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C. R. ONSRUD INC.
OSAI 5 AXIS
F/G-SERIES
CNC ROUTERS
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Table of Contents
Cover Page
Table of Contents
Section - Introduction
-Machine Stickers
- Safety Rules
- Electrical Components
- Spindle Head
10
- Servo Motors
11
12
1
25
- Cutter Recommendation
- Spare Parts
Section - Warranty
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Changes to Equipment:
All operators must read and follow all health and safety
guide lines. Please read and follow all MSDS sheets for
materials being cut on the CNC router. You should be able
to obtain these from your supervisor.
Machine Care:
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SERIAL # 309G140101
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C.R. Onsrud CNC Routers use Electricity and Compressed Air as their Two Energy Sources.
WARNING!! It is the employers responsibility to provide energy isolation devices for this equipment and
ensure that all potential service and maintenance personnel follow lockout/ tagout procedures developed by
the employer in accordance with the Occupational Safety and Health Administrations (OSHA) control of
hazardous energy standard 29 CFR 1910.147
RESIDUAL ENERGIES which may be present after energy sources have been removed per the above
standard include:
Cutting Spindle Rotation could continue to rotate for several seconds after removal of electrical
energy source. Once spindle rotation has stopped this residual energy is dissipated.
The cutting spindle and spindle mounting plate may fall under force of gravity if the pneumatic
energy source (compressed air) has been removed and the Z axis drive belt is removed. Once the
cutting spindle and spindle mounting plate are in the full down position, this residual energy is
dissipated.
Inertia of Moving Gantry could lead to a condition under which the Gantry could continue to move for
several seconds after removal of energy source. Once table motion has stopped, all residual energy in
the Gantry is dissipated.
Inertia of the spindle and spindle mounting plate moving along the Y axis could lead to a
condition under which the spindle and spindle mounting plate could continue to move for several
seconds after removal of energy sources. Once the spindle and spindle mounting plate movement has
stopped this residual energy is dissipated.
WARNING!!: The Variable Speed Spindle Drive Unit (Frequency Inverter) and the Axis Servo Drive units
contain capacitors which remain charged with dangerous electrical voltages for up to ten minutes after turning
off the main circuit power supply. DO NOT touch motor drive components before allowing these components
to discharge.
After removing power source(s) from the equipment, wait at least ten minutes before touching or disconnecting
sections of the equipment that normally carry electrical charges (i.e. capacitors, contacts, screw connections).
To be safe, measure the electrical contact points with a meter before touching the equipment.
Refer to Frequency Inverter instruction manual and Servo Drive instruction manuals for specific information
NOTIFY: All affected employees that the Lock Out is to occur and why.
SHUTDOWN: Disconnect Electrical and Pneumatic power by turning the isolation devices to the OFF
position. Test by attempting to restart the machine. Return all switches to the OFF position.
LOCK: the machine with approved locks from your lockout/ tagout station. Apply tags.
AFTER ALL SERVICING IS FINISHED: Make sure all tools are removed from the area. Replace all guards.
Remove the locks and tags from the energy isolation devices. Clear area of bystanders and restore power
sources.
C.R. Onsrud CNC Routers use two power sources, please follow all OSHA
Standards Lock Out/ Tag Out procedures when servicing these machine.
Each Energy Source will need to be isolated independently from the other.
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The recognized hazards for the tasks to be implemented on the machine are
identified;
b) The protective measures required for the tasks identified are provided and
used in accordance with this standard;
c)
f)
g) Shall obtain the skill standard from the Manufacturer and review with
employee to ensure employee is qualified.
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FIG 2
There are (2) Stay Clear stickers (Part# H6008KDWVPJ) that should be located on either side of
the Machines dust hood. They should be placed
just inside the front air cylinder of the dust
brushes.
FIG 3
FIG 4
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FIG 6
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IF YOU ARE NOT THOROUGHLY FAMILIAR WITH THE SAFE OPERATION OF CNC ROUTERS OBTAIN
ADVICE FROM YOUR PLANT SAFETY DIRECTOR, SUPERVISOR, OR CALL C.R. ONSRUD, INC. AT: 1(704)-528 4528 OR TOLL-FREE IN THE U.S. AT 1-(800)-638-8185.
Please also refer to the American National Standards Institute ANSI 01.1 1992 Safety Requirements for
Woodworking Machinery and the U. S. Department of Labor OSHA 1910.213 Regulations.
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MACHINE SET UP
GW SERIES CNC ROUTERS
GUARDS
This is a very versatile machine which may be
equipped with a wide variety of user-supplied tooling.
Because C.R. Onsrud Inc. can not anticipate the
extensive variety of tooling which may be employed,
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ELECTRICAL CONNECTION
MACHINE VOLTAGE
C.R. ONSRUD ROUTERS are shipped from the
factory pre-wired for a SPECIFIC voltage. The C.R.
Onsrud, Inc. nameplate (which can be found on the
machine's Left Bridge Support) and also an orange
sticker (on the control panel cover) identify this
voltage. If you have any questions about how to
identify the operating voltage for a specific machine,
please call our Technical Department: 1-(704)-5284528, or toll-free in the U.S.1-(800)-638-8185, and for
business after hours call: 1-(866)-667-7837.
All control manufacturers strongly recommend an
isolation transformer on the 3phase input. If you
have ordered an Isolation Transformer with your
machine, it is very important that the customer has
provided us with the proper voltage of the building so
the Isolation Transformer can be tapped properly. The
taps can be checked and verified by a qualified
electrician.
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OVERLOAD PROTECTION
Each of the motor starters is
equipped with overload
protection for the motors and
machine wiring. If tripped, the
overload may be reset by
pushing the reset button on the
overload module (under the
contactor, it is the bottom
portion of the "starter").
There will be a motor starter for A) Drive Power, B)
Frequency Inverter, & C) Indicates a Time Delay
Relay for Emergency Circuit.
The overload does not take the place of a properly
sized circuit breaker or fused disconnect which
should be installed on the incoming power line by
a qualified electrician in accordance with local
and national codes
DANGER!! HAZARD OF FATAL ELECTRICAL
SHOCK! ELECTRICAL CONNECTIONS AND
ADJUSTMENTS SHOULD BE MADE BY A
QUALIFIED ELECTRICIAN ONLY.
FUSES
The machines control voltage
transformer has primary and
secondary side fusing which protect
the machine control wiring from
over current hazards.
DUST COLLECTION
CONNECTION
Onsrud CNC Routers require approximately 35004000 cfm of dust collection flow for machines
fitted with a 12 inch dust outlet, and 1500-2000
cfm for machines fitted with an 8 inch dust outlet.
Make connection with flex hose to the outlet at the top
of the Cutting Spindle hood. Use as little "flex hose"
as possible as the flow characteristics are inferior to
smooth wall pipe. If a blast gate is installed on the
Router's dust outlet to reduce suction, be careful not
to reduce suction excessively or machine
performance and safety could be impaired (see
above). Consult the factory or contact your C. R.
Onsrud distributor.
WARNING: SAWING, SANDING OR MACHINING
WOOD PRODUCTS CAN PRODUCE WOOD DUST
WHICH CAN CAUSE A FLAMMABLE OR
EXPLOSIVE HAZARD.
WARNING: WOOD DUST MAY CAUSE LUNG,
UPPER RESPIRATORY TRACT, EYE AND SKIN
IRRITATION. SOME WOOD SPECIES MAY CAUSE
DERMATITIS AND/OR RESPIRATORY ALLERGIC
EFFECTS.
* Avoid dust contact with ignition source.
* Sweep or vacuum dust for recovery or disposal.
* Avoid prolonged or repeated breathing of wood
dust in air.
* Avoid dust contact with eyes and skin.
WARNING! Aluminum Dust can be highly explosive
in dust collection systems. Aluminum powder is used
in the launching of the space shuttles booster rocket.
Please use caution when cutting Aluminum.
IMPORTANT: IT IS THE EMPLOYERS
RESPONSIBILITY TO ENSURE THAT NOT ONLY
ALL MACHINE OPERATORS, BUT ALSO ALL
OTHER PERSONS EXPOSED TO ENVIRONMENTS
WHERE WOOD DUST MAY BE PRESENT ARE
INFORMED OF WOOD DUST HAZARDS AND ARE
PROPERLY TRAINED IN COMPLIANCE WITH
OSHA 29 CFR 1910.1200 HAZARD
COMMUNICATION STANDARDS!
FIRST AID: If inhaled remove to fresh air. In case of
contact, flush eyes and skin with water. If irritation
persists, call a physician. For additional information,
see the Material Safety Data Sheet provided by your
safety director.
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COMPRESSED AIR
WARNING!! IT IS THE EMPLOYER'S
RESPONSIBILITY TO PROVIDE ENERGY ISOLATION
DEVICES FOR THIS EQUIPMENT AND INSURE THAT
ALL POTENTIAL SERVICE AND MAINTENANCE
PERSONNEL FOLLOW LOCKOUT/TAG OUT
PROCEDURES DEVELOPED BY THE EMPLOYER IN
ACCORDANCE WITH THE OCCUPATIONAL SAFETY
AND HEALTH ADMINISTRATION'S (OSHA) CONTROL
OF HAZARDOUS ENERGY STANDARD 29 CFR
1910.147.
CONNECTION
Connect a non-fluctuating
compressed air line capable
of delivering at least 8 cfm at
100 pounds per square inch
to the 3/8" pipe-thread inlet
located at the control box on
the Rear of the machine.
RESIDUAL ENERGIES which may be present after
pneumatic energy source has been removed per the
above standard include:
Once disconnected from the compressed air line at the
incoming filter regulator the machine stores no residual
pneumatic energy
PRESSURE SWITCH
The machine is equipped with 2 pressure
switches located in the right main
electrical box. 1st provides 100 psi at 8-12
cfm while the 2nd provides 100 psi at
bursts of 40 cfm for counter balance.
Note: If the machine does not have proper
pressure the machine will not allow the
machine to run.
LUBRICATION
SPINDLE BEARING LUBRICATION
The spindle motor bearings are permanently
lubricated for the life of the motor.
SLIDE LUBRICATION
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NOTE: OVER TIGHTENING OF THE NUT CAN OCCUR WITH USE OF TOOL SET UP STAND!! THE
TOOL'S CLAMPING NUT SHOULD HAVE NO MORE THEN 90-95 Ft POUNDS OF TORQUE APPLIED.
SPECIALIZED TORQUE SPANNER WRENCHES CAN BE OBTAINED.
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ELECTRICAL COMPONENTS
(Left Hand Cabinet)
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ELECTRICAL COMPONENTS
(Left Hand Cabinet)
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ELECTRICAL COMPONENTS
(Right Hand Cabinet)
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ELECTRICAL COMPONENTS
(Right Hand Cabinet)
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DATUM SENSORS:
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EXTERNAL COMPONENTS:
Counter Balance & Z axis Ball Screw
The machine is equipped with a counter
balance system on the Z axis.
A) Z axis Ball Screw This drives the
machines head up/ down. The Z axis will
vary between different machines due to
customers requirements for travel stroke
of the axis.
B) Counter Balance Cylinders These
cylinders help to counter balance the
weight of the machine head taking the
strain off of the motor.
C) Z axis Linear Rails Assist in the motion
of the Z axis head.
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C.R. ONSRUD
OSAI MACHINE CONTROL MANUAL
This manual is an introductory overview on the operation of a C.R. Onsrud OSAI CNC Router. This manual will
walk the operator through all basic operations of the machine from machine power up through the cutting of a
2-D 3-axis part. By no means does this manual substitute ones need for factory certified training; just reading
this manual does not qualify one as a machine operator.
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Fig. 1-2
Fig. 1-3
POS. - This area will display the machines
positioning information for each axis. It will provide
Work Position, Programmed Position, Machine
Position, Absolute Position, Distance to Go,
Following Error, and the active Origin number from
the Origins Table.
X- Y- Z- A- C-NOTE: Axes P (& Q) is designated for Tool
tray(s) and not shown in the display.
To activate a particular axis the operator needs to simply touch the corresponding letter on the screen. For
example, if the operator wanted the Y axis to move, one would press the Y under the POS button (highlighted in
above picture), select the Manual button from the Operator panel, and then press and hold the Cycle Start
button. This will move the Y axis in the direction indicated in the Jog Inc. The operator would then release the
Cycle Start button to stop the axis motion.
Fig. 1-4
PROGRAMMED - PERCENT - ACTUAL
Prog. Feed- Controls feed rates in the active
program being run.
Man. Feed- Controls feed rates in Manual
Mode.
Spindle- Controls spindle rpms +/- 25% of
the programmed rpms.
Rapid- Controls the machines automatic
rapid traverse rate.
In this area the operator can monitor the different feeds and speeds of the machine. The controller will monitor
the programmed machine rates, the percentage of the rate that is changed, and calculate the actual rate the
machine is moving. The percentage is controlled by overrides on the Operator Panel.
-NOTE: All selections on the screen are activated by left clicking on the touch pad, or touching of the
display screen with a stylus.
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Fig. 1-6
Fig. 1-7
Fig.1-8
Fig. 1-9
Fig. 1-10
HPG- This selection activates the Hand Pulse Generator wheel found to the right of the
Process Control screen.
JOG RET- Allows the operator to return to the last machine position.
Jog Dir- Indicates the direction a selected axis will move during Manual Jog.
Jog Inc.- Selects distance used by HPG per mark on the dial, and also the distance
traveled when using Incremental Jog.
Set Z Shift This function will shift the Z axis by the amount displayed when running a
program. The value is based on the final depth of the program. (A Z shift is used when the
operator is Dry Running a program)
Table Mode- This selection allows the operator to change which table(s) to run the needed
job(s) on. This feature is only on Multi Table machines and works in conjunction with C.R.
Onsrud Program Select Software and the document Functional Design Spec for
Program Select.
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Fig. 2-1
Fig. 2-2
Fig. 2-3
Fig. 2-4
Fig. 2-5
Fig. 2-6
Fig. 2-7
Fig. 2-8
The LOAD/ AUTO button is only for machines with Table Mode option. This gives the
operator the choice of pendulum processing (continuous machine cutting) multiple
programs on the machine. The operator only needs to press the button to toggle between
the two states of LOAD or AUTO. Please see the section on running jobs in table modes
and refer to the document Functional Design Spec for Program Select.
T/P Enable is active only when the Teach Pendant option is purchased with the machine. This
device is NOT designed for running part programs on the machine.
Retract Z will retract the Z axis to its Park Position. Operators can use this button when stopping
a Dry Run program and to move the Z axis up to a safe position.
Table Load will send the machines tables or gantry to the set load position. This allows the
operator to load the machine table with material to process.
Brushes Up/ Down will allow the operator to manually put the Dust Brushes in the up or
down position. The button toggles between the two states shown.
Message Reset will reset the Yellow error message when displayed in the middle of the Process
Control Screen.
Auto Home will set the Machine X, Y, & Z axes to absolute zero position upon power up of the
machine. The machine should not be run until this step has been executed.
Diagnostics will allow the operator to visually observe the input and output signals of the
machine. This button will change the appearance of the Process Control Screen (see section 4).
Fig. 2-9
Table Set Up allows the operator to set up the table vacuum zones. Zones can be turned on and
off independently or simultaneously. This is also where the operator would manually activate and
deactivate pop up pins for the machine if so equipped. This button will change the appearance of
the Process Control Screen (see section 3).
Fig. 2-10
Tool Set Up allows access to machine functionality that deals with the main router spindle, tool
tray, or Multi Spindle Drill Head. This button will change the appearance of the Process Control
Screen (see section 5).
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Fig. 3-2
button.
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Fig. 5-1
Fig. 5-2
Fig. 5-3
Fig. 5-4
Fig. 5-5
Fig. 5-6
Fig. 5-7
Drill Head Set Up allows the operator to access the Drill Head Set Up screen for the machine. This
button will change the appearance of the Process Control Screen (see Fig. 6-1).
Tool Tray In/ Tool Tray Out allows the operator to activate and deactivate
the Tool Tray In solenoid. The actual tray position is indicated by the color
green. When deactivated the button will be red.
Clamp Tool/ Release Tool allows the operator to actuate the spindles draw
bar for manual loading or unloading toolholders into the spindle. The green
button indicates the present state of the spindles draw bar.
Park Tool allows the operator to park the tool into the tool tray. If there is an Active Tool in the
machine spindle, the button will be Blue.
T/P Enable enables the Machines Hand pad if this machine option was purchased.
Z axis Retract retracts the Z axis to its Park position.
Table Load places the machine tables or gantry into the pre-set load position.
Fig. 5-8
Brushes Up/ Down allows the operator to activate and deactivate the solenoid for the Dust
Brushes on the dust hood.
Fig. 5-9
Message Reset resets the Yellow error messages when displayed in the middle of the Process
Control Screen.
Fig. 5-10
Fig. 5-11
Fig. 5-12
Fig. 5-13
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The Drill Head is a machine purchased option, and is not on all machines. To access it, the operator will press
the
button (see Fig. 2-10) then the
button (see Fig. 5-1). The screen will change and show an
image of the machines head. The image will have a router spindle on the right and a drill head on the left. This
screen allows the operator to manually fire individual or multiple drill spindles. The operator will also be able to
turn the drill head motor on and off. By pressing the
button the operator can drop the drill head into down
position, and activate the Drill Head functions. Please see images below.
Fig. 6-1
The operator now has the choice of selecting which drill spindles to call. Numbers
left of the yellow arrow indicates the tool numbers for individual drills. These
numbers will differ with drill head options (e.g. 9 spindle, 13 spindle, & 15 spindle
are common configurations). The green buttons above the number indicate the
spindles are in the up position. By pressing All Drill Heads Down all of the drill
spindle will fire into the down position. All Drill Heads Up will retract them back up
into the block, and the block will still be down. To retract the Drill Head Up the
operator needs to press the
above.
Fig. 6-2
To activate individual drill spindles the operator will press the gray button below the
tool numbers, the spindle will fire down and the button will turn green. All Drill
Heads Up will bring all spindles back up, or the operator can press the button
above the tool number to retract the individual spindle. Note: Only when there is
one or more spindles down can the Drill Motor be turned on. To turn on the
motor, (e.g. to check rotation of the bit) the operator presses the light blue
button
then presses it again to shut the motor off. When done with
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The machine console has an interacting Keyboard and Operator Panel that work together with the WinMedia
screens shown in the previous pages. These components together are the Control Console. This section will
break down each of these components for the console. When using the OSAI Controller, the operator will need
to make sure that the Caps Lock is turned on on the Keyboard.
Fig. 7-1
Fig. 7-2
The overrides allow the operator to manually control the machine feed and speed rates. By turning the
corresponding dial, these overrides work in conjunction with the PROGRAMMED - PERCENT - ACTUAL
section of the Process Control Screen (please see page 2). The Man Feed, Prog Feed, and Rapid can have
percent rates from 0 to 100%. The Spindle percent rates can go to +/ - 25% of programmed speed.
In example:
Spindle:
Programmed
18000
Percent
125
Actual or
22500 or
Programmed
18000
Percent
75
Actual
13500
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Fig. 7-4
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Fig. 8-2
7. Pull the Emergency Stop (see Fig. 7-3) button out. This will complete the emergency circuit allowing the
machine to power up when Drives On (see Fig. 7-3) is pressed.
8. Press the green Drives On button (see Fig. 7-3). The OSAI Process Controller will display a message
Waiting on M/C powering up. Once the machine finishes powering up the screen will display a message
032 AXES NOT REFERENCED.
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Fig. 9.2-1
To load a tool, the operator will want to select the MDI (Manual Data Input) button (see Fig.
7-1) from the operator panel, and a prompt window will open on the OSAI Process
Controller.
Step 9.2-2
In the prompt window the operator will type M6 T1 into
the provided field (provided that there is a tool in
Fig. 9.2-2
Fig. 9.2-3
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Section 9 (continued)
Step 9.2-4
The operator will need to position the machine to the
middle of the machine table for safety. While still in the
MDI mode (see Fig. 7-1), the operator will type the
coordinates for the middle of the table (this value is
different depending on machine model). Then press
Fig. 9.2-4
Step 9.2-6
With the machine in a safe position and while still in
MDI mode (see Fig. 7-1) the operator will need to start
the router spindle. The operator will type in M3 S9000
Fig. 9.2-5
Fig. 9.2-6
Step 9.2-7
Press the Cycle (Start) button (see Fig. 7-2) on the Operator Panel. Once the
spindle starts, the operator will be able to see the Spindle Load Meter register a
very small percent to confirm spindle starts up (see Fig. 7-4).
Fig. 9.2-7
The operator should warm-up the spindle for a minimum of 10 minutes every morning. Failure to warm-up the
spindle prior to cutting can damage the spindle bearings resulting in premature failure. NOTE: The operator
must understand that the order of the procedures in this section is important. The machine axes must be
referenced before performing the spindle warm up. It must also be noted that the spindle will not start unless
there is a tool in the spindle. (Additional spindle care information is provided in the spindle manufacturers
manual.)
Step 9.2-8
After warming up the spindle for 10 minutes the operator can press the Cycle Pause (Feed
Hold) button (see Fig. 7-2) to stop the spindle.
Fig. 9.2-8
Step 9.2-9
The operator can press the Table Load button (see Fig. 2-4) and load the machine with
material for that days production run.
Fig. 9.2-9
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Fig. 10.1-1
Step 10.1-2
The operator will need to select the desired positive or negative direction from the
Jog Dir (see Fig. 1-6).
Fig. 10.1-2
Step 10.1-3
The operator will press and hold the Green Cycle button to move the axis and release it to
stop the axis motion. The axis will move as long as the button is pressed.
Step 10.2-1 Incremental Jog
Fig. 10.2-1
Select Incremental Jog mode (see Fig. 7-1) and the desired
axis from the OSAI Process Controller screen (see Fig. 1-4)
the operator chooses to move.
Step 10.2-2
The operator will need to select the desired positive or negative direction from the
Jog Dir (see Fig. 1-6).
Fig. 10.1-3
Fig. 10.2-2
Step 10.2-3
Fig. 10.2-3
The operator will need to select the desired distance the axis will move in the Jog
Inc. field. This value ranges from 0.00001 to 1.00000, most common values are
1.00000, 0.10000, 0.01000, and 0.00100, as is changed by pressing the [ - ]
button or [ + ] button.
Step 10.2-4
Fig. 10.2-4
The operator will press and hold the Green Cycle button; the axis will move the determined
distance in Jog Inc. and then automatically stop. The axis will move as long as the button is
pressed, once released the axis will stop moving.
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Section 10 (continued)
Step 10.3-1 HPG (Hand Pulse Generator)
Fig. 10.3-1
Select HPG (see Fig. 1-5) and the desired axis
from the OSAI Process Controller screen (see
Fig. 1-4). A yellow message window 092 HPG
ENABLED will appear letting the operator know
that the HPG is activated. To exit the HPG mode
the operator can press the Manual mode button
Step 10.3-2
The operator will need to select the desired distance the axis will move in the Jog
Inc. field. This value ranges from 0.00001 to 1.00000, most common values are
1.00000, 0.10000, 0.01000, and 0.00100, as is changed by pressing the [ - ]
button or [ + ] button.
Fig. 10.3-2
Step 10.3-3
The operator will then use the Hand Pulse Generator dial (see Fig. 7-4) to move the
selected axis. One full revolution of the dial will cause the axis to move the distance
indicated in the Jog Inc. field. If the increment was 1.00000 the one revolution equals a
full inch of travel, where as one click would move only 0.01 of an inch.
Fig. 10.3-3
Fig.10.4-1
Fig.10.4-2
Step 10.4-3
The operator will need to press the Green Cycle button (see Fig. 7-2) to execute the Home
sequence. The axis selected will move to its zero position. This process is similar to Auto Home
(see Step 9.1-1) except that only one axis will be moving.
Fig.10.4-3
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Step 11.1-7
The operator will need to select the HPG button (see
Fig.1-4) from the OSAI Process Control screen.
Fig. 11.1-6
Fig. 11.1-7
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Section 11 (continued)
Step 11.1-8
The operator then needs to set the Jog Inc. to 1.00000 (or the highest
setting) (see Fig. 1-7) by pressing the [ + ] on the screen.
Fig. 11.1-8
Step 11.1-9
Fig. 11.1-9
Begin rotating the Hand Pulse Generator in a counter clockwise direction to bring the Z
axis down toward the machine spoil board. When the tip of the tool is approximately to 1
inch above the table stop axis motion, and change the Jog Inc. to 0.10000 by pressing the
[ - ]. Begin bringing the tool tip down closer to the spoil board. At approximately 1/8 to 1/4
of an inch above the spoil board, change the Jog Inc. to 0.01000 and finish bringing the tip
of the tool down until it touches the spoil board top.
NOTE: The above step (11.1-9) is setting the Program Z zero position to the bottom of material. If the
operator desires the Program Z zero to be the Top of material repeat the same steps as above (11.1-8 &
11.1-9), except bring the tip of the tool to the top of the material while it is on the machine table.
WE RECOMMEND SETTING PROGRAM Z ZERO TO THE BOTTOM OF MATERIAL.
Step 11.1-10
Fig. 11.1-10
Once the tip of the tool is on the top of the spoil board the operator will press the Tool
Setup button (see Section 2 Tool Setup Screen).
Step 11.1-11
Fig. 11.1-11
When inside the Tool Setup screen the operator needs to press the Man. Tool Set
button from the middle of the screen. A prompt window will open called Tool offset prest
NCxxxxxxxx Proc. #1 [INCH] (this may differ due to machine options and model).
Step 11.1-12
The operator will need to fill in the required fields with information
so the machine knows where to go to retrieve the information. The
fields are:
Fig. 11.1-12
Offset Number: Type the number of the tool that was load into
the spindle (i.e. if Tool 1 was loaded then 1 should be typed).
Reference Axis: This is the axis that the offset value will be
applied to and should be Z.
Tool tip position: This field is used in direct relation to the use of
UAOs (User Absolute Origins see Section 13). If UAOs are
not used this field is left at 0,0.
Once the operator has filled in these fields press the OK button in the prompt window, or press the Enter
button on the keyboard. This will enter the value into the offset address for that tool, and the operator can look
at the Tool Length field of the Process Controller screen (see Fig. 1-2) to see the value entered. NOTE: The
machine will not move any axes after the value has been entered.
Step 11.1-13
Fig. 11.1-13
The operator will press the Z axis Retract brining the Z axis into its raised position. The
operator will then repeat Steps 11.1-1 to 11.1-13 for all tools needing to be touched off.
This method if used will need to be done if the spoil board is surfaced or if a tool is
changed.
Page 16 of 42
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Section 11 (continued)
Step 11.2-1 Measuring Tool Length Off Line If the operator chooses Fig. 11.2-1
this method of entering Tool Lengths the operator will also need to work with
the use of UAOs (User Absolute Origins) (see Section 13).
This method of entering tool length offsets is done with a Digital Bench Top
Tool Setter (see Fig. 11.2-1) that can be purchased by the customer. Turn
power onto the device and bring the indicator to the top face of the base and
press the ZERO/ ABS button to zero out the device. Once zeroed the device
will be ready to use. NOTE: The operator will want to have all router bits,
placed in collets, and locked down in the Tool Holder (see the Maintenance
section of the Owners Manual for proper steps in changing and loading tools).
Step 11.2-2
Fig. 11.2-2
Bring the indicator up away from the base of the device ensuring that there is
enough room to place the tool holder under the indicator tip (see Fig. 11.2-2).
Now place the Tool Holder that needs to be measured into the device, and
bring the indicator back down to the tip of the tool. Verify this number by
checking it more then once.
Record this value on a piece of paper and also note in what tool tray pocket
position the tool will be placed. Repeat Steps 11.2-1 and 11.2-2 for all tools
needing to be measured.
Step 11.2-3
Fig. 11.2-3
The operator will select the Utility button (see Fig. 11.2-3) from the bottom right
of OSAI Process Controller screen. When the menu appears select the option
of Table Editor. This will open a new window called OSAI Table Editor (see
Fig. 11.2-4).
Step 11.2-4
Fig. 11.2-4
Once in the OSAI Table Editor window, the operator will select
the Tables button from the bottom of the screen opening a menu.
Offset
Origin
User
Tools
The operator will select Offset from the menu opening the Offset
Variables Table (see Fig. 11.2-5).
Page 17 of 42
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Section 11 (continued)
Step 11.2-5
Inside the Offset Variable Table the operator will use the
directional arrow keys on the keyboard to select the desired offset
number. The offset number and the tool pocket number should
match. (i.e. If the operator changes the bit in tool pocket position 1,
then performs Steps 11.2-1 & 11.2-2, the operator (in this screen)
will select Offset 1 to enter the value.)
Fig. 11.2-5
NOTE: This method of setting tool length is NOT a standard feature, and would need to be purchased as an
option on your machine. It must also be stated that this method CAN NOT be used with large diameter tools
and profile tools. The large diameter tools and profile tools would need to use the method of measuring tools
offline (see Fig. 11.2-1 to 11.2-5).
Step 11.3-1
Fig. 11.3-1
The operator will begin by removing all Large tools from the Tool Tray. After this is completed
press the Tool Setup button from the OSAI Process Controller screen.
Step 11.3-2
Fig. 11.3-2
The operator will then select the AUTO mode button from the Operator Panel (see Fig. 7-1)
Step 11.3-2
From the Tool Setup screen the operator will press the Auto Tool Set which will open a
prompt window on the screen.
Step 11.3-3
In the prompt window the operator will be asked to Enter a letter
for what it is to be touched off. The letter O stands for only one
tool and a letter A stands for all tools in the tool tray (large tools
have been removed from the tray).
The operator will type a letter O into the box and then press
Enter on the key board.
Fig. 11.3-2
Fig. 11.3-3
Page 18 of 42
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Section 11 (continued)
Step 11.3-4
The operator will then type the tool number of the tool that
needs to be set. Standard machines will have 8 to 12
positions. In example, the operator will want to type in 2 if
the tool in position 2 needs to be set, and press Enter.
Fig. 11.3-4
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The MSB or Multi Spindle Block is an option that is purchased and built onto the machine. This section is
for machines that have this option. If the operators machine does not have a MSB option on the
machine Drill lengths will be measured using one of the methods in Section 11.
Step 12.1
Fig. 12.1
The operator will need to set up the Drill Head tool lengths for
the machine before running jobs. The operator will need to go
to the Drillhead Set Up screen (see Section 6, Fig. 6) and
press the MSB Down button on the screen. This will lower the
drill head into place.
We offer 3 standard configurations of drill heads
9 spindle (all vertical)
13 spindle (all vertical)
15 spindle (11 vertical and 4 horizontal)
Step 12.2
Fig. 12.2
Once the MSB unit is down the operator will fire all the
spindles down in the drill block by pressing the All Drill
Heads Down button on the screen. All the drill spindles in the
head will fire. All drills will be measured at the same time
using the same tool length.
We recommend using standard line boring drills of a 70 mm
length and a shank diameter of 10mm.
Step 12.3
With all of the drill spindles in the down position the MSB unit
is ready to have the offset lengths set by the operator. The
operator will need to activate vacuum on the table.
Fig. 12.3
Step 12.4
Fig. 12.4
The operator will now select the MANUAL
mode button (see Fig. 7-1) from the Operator
Panel, and then select the X axis from the
OSAI Process Controller screen. The
selected axis, will high light in black (see Fig.
12.4 where Y axis is selected).
Step 12.5
Fig. 12.5
The operator will need to position the X axis at approximately 6 inches
using the Jog Dir and pressing the green Cycle button (see Steps 10.1-1
to 10.1-3).
Page 20 of 42
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Section 12 (continued)
Step 12.6
The operator will need to repeat Steps 12.5 and 12.5 to position the Y axis. The operator needs to make sure his
MSB head is entirely over the spoil board of the table.
Step 12.7
Fig. 12.7
The operator now needs to select the Z axis (see Fig.
1-3) from the OSAI Process Control screen.
Step 12.8
Fig. 12.8
The operator will select the HPG button (see
Fig.1-4) from the OSAI Process Control screen.
Step 12.9
The operator then set the Jog Inc. to 1.00000 (or the highest setting)
(see Fig. 1-7) by pressing the [ + ] on the screen.
Fig. 12.9
Step 12.10
Fig. 12.10
Begin rotating the Hand Pulse Generator in a counter clockwise direction to bring the Z
axis down toward the machine spoil board. When the tip of the drills are approximately
to 1 inch above the table stop axis motion, and change the Jog Inc. to 0.10000 by
pressing the [ - ]. Begin bringing the drills down closer to the spoil board. At approximately
1/8 to 1/4 of an inch above the spoil board, change the Jog Inc. to 0.01000 and finish
brining the drills down until the tips touch the spoil board top.
NOTE: The above step (12.10) is setting the Program Z zero position to the bottom of material. If the
operator desires the Program Z zero to be the Top of material repeat the same steps as above (12.1 to
12.10), except bring the tip of the drill to the top of the material while it is on the machine table.
WE RECOMMEND SETTING PROGRAM Z ZERO TO THE BOTTOM OF MATERIAL.
Step 12.12
Fig. 12.12
When inside the Drillhead Set Up screen the operator needs to press the Man.
Tool Set button from the middle of the screen. A prompt window will open called
Tool offset prest NCxxxxxxxx Proc. #1 [INCH] (this may differ due to
machine options and model).
Step 12.13
Fig. 12.13
The operator will need to fill in the required fields with information so
the controller knows where to go to retrieve the information. The fields
are:
Offset Number: The operator will type in the number of the
intersecting bit 36 into this field. All the drills will look to this offset
number for tool length.
Reference Axis: This is the axis that the offset value will be applied
to and should be Z.
Tool tip position: This field is used in direct relation to the use of
UAOs (User Absolute Origins see Section 13). If UAOs are used
the value entered into Axis 3(Z) of the origin is the same value
entered in Tool Tip Position. If UAOs are not used this field is left at
0.0. The operator will then press the OK button.
Page 21 of 42
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Fig. 12.14
Step 12.15
Fig. 12.15
After the drill heads are retracted the operator will now press the MSB Up Button
from the screen. Retracting the entire unit to its parked position. Then press the
Drillhead Set Up button
Step 12.16
From the Tool Setup screen the operator will need to press Z axis Retract button to retract Z
to its park position.
Fig. 12.16
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In this section the operator will learn about the use of Origins in the OSAI Control. An Origin is a variable used
by the control system to shift one or more of the machines axes from a known position. This shift can be
done as an Incremental move or as an Absolute move. In this manual we will discuss the use of User
Absolute Origins or also known as UAOs, and how they are used to shift the machines Absolute Zero
position to match the Program Zero position. There is a table with ten absolute origins the programmer or
operator can use in the program.
To use the UAOs (User Absolute Origins) there are two criteria:
1.) The G-Code program to be run must have a line of code that calls out the use of an Origin and which
Origin to be use. The value is 1-10, and must be in the following format (UAO,x) (note: x represents a
value of 1-10).
2.) The operator must set up and enter the values to be use by the origin. These values are entered at the
machine. Step 13.2 will show the operator how to get to the tables.
Steps 13.1 will give an example of how and where the origin is called in the program. Steps 13.2 will show the
operator how to access the Origin Table and enter the values.
NOTE:
As a CNC manufacturer we will not discriminate as to what CAD/ CAM software a customer uses with our
machine. We will work with any software company to assist them in creating proper code for our machine to
run. The examples given in this step are from the software that we distribute and support.
Step 13.1-1
Fig. 13.1-1
;FILENAME EXAMPLE
To the right is some example G - Code showing the
beginning of a program. Highlighted in red shows how ;MACHINE CONFIGURATION = 0, 0, 148., 1, 1, 0, 1, 0, 0, 1
;(ESTIMATED CYCLE TIME = 0MINS 14SECS)
the UAO is called out before the machine performs a
G70
tool change. When the machine reads this line of code G27
it will go look at the value(s) inside the Origin Table
G90
number 1. This is a very common UAO call for nested G80
G40
base processing.
MOV= 72
VFF= 1
FCT=.0001
G00 G79 Z(@ZPARKP1)
(UAO,1)
;OPERATION CHANGE
M06 T1
Step 13.1-2
To the right is more example of G - Code showing the
beginning of a program. Like the example above the
UAO call is highlighted in red. When the machine
reads this line of code it will activate the value(s)
inside the Origin Table number 2.
Fig. 13.1-2
N25 (UAO,2)
; EXAMPLE2
;*** TOOL LIST ***
; TOOL - 01 DIA. - .5 T1 ;*****************
N5 MOV=72
N10 VFF=1
N15 FCT=.00001
N20 G00 G79 Z(@ZPARKP1)
;( TOOL - 01 )
N30 M06 T1
Page 23 of 42
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Section 13 (continued)
Step 13.2-1
The operator will need to access the machines origin tables in order to enter the desired
values to be used. From the main OSAI Process Controller, the operator will press the
Utility button in the bottom left corner. From the menu that appears, select Table Editor
(see Fig. 13.2-1), this will open the OSAI Table Editor window.
Step 13.2-2
From the bottom of the OSAI Table Editor the operator will need to select
the Tables button (Fig. 13.2-2) to open the menu. From this menu the
operator will select Origin. This will open the Origin Table which is where
the operator will enter his values.
Fig. 13.2-1
Fig. 13.2-2
Step 13.2-3
Fig. 13.2-3
With the Origin Table open the operator will use the directional arrow keys
on the Keyboard to highlight the desired table number. In the image to the
right (see Fig. 13.2-3), Origin Table 1 is highlighted. By pressing the Enter
button on the keyboard, the operator will be able to access the table to enter
new values.
Step 13.2-4
The operator will enter the desired values into the corresponding axes. In this
example we will be shifting the X axis .5 inches, Y axis .5 inches, and the Z
axis .73 inches. Once the values are entered and verified the operator will
press OK, and see the values in the Origin Table under table 1.
Fig. 13.2-4
Page 24 of 42
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Section 13 (continued)
Step 13.2-5
Using the directional arrows, the operator will select the next Origin that needs
to be set up. The operator will repeat Steps 13.2-3 to 13.2-4 for all desired
origins as needed. Fig. 13.2-5 shows origins 1 and 2 with values.
Fig. 13.2-5
To review this section, in Steps 13.1-1 in the program EXAMPLE the program calls out the use of (UAO,1). In
Steps13.2-1 to 13.2-4 the operator entered the desired values into Origin 1 to shift the machine. When the
program executes the UAO call in the program the control will look at the values in Origin and shift the Machine
Absolute Zero by the amounts designated in the table. The program will believe it is running at X0, Y0, and Z0,
but physically the machine will be running it at X0.5, Y0.5, and Z0.73. This is referred to as an Origin Shift or
Work Shift.
Section 14.1 Part Program Management
Once the CAD/ CAM software has produced the G Code program to be run on the machine, the operator will
need to load that program into the UPP Directory (User Part Program Directory). The operator will have two
different ways in which program(s) can be loaded into the UPP Directory.
1.) Connect the machine to the network of the company and create a shared folder in which to place the
program into, so that the operator can access them from the OSAI Operator console.
2.) Place the program(s) onto a USB memory device, then bring the device to the machine and copy the
program into the OSAI Operator Console.
This manual will instruct the operator how to load the programs into the UPP Directory and then call them up to
be run. The instructions will be for the loading of programs off of a USB Memory Device into the UPP.
Step 14.1-1
Fig. 14.1-1
The operator will plug the USB Memory Device into the OSAI WinMedia Panel (the
port is labeled on the right side of the screen) and the Windows operating system
should Auto Play the device opening a prompt window. The operator will select the
option Open folder to view files using Windows Explorer (see Fig. 14.1) from the
screen.
Step 14.1-2
Fig. 14.1-2
The operator will see the prompt window for the device appear. Inside the
window will be a list of jobs that need to be run. The operator will need to
select the job(s) to run on the machine. If this method is used, it is
recommended to keep the Memory Device clean to avoid confusion in
choosing the job to be run.
Page 25 of 42
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Fig. 14.1-4
Step 14.1-5
The operator will click on the Start button (at the bottom left of screen) then select
the My Computer icon from the list on the right. The My Computer window will
open (see Fig. 14.5).
Fig. 14.1-5
Step 14.1-6
The operator will need to open the UPP Drive that should appear in the My
Computer window. This drive should be mapped out, in the example shown the
designation is Upp on NC14580101 (Z:). The operator will double click on the Upp
icon in order to gain access to the UPP folder.
Fig. 14.1-6
Step 14.1-7
The operator will then select the UPP Folder and double click it to open the folder.
This gives the operator access to the storage area for the part programs (jobs) to
be run.
Fig. 14.1-7
Step 14.1-8
Fig. 14.1-8
The UPP Directory will open. The operator will press Ctrl & V this will paste the
programs in the UPP. The operator will see the new programs highlighted in the
screen. This is the storage area that the operator will store the programs in. The
operator can create sub directory folders inside the UPP to help organize the UPP
directory. The programs stored in this area can have one of three extensions those
extensions are:
.txt
.nc
.anc
NOTE: The operator can close the windows discussed in the previous steps (see Steps 14.1 to 14.8)
and Maximize the OSAI Process Controller.
Page 26 of 42
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Fig. 14.2-1
Fig. 14.2-4
NOTE: For operators whom are not familiar with running and programming a CNC
router we recommend that the operator Dry Runs the program at the beginning to
become comfortable and familiarize themselves with the CNC machine and it
motions.
NOTE: Prior to running a job the operator will want to ensure all variables are entered into the control
and that all safety measures are taken. Below are 7 steps that the operator can take to ensure prior
running:
1.) Tool Length: Ensure tool lengths are correct and entered into the control
2.) Origins: Ensure that Origin (Fixture Offsets) are correct for the program being run
3.) Z Shift:
Ensure that the proper Z Shift (Material Offset) is set for a Dry Run or set to Zero for
actually cutting material
4.) Program:
Check and ensure that the program is loaded in the control and Activated to run
5.) Overrides:
Ensure that all the overrides are in the correct position for running the program
6.) Vacuum:
Ensure vacuum is on and applied to the work piece and overrides are in correct safety
position
7.) Dust Collection: Ensure Dust Collector is on and blast gates are open
Page 27 of 42
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Fig. 14.3-1
Step 14.3-2
Fig. 14.3-2
The Z axis Material Offset window will open. The operator will enter the
shift needed into the Enter Z value on the screen. This shift value will
change based on the material thickness being run. The shift is based off of
the Z axis final depth in the part program. This value should be larger then
the material thickness.
Step 14.3-2
In example, if the material to be cut is 1 inch thick, then the Z shift value should be 1.25 inches or greater.
When the program runs, the tip of the tool will be .25 inches off the top of the material. Once the Dry Run is
completed (it is recommended to run through all tool changes in the program) the operator will need to change
the Z Shift back to 0.0 (zero) in order for the tool to cut the material.
Page 28 of 42
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FUNCTION
Machine Rapid Move
Program Feed Move
Clockwise Interpolation of an arc
Counter clockwise Interpolation of an arc
Free Interpolation Plane Selection (used for
interpolation of slave axis)
XY Interpolation Plane
M-Code
M00
M01
M02
M03
M04
FUNCTION
Program stop/ Pause
Program stop optional
End of Program
Spindle Rotation CW
Spindle Rotation CCW
M05
Spindle Stop
M06
M30
M98
Brushes Down
Inch units
Metric units
Absolute (in ref. to home position)
Absolute (in ref. to current origin)
Incremental (in ref. to previous move)
M99
Brushes Up
Specific
G-Code
G200
FUNCTION
FUNCTION
G352
G353
G500
G600
G320
G699
G321
G700
G322
G999
G201
G300
G301
G302
G310
G311
G330
Specific
G-Code
G331
G350
G351
Page 29 of 42
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FUNCTION
Specific MCodes
FUNCTION
M18
M20
M21
M22
M23
M24
M130
M131
M132
M133
M134
M135
M25
M34
M136
M137
Vacuum Zone 6 on
Vacuum Zone 7 on
M138
M139
M140
M141
M142
M143
Vacuum Zone 8 on
Vacuum Zone 9 on
All Vacuum Zones off
M144
M145
M146
M147
M148
M149
M154
M155
M156
M157
M158
M159
M200
M87
M88
M89
M90
M91
M100
M201
M202
M203
M204
M205
M206
Head 1 Up
Head 2 Up
Head 3 Up
Head 4 Up
Head 5 Up
Head 6 Up
M101
M110
M111
M207
M208
Head 7 Up
Head 8 Up
M35
M66
M70
M71
M72
M73
M74
M75
M76
M77
M78
M79
M80
M81
M82
M83
M84
M85
M86
Vacuum Zone 1 on
Vacuum Zone 2 on
Vacuum Zone 3 on
Vacuum Zone 4 on
Vacuum Zone 5 on
Page 30 of 42
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FUNCTION
All Heads Down
Head 1 Down
Head 2 Down
Head 3 Down
Head 4 Down
M215
M216
M217
M218
M220
M221
M222
Head 5 Down
Head 6 Down
Head 7 Down
Head 8 Down
All Brushes Up
M223
M224
M225
M226
M227
M228
Head 3 Brushes Up
Head 4 Brushes Up
Head 5 Brushes Up
Head 6 Brushes Up
Head 7 Brushes Up
Head 8 Brushes Up
All Brushes Down
M230
M231
M232
M233
M234
M235
Head 1 Brushes Up
Head 2 Brushes Up
Specific MCodes
M300
M301
M302
M303
M304
FUNCTION
All Tools Clamp
Head 1 Tool Clamp
Head 2 Tool Clamp
Head 3 Tool Clamp
Head 4 Tool Clamp
M305
M306
M307
M308
M310
M311
M312
M313
M314
M315
M316
M317
M318
M320
M321
M322
M323
M324
M325
M236
M237
M238
M240
M241
M242
M243
M326
M327
M328
M330
M331
M332
M333
M250
M251
M252
M253
M290
M291
Tray #2 Out
Tray #2 In
Tray #2 Down
Tray #2 Up
Enable X axis +ve s/w limit
Disable X axis +ve s/w limit
M334
M335
M336
M337
M338
Page 31 of 42
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FUNCTION
Raise All Vacuum Pop-ups
Raise Vacuum Pop-up 1
M342
M343
M344
M345
M346
M347
M348
M349
M350
M351
M352
M353
M354
M355
M356
M360
M361
M362
M363
M364
M365
M366
M367
M368
M369
M370
M371
M372
M373
M374
M375
M376
Page 32 of 42
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Message
Description
Remedial action
Erroneous encoder
configuration. Non-locking
error (ERRO status).
EE003
Encoder phase
error
EE004
EE005
Inpos tolerance
error
EE006
Broken wire
detection
EE008
Divide by zero
axis
EE009
Invalid command
axes
Software
EE011 overtravel limit
with HPG
HPG software
EE012
overtravel exit
CAN
EE014 communication
error
Page 33 of 42
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FastWire
EE016 communication
error
EE020
Plus shutdown
request
EE022
Plus divide by
zero
EE023
EE024
WinPlus/Coprocessor error in
the logic task. Locking error
(EMERG status).
Plus coprocessor
exception
EE025 or
WinPlus
Exception
EE026
Axis hw
EE027 overtravel limit
reached
Note: It is a warning.
EE028
EE031
Front Panel
anomaly
Page 34 of 42
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Unrecoverable
EE033 Remote I/O
Failure
Recoverable
EE034 Remote I/O
Failure
0203, 0206,xxxx.
Indicates one or more of the
following errors:
Power supply error (PSU)
Blocked motor
EEPROM error
Op System Error
Drive Error
Description
Remedial action
15
Over signal
EE040 distorsion on
optical fibre
14
14
Interrupt
EE041 trasmission on
optical fibre
13
13
AT Telegram
EE042
missing
12
12
D.S.I.
EE043 Initialization
phase error
11
Anomaly on
service channel
System reset.
10
10
Anomaly on
EE045 D.S.I.command
execution
0201,0205
Bus Overvoltage, or Power group
overtemperature
0202
Overcurrent
Code
EE044
EE046
Message
0601,0602
Excessive position Error
11
Shut down
EE047 warning: class 2
diagnostic
D.S.I. Fault:
EE048 anomaly during
anomaly
Axis enable
EE049 request not
allowed
0300>0304,0800>0808,0A00>0A08
Error in encoder 1 (X24) and/or
Encoder 2 (X25)
0204
Interference on the 24v PSU
Page 35 of 42
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3
2
3
0501
Motor overtemperature
0401
Software motor temperature
protection
MECHATROLINK ANOMALIES
EE050 Axis board
memory failure
EE052 Communication
error
Check drive
parameters and, if it is
a dynamics problem,
extend check to AMP
dynamic parameters.
Eliminate drive alarm
cause and RESET
system.
EE054 Command
timeout
Fastwire
Axes Board
EE055 Memory Test
Failed
Drive Command
EE057 Error Axis n
Error:eeee
Description
Possible causes
1000
invalid axis ID
1001
1002
communication channel
engaged
1003
Code eeee
Page 36 of 42
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1004
1005
invalid request
application error
1006
invalid command
2002
command failed
2003
invalid drive ID
2004
Drive engaged
2005
invalid request
2007
2101
illegal operation
2102
request to monitor
more than 16 variables
2103
Monitoring already
active
2104
No variable to be monitored
No variable to be
monitored
2105
Malfunctioning on the
internal serial port
2106
Malfunctioning on the
internal serial port
2107
Malfunctioning on the
internal serial port
2108
checksum error
Malfunctioning on the
internal serial port
2109
echoing error
Malfunctioning on the
internal serial port
2110
Hyperface error
Malfunctioning on the
encoder serial port
2111
2112
wrong variable ID
2113
2114
wrong parameter ID
2115
2116
2117
2118
2119
2120
2121
synchronisation timeout on
ROTC
2122
2123
reprogram FPGA
Page 37 of 42
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2124
2125
2126
2127
power error
30 (Models B &
C only)
Description
DSP malfunction
power board
malfunction
Eliminate the cause
and Reset
Possible causes
Type
of
stop
Recommended action
31
DSP Watchdog
Firmware version
error.
IGBT
Open
32
NMI triggered
Firmware version
error.
IGBT
Open
33
faulty drive
34
40
Drive overheat
41
42 (A)
overcurrent in the
drive.
Dyn.
0 Vel
IGBT module
overtemperature
42 (B & C)
Drive overcurrent.
43 (B & C)
44 (B & C)
IGBT
Check brake resitor connections
Open
HW over/undervoltage
protection (380V)/(400V)
Ramp
Down
45
Dyn.
0 Vel
Page 38 of 42
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46
47
Bus overvoltage
Dyn.
0 Vel
48
Bus undervoltage
Ramp
Down
49
50
51
52
53
Dyn.
2 Sec.
54
55
Ramp
Check the setting
Down
56
Ramp
Check the setting
Down
57 Mov01
58
Ramp
Down
Ramp
Down
59
Wrong parameter
Parameter 42 or 45 has
value 0. Some
IGBT
parameters are wrong.
Check the parameters.
Open
60
Power Lost
Unrecognized alarm
the power card.
61
SinCos Error
Dyn.
2 Sec. Re-enable the drive.
62
Tuning limit
Ramp
Down
Page 39 of 42
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63
(only B & C)
64
65
ramp
down
66
Excessive position
error
Dyn.
0 Vel
67
Excessive velocity
error
Dyn.
0 Vel
68
Collision
Maximum admissable
current is applied and
motor does not move
for 0.5s
IGBT
Open
69
Description
Possible causes
IGBT
Open
01
Flash Checksum
IGBT
Open
02
External Data
IGBT
Open
03
Block B0 Program
IGBT
Open
04
Block B0 Data
IGBT
Open
05
Block B1
IGBT
Open
06
Block B2
IGBT
Open
07
Block SARAM
IGBT
Open
08
Dualport
IGBT
Open
09
IGBT
Open
10
IGBT
Open
11
IGBT
Open
12
IGBT
Open
13
IGBT
Open
14
E2PROM
IGBT
Open
Page 40 of 42
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15
16
Emergency Clear
Emergency request.
The CNC has
generated an
Emergency Clear
(broadcast) message
Ramp
Down
17
18
WatchDog CN_DSP
communication with
the CNC interrupted
Ramp
Down
19
Mov 01
Ramp
Down
20
Mov 01
Sequencer Error
EE060 Drive
Initialisation
Error Axis X
Error:eeee
Error: eeee
Possible causes
1000
invalid axis ID
1001
1002
communication channel
engaged
1003
1004
1005
invalid request
application error
1006
invalid command
2002
command failed
2003
invalid drive ID
2004
Drive engaged
2005
invalid request
2007
2101
illegal operation
2102
request to monitor
more than 16 variables
2103
Monitoring already
active
2104
No variable to be monitored
No variable to be
monitored
2105
Malfunctioning on the
internal serial port
2106
Malfunctioning on the
internal serial port
2107
Malfunctioning on the
internal serial port
Page 41 of 42
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2108
checksum error
Malfunctioning on the
internal serial port
2109
echoing error
Malfunctioning on the
internal serial port
2110
Hyperface error
Malfunctioning on the
encoder serial port
2111
2112
wrong variable ID
2113
2114
wrong parameter ID
2115
2116
2117
2118
2119
2120
2121
synchronisation timeout on
ROTC
2122
2123
2124
2125
2126
2127
power error
reprogram FPGA
DSP malfunction
power board
malfunction
Page 42 of 42
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Page 1 of 2
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LOAD METER
ROUTING
WARNING!! DO NOT START OR RUN ANY
MACHINE WITH THE DOORS OPEN OR GUARDS
OUT OF PLACE.
WARNING!! WEAR EYE PROTECTION AND
HEARING PROTECTION WHEN OPERATING THIS
OR ANY OTHER WOODWORKING MACHINE.
WHERE WOOD DUST IS NOT TOTALLY
CONTROLLED, RESPIRATORY PROTECTION
SHOULD BE USED.
Page 2 of 2
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Page 1 of 2
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Questions?
Page 2 of 2
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DAILY MAINTENANCE
The operator should perform a walk around the machine before powering it up. Check to make sure there
are no obstructions in the path of any of the axes strokes that would hinder machine movement or cause
damage to the machine.
The machines air pressure should be checked daily. In the morning, check to ensure that the machine has
proper air pressure at the regulator, and also check the filter indicator. If the indicator is green, then the filter
is OK; if the filter is turning red, try cleaning the filter or order a new filter for the air regulator.
NOTE: The filter in the machines Eliminizer should be replaced every 6 month(s).
The operator is required to warm the spindle every morning prior to cutting any material. Your router spindle
can run at 24,000 rpm! In the morning, or whenever the machine has not been run for several hours: load
a tool, start the spindle at a speed of 9,000 rpm (assuming this does not exceed the recommended rpm
of the tool), let the spindle run at this warm up speed for 15 minutes to allow the bearing grease to loosen
up. Once warmed up, stop the spindle rotation and park the tool. Note: The morning warm up should
only be done after the machine has been homed.
DO NOT LEAVE THE MACHINE UNATTENDED WHILE THE SPINDLE IS WARMING UP!!
Check that the tool tray appears to be in proper alignment with the spindle as tools are being loaded and
parked. Keep the tool tray and tool holders clean of debris. Observe that the dust brushes are going up and
down properly.
Tool holders should be broken down and cleaned thoroughly whenever a bit is changed. Whether the bit is
being changed due to dulling of the bit or breaking of the bit. Tighten bits in the tool holder securely, but do
not tighten so tightly that the collet is forced down into the taper of the tool holder, thus distorting the collet
and causing uneven gripping of the shank of the bit. Over tightening can also cause damage to the bearing
ring located in the clamping nut. Collets wear out! Replace a collet at least every month of running time.
(Worn collets WILL cause bit breakage. New collets are less expensive than most router bits.)
The operator should also clean off the machine of any debris, dust, or chips at the end of each working shift.
The operator should closely inspect the spindle taper, clean and lubricate as needed. The operator should
not allow any debris or contaminants to build up in this area as it may cause premature damage to the
spindle. See the spindle manufacturers manual for further details.
The operator should wipe down the ends of the linear rail on the machine. The operator should only need to
wipe the accumulation that appears at the ends of each of the axes stroke. Throughout the shift when the
machine is idle the operator will want to check the rails to make sure grease is being applied. By running a
finger along the face of the rail the operator should feel a fine greasy film on the rail. If the film cant be felt
immediately, grease the machine.
On Moving Gantry machines check the rack on axes with rack for build up and or debris.
Clean / Remove, any build up, as this will cause premature wear and inaccuracy.
The operator should check and observe the machine movements throughout each shift that the machine
runs, noting and investigating any unusual noises, loose and/ or odd moving components, also
any inconsistencies the machine might be creating or experiencing (i.e. inconsistent cutting depth).
Operator should always park tool at the end of the day. As the hot spindle cools it may tighten up on the
taper of the tool holder making it VERY difficult to remove the tool holder from the spindle.
Page 1 of 25
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WEEKLY MAINTENANCE
Perform all daily maintenance checks on the machine mentioned in the Daily Maintenance section.
Clean and blow out the filter(s) on the vacuum pump(s).
Check that the machines cooling fans are operating. There is a fan on the top of the spindle, and
inside the electrical cabinet.
Check the nose of the spindle and clean the spindle nose of any debris or build up.
Check the spindles Bullet distance as it protrudes out of the spindle. Extend the bullet from the
spindle and using a depth micrometer measure the distance this should be approximately .414
inches (+/- 0.002) refer to the spindle manual for an exact value. Ensure that the bullet is not loose.
Check the dust brushes and dust hood components ensure that the up/ down travel is not binding
cause trouble with the motion of the hood and also ensure that the brushes are not mangled, curled
inward, or deformed due to debris.
Grease the machine at the models standard greasing points. For grease point locations please refer
to the components section of your machine owners manual. NOTE: The spindle motor bearings
are permanently lubricated for the life of the motor.
Linear Bearings: The Linear Bearing Block (Trucks) should be greased every 40 hours that the
machine runs. You should put in 2 pumps of the recommended NLGI #1 Lithium based grease into
each zerk fitting.
Ball Screw & Nut: The Ball Screws should be greased every 40 hours that the machine runs. You
should put in 3 - 4 pumps of the recommended NLGI #1 Lithium based grease into each zerk fitting.
Below are some examples of grease points on a machine. Please refer to the Components Section
of the manual for the specific grease points for your machine model.
Note: All grease points should be greased with the proper Multifak EP1 grease every 40 working hours. The proper
grease can be ordered from our parts department. Part #: 274502 - Description - Multifak EP1.
Page 2 of 25
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MONTHLY MAINTENANCE
Perform all daily maintenance checks on the machine mentioned in the Daily Maintenance section.
Perform all weekly maintenance checks on the machine mentioned in the Weekly
Maintenance section.
Check the emergency circuit to ensure each emergency device is working properly and resetting correctly.
(WITH MACHINE POWER OFF)
Perform these steps after turning off all the machine power and performing proper OSHA regulated
lock out procedures!!
Check axes strokes by manually pushing each of the axes (with power off to the machine) the full stroke of
the axis. Check for any type of noticeable resistance during the travel.
Open the machines electrical cabinets located on the rear of the bridge (see the machine Owners
Manuals Component Section for reference). Using a Shop Vac, or Dust Buster clean the dust out of the
cabinets. NOTE: DO NOT USE ANY TYPE OF COMPRESSED AIR TO CLEAN THE CABINETS.
COMPRESSED AIR HAS MINUTE AMOUNTS OF MOISTURE THAT CAN CAUSE EXTREME DAMAGE
TO YOUR ELECTRONICS INSIDE THE CABINETS!!
Check the electronic devices for dust build up. Use a proper electronics cleaner to remove the dust
(computer, and electronics stores carry these cleaners) if dust is evident clean the components with the
fore mentioned cleaner.
Check and clean the rack along X axis of moving gantry machines, checking both the tool tray and non tool
tray side of the axis. The rack should be cleaned of debris on a regular basis in between each tooth of the
rack to clean out the debris.
Lubricate, clean, and verify the adjustment of the spindle bullet and clamping group on the router
spindle(s). Proper care and adjustment of these components is vital for safe and accurate use if the electro
spindle. Refer to the manufacturers manual for further details.
Page 3 of 25
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Tooling Accessories:
200 TH
Torque Wrench
Helps ensure the user is following the manufacturers torque specifications for collets &
clamping nuts.
03690-25
90-002 GLC
91-125
10 pk Inserts
91-130
91-136
Torque wrench
33-10
Contains 4 brushes ranging from in to in for proper cleaning of tool holder collets.
33-21
Cleaning kit for tool holders and collets includes a T-9 lubricant and cleaner.
33-66
Used for properly wiping out the taper of the spindle nose.
Clamp Tool
VTM-2525
Vacuum Gasket
XM3150
HSK63-F
HSK63-A
727-CROHSK63 Digital
Bench Top Tool Setter
SYOZ25 (RDO 35)
Using in tool preparation for measuring the tool length. Helps to increase cycle time by
lower downtime on the machine for tool maintenance.
Collets for HSK 63F(SYOZ25) Tool Holders range from 1/8 in to 1 in and various metric
sizes
**** Please ensure that the appropriate SYOZ25 collet sizes are ordered for each shank diameter size of cutters ordered for the machine
production. It is also recommended to have 1 extra of each size. For our first time customers these should be ordered and arrive PRIOR to
the technicians arrival!! ****
TOOLING APPLICATIONS:
LAMINATED WOOD MATERIALS:
OC
60-100 SERIES
DE SC COMPRESSION
OC
60-100C SERIES
OC
60-100MW
VT
Series 3100
DE SC COMPRESSION
VT
Series 3100M
DE SC MORTISE COMPRESSION
VT
Series 3100XP
AE
DD05070
5mm x 70mm x 10mm shank line boring drills. Available in 57mm length for Brad & Thru Points in line boring
applications.
AE
DD08070
8mm x 70mm x 10mm shank line boring drills. Available in 57mm length for Brad & Thru Points in line boring
applications.
Page 4 of 25
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Recommendation for general purpose cutting and for most grades of plywood
OC
48-000 SERIES
OC
48-700 SERIES
VT
Series 4000
SC DE STRAIGHT FLUTE
SOLID WOOD:
OC
52-200 SERIES
DE SC UP CUT
OC
57-700 SERIES
DE SC DOWN CUT
VT
SERIES 1200
VT
SERIES 1300
CRO
CRO SERIES
CRO
CRO D SERIES
PLASTICS:
OC
63-700 SERIES
VT
SERIES 5600
OC
63-750 SERIES
VT
SERIES 5600S
OC
52-700 SERIES
DE SC UP CUT SPIRAL for Pocketing Application where bottom finish is not vital
OC
66-300 SERIES
OC
52-200 B SERIES
DE SC BALLNOSE UP CUT
VT
SERIES 2200
OC
37-00 SERIES
VT
SERIES 3800
ALUMINUM:
OC
63-600 SERIES
VT
SERIES 5600A
FOAM:
OC
52-700 SERIES
COMPOSITE:
SC DE DOWN CUT -
This encompasses many different materials, please consult your local tool rep for special applications
OC
54-200 SERIES
3E & 4E SC SPIRAL for Fiberglass & Composites (Coated against abrasive characteristics)
OC
66-800 SERIES
OC
66-900 SERIES
VT
SERIES 6100
AEROSPACE/ AUTOMOTIVE:
OC
34-000 SERIES
HONEYCOMB:
For general applications in Aluminum Grade 6000 & 7000 see the OC AMC series catalog. Also see the EMC
Series catalog.
MODULAR TOOL used for application where potting of precut slots in panels is needed.
OC
29-050 SERIES
OC
29-100 SERIES
SC HONEYCOMB HOGGER (Coated) Coated with ZRN for increased tool life.
OC
30-700 SERIES
REDUCED WEIGHT HONEYCOMB CUTTER 35% weight reduction for better performance on 3 & 5 axis
applications.
ENGRAVING:
OC
37-00 SERIES
OC
37-20 SERIES
OC
37-50 SERIES
**For more details please reference your Catalog (OC) from Onsrud Cutter or your Catalog (VT) from Vortex Tooling. Also note that CRO
SERIES bits are designed by C.R. Onsrud and have been tested in many soft material applications outside of wood and wood composites.**
Page 5 of 25
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NOTE: C.R. Onsrud does not "endorse" any Moulder Aggregates of any kind, due to safety
concerns!!
Moulder Aggregates should NEVER be used without "OSHA" approved Guarding.
It is the expressed opinion of C.R. Onsrud Inc.:
A moulder head should not be used on any machine, of any model, without a protective
enclosure around the machine! Many moulder aggregates are physically too large and
heavy to be used on machines that have not been custom configured!
WARNING: Any customer that chooses to use moulder aggregates, after the above mentioned opinion,
does so at their own risk. Any modifications to the machines tool tray, tool clips, or machine set up in
order to accommodate such a large aggregate will void the machines warranty. C.R. Onsrud Inc. will
not take any responsibility for damage to the machine, tool, or personnel.
WARNING: Customers using Large Profile Tools must follow the spindle manufacturers
recommendations along with the tool manufacturers recommendations for weights, center of gravity,
spindle speeds and feed rates. It is the customers responsibility to maintain the tools integrity and
balance failure to do may cause catastrophic failure of the tool resulting in machine damage, personal
injury or death!!
Page 6 of 25
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SPOILBOARD REPLACEMENT:
Here are some guide lines for replacing the spoilboard(s) on the machine table of a C.R. Onsrud CNC Router.
NOTE: Soilboard(s) material should consist of LDF, Ultralight MDF, or Trupan. These materials allow the
most vacuum to access the materials surface area on the machine table. This in turns results in better hold
down of the sheet stock being cut. We do not recommend using MDF due to vacuum restriction.
1.) Place the material on top of existing spoilboard(s). Surface the top of the material removing between 0.005
- 0.015 from the top. It is important to remove this material, due to the glaze that the manufacturer applies
during manufacturing. By removing this glaze on the top and bottom surface the vacuum will produce better
flow to the surface area of the sheet stock.
2.) Flip the newly surfaced material over. Machine the material to desired length and width (X&Y) dimensions
to fit the machine table. Finish the material off by drilling or routing the holes and countersinks for bolt down.
3.) Remove the new spoilboard(s) and seal the four edges of the board(s). This is step is to ensure that there
is no vacuum loss around the edge of the new spoilboard(s) and all the vacuum is directed at the surface area
of the sheet stock.
4.) Remove the old spoilboard(s) from the machine table. Inspect the gasket around each of the zones of the
machine table. Replace the gasket in areas that are cracked, twisted, and/or squashed.
5.) Place the new spoilboard(s) on the machine table, align, and then bolt them down to the machine table.
6.) Once bolted down surface the top side of the new spoilboard(s) to flatten the material and also to remove
the glaze as done in Step 1. Once the new board has been surfaced the machine is ready for production.
Page 7 of 25
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Quarterly Maintenance on the Clamp Group for HSK63 F: Using the Clamp Tool
Items Needed:
4mm T Handled Allen Wrench
Adjustable Wrench
Needle Nose Pliers
Bullet Gauge Block/ Depth Micrometer
Spindle Wiper
C.R. Onsrud Clamp Tool
Extra Fine Scotch Brite Pad & Clean dry rags
Blue Loc-Tite
MetaFlux grease
NOTE: The procedure shown can be done with the spindle mounted on the machine. In the following document the steps shown are done
on a spindle that was removed from a machine. The spindle DOES NOT need to be removed from the machine to perform this maintenance.
1.
2.
Using the machine control, activate the output to extend
the bullet. This will put the machine spindle in the state of
Tool Release and the bullet state will be extended. The
spindle will not be able to be turned by hand.
3.
Using an Adjustable Wrench hold the Bullet stationary, place the 4mm
Allen Wrench inside the center of the Bullet and loosen the set screw
inside the Bullet.
Page 8 of 25
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4.
Remove the set screw from the spindle
bullet. Clean the set screw with an extra
fine piece of Scotch Brite.
**NOTE: Place set screw to the side as it will be
used to set the bullet distance later in the
procedure.**
5.
Once the Bullet is broken loose, remove the Bullet from the spindle nose. See images below of the
Bullet being removed.
6.
Using a pair of Needle Nose Pliers, remove one of the Clamp Group fingers from the spindle nose.
Once the first finger is removed, continue removing the remaining fingers from the nose using the same
technique.
7.
Once the Bullet and the Clamp Group are out of the
spindle nose, use the Needle Nose Pliers to remove
the Clamp Group Hub from inside the spindle nose.
Page 9 of 25
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8.
Ensure that both the white Ceramic Spring Bushing
(A) and the Clamp Group Hub (B) come out of the
spindle. Clean both by wiping of any build up and
debris that may be on them. Once clean place them
to the side.
9.
Using a clean lint free rag, clean the inside of the spindle nose
removing any debris from inside the spindle nose.
10.
Inspect and clean the Clamp Group Fingers, the Bullet, The Clamp Group Hub, and the Ceramic
Bushing. Inspect for any damage such as dings, burrs, scratches, and such, on the surfaces of the
clamp group fingers, clamp group hub and the Bullet. Use a small amount of Metaflux grease to the
contact points between the clamp group hub and the clamp group fingers. Wipe down all components
of any excess grease.
11.
Once everything is clean, slip the
Ceramic Bushing and the Clamp
Group Hub back up inside the
spindle nose.
12.
Using the Clamp Tool, place the Clamp Group Fingers into
the recess at the bottom of the guide shaft.
**NOTE: If doing this procedure while the spindle is on the machine,
combine steps 11 & 12 by placing the Clamp Group Hub & Ceramic
Bushing on top of the fingers, then proceed to the next step.**
Page 10 of 25
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13.
Guide the Clamp Tool into the spindle nose and gently slide
the all the way up into the nose. Once the Clamp group is all to
the top of the spindle nose, give the Clamp Tool a slight push
upward to seat the Clamp Group (there will be a minor click as
the group seats into the recess inside the spindle nose).
**NOTE: If you followed both steps 11 & 12 be sure to align the Clamp Group
Fingers with the Clamp Hub in order to seat everything properly.**
14.
15.
Slide the Spindle Bullet into the center of Clamp Group
and begin screwing the bullet on to the end of the draw
bar shaft.
16.
At this point the Bullet distance will need to be set. It is important to set this distance
correctly for the proper functionality of the spindle. Using either the aluminum Gauge Block,
or a Depth Micrometer set the distance of the Bullet.
Page 11 of 25
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17.
Once the distance is set, place a small drop of Blue Loc-Tite on to the Bullet Set Screw.
Using the 4mm Allen Wrench and gently holding the Bullet still, re insert the set screw into
the Bullet and snug the set screw down. Ensure to verify that there was no change in the
Bullet distance and tighten down the set screw using an Adjustable Wrench and the 4mm
Allen Wrench.
Once the procedure is finished, you will want to follow the steps to verify the spindle sensor
activation. If you do not have this procedure please contact the C.R. Onsrud Technical
Support Department at 704-508-7000 Mon. through Fri. 8:00 am to 5:00 pm (EST) or via
email at techsupport@cronsrud.com to obtain the procedure. Also contact Technical
Support with any questions our concerns regarding performance of the above steps.
Please contact C.R. Onsruds Parts Department at 704-508-7000 or via email at
parts@cronsrud.com to purchase the specialty tools mentioned in the above procedure:
Clamp Tool
Bullet Gauge Block
Spindle Wiper
Metaflux
Page 12 of 25
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Page 13 of 25
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SPINDLE REINSTALLATION
DANGER!! REMOVE AIR AND ELECTRICAL POWER PER YOUR EMPLOYER'S OSHA CONTROL OF
HAZARDOUS ENERGY STANDARD 29 CFR 1910.147 LOCK OUT/ TAG OUT PROCEDURE.
(Reverse the removal procedure on the previous page)
Be sure your tool holders are clean and your cutting tools are in balance.
ANY QUESTIONS? PLEASE CALL OUR TECH-SUPPORT HOT LINE:
(1)704-508-7000 or (1)866-667-7837
Page 14 of 25
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Date:
Serial Number:
*This checklist contains routine procedures that a Certified C.R. Onsrud Technician will investigate while on a
Preventative Maintenance Service call. Any known specific machine issues and/or concerns need to be diagnosed prior
to arrival so that all parts that may potentially be needed are ordered and on site when the technician arrives.
PRIOR TO MACHINE POWER UP
1.
Safety stickers are on the machine and have not been removed
YES
NO
Notes:
Additional Comments/Recommendations:
2.
Check all axes datum switches (There is a minimum of 5 switches X, U, Y, Z, and V (Tool Tray). There may be more
switches depending on the machine model):
Datum switches are clean
YES
NO
Notes:
Distance from the block is good and the connections are tight
YES
NO
Notes:
Additional Comments/Recommendations:
3.
While observing the track when the machine is in operation, it lies properly in the J channel support
YES
NO
Notes:
Additional Comments/Recommendations:
Page 15 of 25
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4.
Manually check the X and U axis runner blocks by pushing the axes from one end of the stroke to the other.
Are there noticeable tight spots where travel becomes difficult, or any grinding as the axis is traveling
YES
NO
Notes:
Additional Comments/Recommendations:
5.
6.
NO
Notes:
The U axis linear rail is free of visible damage (i.e. dings, gouges, missing caps, etc.)
YES
NO
Notes:
Additional Comments/Recommendations:
7.
The X axis motor mounts, brackets, bolts, and cable connections are secure and free of visible damage.
(NOTE: On Fixed Bridge models, Check and tighten belt as needed, check that there are NO
missing teeth, cracks or fraying in the belt. Replace as necessary.)
YES
NO
Notes:
The U axis motor mounts, brackets, bolts, and cable connections are secure and free of visible damage.
(NOTE: On Fixed Bridge models, Check and tighten belt as needed, check that there are NO
missing teeth, cracks or fraying in the belt.)
YES
NO
Notes:
Additional Comments/Recommendations:
Page 16 of 25
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8.
Y axis runner blocks and ball screw - Manually move the axis from one end of the stroke to the other by rotating the
ball screw pulley.
Tight spots noticeable where travel becomes difficult, or any grinding as the axis is traveling
YES
NO
Notes:
The lock nut on the pulley end of the ball screw is tight as well as the set screw for the lock nut
YES
NO
Notes:
Additional Comments/Recommendations:
9.
Check the Ball Nut support Bolts going through the Back Plate to the Y axis Ball Nut Also check the
mounting bolts for the Ball Nut and Servo Motor carrier.
Notes:
Check the mounting bolts for the Ball Nut and Servo Motor carrier
Notes:
Additional Comments/Recommendations:
NO
Notes:
Additional Comments/Recommendations:
11.
The Y axis motor mount bolts, support bracket bolts, and cable connections are secure and free of visible
damage
YES
NO
Notes:
Check and tighten belt as needed, ensure that there are NO missing teeth, cracks or fraying in the belt
Notes:
Additional Comments/Recommendations:
Page 17 of 25
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Notice any visible damage to the track, or to any hoses and cables inside the track
YES
NO
Notes:
Additional Comments/Recommendations:
13. Z axis runner blocks and ball screw - Manually move the axis from one end of the stroke to the other by rotating the
ball screw pulley.
Tight spots noticeable where travel becomes difficult, or any grinding as the axis is traveling
YES
NO
Notes:
The lock nut on the top end of the ball screw is tight as well as the set screw for the lock nut
YES
NO
Notes:
Additional Comments/Recommendations:
The Z axis linear rail is free of visible damage (i.e. dings, gouges, missing caps, etc.)
YES
NO
Notes:
Additional Comments/Recommendations:
15.
Check the Ball Nut support bolts going through the front spindle plate to the Z axis ball nut
Notes:
Additional Comments/Recommendations:
16.
The Z axis motor mount bolts, support bracket bolts, and cable connections are secure and free of visible
damage
YES
NO
Notes:
Check and tighten belt as needed, ensure that there are NO missing teeth, cracks or fraying in the belt
Notes:
Additional Comments/Recommendations:
Page 18 of 25
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Notice any visible damage to the track, or to any hoses and cables inside the track
YES
NO
Notes:
Additional Comments/Recommendations:
Ensure tool tray mounting is secure, and that the tray is level
Notes:
Check all sensors and cable connections at the tool tray are secure and in place
Notes:
Additional Comments/Recommendations:
Note the condition of the brushes; check the back brush flap for proper mounting and proper motion
Notes:
Additional Comments/Recommendations:
The outside of the rear electrical cabinets are free of dust and/or debris
YES
NO
Notes:
The inside of the rear electrical cabinets are free of dust and/or debris
YES
NO
Notes:
Additional Comments/Recommendations:
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All grease lines are connected properly and are free of visible damage
YES
NO
Notes:
All runner blocks and ball screws are lubricated with Chevron NLGI No. 1 Grease
YES
NO
Notes:
Additional Comments/Recommendations:
23. Grounding:
Additional Comments/Recommendations:
24. Fans:
Additional Comments/Recommendations:
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25. Control System (depending on control unit in place, these steps may vary):
All Emergency Stop buttons are functioning properly (press & reset)
YES
NO
Notes:
Additional Comments/Recommendations:
Check the mesh on both the X axes and the U axes front and back of the column. Indicate each column at
the front (i.e. X 0), middle (i.e. X 60 to 72) and at the back (i.e. X 120 to 145) of the machine. Adjust
mesh as needed.
Front:
Middle:
Back:
Additional Comments/Recommendations:
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28. Datum/ Home the machine ensuring proper homing direction and location. After cycle is complete verify the Machine
Zero position bringing a V-Bit down to the front corner.
*Note: Fixed Bridge machines will need to have Table 2 Machine Zero Position checked.
Additional Comments/Recommendations:
29. Manually Jog each of the axes to ensure smooth motion, and that there is no motor noise during the axes
acceleration, deceleration, and actual travel.
Additional Comments/Recommendations:
30. Check all tool holders & collets for rust, buildup or damage.
*If Needed: Clean with some fine grade scotchbrite and lacquer thinner.
Additional Comments/Recommendations:
Check tool tray pockets for wear and tear. Replace damaged clips as needed.
Notes:
Aggregate Changer: Check and verify its change position (if applicable)
Notes:
Additional Comments/Recommendations:
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Check the spindle drawbar bullet adjustment and adjust the distance if it is protruding from the nose of the
spindle cartridge if necessary.
Notes:
Check spindle sensor activation during a tool change. Ensure that the sensors are activating and
deactivating in proper sequence.
Notes:
Check the cone air blast to be sure that there is no restriction of airflow during tool change routine.
Notes:
Check the Tool Release, Tool Lock, and Tool Capture sensors at the circuit board in the electrical cabinet.
Notes:
Perform a preliminary field diagnosis of the spindle bearing by first checking the free spin of the spindle.
Then perform a spindle start up at 9,000 rpm listening for any bearing damage. Step the rpm of the spindle
up by 2,000 rpm every 2 minutes until reaching 18,000 rpm.
*Note: If a Spindle hour meter is present, record the reading below.
Hour Meter Reading:
Notes:
Check the spindle for run out using a 12 Alignment Rod. Also perform a spindle tram check. Ensure that the
spindle is perpendicular to the table.
Notes:
If applicable, verify Drill Head Offset Distance is correct for the intersecting bit of the drill block to the center
of the spindle. Adjust as needed.
Notes:
Additional Comments/Recommendations:
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Totally seal one zone at a time to check vacuum gauges for a good pressure reading.
Notes:
Additional Comments/Recommendations:
34.
Send a program supplied by customer to the machine checking for proper communication in the download.
Verify that program was received at the controller, and run the job.
Notes:
Check and make sure the finished part for square, edge finish quality, and if part is cut to size.
Notes:
Additional Comments/Recommendations:
35. Discuss options for additional control training, machine operation training, applications training, and software training
(if it is software purchased from C.R. Onsrud) with the customer.
Additional Comments/Recommendations:
36. Perform a complete control system back up of any parameter changes made leaving one copy for the customer and
providing one for C.R. Onsrud, Inc.
Additional Comments/Recommendations:
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The items listed in this Preventative Maintenance Checklist have been completed as described above to the satisfaction
of the authorizing party.
Signed:
Date:
Please Print
Name:
Additional
Comments:
Date:
Please Print
Name:
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