine along its Y-axis, forward, until it touches its left and right limit sensors sequentially. The be able to intervene at all times, the emergency stop has to be positioned at a suitable place, as shown in the
purpose of this procedure is to square the machine’s gantry with the Y axis. assembly guide.
• Measure Tool Length procedure, activated by the user by clicking on a numerical button. This procedure
makes the machine descend at reduced speed along its Z axis until its tool comes into contact with a remov- By pressing the emergency stop switch, the emergency stop is triggered. The control of the machine is immedi-
able sensor previously placed by the user. ately interrupted. Additionally, the control software receives the signal to stop the operating process, freezing
the user interface. The machine stops moving immediately and the spindle stops turning at the same moment.
• Normal operating mode, where the machine moves automatically according to a machine code, called
G-code, previously loaded by the user.
If you want to deactivate the emergency stop status, reactivate the control by turning the emergency stop
• Manual control mode using a terminal, the machine moves according to a machine code, called G-code, switch to the right. The operating process has to be restarted.
entered directly by the user.
If you have any questions on this matter, please do not hesitate to contact us.
The plausible and reasonable scope of interventions include:

• Manual movement of the machine to access certain zones.

• Manual rotation of the ball screws to align the X axis (gantry) with respect to the Y axis.
• Changing the cutting tool on the milling spindle. RESIDUAL RISK
• Attachment/removal of the dust shoe.
• Attachment/removal of the raw material to be machined on the work surface. Despite all safety precautions against the contact with rotating or hot tools and the protection from crushes, a
• Switching on, pausing and stopping a machine code (G-code). residual risk remains due to a careless handling and automatic movements of the CNC system.
• Connection/disconnection of external machine cables.
• Opening of the cable entry chains to access the cables.

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 MACHINE DESCRIPTION
CHECKLIST FOR A SAFE USE OF THE MACHINE

BE PREPARED WORK SAFE FINISH RIGHT

The Mekanika Pro CNC Milling Machine is a digitally controlled milling machine, which can be used for a regular
processing of wood, plastics and non-ferrous metals.
• Use appropriate personal • Never plug or unplug • When you are finished with
protective equipment : cables from the control your work, shut down the
The machine has three axes, which are offset by 90°. This way, it is possible to travel to any point within the
unit while the machine is Raspberry Pi before turning
- Safety Glasses working space. Each axis is equipped with one or two stepper motors and with one or two inductive sensors.
powered. off the power switch of the
- Hearing protection The stepper motors drive the movable axes elements via the ball screws. The position of the axis is determined
control unit (not doing so
• Ensure that the workpiece during the homing procedure, at the beginning of the job, with the aid of the inductive limit sensors.
- Safety Shoes might corrupt the SD card).
is firmly and securely
• Remove rings, bracelets, clamped. • If the ball screws are dusty, The Mekanika Pro CNC Milling Machine is delivered as a kit and includes the following components:
watches and necklaces blow them with pressurised
• Check that the tools are
before work. air to keep them clean and • A 3-axis CNC router, with 4 motors and 6 inductive limit switches
sharp and set correctly.
greased. • A plug-and-play electronic control unit, already assembled and tested, with its power cable (EU plug)
• Tie and confine long hair. • Use a brush or a vacuum • A plug-and-play interface unit, composed of a touch screen and bluetooth keypad
• Clean the floor and work
• Wear tight fitting clothing cleaner to clean chips off • PlanetCNC software, pre-installed on a Raspberry Pi 4 and already configured (software used to control your
area around the machine.
and roll up sleeves to surfaces. machine)
prevent snagging. • Clean and put away person- • A lifetime license of PlanetCNC
• Never reach into the
al protection equipment. • A power cable for the control unit (EU plug)
• Inspect the equipment to machine while it is running
and keep your hands away • Tag any defective equip- • An AMB 1400 FME-P DI spindle, which is controlled by the software
ensure there are no obvious
from any moving part ment and contact us if you • A touch probe device to locate your workpieces easily
defects, damaged chucks ,
during machining. encounter any trouble. • All the basic tools necessary to assemble the machine
dull or cracked tools.
• A USB key
• Ensure you have the required • Stand clear of the machine
knowledge of the use of a whenever it is operational.
CNC milling machine. You should also warn other
people near the risk of
• Do not use gloves. being too close to it
• Check where the emergency • Keep hands clear during
stop button is located. manual adjustments. When-
ever you are handling or
passing tools, avoid touch-
ing the cutting edges

SAFETY SYMBOLS

In addition to the above mentioned items, you will need the following ones in order to be able to properly use
the machine:
• A spoilerboard. At first, a simple wood panel is enough to get a grasp on CNC machining and we don’t think
it’s relevant to ship such an bulky object, which is easy to find at your local hardware shop. When being
more experienced, we suggest building a threaded insert grid on a surfaced spoilerboard.
• A vacuum cleaner and a dust shoe, to help you work in a clean environment and to be protected from the
rotating tool while the machine is working.
• A CAM software. You will need a Computer Aided Manufacturing software to translate your 3D models into
a G-code readable by the machine. We suggest to use Fusion360.
• A table which can bear the weight of the machine. It needs to be robust and stiff, as vibrations will affect
the precision of your cuts.

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