Bridge Replacement

Disconnect NOVA from power

Ensure that NOVA is turned off with the power button and then unplug the power cable.

Rotate NOVA

First, rotate NOVA so that you can access the back panel.

Remove NOVAs back panel

With a T20 Torx bit remove the 6 screws (2 on the back side, 4 on the bottom of the panel) securing the back panel.

Once the screws are out you can pull the back panel out by tilting it up slightly and then pulling away from the machine.

Remove NOVAs side cover panels

Using a flat head screwdriver or larger hex key pry the side panel friction clips loose and slide the side cover panel out the back of NOVA.

Use a piece of tape to label which side of NOVA the cover panel came off of for later.

Unplug NOVAs power button

With a pair of flush cutters, clip and remove the zip tie securing NOVAs power cable.

Unplug the power cable by pressing down on the cables release tab and pulling it out of the connector.

Remove NOVAs side fenders

With a T20 Torx bit remove the 11 screws securing each of NOVAs side fenders (5 on the outer side, 4 on the inner side, and 2 on the bottom side).

Remove both fenders by lifting up on the backside and sliding the fender forward and out.

Remove the ribbon cable clamps

Using a T10 Torx bit remove the 3 cable clamps securing NOVAs gantry ribbon cables.

Disconnect the Y-carriage PCB

First, disconnect the four ribbon cables connected to the Y-carriage PCB.

Next, disconnect the motor cable by pressing down on the cables release tab and pulling it out of the connector.

Remove the Y-carriage PCB

Using a T10 Torx bit remove the 4 screws securing the Y-carriage PCB.

With the Y-carriage PCB removed, temporarily pull out the gantry ribbon cables and allow them to hang behind NOVA.

Remove NOVAs cable trays

With a T20 Torx bit remove the 8 screws and washers securing NOVAs left and right cable trays (4 in the back and 4 in the front).

Remove NOVAs bridge

With a T25 Torx bit remove the 4 screws securing NOVAs bridge (2 left, 2 right).

Install the new bridge

Install the new bridge onto NOVA. Using a T25 Torx bit tighten (Torque Setting 13 on Dewalt Driver) the 4 screws securing NOVAs bridge (2 left, 2 right).

Attach the dial indicator

Attach the dial indicator to NOVAs right tool port. Push NOVAs module hub to the right most side of NOVA supporting the top and bottom of the hub.

Level the bridge

Bring the bridge to the front of NOVA and manually lower the tool port by pressing down on the top of the port with your thumbs. Lower the tool port until the dial indicator pushes into NOVAs body.

Turn the dial indicator on. Press and hold the ORIGIN button to zero the dial indicator. Take note of the value on the dial indicator.

Push the module hub across NOVA to the very left side.

Now take note of the new height value.

Dial indicator is positive (Left side is low)

Dial indicator is negative (right side is low)

Place the bridge levelling jig on the LEFT side of NOVAs bridge (Low side).

You will have received one of the bridge levelling jigs below.

Using a T25 Torx bit lslightly loosen the 2 screws securing NOVAs bridge to the mounting bracket.

Rotate the bridge levelling jig clockwise using your finger or a M3 hex key to raise the bridge. Stop when the dial indicator reaches close to 0.000 (±0.010).

Using a T25 Torx bit tighten the 2 screws securing NOVAs bridge to the mounting bracket to lock in the height. Torque Setting = Dewalt Driver 13

Now push NOVAs module hub back to the very right side of NOVA to confirm that the height is within 100µm (0.100mm) of the left side.

The bridge must be level to within 100µm (0.100mm) on either side for factory specification. We always try to get as close to 0.000 within reason!

Move the bridge levelling jig and adjust the height as required.

Press and hold the ORIGIN button to zero the dial indicator to the left side. Take note of the value on the dial indicator.

Push the module hub across NOVA back to the right side. The value displayed on the dial indicator should be positive.

Place the bridge levelling jig on the RIGHT side of NOVAs bridge (Low side).

You will have received one of the bridge levelling jigs below.

Using a T25 Torx bit slightly loosen the 2 screws securing NOVAs bridge to the mounting bracket.

Rotate the bridge levelling jig clockwise using your finger or a M3 hex key to raise the bridge. Stop when the dial indicator reaches close to 0.000 (±0.010).

Using a T25 Torx bit tighten the 2 screws securing NOVAs bridge to the mounting bracket to lock in the height. Torque Setting = Dewalt Driver 13

Now push NOVAs module hub back to the very left side of NOVA to confirm that the height is within 100µm (0.100mm) of the left side.

The bridge must be level to within 100µm (0.100mm) on either side for factory specification. We always try to get as close to 0.000 within reason!

Move the bridge levelling jig and adjust the height as required.

Install NOVAs cable trays

With a T20 Torx bit attach NOVAs cable trays using the 8 screws and serrated washers securing NOVAs left and right cable trays (4 in the back and 4 in the front). Torque Setting = Hand Tight

Install the Y-carriage PCB

Replace the gantry ribbon cables on top of the cable tray.

Using a T10 Torx bit attach the Y-carriage PCB using the 4 screws (M3 x 0.8 x 6mm Button Head). Torque Setting = Dewalt Driver 8

Connect the 4 ribbon cables and the black motor cable to the Y-carriage PCB.

Install the ribbon cable clamps

Using a T10 Torx bit install the 3 cable clamps securing NOVAs gantry ribbon cables. Torque Setting = Hand Tight

Install NOVAs side fenders

With a T20 Torx bit install NOVAs side fenders. There are 11 black screws that secure each of the fenders (5 on the outer side, 4 on the inner side, and 2 on the bottom side). Torque Setting = Dewalt Driver 13

Attach the bottom screws last. Torque Setting = Dewalt Driver 13

Connect NOVAs power button

Plug in NOVAs power cable and secure the power and LED cable with a small zip tie.

Install NOVAs back plate

With a T20 Torx bit install NOVAs back plate. There are 6 screws (2 on the back side, 4 on the bottom of the panel) securing the back plate. Torque Setting = Dewalt Driver 13

Open the console

Inside NOVA's software you can open the console by pressing the ~ key. If you're using a different language keyboard you may need to find the right key to press or use a virtual keyboard. For example in Germany it's Shift + |

Run an M520 Command

In the console type M520 and hit enter to run the command. This will display all the current factory setting values. You may need to scroll to see the results:

Copy the Backlash Values

Copy and past the Backlash Compensation values to a text editor and remove all the colons (:). This will prepare the command needed (M507) to set the updated values: M507 X0.031000 Y0.015000 Z0.000000 C0.000000 H0.000000

Add the Values Provided

With the replacement bridge, Voltera will have provided backlash values affected by the new bridge. Insert these new values into your command ensuring all 6 decimal places are intact.

x: 0.01 c: 0.0028 z: 0.006

M507 X0.010000 Y0.015000 Z0.006000 C0.002800 H0.000000

Run M507 Command

With the M507 command prepared, copy and past it into the console and hit enter. When complete, you should se a line stating "Calibration Stored". You can double check the values were stored by running the M520 command again.

Access Factory Settings

The gantry burn in is hidden in a factory settings menu. To access this you'll need to press Shift + 2 + 4 on your keyboard. If your keyboard is international, the keys you'll need to press are @ + $ where ever they are placed on your keyboard. In factory mode a few more icons are visible in the bottom left menu. Click on the tools icon to open the factory settings:

Run Burn In

Under Burn In, press the GANTRY button. This will have NOVA run through a range of motions for a few hours. You don't need to run it that long so you will manually stop it in the next step.

Stop Burn In

After 30 minutes you can manually stop the Burn In. This is enough time for the new bridge to settle into its new home. To stop the Burn In press the stop button in the top menu. Once stopped, home the machines using the Home button.

Place Vacuum Module

Before starting the port to port test, make sure that the vacuum module is in place on NOVA. No substrate is needed for this test.

Run Port to Port for C Axis

Place the probe on the left port. Then, in the Factory Settings run the Port to Port Comparison for the C Axis. This will have the probe measure a grid of points across the vacuum module of the bed. Once complete the gantry will return to the home position.

Run Port to Port for Z Axis

Next, place the probe on the right port and run the Port to Port Comparison for the Z Axis. This will have the probe measure the same grid of points across the vacuum module of the bed. Again, once complete the gantry will return to the home position and you can remove the probe.

Download the Data

The results of this test are stored locally as a CSV file for each port in a data folder on NOVA. To access them add /data/factory to the machine's browser address. ex. cool-sea.myvoltera.io/data/factory or 10.42.2.1/data/factory

Search in this folder for the CSV files of portToPort-0 and portToPort-1 with the date you ran the test and click on them to download.

Send Voltera the Files

This test is done before the replacement bridge is sent out and running it again on the new machine is an extra check to make sure nothing has happened to the bridge in transit. Because of this, the simplest way to analyze the data currently is to send it to [email protected] and we can double check it.

Place Standoffs

To attach the scale & skew jig, start by screwing in the standoffs into the 4 corners of the mounting grid. Hand tight is all that is needed.

Attach Jig

Next, place the jig on top of the standoffs aligning the holes in the 4 corners. Tighten down the 4 screws to hold down the jig securely using an M3 hex key.

Run Scale & Skew

Open up the Factory Settings and click on the Scale & Skew button to run the test. This will have NOVA find each of the circles in the 4 corners of the jig and do some math to compensate for any skew. Once complete it will return to the home position.

Confirm Calibration

Run the M520 command in the console and confirm that the Scaling and Skew values have been updated:

Once confirmed, remove the Scale & Skew jig from NOVA.

Mount the Camera Calibration Jig

Place the Camera Calibration jig over NOVAs mounting grid aligning to the 4 corners. Fasten it down with the supplied thumbscrews ensuring the jig is flat on NOVA's surface. Tow thumbscrews in opposite corners should be sufficient:

Open the Camera Settings

Open the camera settings from the bottom left menu:

Run the Calibration

Under the camera stream there is an icon that looks like a factory. Click on this to start the camera calibration.

The calibration will take a series of pictures across the surface of the jig. It will then pause for a moment to make some calculations. It will then take one final picture in the center of the jig. Once complete it will home the gantry.

Confirm the Calibration

The results of the calibration are stored locally on NOVA. To access them add /data/calibration to the machine's browser address. ex. cool-sea.myvoltera.io/data/calibration or 10.42.2.1data/calibration

You should see to jpg files labeled device-name-camera-corrected.jpg and device-name-camera-uncorrected.jpg Open the uncorrected image first by clicking on it and take note of the number of lines detected in the top left corner (ex. 31):

Click back in the browser to return to the calibration files page and open the corrected image. The number of lines should be smaller than the uncorrected image (ex. 27):