CNC-Step T-Rex 0609 Operating Instructions Manual Download Page 7 | Manualshive

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Operating instructions

T-Rex N-Serie (Stepper)

CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany

Page 7

Support: +49 (0)2831/91021-50

07.03.2022

1

General

This manual allows the safe and efficient handling of the machine. The instructions are
part of the machine and must be always kept in the immediate vicinity of the machine
accessible to the personnel.

Staff must have carefully read and understood these instructions before commencing all
work. The basic prerequisite for safe working is compliance with all specified safety
instructions and instructions in this manual.

In addition, the local accident prevention regulations and general safety regulations apply
to the area of application of the machine.

Illustrations in this manual are for basic understanding and may differ from the actual execution.

In addition to these instructions, the instructions for the built-in components in the appendix apply.

1 . 1

D e s c r i p t i o n o f S y m b o l s

Safety instructions are marked by symbols in this manual. The safety instructions are

introduced by signal words that express the extent of the hazard.

HINT:

This combination of symbol and signal word indicates a potentially dangerous situation

that can lead to property and environmental damage if not avoided.

WARNING:

This combination of symbol and signal word indicates a potentially dangerous situation

that can lead to death or serious injury if not avoided.

CAUTION:

This combination of symbol and signal word indicates a potentially dangerous situation

that can lead to minor or minor injuries if not avoided.

DANGER:

This combination of symbol and signal word indicates an immediately dangerous

situation that leads to death or serious injury if not avoided.

Prohibition for people with pacemakers

This mark precedes activities in areas that are prohibited for people with pacemakers.

Warning of dangerous electrical voltage

This mark precedes activities on live system components.

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Summary of Contents for T-Rex 0609

Page 1: ...22 Operating instructions T Rex N Serie Stepper Rev 1 3 April 2021 T Rex 0609 T Rex 0615 T Rex 1212 T Rex 1218 T Rex 1325 T Rex 1530 T Rex 2030 T Rex 2040 Technical and optical changes reserved https www cnc step com ...

Page 2: ...he slides takes place via gear drives in X and Y and ball screws in the Z axis driven by stepper motors The stepper motors for the process of the individual axes are controlled via further interfaces This operating manual describes the installation commissioning and maintenance of the CNC gantry system This guide refers to the T Rex N series in the standard configuration with a 3 5KW HF spindle fr...

Page 3: ...om radiation 14 2 2 6 Hazards from chemical substances 15 2 2 7 General hazards in the workplace 16 2 3 Responsibility of the operator 17 2 4 Staff requirements 18 2 4 1 Qualifications 18 2 4 2 Instruction 19 2 5 Personal protective equipment 19 2 6 Safety 20 2 6 1 Description of the safety devices installed 21 2 6 2 Safety devices that the operator must retrofit 23 2 7 Behavior in the event of a ...

Page 4: ...8 4 3 3 Z axis 39 4 3 4 Z axis 300mm Optional 40 4 3 5 Z axis 400mm Optional 40 4 3 6 Tool Holder 40 4 3 7 Central Lubrication 41 4 4 Operator terminal 43 4 4 1 Machine Control 44 4 4 2 Connections on the controller 45 4 5 Connections on the machine 46 4 5 1 Tool length Probe 46 4 5 2 Compressed Air Supply Accessories Optional 46 4 6 HF Spindle 47 4 7 Vacuum clamping system 48 4 7 1 Vacuum table 4...

Page 5: ...he controller 61 6 4 First Installation 61 7 BEDIENUNG FEHLER TEXTMARKE NICHT DEFINIERT 7 1 Safety instructions for operation 62 7 2 Activities before use 62 7 3 Turn on 63 7 4 Activities during operation 64 7 4 1 Operate the machine 64 7 4 2 Change tool 67 7 5 Switch off 67 7 6 Activities after use 68 7 7 Shutdown Emergency 68 8 MAINTENANCE 69 8 1 Safety instructions for maintenance 69 8 2 Spares...

Page 6: ...ning after fault has been resolved 80 10 TRANSPORT PACKAGING AND STORAGE 81 10 1 Safety instructions for transport 81 10 2 Transportinspektionen 82 10 3 Packaging 82 10 4 Symbols on the packaging 83 10 5 Transport 84 10 6 Storage 85 11 DISMANTLING AND DISPOSAL 86 11 1 Safety instructions for dismantling and disposal 86 11 2 Dismantling 86 11 3 Disposal 87 12 ACCESSORIES 88 13 CUSTOMER SERVICE 89 ...

Page 7: ...ons for the built in components in the appendix apply 1 1 Description of Symbols Safety instructions are marked by symbols in this manual The safety instructions are introduced by signal words that express the extent of the hazard HINT This combination of symbol and signal word indicates a potentially dangerous situation that can lead to property and environmental damage if not avoided WARNING Thi...

Page 8: ... of non trained personnel arbitrary conversions of any kind technical changes of any kind Use of non approved spare parts or third party accessories The actual scope of delivery may deviate from the explanations and illustrations described here in the case of special designs the use of additional order options or due to the latest technical changes The obligations agreed in the delivery contract t...

Page 9: ...se instructions Any use that goes beyond the intended use or is otherwise deemed to be misuse WARNING Danger in case of misuse Misuse of the CNC portal milling machine can lead to dangerous situations Operation outside the values specified in the Technical Data Bypassing and overriding safety devices Conversion conversion or modification of the construction or individual pieces of equipment with t...

Page 10: ...t with live parts there is an immediate danger to life due to electric shock Damage to insulation or individual components can be life threatening Work on the electrical system can only be carried out by qualified electricians In the event of damage to the insulation switch off the power supply immediately and arrange for repair Before starting work on active parts of electrical systems and equipm...

Page 11: ... example a milling spindle can lead to serious personal injury or property damage Before starting work ensure that all covers and safety devices are installed and functioning properly Do not reach into moving tools during operation Before replacing the tools always unplug the milling motor or switch off the machine and secure it against reactivation Axis movement WARNING Risk of injury due to axis...

Page 12: ...ue to unexpected start up of the machine The machine and the tools used with it can start unexpectedly change direction or stop This allows limbs to be detected Make sure that no body parts get into the danger area of the machine Secure workspace from accidental access Tools CAUTION Risk of injury due to negligent handling of tools Negligent handling of the tools can cause bruises or cuts Handle t...

Page 13: ...es Before all work ensure that all surfaces have cooled to ambient temperature 2 2 4 Fire hazards Highly flammable substances WARNING Fire hazard due to highly flammable substances Organic dusts of coal or wood or inorganic dusts of magnesium aluminum zinc or titanium can catch fire and cause serious to fatal injuries Do not smoke within the danger zone and in the immediate vicinity Do not deal wi...

Page 14: ...s up to death as well as significant property damage People with pacemakers should not be near the machine The function of the pacemaker could be impaired Persons with metal implants must not be near the machine Implants can heat up or be tightened Before maintenance work place metal objects jewelry watches writing instruments etc Do not bring electronic devices near the magnetic source These coul...

Page 15: ...tective clothing and chemical resistant protective gloves Avoid direct skin contact Remove skin impurities immediately especially before breaks and after the end of work Eat and drink exclusively in the designated break room CAUTION Risk of damage to health due to contact with cooling emulsion Contact with cooling emulsion can lead to damage to health Avoid skin contact Remove cooling emulsion fro...

Page 16: ...aring damage Always wear hearing protection when working Only stop in the danger zone if necessary Dirt and objects lying around CAUTION Risk of injury due to falling over dirt and objects lying around Dirt and objects lying around form sources of slipping and tripping In the event of a fall injuries can be caused Always keep work area clean Remove objects that are no longer needed from the work a...

Page 17: ...d arising from the special working conditions at the place of use of the machine He must implement these in the form of operating instructions for the operation of the machine During the entire period of operation of the machinery the operator must check whether the operating instructions he has drawn up correspond to the current state of the regulations and if necessary adapt them The operator mu...

Page 18: ...ucted by the operator about the tasks assigned to him and possible dangers in the event of improper behavior Tasks that go beyond operation in normal operation may only be carried out by the operator if this is specified in these instructions and the operator has expressly entrusted him with this Electrician Due to his professional training knowledge and experience as well as knowledge of the rele...

Page 19: ...t is used to protect people from adverse effects on safety and health at work Personnel must wear personal protective equipment during the various tasks on and with the machinery which will be referred to separately in the various sections of this manual Description of personal protective equipment The personal protective equipment is explained below Protective Clothing Protective clothing is tigh...

Page 20: ...essible Protective Helmet Industrial safety helmets protect the head against falling objects oscillating loads and bumps on fixed objects Goggles The goggles are used to protect the eyes from flying parts and liquid splashes Gloves Protective gloves are used to protect the hands from friction abrasions punctures or deeper injuries as well as from contact with hot surfaces Protective Hood The prote...

Page 21: ... the energy supply or by mechanical separation from the drives After an emergency stop button has been pressed it must be unlocked by turning it so that it can be switched back on WARNING Danger to life due to uncontrolled reactivation Uncontrolled reactivation of the machine can lead to serious injuries and even death Before switching back on make sure that the cause of the emergency stop has bee...

Page 22: ...1 50 07 03 2022 Location of the emergency stop buttons The EMERGENCY stop switch Fig 2 2 is located at the terminal directly next to the touch panel The main switch Fig 2 1 also serves as an EMERGENCY STOP switch This is only rotated and switches off the machine completely Fig 2 Operator terminal 1 Main switch 2 Emergency stop button 1 2 ...

Page 23: ...eased need for medication in asthmatics Increased hospital admissions Increase in mortality due to respiratory diseases and cardiovascular problems 2 7 Behavior in the event of a fire outbreak and accident Preventive measures Always be prepared for fire and accidents Keep first aid kits first aid kits blankets etc and fire extinguishing equipment functional and at hand Familiarize personnel with a...

Page 24: ... the environment take appropriate measures immediately In case of doubt inform the competent local authority about the damage and inquire about appropriate measures to be taken Lubricants Lubricants such as greases and oils contain toxic substances They must not be allowed to enter the environment Disposal must be carried out by a specialist waste management company Gear oil Gear oil contains toxi...

Page 25: ... and necessary operating instructions cannot be followed As a result there is a risk of injury Keep all safety warning and operating instructions in an easy to read condition all the time Replace damaged signs or stickers immediately 2 9 1 Mandatory Signs Follow the instructions Use the marked machine only after reading the instructions 2 9 2 Prohibition Signs Bans for people with pacemakers In th...

Page 26: ...eration with tie prohibited There is a risk from retraction or entanglement on moving parts Remove the tie before entering the marked area Operation with long hair prohibited There is a risk from retraction or entanglement on moving parts People with long hair must use a hairnet or hood 2 9 3 Warnings Voltage Only electricians are allowed to work in the work area marked this way Unauthorized perso...

Page 27: ...tinguish the fire trigger an alarm via the fire alarm telephone As an exception a fire alarm telephone can also be a simple telephone that directly establishes a telephone connection to the fire brigade the company guard or to a person who is constantly present In such cases the following information is required Who is reporting What happened How many are affected injured Where did something happe...

Page 28: ...nor injuries use the material in the first aid kit for the first aid of the injured person When using or removing first aid materials entries must be made in the bandage book Emergency exit In an emergency leave the danger zone through this door Emergency Phone In case of emergency use the phone to alert Transmit the following information to the emergency call center Who is reporting What happened...

Page 29: ...ight H Standard Z axis 300mm Opt Z axis 400mm Opt 1950 mm 2400 mm 2850 mm 1950 mm 2400 mm 2850 mm 1950 mm 2400 mm 2850 mm 1950 mm 2400 mm 2850 mm Weight approx 350 kg approx 500 kg approx 700 kg approx 1000 kg Clamping Area L x W 930x630mm 1530x630mm 1230x1320mm 1830x1320mm Clearance Standard Z axis 300mm Opt Z axis 400mm Opt 220 mm 320 mm 420mm 220 mm 320 mm 420 mm 220 mm 320 mm 420 mm 220 mm 320...

Page 30: ...prox 1200 kg approx 1400 kg approx 1500 kg approx 1700 kg Clamping area L x W 2530x1320m m 3030x1520m m 3030x2020mm 4030x2020mm Clearance Standard Z axis 300mm Opt Z axis 400mm Opt 220 mm 320 mm 420 mm 220 mm 320 mm 420 mm 220 mm 320 mm 420 mm 220 mm 320 mm 420 mm Passage height measured Lower edge bridge to the vacuum table without accessories 220mm Load capacity Z axis attachment weight 20 KG 20...

Page 31: ... min 17m min 17m min 17m min Working Speed XY 12m min 12m min 12m min 12m min Positioning Speed Rapid Z 4 8m min 4 8m min 4 8m min 4 8m min Module size rack X Y axis Steps per mm Programmable resolution X Y 1 25 ca 104 40 approx 0 01 mm 1 25 ca 104 40 approx 0 01 mm 1 25 ca 104 40 approx 0 01 mm 1 25 ca 104 40 approx 0 01 mm Ball Screw Z axis Pitch Steps per mm Programmable resolution Z Ø25mm 10mm...

Page 32: ...12m min Positioning speed Rapid Z 4 8m min 4 8m min 4 8m min 4 8m min Module size rack X Y axis Steps per mm Programmable resolution 1 25 ca 104 40 approx 0 010 mm 1 25 ca 104 40 approx 0 010 mm 1 25 ca 104 40 approx 0 010 mm 1 25 ca 104 40 approx 0 010 mm Ball Screw Z axis Slope Steps per mm Programmable resolution Z axis Ø25mm 10mm 200 0 005mm Ø25mm 10mm 200 0 005mm Ø25mm 10mm 200 0 005mm Ø25mm ...

Page 33: ...ctrical total Supply line 380V 20A 32A CEE Plug Specification Value Unit Voltage 380 Volt Frequency 50 Hz power consumption maximum 5 50 KW 3 3 Performance Feed Drive X Y Z Specification Leadshine Microstep Driver Unit Stepmotordrive Motor X axis 4 28 A Stepmotordrive Motor Y axis 4 28 A Stepmotordrive Motor Z axis 4 28 A Stepmotordrive Motor 4th axis Max 4 28 A 3 4 Service conditions Environment ...

Page 34: ... in one piece 100 h Pause until the next operation 2 h 3 5 Supplies Specification Rackoil GLP 68 Optimal Products Central Lubrication 3 6 Emissions Specification Value Unit Noise emission machine only ca 50 dB A 3 7 Nameplate The nameplate Fig 4 is located at the back of the terminal and contains the following information Fig 4 Type plate Manufacturer Machine Type Year of construction Serial numbe...

Page 35: ...5 Machine 1 Stepper motor of the X axis under the cover 2 Stepper motor of the Y axis under the cover 3 Stepper motor of the Z axis under the cover 4 X axis with slide 5 Y axis with carriage bridge 6 Z axis with slide 7 RF Spindle 8 Energy Cable Chain 9 Bellows 10 Operator minimum control 11 Main switch 12 Emergency Stop Button 13 Vacuum table 14 Vacuum sections 1 4 3 5 2 9 7 10 8 11 12 14 6 13 3 ...

Page 36: ...KinetiC NC In a CAD or CAD CAM program for example ConstruCam 3D EstlCam Fusion360 Corel Draw AutoCad etc the drawings are created and then saved in a compatible file format The interface between the CAD CAM program and the KinetiC NC software is the postprocessor This outputs the finished G code for the KinetiC NC Many CAD CAM programs on the market already include the postprocessor for KinetiC N...

Page 37: ...complete Y bridge is moved back and forth via the linear guides of the X axis 1 Stepper motor X axis 4 Homing switch inductive 2 Transmission via timing belt 5 Activator for Homing switch 3 Distributor central lubrication 6 Mechanical end stop 1 Linear guides 3 Mechanical end stop 2 Rack The conversion of the rotary movement of the motor into the linear movement of the X axis takes place via the g...

Page 38: ...e 4 3 2 Y axis 1 Reference switch inductive 4 Rack 2 Activator for Homing switch 5 Linear Guide 3 Mechanical end stop 1 The stepper motor of the Y axis can be found behind the sheet metal of the Z axis 2 Cable Chain 3 Central lubrication oil tank with pump The conversion of the rotational movement of the motor into the linear movement of the Y axis takes place via the gear wheel on the rack 3 1 4 ...

Page 39: ... Activator Homing switch 3 Cable Chain 9 Linear guide 4 Distributor central lubrication 10 Ball screw 5 Air connection for optional accessories 11 Stepper motor with timing belt 6 HF Spindle The two profile rail guides Fig 8 2 7 guide the Z axis With help of the Ballscrew Fig 8 2 8 the Z axis is moved up and down on the profile rails The transfer from the stepper motor to the ball screw is carried...

Page 40: ... axis 400mm option the travel of the Z axis increases from 200 to 400mm At the same time the passage height between the bridge and the vacuum plate is correspondingly greater The structure of the Z axis differs from the two smaller variants The hood is firmly connected to the Z axis and moves up and down together with the HF spindle 1 Cylinder for Z axis support The cylinder is for supporting the ...

Page 41: ...e pump with the oil reservoir is located at the back of the machine at the Y bridge The display on the storage container is deactivated The system is controlled via the Sofware Kinetic NC The software also monitors the oil level and issues an error message if it falls below it The pump transports the oil via hoses to the lubrication points There are also oil distributors on all axis 1 Oil distribu...

Page 42: ...ftware under the following tabs Configuration Machine Maintenance Runtime Standard 240min The machine runtime is recorded in the background All movements 1sec are considered both during manual driving and in program mode Total elapsed time The recorded total time is independent of the machine or software runtime Distance travelled Here is measured how many meters all axes have moved together Impul...

Page 43: ... has a control element via which all functions are called and the Movement of the machine is controlled In addition to the actual machine control the terminal contains an industrial PC with touch screen and the KinetiC NC control software 1 Main switch 2 Emergency stop button 3 Control On Reset 4 Vacuum pump s on off 5 Industrial PC 6 USB Connections Fig 10 Operator terminal 5 3 4 2 1 6 ...

Page 44: ...C axes The controller is thus already prepared for the operation of a 4th axis such as a rotary axis or an oscillating knife cutting module 1 Main Control Board 2 Stepper motor power amplifier 4 Axis 3 Stepper motor power amplifiers X1 X2 Y Z channel Here is the main power supply and the converter for the operation of the HF spindle 1 Inverter for HF spindle 2 Power supply 24V motherboard etc 3 Tr...

Page 45: ...ts and outputs 24V DC can be connected directly to the motherboard inside the controller 1 Connection 4 Axis 2 Connection safety fence 3 Connection possibility network LAN 4 Connection vacuum pump s on off 5 Power Connection 380V 32A Attention The LAN connection for integrating the machine into the company network or the Internet can only be used if a network switch has been ordered for the machin...

Page 46: ...essed air supply are also located at this point Either as a simple connection nipple or with one or two compressed air control valves with pressure monitor etc Pressure monitor For critical applications we use pressure monitors to monitor the applied compressed air This is the case for example with tool changing systems where otherwise without compressed air the changing process could not be carri...

Page 47: ... 3 5 KW Voltage Current 380V 7 0A Speed Frequency 18 000 rpm 300Hz Air cooled Collet ER25 Weight 8 0KG Inverter Delta 3 7KW Fig 11 HF spindle 3 5 kW 2 keys are required to change the tool The wrench holds the spindle tightly while the ER key is used to loosen or tighten the nut All tools used must be right handed If other HF spindles or interchangeable systems are used please refer to the separate...

Page 48: ...ller than the material to be stretched In addition a vacuum pump optional must be connected to the pipe system to create a vacuum Depending on the size of the table the required power of the pump also varies See Chapter 4 7 2 To activate the vacuum the vacuum pump must be switched on and the covers of the corresponding fields must be removed Expiration 1 Measuring the workpiece 2 Select vacuum fie...

Page 49: ...Serie Stepper CNC STEP GmbH Co KG Siemensstrasse 13 15 47608 Geldern Germany Page 49 Support 49 0 2831 91021 50 07 03 2022 Fig 12 1 Vacuum zones and shut off valves Fig 12 2 Vacuum meters Fig 12 Machine with vacuum table and C rails ...

Page 50: ... STEP GmbH Co KG Siemensstrasse 13 15 47608 Geldern Germany Page 50 Support 49 0 2831 91021 50 07 03 2022 1 Closure Plug Vakuumzone 1 Open Vacuum Hose 2 Sealing Cord Fig 12 3 Closure plugs vacuum zone Fig 12 4 Vacuum opening vacuum sealing cord 1 2 1 ...

Page 51: ...rol cable and switched on via the operating terminal 1 Side channel compressor 2 Suction filter 3 Silencer 4 Vacuum limiting valve 1 Fuse 2 Power connection 3 Control cable for machine control The side channel compressor has its own power connection The control cable is connected to the machine control For example the side channel compressor can be switched on and off via the button on the control...

Page 52: ...resh air and does not overheat These are subject to the size of the pump Recommendations for the appropriate side channel compressor Maschinengröße Size of Channel Compressor Remark T Rex 0609 1x 2 2KW T Rex 0615 1x 2 2KW T Rex 1212 1x 5 5KW T Rex 1218 1x 5 5KW T Rex 1325 1x 5 5KW T Rex 1530 1x 7 5KW T Rex 2030 1x 7 5KW 2x 5 5KW Selection depends on the material T Rex 2040 2x 5 5KW 2x 7 5KW Select...

Page 53: ...al construction 4 9 Minimum Lubrication Optional For the processing of some materials such as aluminium it is necessary to lubricate or cool during the milling process Various systems are available for this purpose Compressed air is required for all systems 4 9 1 DynaCut MDE This system is a low pressure system with coaxial spray nozzle for mist free coolant application With this system the coolan...

Page 54: ...ge tank for lubricant 1 5l 4 Main switch Fig 16 Minimum quantity lubrication MDE The pressure on the container must not exceed 2 0 bar If necessary adjust up or down via the adjusting screw of the pressure display The lubrication system can be switched on and off separately via the green main switch 1 Air Lube mixture head 2 Regulating valve for Air 3 Regulating Valve Lubrication 4 Spray nozzle Fi...

Page 55: ...a a throttle valve see figure the ratio of air liquid quantity can be finely dosed Full flexibility The atomizer can be attached to any point on the machine and can be specifically aligned to the workpiece by means of the flexible plastic hose A built in check valve in the hose prevents the liquid from sinking The spray angle is infinitely adjustable from 10 to 30 Little effort high performance Th...

Page 56: ... a safety fence can also be designed as a U shape or L shape If the machine is in a niche it is enough to secure only the front The only important thing is that access to the running machine is not possible As soon as the access door is opened the machine must stop Attention A machine without a safety fence is not CE compliant Without a safety fence this machine does not receive a CE declaration f...

Page 57: ...2831 91021 50 07 03 2022 5 Working and hazardous areas 5 1 Workspace Fig 18 Work areas 1 Operating Terminal 2 Area of the tool holder when switched off 3 Range of motion of the axes when switched off For clamping workpieces 5 2 Danger zone Fig 18 1 Danger zone 4 Entire range of machinery within the fence during operation 3 2 1 4 ...

Page 58: ...t twist Place the load when leaving the workplace Improper installation and initial commissioning WARNING Risk of injury due to improper installation and initial commissioning Improper installation and initial commissioning can lead to serious injuries and significant property damage Ensure sufficient freedom of installation before the start of the work Handle open sharp edged components carefully...

Page 59: ...es Do not tighten screws on the machine 6 2 Preparations 6 2 1 Setting up the machine Personal Professionals Protective equipment Protective Clothing Safety shoes Protective Helmet CAUTION Risk of injury due to undersized buildings Overloading of ceiling structures can lead to serious property damage and bodily injury If the machine is placed on a self supporting building ceiling observe the dynam...

Page 60: ...sibly mark the course of the line 6 2 3 Install accessories HINT The installation of the accessories is carried out in accordance with the instructions for operation and assembly belonging to the accessory WARNING Risk of injury due to improperly fastened accessories Improperly attached accessories can fall or be ejected uncontrollably during operation causing serious injuries to the skin and eyes...

Page 61: ... of all EMERGENCY STOP devices 3 Turn on the main switch 4 Turn on the control press the reset button on the control panel Chapter 4 4 5 Starting the Kinetic NC control software 6 4 First Installation Personal Professionals 1 Ensure that the machine is set up and aligned 2 Ensure that all lines are connected for operational readiness 3 Ensure that the operator minimum is connected to the machine 4...

Page 62: ...ers and safety devices are installed and functioning properly Ensure that there are no people in the danger zone Never override or bridge safety devices during operation 7 2 Activities before use 1 Ensure that all covers are installed on the machine 2 Ensure the firm fit of all plug connections 3 Make sure none of the emergency stop switches have been pressed 4 Make sure all doors on the safety fe...

Page 63: ... or other foreign objects in the machine or plant 6 Ensure that there are no people in the danger zone 7 Carry out the reference trip see note 8 9 Define Workpiece Offset Start job Homing When the machine is switched on homing must be performed The reference switch runs over the reference flag and determines the reference point zero point of the individual axes After the reference run has been car...

Page 64: ...nsure that all covers and safety devices are installed and functioning properly Do not reach into moving tools during operation Before replacing the tools always unplug the milling motor or switch off the machine and secure it against reactivation Axismovement WARNING Risk of injury due to axis movements Collision of persons with components of the machine Y bridge mobile unit rotary table with wor...

Page 65: ...ic devices near the magnetic source These could be damaged Do not bring storage media credit cards etc close to the magnetic source Data can be deleted Falling materials WARNING Injuries caused by falling materials During operation chips tools or parts of them can fall or be ejected uncontrollably causing serious injuries to the skin and eyes Wear face protection or all round closed glasses protec...

Page 66: ...ot deal with open fire or ignition sources Have fire extinguishers ready Avoid processing light metal alloys such as magnesium aluminium zinc and titanium without suction device and appropriate safety measures In the event of a fire stop work immediately Leave the danger zone until the all clear is given Cooling emulsion CAUTION Risk of damage to health due to contact with cooling emulsion Contact...

Page 67: ... free power switch or power plug CAUTION Risk of burns due to hot surfaces Risk of cutting due to tools and chips Contact with hot components can cause burns Tools and chips can cause injuries when touched Wear protective gloves when changing tools 2 Change tool see separate operating instructions for tool holder 3 Make sure that the tool spindle is again provided with voltage power switch or powe...

Page 68: ... Cleaning the machine see Maintenance 7 7 Shutdown Emergency In dangerous situations the movements of components must be stopped as quickly as possible and the power supply switched off Shutdown in an emergency 1 Immediately trigger emergency stop by emergency stop device 2 If there is no danger to one s own health rescue people from the danger zone 3 If necessary initiate first aid measures 4 Ale...

Page 69: ... emulsion Contact with cooling emulsion can lead to damage to health Avoid skin contact Remove cooling emulsion from the skin immediately Do not inhale vapors Electrical system DANGER Danger to life due to electric current In case of contact with live components there is a danger to life Switched on electrical components can perform uncontrolled movements and lead to the most serious injuries Befo...

Page 70: ...crew tightening torques Before recommissioning please note the following Ensure that all maintenance has been carried out and completed in accordance with the instructions and instructions in this guide Ensure that there are no people in the danger zone Ensure that all covers and safety devices are installed and functioning properly Environmental protection Observe the following information on env...

Page 71: ...you have any doubts always contact the manufacturer Loss of waranty If non approved spare parts are used the manufacturer s warranty expires Purchase spare parts from authorized dealers or directly from the manufacturer The spare parts list is available on request Indicate the following points when ordering spare parts Type of machine Year of construction Series No Execution Quantity Designation D...

Page 72: ...be found in the separate operating instructions Modell T Rex Interval Maintenance work To be executed by Daily Check machine for damage and wear Professionals Verify security components Emergency stop door contacts safety fence Professionals 10 operating hours Verification of the function of the automatic central lubrication Professionals Check the oil level of central lubrication Operator Monthly...

Page 73: ... of the T Rex series machine Never use compressed air to clean the T Rex series machine Personal Operator Protective equipment Protective Clothing Safety shoes Gloves 1 Set the power switch to the terminal in position 0 or Off Disconnect compressed air 2 Free the machine from chips with the help of brushes or brooms CAUTION Risk of injury due to chips Chips can be sharp edged and cause deep cuts A...

Page 74: ...ee Chapter 4 3 7 The lines and distributors of the central heating system must be checked daily for leaks and replaced if necessary In addition to central lubrication all metallic components of the machine should be cleaned regularly and wetted with a resin and acid free oil or grease CAUTION Risk of damage to health due to contact with oil and grease Contact with oil and fat can lead to damage to...

Page 75: ...achine perform the following steps 1 Check all previously loosened bolted connections for a firm fit 2 Verify that all previously removed guards and covers are properly reinstalled 3 Ensure that all tools materials and other equipment used have been removed from the workspace 4 Clean the working area and remove any leaked substances such as for example liquids processing material or the like 5 Ens...

Page 76: ...bleshooting Electrical system DANGER Danger to life due to electric current In case of contact with live components there is a danger to life Switched on electrical components can perform uncontrolled movements and lead to the most serious injuries Before starting the work switch off the electrical supply and secure it against reactivation Moving components WARNING Risk of injury due to moving com...

Page 77: ...ng torques Before recommissioning please note the following Ensure that all troubleshooting work has been carried out and completed in accordance with the information and instructions in these instructions Ensure that there are no people in the danger zone Ensure that all covers and safety devices are installed and functioning properly Behaviour in the event of disturbances 1 In the event of distu...

Page 78: ... doors Operator Malfunctions and problems with the machine Loss of Steps Travel speed too high Check the setting in the software Operator Stepper motor no longer moves Timing belt torn on the Z motor Replace the timing belt on the Z axis motor Professionals Insufficient lubrication Check hoses of the central lubrication leakage Incorrect lubrication intervals Checking the hoses and distributors of...

Page 79: ...ut Increased play of rack and pinion with gear achieved due to lack of maintenance or service life Replacement or repair If possible recreate the game Check the distance between the gear and the rack Manufacturer If a fault is not included in the fault table contact customer service The troubleshooting of the access components can be found in the separate operating instructions 9 3 Troubleshooting...

Page 80: ...2831 91021 50 07 03 2022 9 4 Commissioning after fault has been resolved After resolving the fault perform the following steps for recommissioning 1 Reset emergency stop devices 2 Acknowledge fault in the controller 3 Ensure that there are no people in the danger zone 4 Start according to the instructions in the chapter Operation ...

Page 81: ...into the swivel range of suspended loads Move loads only under supervision Use only approved hoists and slings with sufficient load capacity Do not use torn or scrubbed hoists such as ropes and straps Do not attach hoists such as ropes and straps to sharp edges and corners knot and do not twist Place the load when leaving the workplace Off center focus WARNING Risk of injury due to falling or tilt...

Page 82: ...the event of externally recognizable transport damage proceed as follows Do not accept delivery or only with reservation Note the extent of damage on the transport documents or on the carrier s delivery note Initiate a complaint HINT Complain about any defect as soon as it is detected Claims for damages can only be asserted within the applicable complaint periods 10 3 Packaging To the packaging Th...

Page 83: ... the environment Dispose of packaging materials in an environmentally friendly manner Observe the locally applicable disposal regulations If necessary commission a specialist company with the disposal 10 4 Symbols on the packaging The following symbols are affixed to the packaging Always observe the symbols during transport Fragile Identifies packages with fragile or delicate contents Treat the pa...

Page 84: ...ig 24 Lifting equipment 1 Attach ropes belts or multi point hangers to the pallet accordingly Fig 20 and secure the pallet against slipping 2 Check whether the transport pieces are not damaged by the slings If necessary use other slings 3 Ensure that the pallet cannot tilt when the center of gravity is out of center of gravity 4 Start transport Transport of pallets by forklift Transport items atta...

Page 85: ...he pallet with transport piece and start the transport 10 6 Storage Storage of packages Store packages under the following conditions Do not store outdoors Store in a dry and dust free place Do not expose to aggressive media Protect from sunlight Avoid mechanical vibrations Storage temperature 10 to 35 C Relative humidity max 60 When stored for more than 3 months regularly check the general condit...

Page 86: ...ore the start of the work Handle open sharp edged components carefully Pay attention to order and cleanliness at the workplace Components and tools lying loosely on top of each other or around are sources of accidents Professionally dismantle components Pay attention to the sometimes high dead weight of the components If necessary use hoists Secure components so that they do not fall In case of am...

Page 87: ...ve plastic elements for recycling Dispose of other components sorted according to material properties HINT Danger to the environment due to incorrect disposal Incorrect disposal can create risks for the environment Have electronic waste electronic components lubricants and other auxiliary materials disposed of by approved specialist companies In case of doubt obtain information on environmentally ...

Page 88: ... suction shoes Minimum Quantity Lubrication Vacuum pump Clamping Elements Clamping elements groove stones vices Tools Milling engraving drilling ATC HF spindles for automatic tool change Milling cutters for various applications and materials engraving stitches drills Tools for various applications Tangential cutting modules oscillating or fixed creasing modules Rotation axes tailstocks and jaw lin...

Page 89: ...H Co KG Siemensstrasse 13 15 D 47608 Geldern Telephone 49 0 2831 91021 50 Mon Fri 07 00 15 00 o clock Mobile 49 0 2831 91021 20 Only in urgent cases Mon Thu 15 30 18 00 Fax 49 0 2831 91021 99 Email support cnc step de Internet https www cnc step com If you have any questions please contact our customer service by e mail or telephone We will be happy to advise you Numerous suggestions and informati...

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