CNC-Step High-Z S-1000T, Operating Instructions Manual

Page 1: ...Operating instructions CNC portal system S 400 T S 720 T S 1000 T www cnc router com Erstellt am 15 02 2014 Ge ndert am 27 09 2014...

Page 2: ...ludes the complete mechanics for three dimensional movement The linear carriage movement takes place via threaded spindles powered by step motors Two drives are used on the x axis The activation of th...

Page 3: ...4 2 Instruction 17 2 5 Personal protective equipment 17 2 6 Safety installations 18 2 6 1 Description of the installed safety installations 18 2 6 2 Safety installations which have to be updated by th...

Page 4: ...nstructions for the installation and commissioning 43 6 2 Preparations 44 6 2 1 Install machine 44 6 2 2 Install worktop 45 6 3 Installation 45 6 3 1 Connecting the computer 45 6 3 2 Connecting the st...

Page 5: ...resolution 69 9 3 1 Cancel the emergency stop 69 9 3 2 Check axes for perpendicularity 70 9 3 3 Description of process for aligning the machine with respect to perpendicularity 70 9 4 Commissioning a...

Page 6: ...n components are found in the appendix of this description 1 1 Symbol description Safety instructions are designated by symbols In addition there is always a signal word heading the information indica...

Page 7: ...er options or because of the most recent technical changes The responsibilities agreed in the delivery contract the General Terms and Conditions as well as the delivery conditions of the manufacturer...

Page 8: ...to misuse Improper use of the CNC portal machine can cause dangerous situations Operation outside the values specified in the section Technical data Bypassing the safety devices Remodelling refitting...

Page 9: ...voltage free state throughout the duration of the work this must take place according to the 5 following safety regulations Activation Secure it from being switched on again Determine voltage free st...

Page 10: ...ion WARNING Risk of injury by axis motion Collision by people with components of the machine Y bridge Units turntable with work piece tools can cause severe injuries Body parts are kept away from movi...

Page 11: ...Protect working area against unintentional access Tools ATTENTION Risk of injuries by negligent handling of tools By handling tools negligent lacerations and crushing injuries can be caused Tools mus...

Page 12: ...o the ambient temperature 2 2 4 Risk of fire Highly flammable materials ATTENTION Risk of fire by highly flammable materials Organic dust produced by coal or wood or inorganic dust from magnesium alum...

Page 13: ...Jewellery watches pens etc before starting maintenance operation No electronica equipment is to be taken into the magnetic source area These could get damaged No storage media credit cards etc are to...

Page 14: ...and fat immediately from skin Do not inhale vapours 2 2 7 General work related dangers Noise ATTENTION Risk of injury by noise The noise levels occurring in the operating area may cause severe hearing...

Page 15: ...conditions at the place of operating the machine He must implement this in the form of operating instructions for the operation of the machine During the complete usage time of the machine the owner...

Page 16: ...The operator was instructed by the operating company in a briefing about the tasks assigned to them and instructed about possible hazards because of improper conduct Tasks die which are carried out be...

Page 17: ...have to wear personal protective equipment while working on the machine which are mentioned in different sections of this instruction Description of personal protective equipment Protective clothing P...

Page 18: ...utton Abb 1 Emergency stop button By pressing the emergency stop button Abb 1 the machine is shut down by immediately switching off the energy supply to the machine drives After pressing the emergency...

Page 19: ...on on Y bridge Abb 3 Emergency stop button on step motor controller 2 6 2 Safety installations which have to be updated by the owning operator Extraction When processing light metal alloy such as magn...

Page 20: ...y Call the fire brigade and or rescue service Fire Fight fire with fire extinguishers if there is no risk for own health Continue fire fighting until fire brigade arrives Inform responsible persons at...

Page 21: ...h as glycol They must not reach the environment The disposal must be taken place by a specialised waste management company 2 9 Signage Following symbols and signs are found in the working area They ap...

Page 22: ...implants Persons with metallic implants must not be allowed in the area of the machine Implants can heat themselves up or be drawn in by the electro magnetically field Operation with necklace is proh...

Page 23: ...all moving parts risk of hands hair and clothing being drawn in Hot surface Hot surfaces such as hot machine parts container and materials may not always be noticeable Do not touch without protective...

Page 24: ...sionals are additionally available In case of an emergency even for minor injuries use the material in the first aid kit for first aid treatment of the injured person When using or taking out first ai...

Page 25: ...1336 mm Width W 570 mm 690 mm 870 mm Height H 570 mm 570 mm 570 mm Weight without work surface and tool ca 32 5 kg ca 39 5 kg ca 45 kg Clamping surface LxW 730 x 390 mm 1050 x 510 mm 1330 x 690 mm Pas...

Page 26: ...00 2000 Thread pitch XY 10 mm 10 mm 10 mm Thread pitch Z 6 mm 6 mm 6 mm Round bar guide XY 22 mm 22 mm 22 mm Circular waveguide Z 16 mm 16 mm 16 mm Programmable resolution XY 0 005 mm 0 005 mm 0 005 m...

Page 27: ...tions Environment Specifications value unit temperature range 15 30 C Relative humidity maximum 60 Duration Specification value unit Maximum operating time per session 100 h Pause until the next sessi...

Page 28: ...ern Tel 49 0 2831 91021 20 Page 28 15 02 2014 3 6 Type plate The type plate is located on the frame of the portal system Abb 5 Arrow and includes the following information Abb 5 Location of type plate...

Page 29: ...s 3 Z axis with carriage 4 Y axis with carriage Y bridge 5 X axis with carriage 6 Stepper motors of the X axis 7 Terminal boxes of the step motors of the X axis 8 Frame 9 Stepping motor control cable...

Page 30: ...on with struck up control software e g WinPc NC Mach3 USBCNC and a stepper motor control e g Zero3 Tool with 43mm intake for direct clamping into the holder provided Accessories see Appendix The machi...

Page 31: ...along the Z linear guides Abb 8b Z Carriage 1 Reference switch Z axis 2 Magnetic contact The reference switch Fig 8b 1 responds to the magnetic field of the incoming homing magnet Fig 8b 2 If the magn...

Page 32: ...ich can be moved with a suitable tool 43H7 holder Abb 9b Y Carriage 1 Reference switch Z axis 2 Magnetic contact The reference switch Fig 9b 1 responds to the magnetic field of the incoming homing mag...

Page 33: ...ich the Y bridge is moved Fig 10a 1 along the X linear guides Abb 10b X Carriage 1 Reference switch Y axis 2 Magnetic contact The reference switch Fig 10b 1 responds to the magnetic field of the incom...

Page 34: ...10c 2 loosen the fixing screw Fig 10c 3 move the magnet holder along the groove to the desired position and secure with the fixing screw to prevent loosening HINT If the position of the magnet holder...

Page 35: ...axis Fig 12 2 Plug Z stepper motor Z axis Fig 12 3 Connector ST Emergency Ref switch and socket Pin15 Figure 13 Connection ST and Motor connection The connection of the stepper motors or the reference...

Page 36: ...nding A 3 8 Motor winding B 4 9 Motor winding B 5 Ground shield 4 5 3 MiniXLR pin socket Pin15 Abb 16 miniXLR socket The pin 15 is connected via socket which is available on the machine Fig 16 This al...

Page 37: ...37 15 02 2014 4 6 Work and danger areas 4 6 1 Working area Abb 18 Working area PC Accessories area of the tool holder Fig 18 1 when turned off Range of motion of the axes Fig 18 2 when turned off in o...

Page 38: ...o the swivel area of a suspended load Loads are only to be moved only under supervision Use only approved lifting gear and lifting gear with sufficient load bearing capacity Do not use damaged or fray...

Page 39: ...damage Proceed in case of visible damage as follows Do not accept the delivery or only under reserve Record the scope of the damage on the transport documents of the carrier or on the delivery note Lo...

Page 40: ...disposal of packaging materials may lead to risks to the environment Dispose packaging material environmentally friendly Adhere to the valid local regulations for disposal 5 4 Symbols on packaging The...

Page 41: ...helmet Abb 20 lifting gear 1 Sling on ropes belts accordingly Fig 20 to the pallet and secure pallet against slipping 2 Check whether the transport pieces are not damaged by the slinging materials If...

Page 42: ...transport piece and start the transport 5 6 Storage Storage of packages Packages should be stored under the following conditions Do not store outdoors Dry and dust free Not exposed to corrosive media...

Page 43: ...edges and corners do not twist or knot When leaving the workplace settle the load Improper installation and commissioning WARNING Risk of injury by improper installation and commissioning Improper in...

Page 44: ...chine Personnel Specialist personnel Safety equipment Protective clothing Safety shoes Industrial protective helmet ATTENTION Risk of injury by under sized buildings Overload of ceiling structures can...

Page 45: ...720T 930 x 510mm S 1000T 1210 x 690mm Modell HIGH Z Dimensions of the worktop on frame S 400T 730 x 390mm S 720T 1050 x 510mm S 1000T 1330 x 690mm Fixing the worktop is done by yourself As a recommend...

Page 46: ...f the stepping motor and control lines Fig 23 arrow are labelled Personnel specialist personnel Figure 24 Stepper motors of axes 1 Connect the plug of the stepper motor and control cable with the foll...

Page 47: ...accessories professionally according to the safety regulations Install milling motor Personnel Specialist personnel Figure 25 Tool holder with milling 1 Tool for example milling motor with 43mm neck E...

Page 48: ...hat the computer is connected to the stepper motor control of the machine 4 Ensure that required accessory is installed and connected to the power supply 5 Ensure that the appropriate software is inst...

Page 49: ...vers and safety devices are installed and working properly Ensure that there are no persons in the danger zone Never bridge or disable safety devices during operation 7 2 Operations before usage 1 Mak...

Page 50: ...older if necessary change the tool and see the separate operating instructions for the accessories 4 Ensure that no tools or other foreign objects are in the machine or system 5 Make sure that no pers...

Page 51: ...evices are installed and working properly Do not reach into moving tool during operation Before replacing the tools always pull power plug of the milling motor or turn off the machine and secure again...

Page 52: ...nic devices in the vicinity of the magnetic source These could be damaged No storage media credit cards etc placed in the vicinity of the magnetic source Data can be deleted Falling materials WARNING...

Page 53: ...r sources of ignition Keep fire extinguisher ready Processing of light metal alloys such as magnesium aluminium zinc and titanium without suction and appropriate security measures is not allowed Stop...

Page 54: ...from hot surfaces Risk of being cut by tools and chips Contact with hot components can cause burns Tools and chippings can cause injury when touched When changing tools wear protective gloves 2 Change...

Page 55: ...see page 58 8 4 7 7 Emergency Shutdown In hazardous situations movements of components must be stopped as soon as possible and the power supply must be switched off Stopping in an emergency 1 Immediat...

Page 56: ...re starting work and secure against reconnection Improperly performed maintenance WARNING Risk of injury by improperly performed maintenance Improper maintenance can lead to severe injuries and substa...

Page 57: ...use of incorrect or faulty spare parts can lead to hazards to personnel and malfunction or failure of the machine Only use original spare parts from the manufacturer or manufacturer approved replaceme...

Page 58: ...tact details on page 7 Refer to the separate operating instructions for the maintenance of the supplied components Modell HIGH Z Series S 400 S 720 S 1000 Interval Maintenance To be carried out by Dai...

Page 59: ...hing Safety shoes protective gloves 1 Turn power switch on the stepper motor control to 0 or Off see separate operating instructions for the step motor control 2 Free machine from chips ATTENTION Risk...

Page 60: ...gloves Abb 26 Lid Y axis 1 2 Switch off the machine and secure against re start Grease Trapezoidal spindle Z axis Fig 27 1 with a low friction grease applied on a cleaning cloth DIN 61650 or alternat...

Page 61: ...ecure against re start Grease the linear guides of the X axis Fig 28 1 the Z axis Fig 28 2 well using a low friction grease wetted cloth DIN 61650 or alternatively apply the fat with a suitable brush...

Page 62: ...equipment protective clothing Safety shoes Chemical resistant gloves Special tool Grease gun Grease nipple X axis 2 pcs Figure 31 grease nipple X axis 1 Switch off the machine and secure against re s...

Page 63: ...12 Remove Grease Gun Kugelumlaufmutter schmieren The machines of the T series are equipped with ball screws on the X and Y axis These need care in form of regular greasing of the ball nuts If the fat...

Page 64: ...ks from the entry and exit point of the ball screw 6 Put grease gun on grease hole of the ball nut on the other side of the X axis 7 Press grease gun once or twice until the grease leaks from the entr...

Page 65: ...ing steps 1 Check all previously loosened screw connections for tightness 2 Verify that all previously removed protective devices and covers are reinstalled correctly 3 Ensure that all tools materials...

Page 66: ...utions for Troubleshooting Electrical System DANGER Danger to life due to electric current Contact with live components can be fatal Activated electrical components can run uncontrolled movements and...

Page 67: ...ightening torques Note the following before restarting Ensure that all work and troubleshooting according to the information and instructions in this manual have been carried out and completed Ensure...

Page 68: ...s power failure physical influence see page 67 9 3 3 Operator Travel speed too high Correct the setting in software Operator Angular deviation in the milling result Y the bridge is not at right angles...

Page 69: ...eplacement or repair Personnel Manufacturer Increased backlash Worn Nylatronnut achieved by lack of maintenance or reached service life Replacement or repair manufacturer Trapezoidal spindle worn by l...

Page 70: ...ete structure of the portal system including controller PC and software Using the control software of the machine X axis drive against the movable bearing brackets of the X axis see page 29 by manual...

Page 71: ...014 9 4 Commissioning after fault has been rectified Perform the following steps to restart after correcting the fault 1 Reset the emergency stop devices 2 Acknowledge the fault of the control 3 Make...

Page 72: ...Before starting any work ensure sufficient space Take care with sharp edged components Maintain order and cleanliness in the workplace Loosely stacked or scattered components and tools are accident s...

Page 73: ...ems for recycling Other components dispose sorted by material nature HINT Threat to the environment due to improper disposal Incorrect disposal may cause environmental hazards may electrical scrap ele...

Page 74: ...tter for many different applications and materials engraving drill Axes of rotation and jaw chuck depth sensor tool length sensor suction minimum quantity lubrication etc Tools for various application...