Hulk CNC
External Documents:
Basic Setup
Jog the machine closer to the back left corner (not too far, we don't want to hit limit switches)
Select the "Home" menu, and click "Seek Home"
If not, then go to: File>Open Setup
Starting Hulk Checklist
The Hulk is turned on
The computer is connected to the Hulk
Home the Hulk
Turn on the vacuums (BEFORE Zero-ing the bit)
Zero the bit
Setting up Jigs & Wasteboards
The CNC has 2 vacuums that suck from 4 ports.
The ports are numbered 1-4 from Front to Back, as shown above.
Regardless of where you are machining, you must leave both ports open when the vacuum is on, so that it does not over-heat and shut-off.
To avoid overheating while maintaining good suction, place a piece of hardboard over the section that will not be machined.
The bed of the CNC is made of black phenolic. We do NOT want to cut this, so we put a jig and/or a waste-board of MDF overtop.
To properly set up the jig/wasteboard, we block off the suction of the vacuum using foam gasketing.
You'll only ever need to change the front section of gasket.
You want to place the gasket around the perimeter of each jig/wasteboard. This allows for maximum suction and consistent machining.
Example: The red lines above show where the gasket is placed underneath the wine tray handle jig.
You'll also see that there is hardboard placed in section 2 above the jig to keep the suction.
Using the "Jump to Line"
Sometimes you will need to start from a specific line in the file
You'll need to do this if the bit breaks, if you have to re-cut a certain area, etc.
Use the map and/or line of G-Code (if you know it), and click the spot/line that you want to start from.
If starting from a spot where the bit broke, it's best to choose a line a little earlier than where it broke.
Hit "Aux" --> "On" BEFORE starting from the new line.
Click start.
Click "Move and start"
Common Errors:
Front-Panel E-Stop Tripped:
*UPDATE 11/3/22: We have turned off the setting in the program for the front-panel E-Stop, so this should no longer be an issue, as long as machine setup "No Front Estop" is open.
The manufacturer of machine said they don't know why this happens and only solution is to follow the below instructions as many times as necessary. It happens less when the machine is left on constantly, which is why you should never turn the Hulk off.
Sometimes Hulk will stop mid-file and display "Error Code 2000"
Hit the E-Stop switch and re-home the machine
Repeat as necessary
Re-Zero the bit to the appropriate height
See "Run From Line" instructions above if this happened in middle of file.
Drive Fault Error:
Occurs when the machine runs into something and cannot complete the move it was expecting to make
To clear the error, reset the machine (turn all the way off & back on), reconnect the software, and you should be able to clear it.
Home the machine
If error occurs during the homing process, adjust the homing switch to make sure the machine isn't running into the limit pegs (shown below)
After adjustment is made, adjust the G54 Coordinates on Velocity.
Configuration --> Machine --> Fixture Offset
Adjust appropriate G-Code Offset so that 0,0 is where you think it should be (front left corner of black phenolic)
FAQ
The piece being machined got stuck on the bit and is being dragged around. What do I do?
Hit either of the big red E-Stop buttons IMMEDIATELY. There is one on the front of the machine (next to the power button) and one on the computer stand. Remove the stuck piece and re-home the machine. You will also have to re-zero the Z-Axis. Make sure the jig is set and everything looks good before starting the file again.
I changed bits, do I need to re-zero the Z-Axis?
Yes! Any time you change bits, make sure you re-zero the Z-axis since the bits are different heights.
Do I need to turn on the vacuum pumps?
Yes. Any time you run a file, make sure the vacuum pumps are on. This holds down the waste-board and makes sure the surface is as flat as can be.
The CNC randomly stopped with the error code “[INSERT ERROR CODE]”
First, take a note of what line of G-Code the file was on.
Hit “Okay.” And then press the E-Stop button. From here, “Seek Home” on the machine, and it will relocate itself.
You will have to “Jump to Line” to a few lines BEFORE where the machine was.
Should the CNC Bed be flat against the CNC phenolic (the black base)?
Yes (when the vacuum is on)! Sometimes the corner will be flared up a small amount, but it should be flat for the most part.
Why did the bit break?
The reasons a bit breaks could be any of the following:
Screw/other metal in workpiece that it hit
Not tight enough in the collet
Dense spot/knot in the workpiece
The workpiece is not held in place well enough, causing it to vibrate and move around while machining
The speed of the router is too fast/slow
The feed rate of the machine is too fast/slow
This is the limit peg. Do not run into this.
Hulk Maintenance
Hulk should be cleaned and greased at least once a week.
Move the Hulk to the front and center of the CNC table. Locate the grease fittings on the sides of the rails. ** There are also grease points on the lateral rails. **
Clean off the grease fittings with a paper towel (Your hands will get dirty)
Obtain the grease gun box from the tool cabinet, bring it over to the Hulk
Attach the grease gun to each fitting and give it two full squeeze's of grease. It is ok for grease to ooze out of the rails/fittings. Make sure to get all 12 fittings. [Clean off any excess dirt/grime after you grease the fittings.]
To attach the grease gun to the fittings, squeeze the nozzle to expand the end, and insert the fitting before releasing and closing the nozzle.
Drive the Hulk around to work the new grease into the rails. Drive it back and forth on each axis.
Home the Hulk before use again