Excalibur 16” X 24” CNC Carving Machine with FlashCut Controller User Manual

Excalibur 16” X 24” CNC Carving Machine with FlashCut Controller User Manual

THANK YOU for choosing this Excalibur by General International model EC-617 M1 16” x 24” CNC carving machine with FlashCut™ controller. This machine has been carefully tested and inspected before shipment and if properly used and maintained, will provide you with years of reliable service. For your safety, as well as to ensure optimum performance and trouble-free operation, and to get the most from your investment, please take the time to read this manual before assembling, installing and operating the unit.

The manual’s purpose is to familiarize you with the safe operation, basic function, and features of this CNC carving machine as well as the set-up, maintenance and identification of its parts and components. This manual is not intended as a substitute for formal woodworking instruction, nor to offer the user instruction in the craft of woodworking. If you are not sure about the safety of performing a certain operation or procedure, do not proceed until you can confirm, from knowledgeable and qualified sources, that it is safe to do so.

Once you’ve read through these instructions, keep this manual handy for future reference.

DISCLAIMER: The information and specifications in this manual pertain to the unit as it was supplied from the factory at the time of printing. Because we are committed to making constant improvements, General International reserves the right to make changes to components, parts or features of this unit as deemed necessary, without prior notice and without obligation to install any such changes on previously delivered units. Reasonable care is taken at the factory to ensure that the specifications and information in this manual corresponds with that of the unit with which it was supplied. However, special orders and “after factory” modifications may render some or all information in this manual inapplicable to your machine. Further, as several generations of this model of CNC carving machine and several versions of this manual may be in circulation, if you own an earlier or later version of this unit, this manual may not depict your machine exactly. If you have any doubts or questions contact your retailer or our support line with the model and serial number of your unit for clarification.

RULES FOR SAFE OPERATION

To help ensure safe operation, please take a moment to learn the machine’s applications and limitations, as well as potential hazards. General® International disclaims any real or implied warranty and holds itself harmless for any injury that may result from improper use of its equipment.

1. Be sure to read and understand owner’s manual before operating.
2. Do not operate the CNC carving machine when tired, distracted, or under the effects of drugs, alcohol or any medication that impairs reflexes or alertness.
3. The work area should be well lit, clean and free of debris.
4. Keep children and visitors at a safe distance when the CNC carver is in operation; do not permit them to operate the CNC Carver.
5. Childproof and tamper proof your shop and all machinery with locks, master electrical switches and switch keys, to prevent unauthorized or unsupervised use.
6. Stay alert! Give your work your undivided attention. Even a momentary distraction can lead to serious injury.
7. Fine particulate dust is a carcinogen that can be hazardous to health. Work in a well-ventilated area and whenever possible use a dust collector and wear eye, ear and respiratory protection devices.
8. Do not wear loose clothing, gloves, bracelets, necklaces or other jewelry while the CNC carving machine is in operation. Wear protective hair covering to contain long hair and wear non-slip footwear.
9. Be sure that adjusting wrenches, tools, drinks and other clutter are removed from the machine before operating.
10. Keep hands well away from the spindle, cutting tools, and all moving parts. Use a brush, not hands, to clear away chips and dust.
11. Before turning on the CNC carving machine, make sure the piece is properly secured.
12. Use of parts and accessories NOT recommended by GENERAL® INTERNATIONAL may result in equipment malfunction or risk of injury.
13. Never stand on machinery. Serious injury could result if the tool is tipped over.
14. Always disconnect the tool from the power source before servicing, changing accessories, performing any maintenance or cleaning, or if the machine will be left unattended.
15. Make sure that switch is in the “OFF” position before plugging in the power cord.
16. Make sure the tool is properly grounded. If equipped with a 3-prong plug it should be used with a three-pole receptacle. Never remove the third prong.
17. Do not use this CNC carving machine for any purpose other than  its intended use. If used for other purposes, GENERAL® INTERNATIONAL disclaims any real or implied warranty and holds itself harmless for any injury, which may result from that use.
18.  To reduce the risk of electric shock, do not operate the machine with wet hands.
19. Respect the rated limits of this machine.
20. To ensure safety, all maintenance should be performed by a qualified technician.
21. To avoid electrical shock, do not touch the transformers, motors or  control box when the power is on.
22. Make sure to always have full unimpeded access to the emergency stop button at all times.
23. To ensure safety, do not tamper with the safety cover, limit switch or any other accessories.
24. Be sure to keep a record before changing any settings on the machine.
25. Place the unit on a sturdy surface, in a dry area.
26. Avoid exposing the machine to extremely high temperatures.
27. Unplug the unit from the power source before replacing fuses. Use only recommended fuses.
28. Be sure to turn off the machine when the power source is unstable.

ELECTRICAL REQUIREMENTS

BEFORE CONNECTING THE MACHINE TO THE POWER SOURCE, VERIFY THAT THE VOLTAGE OF YOUR POWER SUPPLY CORRESPONDS WITH THE VOLTAGE SPECIFIED ON THE MOTOR I.D. NAMEPLATE. A POWER SOURCE WITH GREATER VOLTAGE THAN NEEDED CAN RESULT IN SERIOUS INJURY TO THE USER AS WELL AS DAMAGE TO THE MACHINE. IF IN DOUBT, CONTACT A QUALIFIED ELECTRICIAN BEFORE CONNECTING TO THE POWER SOURCE.
THIS TOOL IS FOR INDOOR USE ONLY. DO NOT EXPOSE TO RAIN OR USE IN WET OR DAMP LOCATIONS.

GROUNDING INSTRUCTIONS

In the event of an electrical malfunction or short circuit, grounding reduces the risk of electric shock. The motor of this machine is wired for 110V single phase operation and is equipped with a 3-conductor cord and a 3-prong grounding plug A to fit a grounded type receptacle B.

Do not remove the 3rd prong (grounding pin) to make it fit into an old 2-hole wall socket or extension cord. If an adaptor plug is used C, it must be attached to the metal screw of the receptacle.

Note: The use of an adaptor plug is illegal in some areas. Check your local codes. If you have any doubts or if the supplied plug does not correspond to your electrical outlet, consult a qualified electrician before proceeding.

CIRCUIT CAPACITY

Make sure that the wires in your circuit are capable of handling the amperage draw from your machine, as well as any other machines that could be operating on the same circuit. If you are unsure, consult a qualified electrician. If the circuit breaker trips or the fuse blows regularly, your machine may be operating on a circuit that is close to its amperage draw capacity. However, if an unusual amperage draw does not exist and a power failure still occurs, contact a qualified technician or our service department.

EXTENSION CORDS

If you find it necessary to use an extension cord with your machine, use only 3 wire extension cords that have 3-prong grounding plug and a matching 3-pole receptacle that accepts the tool’s plug. Repair or replace a damaged extension cord or plug immediately.

Make sure the cord rating is suitable for the amperage listed on the motor I.D. plate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. In some cases this may cause the machine to stop its cutting operation and an error message will appear on your controller. The accompanying chart shows the correct size extension cord to be used based on cord length and motor I.D. plate amp rating. If in doubt, use the next heavier gauge. The smaller the number, the heavier the gauge.

TABLE – MINIMUM GAUGE FOR CORD

EXTENSION CORD LENGTH
AMPERES| 50 feet| 100 feet| 200 feet| 300 feet
< 5| 18| 16| 16| 14
6 to 10| 18| 16| 14| 12
10 to 12| 16| 16| 14| 12
12 to 16| 14| 12| *NR*| NR*
NR = Not Recommended

FEATURES

New! Renowned Excalibur by General International design expertise now available in CNC technology.
Steel stand and built-in dust collector included*
FlashCut™ controller** and FlashCut™ programming software included www.FlashCutcnc.com
FlashCut™ CNC is the only Windows CNC solution offering a dedicated CNC controller ensuring smooth and uninterrupted motion using 32 or 64-bit Windows 10, 8 or 7 with a USB connection on a laptop or desktop computer – includes phone and e-mail support.
Powerful 550 watt variable frequency motor for excellent performance and low maintenance. Smooth and accurate ball screw transmission on all axis.
Positional accuracy up to +/- 0.004 inches.
Variable cutting speeds up to 118 inches per minute. Spindle speeds up to 24,000 rpm with automatic spindle on/off control.
Aluminum table with integrated hold down clamps.
1 year limited warranty

• Optional safety enclosure also available #EC617X – ideal for educational users.
  ** FlashCut™ controller options: EC-617FSB Basic or EC617FSS Standard (with tethered remote)

SPECIFICATIONS

• Cutting capacity (X, Y Z axis): 16”, 24”, 4”
• Positional accuracy: ±0.004”
• Assembled dimensions
  • EC-617 M1 only: 27 ¾” x 38 ½” x 27 1/2” (704 x 980 x 700 mm)
  • With stand: 40 1/8” x 31 ½” x 55 1/8” (1020 x 800 x 1400 mm
  • With stand & optional enclosure (EC617X): 32 ¼” x 43 ¼” x 56 ¼” (820 x 1100 x 1430 mm)
• Spindle speed / Cutting speeds: 0 – 24,000 rpm / variable – up to 118” per minute
• Spindle/ motor type: 550 W – variable frequency motor
• Table surface material: Aluminium
• Programming software included: FlashCut™ CNC4
• Input power requirements: 110/115v – 9 A
• ColletL 1 x ¼” (6 mm)
• Weight (shipping/net) EC-617 M1 without enclosure: 308/264 lbs (140/120kg)

IDENTIFICATION OF MAIN PARTS AND COMPONENTS

• A. BASE CABINET
• B. FRAME
• C. SIDE RAIL
• D. WORK TABLE
• E. GANTRY
• F. Y AXIS SYSTEM
• G. CABLE CHAIN
• H. Z AXIS SYSTEM
• I. CONTROL BOX
• J. CUTTING TOOL (BIT)
• K. WORKPIECE CLAMPS
• L. POWER ON/OFF SWITCH
• M. EMERGENCY STOP BUTTON

UNPACKING AND PREPARATION FOR SET-UP INSTALLATION

THE MACHINE IS HEAVY (132 LBS – 60 KG). DO NOT OVEREXERT. ARRANGE TO HAVE HELP NEARBY AND READY FOR UNPACKING AND SET UP. THE SOUND LEVEL OF THIS MACHINE IS RATED AT APPROXIMATELY 85-95 DB DURING OPERATION. MAKE SURE THAT ADEQUATE HEARING PROTECTION IS USED AND THAT THE OVERALL SOUND LEVEL WITHIN THE WORKING ENVIRONMENT IS TAKEN INTO CONSIDERATION.

UNPACKING

Depending on the model ordered, your EC-617 M1 is supplied as a standard version CNC Carving machine with stand and dust collection included, and a choice of two control systems: FlashCut™ Basic (Model EC-617FSB), or FlashCut™ Standard (Model EC-617FSS) which includes a tethered hand-held remote control.

NOTE: A safety enclosure with auto lock-out switch #EC-617X is also available as an optional accessory (see the section “Optional accessories”).

The standard unit is shipped in two cartons. The machine with controller in one carton and the stand and dust collection in the second.

Carefully unpack and remove the Carver and its components from the cartons and check for damaged or missing items as per the parts list in this manual.

NOTE: Please report any damaged or missing items to your General International distributor immediately.

PLACEMENT WITHIN THE SHOP / SAFETY ZONE

THIS MODEL EC-617 M1 CNC CARVING MACHINE IS HEAVY – 264 LBS (120 KG), WITH STAND. DO NOT OVER-EXERT. THE HELP OF AN ASSISTANT WILL BE NEEDED FOR THE INSTALLATION. SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO.

PLACEMENT WITHIN THE SHOP

This machine should be installed and operated only on a solid, flat and stable work surface that is able to support the weight of the i Carver and the workpiece.
Using the dimensions shown as a guideline, plan for placement within your shop that will allow the operator to work unencumbered and unobstructed by foot traffic (either passing shop visitors or other shop workers) or other tools or machinery. (use coverpage pics and dims as follows: L-40 1/8” x W-31 ½” x H-55 1/8”)

ESTABLISHING A SAFETY ZONE
For shops with frequent visitors or multiple operators, it is advisable to establish a safety zone around shop machinery. A clearly defined “no-go” zone on the floor around each machine can help avoid accidents that could cause injury to either the operator or the shop visitor. It is advisable to take a few moments to either paint (using non-slip paint) or using tape, define on the floor the limits or perimeter of each machines safety zone. Take steps to ensure that all operators and shop visitors are aware that these areas are off limits whenever a machine is running for everyone but the individual operating the unit.

ASSEMBLY AND INSTALLATION INSTRUCTIONS

SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLETED THE INSTALLATION AND ASSEMBLY STEPS. DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO

For your convenience this CNC Carver is shipped from the factory partially assembled and requires only minimal assembly for the stand, and minor set up before being put into service.

ASSEMBLING THE STAND

Using the parts diagram in the section “Parts and diagrams” as a guide, assemble the stand with the supplied fasteners.

Attach the dust collection/controller cabinet and secure the CNC carver to the stand and cabinet as shown. Then connect the end of dust hose to the dust port on the cabinet and the other end of the dust hose with mounting bracket to the spindle head.

Note: If ordered with the optional EC-617X safety enclosure, proceed with enclosure installation before connecting the dust hose.

ASSEMBLING & INSTALLING THE OPTIONAL EC-617X SAFETY ENCLOSURE

Using the parts diagram below as a guide, assemble the enclosure with the supplied fasteners.

Secure the enclosure to the base. Install two flat washers between the cut-off swtich and the frame of the safety enclosure as shown below.

Connect the wires from the cut-off switch on the enclosure in place of ones supplied with the basic unit.
Note: Take care during installation that the main power cable does not to obstruct the rear door.

CUTTING TOOL INSTALLATION / REMOVAL

TO AVOID SERIOUS PERSONAL INJURY AND/OR DAMAGE TO THE SPINDLE, ALWAYS MAKE SURE THAT THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED BEFORE INSTALLING /REMOVING A CUTTING TOOL. KEEP HANDS WELL AWAY FROM THE SPINDLE, CUTTING TOOL, AND ALL MOVING PARTS AT ALL TIMES.

The spindle’s collet on this unit is designed to accept standard ¼” or 6mm bits. A wide range of bits in various cutting shapes can be used based on the project and type of cutting tool needed. See your retailer for details of the various bits that may be available in your area.

To install a cutting tool (bit) , insert the cutting tool in the collet and use the supplied 13 mm and 17mm wrenches to hold the spindle and tighten the collet onto the bit.

LOADING PROJECTS AND OPERATING THE CONTROLLER

Carving projects can be created from most commonly used image file formats. The FlashCut™ controller and FlashCut™ CNC4 programming software are fully compatible with Windows™ 7, 8, and 10, 32 bit or 64 bit operating systems.

For full details on creating, loading, and running projects with FlashCut™ CNC4 software, as well as complete operating instructions for the controller, please refer to the detailed instruction manuals supplied with your FlashCut™ controller.

Personal liability reminder: Be aware that images copie from the internet or from other sources may be subject to copyrights and that the use of any copyrighted images or logos for commercial and even personal projects, may leave you open to personal liability.

In particular, do not use copyrighted images for commercial (for pay) projects without first securing specific written permission from the owner of the image or logo. Sports teams and leagues as well as trademarked brands can be quite aggressive about protecting their copyrights.

CONNECTING TO A POWER SOURCE

TO REDUCE THE RISK OF SHOCK OR FIRE DO NOT OPERATE THE UNIT WITH A DAMAGED POWER CORD OR PLUG. REPLACE DAMAGED CORD OR PLUG IMMEDIATELY. TO AVOID UNEXPECTED OR UNINTENTIONAL START-UP, MAKE SURE THAT BOTH OF THE POWER SWITCHES ARE IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE.

Once the assembly steps have been completed and the unit is safely secured to its stand, uncoil the power cord and plug the power cord into an appropriate outlet.Refer back to the section entitled “Electrical Requirements” and make sure all requirements and grounding instructions are followed. When carving operations have been completed unplug the CNC Carver from the power source.

SPEED SELECTION

Selecting the appropriate feed rate is dependent on a variety of factors: type and density of the material to be machined, depth of cut per pass, type of bit or cutting tool being used, required finish quality, as well as the amount of fine detail in the image being machined. There are no hard and fast rules. Practice and experience will be your best teacher. There are however some general guidelines to consider and the following information will help you in selecting the correct feed rate:

• SLOWEST SPEED – Recommended for projects designed with small/fine detailing in the image to be machined.
• SLOW TO MEDIUM SPEED – For projects where material density is extremely high – not commonly used.
• MEDIUM TO HIGH SPEED – Best speed for simpler less detailed designs when using dense woods, or where machining depths exceed 1/4” per pass.
• HIGHEST SPEED – For simpler less detailed designs in less dense woods with machining depths of 1/4” or less per pass.

PERIODIC MAINTENANCE

MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORMING ANY MAINTENANCE.

• Inspect/test the ON/OFF switch before each use. Do not operate the CNC Carver with a damaged switch; replace a damaged switch immediately.
• Keep the machine clean and free of saw dust, woodchips, pitch or glue. Vacuum or brush off any loose debris after each use, and wipe down the machine and table occasionally with a damp rag.
• Periodically inspect the power cord and plug for damage. To minimize the risk of electric shock or fire, never operate the CNC Carver with a damaged power cord or plug. Replace a damaged power cord or plug at the first visible signs of damage.
• Regularly inspect carved workpieces for signs of cutting tool damage or wear and replace damaged or worn cutting tools immediately.
• After a prolonged period without being used (1 month or more) run the spindle at 10% speed for 30 minutes to warm the unit up before cutting/carving.

LUBRICATION

The only part of the CNC carver that requires regular lubrication is the ball screw rod. Apply a liberal amount of a #2 lithium-based grease to the rod at least once every 90 days.

OPTIONAL ACCESSORIES

Recommended optional accessories are available from your local General International dealer. For more information about our complete line of products, please visit our website at www.general.ca

SAFETY ENCLOSURE # EC-617X

ISee-through impact resistant enclosure with safety inter-lock doors (auto- shut off). Designed specifically for Model EC-617 M1 only.

DIAGRAM

PARTS LIST

IMPORTANT: When ordering replacement parts, always give the model number, serial number of the machine and part number. Also a brief description of each item and quantity desired.

DIAGRAM – BASE

PARTS LIST

IMPORTANT: When ordering replacement parts, always give the model number, serial number of the machine and part number. Also a brief description of each item and quantity desired.

DIAGRAM – STAND

IMPORTANT: When ordering replacement parts, always give the model number, serial number of the machine and part number. Also a brief description of each item and quantity desired.

DIAGRAM – OPTIONAL ENCLOSURE

IMPORTANT: When ordering replacement parts, always give the model number, serial number of the machine and part number. Also a brief description of each item and quantity desired.

GENERAL® INTERNATIONAL WARRANTY

All component parts of Excalibur by General International products are carefully inspected during all stages of production and each unit is thoroughly inspected upon completion of assembly.

Standard 1-Year Limited Warranty
Because of our commitment to quality and customer satisfaction, General International agrees to repair or replace any part or component which upon examination, proves to be defective in either workmanship or material to the original purchaser for a period of 1 year (12 months) from the date of purchase, subject to the “conditions and exceptions” as listed below.

To file a Claim
To file a claim under our Standard 1-year Limited Warranty, all defective parts, components or machinery must be returned freight or postage prepaid to General International or to a nearby distributor, repair center or other location designated by General International.

For further details call our technical support department at 1-888-949-1161. Along with the return of the product being claimed for warranty, a copy of the original proof of purchase and a “letter of claim” must be included (a warranty claim form can also be used and can be obtained, upon request, from General International or an authorized distributor) clearly stating the model and serial number of the unit (if applicable) and including an explanation of the complaint or presumed defect in material or workmanship.

CONDITIONS AND EXCEPTIONS:

This coverage is extended to the original purchaser only. Prior warranty registration is not required but documented proof of purchase i.e. a copy of original sales invoice or receipt showing the date and location of the purchase as well as the purchase price paid must be provided at the time of claim.

Warranty does not include failures, breakage or defects deemed after inspection by General International to have been directly or indirectly caused by or resulting from; improper use, or lack of or improper maintenance, misuse or abuse, negligence, accidents, damage in handling or transport, or normal wear and tear of any generally considered consumable parts or components.

Repairs made without the written consent of General® International will void all warranty.

Support

8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3
Tel.: 514-326-1161
Fax: 514-326-5565
Parts & Service: 514-326-5555 – Order Desk
orderdesk@general.ca
www.general.ca
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Documents / Resources

| Excalibur 16” X 24” CNC Carving Machine with FlashCut Controller [pdf] User Manual
16 X 24 CNC Carving Machine with FlashCut Controller, Carving Machine with FlashCut Controller, Machine with FlashCut Controller, FlashCut Controller, FlashCut Controller Carving Machine
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References

• CNC Solutions & Controls | FlashCut CNC

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