CNC-Step High-Z Standard S-400 User manual

Status: 01.03.2017
Operating Instructions
High-Z Standard-Series
Rev 1.5 - FaceLift2016
S-400 ▪ S-720 ▪ S-1000
https://www.cnc-step.de/en/

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 2
Support: +49 (0)2831/91021-50
15.02.2014
High-Z Standard-Series
Short description
The machine includes the complete mechanics for three-dimensional movement. The linear
carriage-movement takes place via threaded spindles, powered by step motors. Two drives are used
on the x-axis. The activation of the step motors, in order to operate every single axis, is done by
using further interfaces. This operating description will show you how to install, operate and service
a CNC- portal system.

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 3
Support: +49 (0)2831/91021-50
15.02.2014
Contents
1GENERAL.....................................................................................................................7
1.1 Symbol description...................................................................................................................7
1.2 Limitation of Liability..............................................................................................................8
1.3 Copyright ..................................................................................................................................8
2SAFETY ........................................................................................................................9
2.1 Intended use..............................................................................................................................9
2.2 Fundamental dangers ............................................................................................................10
2.2.1 Hazards from electrical power...........................................................................................10
2.2.2 Dangers by mechanics.......................................................................................................11
2.2.3 Dangers by high or very low temperatures........................................................................13
2.2.4 Risk of fire.........................................................................................................................13
2.2.5 Radiation hazards ..............................................................................................................14
2.2.6 Hazards of chemicals.........................................................................................................14
2.2.7 General work-related dangers............................................................................................16
2.3 Responsibility of the operator...............................................................................................17
2.4 Staff requirements..................................................................................................................18
2.4.1 Qualification......................................................................................................................18
2.4.2 Instruction..........................................................................................................................19
2.5 Personal protective equipment..............................................................................................19
2.6 Safety installations..................................................................................................................20
2.6.1 Description of the installed safety installations.................................................................21
2.6.2 Safety installations, which have to be updated by the owning operator............................22
2.7 Behaviour in case of fire or accidents...................................................................................22
2.8 Environmental protection......................................................................................................23
2.9 Signage.....................................................................................................................................23
2.9.1 Mandatory signs ................................................................................................................24
2.9.2 Prohibition signs................................................................................................................24
2.9.3 Warnings............................................................................................................................25
2.9.4 Fire protection signs ..........................................................................................................26
2.9.5 Exit signs ...........................................................................................................................27
3TECHNICAL SPECIFICATIONS................................................................................28
3.1 General information...............................................................................................................28
3.2 Power values ...........................................................................................................................30

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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3.3 Operating conditions..............................................................................................................30
3.4 Working materials..................................................................................................................30
3.5 Emissions.................................................................................................................................30
3.6 Type plate................................................................................................................................31
4STRUCTURE AND FUNCTIONS................................................................................32
4.1 Overview .................................................................................................................................32
4.2 Brief description of the application range............................................................................33
4.3 Module Description................................................................................................................34
4.3.1 Z-axis with carriage...........................................................................................................34
4.3.2 Manual adjustment of the Z-Axis......................................................................................34
4.3.3 Y-axis with carriage...........................................................................................................35
4.3.4 X-axis with carriage...........................................................................................................36
4.3.5 Tool holder ........................................................................................................................37
4.4 Controls...................................................................................................................................37
4.5 Connections.............................................................................................................................38
4.5.1 Control signals (ST)...........................................................................................................39
4.5.2 Motor connector (X1,X2,Y,Z)...........................................................................................39
4.5.3 MiniXLR pin socket (Pin15).............................................................................................40
4.6 Work and danger areas .........................................................................................................41
4.6.1 Working area .....................................................................................................................41
4.6.2 Danger zone.......................................................................................................................41
5TRANSPORT, PACKAGING AND STORAGE ...........................................................42
5.1 Safety instructions for transport...........................................................................................42
5.2 Transport inspections ............................................................................................................43
5.3 Packaging................................................................................................................................44
5.4 Symbols on packaging............................................................................................................45
5.5 Transport ................................................................................................................................45
5.6 Storage.....................................................................................................................................47
6INSTALLATION AND COMMISSIONING.................................................................48
6.1 Safety instructions for the installation and commissioning................................................48
6.2 Preparations............................................................................................................................49
6.2.1 Install machine...................................................................................................................49
6.2.2 Install worktop...................................................................................................................50

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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6.3 Installation ..............................................................................................................................50
6.3.1 Connecting the computer...................................................................................................50
6.3.2 Connecting the stepper motor and control cable...............................................................51
6.3.3 Installing Accessories........................................................................................................52
6.4 Initial start-up.........................................................................................................................53
7OPERATION...............................................................................................................54
7.1 Safety guidelines for operation..............................................................................................54
7.2 Operations before usage ........................................................................................................54
7.3 Switching on............................................................................................................................54
7.4 Activities during operation....................................................................................................55
7.4.1 Operating machine.............................................................................................................55
7.4.2 Change tool........................................................................................................................58
7.5 Switching off ...........................................................................................................................58
7.6 Activities after use..................................................................................................................59
7.7 Emergency Shutdown............................................................................................................59
8MAINTENANCE.........................................................................................................60
8.1 Safety Instructions for maintenance.....................................................................................60
8.2 Spare parts..............................................................................................................................61
8.3 Maintenance Schedule ...........................................................................................................62
8.4 Maintenance............................................................................................................................63
8.4.1 Cleansing of the machine ..................................................................................................63
8.4.2 Lubricate machine .............................................................................................................64
8.5 Measures after maintenance .................................................................................................68
9FAILURES ..................................................................................................................69
9.1 Cautions for Troubleshooting...............................................................................................69
9.2 Diagnosis Chart......................................................................................................................71
9.3 Problem resolution.................................................................................................................73
9.3.1 Cancel the emergency stop................................................................................................73
9.3.2 Check axes for perpendicularity........................................................................................73
9.3.3 Description of process for aligning the machine with respect to perpendicularity ...........74
9.4 Commissioning after fault has been rectified......................................................................74
10 DISMANTLING AND DISPOSAL............................................................................75

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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10.1 Safety regulations for the disassembling and disposal ....................................................75
10.2 Disassembling......................................................................................................................75
10.3 Disposal................................................................................................................................76
11 APPENDIX...............................................................................................................77
11.1 Accessories...........................................................................................................................77
12 CUSTOMER SERVICE ............................................................................................78

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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1General
This instruction provides guidelines which enable a safe and efficient handling of the machine. The
manual is an integral part of the machine and must be kept in the immediate vicinity of the machine
and accessible at any time for the personnel.
Before starting all tasks, personnel must carefully read and understand these instructions.
Adherence to all the specified safety instructions and instructions for actions in this operating
manual is a fundamental requirement for working safely.
Furthermore, the local accident prevention regulations and general safety conditions for the
application of the machine are also applicable.
Illustrations in this manual are intended to facilitate basic understanding, and may differ from the
actual design.
Further guidelines regarding built-in components are found in the appendix of this description.
1.1 Symbol description
Safety instructions are designated by symbols. In addition, there is always a signal word
heading the information indicating the severity of the danger or hazard that may be
encountered.
HINT:
Indicates a potentially hazardous situation which, if not avoided, could result in
property damage or environmental contamination.
WARNING:
This signal word and symbol indicates a risk which can lead to severe injury or even
death, if not avoided.
ATTENTION:
This signal word and symbol indicates a risk which can lead to small injuries, if not
avoided.
Danger:
This signal word and symbol indicates a risk which can lead to severe injury or even
death, if not avoided.
Prohibition for people with pacemakers
This sign stands for activities involving risks for people with pacemakers. These areas
are prohibited for people with pacemakers!!

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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1.2 Limitation of Liability
All data and notes in these instructions were prepared with consideration to the statutory standards
and regulations, the present state of technology, as well as our many years of knowledge and
experience.
Under the following circumstances the manufacturer will not assume any liability:
Non-compliance with these instructions
Used other than for the intended purpose
Unauthorized or unapproved personnel
Unauthorised rebuilds or modifications
Unauthorized technical changes
The use of unauthorized replacement parts or non-original accessories
The actual scope of delivery can, by special designs, deviate from the explanations and
presentations given here, because of the utilization of additional order options, or because of the
most recent technical changes.
The responsibilities agreed in the delivery contract, the General Terms and Conditions as well as the
delivery conditions of the manufacturer and the statutory regulations valued at the time of
conclusion of the contract are effective.
1.3 Copyright
The contents of this instruction are copyrighted. It is to be used for the purpose of operating the
machine, only. Any other use without a written permission is forbidden.
Warning of hazardous electrical voltage
This sign stands for activities on all components carrying live voltage.
Danger due to hot surface
This sign stands for activities involving contact with hot objects.

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2Safety
This section gives an overview of all important safety aspects for optimum protection of the
personnel, as well as for the safe and fault-free operation. Other task-based guide-lines are included
in the sections regarding the individual phases of life.
2.1 Intended use
The CNC-Portal system is exclusively used for holding provided tools that serve to process various
materials and surfaces.
The machine is meant to be built into a complete system and does not have its own control unit.
Intended use also includes compliance with instructions specified by the manufacturer concerning
operation, servicing and maintenance.
Every application in excess of the intended use and/or other use, can lead to hazardous situations
and is considered misuse.
WARNING:
Danger due to misuse!
Improper use of the CNC-portal machine can cause dangerous situations.
Operation outside the values specified in the section „Technical data“.
Bypassing the safety devices.
Remodelling, refitting or changing of the device or parts of it, with the
intention to alter functionality or usability.
If machining process involves flammable cooling lubricants.
Processing light alloys such as aluminium, magnesium and titanium alloys
without extraction attachments and corresponding safety measures.
Operating the machine, although it is not in perfect condition from a technical
point of view.
Operating the machine in potentially explosive environment.
The manufacturer shall not be held liable for any and all damage due to misuse of this equipment.

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.2 Fundamental dangers
In following section, all residual risks are named that can still result from the machine, even when
the appliance is used as intended.
In order to minimize personal injuries and property damage and avoid dangerous situations, all here
mentioned safety-guidelines and those mentioned in further sections must be followed.
2.2.1 Ha z a rds from ele c t r i cal po wer
Electric current
DANGER:
Life Hazard through electrical shock!!
Touching conductive parts causes a direct danger to due to electrical shock.
Damage to the insulation or individual components can mean danger to life.
Any work required at the electrical system may only be carried out by a
qualified electrician in compliance with electro-technical regulations.
In case of damage to the insulation, switch off the power supply
immediately and have repairs carried out.
Before starting to work on active parts of electrical systems and equipment,
establish a voltage-free state throughout the duration of the work, this must
take place according to the 5 following safety regulations:
Activation.
Secure it from being switched on again.
Determine voltage free status.
Earth and short circuit.
Provide protection by covers or barriers for any neighbouring live parts.
Never attempt to bypass or de-activate fuses or cut-outs. When replacing fuses
or circuit breakers make sure to adhere to the correct ampere rating. Keep
moisture away from live parts.

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Stored charge
Danger:
Risk of death due to stored voltage!
Electronic charges could be stored in electric components that still exist after
switching off and disconnecting from power-supply. Contact with these components
can lead to severe injury or even death.
Before starting work disconnect mentioned components from power-supply.
Wait 10 minutes, in order to assure that the internal capacitors discharge
completely.
2.2.2 D a ngers b y mecha ni cs
Rotating tools
WARNING:
Risk of injury from rotating tools!
Clamped tools such as milling spindles can lead to severe personal injury or
material damage.
Before the start of any work, ensure that all covers and protective devices are
correctly installed and function correctly.
Never touch moving tool during operating process!
Before exchanging tools, always pull power plug of the milling motor or turn
off the machine and secure against restarting.
Axis motion
WARNING:
Risk of injury by axis motion!
Collision by people with components of the machine (Y-bridge, Units, turntable with
work piece, tools) can cause severe injuries.
Body parts are kept away from moving components and axis limit switches.
Do not reach into gaps between trapezoidal screws and adjacent
components.
Do not reach into gaps between unit and Y-bridge.
Only work on the machine when it is idle.
Only work with personal safety equipment.

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Falling materials
WARNING:
Injuries by falling materials!
During operation chips, tools (or parts of it) could be thrown out uncontrollably or
cause severe injuries to skin and eyes.
Wear face shield or fully closed and tight-fitting goggles, protective
clothing, protective gloves and safety shoes.
If particles enter your eyes, immediately get medical attention!
Unexpected start-up of the machine
WARNING:
Risk of injury caused by unexpected start-up of the machine
The machine and the used tools can start-up unexpectedly, change their direction or
stop. Limps can get trapped.
It must be ensured that, no body parts get in the danger zone of the machine.
Protect working area against unintentional access.
Tools
ATTENTION:
Risk of injuries by negligent handling of tools!
By handling tools negligent, lacerations and crushing injuries can be caused.
Tools must be handled with care and used in accordance with the
regulations.
Take weight into account when transporting tools.
Wear safety shoes and protective gloves.
Sharp edges and corners
ATTENTION:
Risk of injuries by sharp edges and corners!
Sharp edges and corners can cause abrasions and cuts on your skin.
Working near sharp edges and corners should be done with great caution.
If in doubt wear protective gloves.

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.2.3 D a ngers by hi g h or ve ry l ow te mp erat u res
Hot surfaces
ATTENTIONS:
Risks by hot surfaces!
Tools, work pieces and chips can heat up during operation. Skin contact with hot
surfaces causes serious burns of the skin.
As a matter of principle, for all tasks with tools, work pieces and chips,
protective clothing and gloves must be worn.
Before all tasks, make sure that all surfaces have cooled down to the
ambient temperature.
2.2.4 R i sk of f i re
Highly flammable materials
ATTENTION:
Risk of fire by highly flammable materials!
Organic dust produced by coal or wood or inorganic dust from magnesium,
aluminium, zinc or titanium can catch fire and cause severe injuries and death.
Do not smoke within the danger zone and the immediate vicinity. Refrain
from contact with open flames or sources of ignition.
Keep a fire extinguisher at hand in the immediate vicinity of the work area.
Do not process light alloys such as magnesium, aluminium, zinc and
titanium without an extraction system and relevant security measures.
Suspend any work activities in case of fire. Leave the danger zone until the
all clear signal is given

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.2.5 R a diatio n haza rd s
Magnetic fields
DANGER:
Danger to life by magnetic fields!
Magnetic fields of step motors can cause severe injuries or death, as well as serious
damage to materials.
Persons with pacemakers must keep away from the machine! It can
effectively provoke a dysfunction of the pacemaker.
Persons with metallic implants must not be allowed in the area of the
machine. Implants can heat themselves up or be drawn-in.
Take off all metal objects (Jewellery, watches, pens etc.) before starting
maintenance operation.
No electronica equipment is to be taken into the magnetic source area. These
could get damaged.
No storage media, credit cards etc. are to be taken into the magnetic source
area. Containing data may be deleted.
2.2.6 Ha z a rds o f chemi c als
Cooling emulsion
WARNING:
Danger of serious damage to health by polluted cooling emulsion!
Polluted cooling emulsion can cause inflammations when coming in contact with
skin.
Cooling emulsion must be checked at regular intervals.
When handling with polluted cooling emulsion protective clothing and
chemical-resistant safety-gloves must be worn.
Avoid direct skin contact. Cleanse skin, especially before breaks and when
finishing work.
Eat and drink in relevant break room only!

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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ATTENTION:
Health risks due to contact with cooling emulsion!
Contact with cooling emulsion may lead to health risks.
Avoid contact with your skin.
Remove cooling emulsion from the skin immediately.
Do not inhale the vapours.
Oil and fat
ATTENTION:
Risk of health due contacting with oil and fat!
Contact with oil and fat may lead to health risks.
Avoid skin contact.
Remove oil and fat immediately from skin.
Do not inhale vapours.

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.2.7 G eneral w o rk-rela t e d da n g er s
Noise
ATTENTION:
Risk of injury by noise!
The noise levels occurring in the operating area may cause severe hearing damage.
Always wear hearing protection when working.
Only stay in the danger area when required.
Dirt and objects lying around
Attention:
Risk of tripping by dirt and objects lying around!
Soiling and objects left lying around are sources of slipping and stumbling and can
cause considerable injuries.
Always keep the work area clean.
Remove any objects which are no longer required from the working area,
especially those near ground.
Designate tripping positions with yellow-black marker band.

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.3 Responsibility of the operator
Operator
Operator is the person who operates the machine for commercial or economic purposes, or leaves
the use / application to a third party and bears responsibility during the operation of the product for
the protection of the user, the staff and third party.
Operator obligations
The machine is used in the commercial sector. The operator of the machine is therefore subject to
the legal obligations concerning occupational safety. Apart from the safety instructions given in this
manual, it is necessary to meet all safety, accident prevention and environmental protection
requirements applicable to the equipment's field of use and operating site.
The following principles apply in particular:
The operating company must inform itself about the effective industrial regulations and
determine additional hazards in a risk assessment that result through the special working
conditions at the place of operating the machine. He must implement this in the form of
operating instructions for the operation of the machine.
During the complete usage time of the machine, the owner must check whether the
operating instructions created by him correspond with the current status of the regulations
and must adapt them if necessary.
The owner must clearly regulate and specify the responsibilities for installation, operation,
maintenance and cleaning
The operator of the machine must ensure that all persons having access to it, have read and
understood these instructions. In addition he must at regular intervals train the employees in
how to deal with the machine and inform them about potential hazards.
The operating company must provide the required safety equipment for the personnel and
order to wear protective equipment.
Moreover, the equipment operator is responsible for ensuring that the equipment is in proper
technical condition at all times.
Thus, following applies:
The operating company must make sure that any and all maintenance intervals described in
this instruction are carried out.
The owner must arrange for all safety equipment to be checked regularly for functionality
and completeness.

Operating Instructions
High-Z Standard-Series
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.4 Staff requirements
2.4.1 Q ua lific a ti on
The different Tasks contained in this instruction require different qualifications auf persons that are
intrusted with these tasks.
WARNING:
Risks caused by insufficient qualifications of persons!
Insufficient qualified persons cannot assess the extent to which they represent a risk
handling with the machine and therefor run the risk of injuries or death for
themselves and others.
Work on or in the unit must be done only by duly qualified staff and in full
compliance with the appropriate instructions and pertinent regulations...
Keep insufficiently qualified persons away from the work area.
Only persons of whom it may be expected that they perform their work reliably are permitted as
personnel. Persons whose responsiveness is affected, e.g. by drugs, alcohol or medicines are not
authorized.
In this instruction all required qualifications, for the different people, with different tasks are
named:
Operator
The operator was instructed by the operating company in a briefing about the tasks assigned to them
and instructed about possible hazards because of improper conduct. Tasks, die which are carried out
beyond the normal operation, only are allowed to be carried out by an operator if this is mentioned
in this instruction and the operating company has assigned the operator expressly.
Electrician
An electrician whose technical training, skills and experience together with their knowledge of
pertinent regulations and documentation means that they are capable of assessing the work to be
carried out and detect and prevent any possible dangers.
An electrician is trained especially for its working environment, and knows the relevant standards
and regulations.
Qualified personnel
Qualified personnel based on their professional training, know-how and experience as well as
knowledge of the applicable standards and regulations is able to perform assigned work activities
and to detect and to avoid possible dangers on their own.

Operating Instructions
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Manufacturer
Curtain maintenance work is only allowed to be carried out by authorized and skilled personnel.
Other personnel is not authorised to carry out these tasks. In order to carry out this maintenance
work, please call our customer service!
2.4.2 I n s tru c t ion
The owner must train staff regularly. For record-keeping purposes, a log of training conducted must
be kept with following minimum contents:
Date of training
Name of trained person
Contents of training
Name of trainer
Signature of trained person and trainer
2.5 Personal protective equipment
Personal protective equipment prevents from impairments with respect to the safety of personnel
during work.
Personnel have to wear personal protective equipment while working on the machine, which are
mentioned in different sections of this instruction.
Description of personal
protective equipment
Protective clothing
Protective clothing is close fitting, with low resistance to tearing, with narrow sleeves
and without protruding parts.
Chemical resistant safety gloves
Suitable chemical resistant safety gloves have to worn to protect your skin from
aggressive chemicals.

Operating Instructions
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2.6 Safety installations
WARNING:
Malfunctioning safety installations may pose a fatal risk!!
Malfunctioning or deactivated safety installations may cause severe injuries and
even death!
Before starting to work, check all safety installations regarding their
functional efficiency and correct installation.
Never deactivate or bypass safety equipment.
Take care to ensure that safety installations are always accessible.
Hearing protection
Hearing protection prevents irreversible damage to hearing.
Industrial protection helmet
Industrial protection helmet prevents from injuries by falling or suspended objects.
Safety glasses
Safety glasses prevent injuries in eyes from parts flying around or squirts of fluids.
Protective gloves
Protective gloves protect the hands from rubbing, abrasions, cuts or more profound
injuries, as well as when touching hot surfaces.
Protective cover
Wear protective cove to protect long hair from being caught, wrapped up in, or drawn
into moving parts.
Employees are required to wear protective covers, if their hair is longer than the extent
of the shaft and its moving parts.
Safety boots
Safety shoes protect the wearer's feet against falling objects, from being crushed,
slippery surfaces and being run over by vehicles.