CNC-Step T-Rex Servo Series User manual

Status: 07.03.2022
Operating instructions
T-Rex Servo-Serie
Rev. 1.3 (April 2021)
T-Rex 0609 ▪ T-Rex 0615 ▪ T-Rex 1212 ▪ T-Rex 1218
T-Rex 1325 ▪ T-Rex 1530 ▪ T-Rex 2030 ▪ T-Rex 2040
Technical and optical changes reserved.
https://www.cnc-step.de/

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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23.09.2020
T-Rex Servo-Serie
Brief description
The machine includes the complete mechanics for a three-dimensional movement. The linear
movement of the slides takes place via gear drives in X and Y and ball screws in the Z-axis, driven
by Servo motors. The Servo motors for the process of the individual axes are controlled via further
interfaces.
This operating manual describes the installation, commissioning, and maintenance of the CNC
gantry system.
This guide refers to the T-Rex servo series in the standard configuration with a 3.5KW HF
spindle from HQD.
There are many other options available, which are then described in separate instructions.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Table of Contents
1GENERAL.....................................................................................................................7
1.1 Description of Symbols ............................................................................................................7
1.2 Limitation..................................................................................................................................8
1.3 Copyright ..................................................................................................................................8
2SAFETY ........................................................................................................................9
2.1 Intended use..............................................................................................................................9
2.2 Basic dangers..........................................................................................................................10
2.2.1 Dangers from electrical energy..........................................................................................10
2.2.2 Dangers from mechanics ...................................................................................................11
2.2.3 Hazards from high or low temperatures............................................................................13
2.2.4 Fire hazards........................................................................................................................13
2.2.5 Dangers from radiation......................................................................................................14
2.2.6 Hazards from chemical substances....................................................................................15
2.2.7 General hazards in the workplace......................................................................................16
2.3 Responsibility of the operator...............................................................................................17
2.4 Staff requirements..................................................................................................................18
2.4.1 Qualifications.....................................................................................................................18
2.4.2 Instruction.........................................................................................................................19
2.5 Personal protective equipment..............................................................................................19
2.6 Safety.......................................................................................................................................20
2.6.1 Description of the safety devices installed........................................................................21
2.6.2 Safety devices that the operator must retrofit....................................................................23
2.7 Behaviour in the event of a fire outbreak and accident......................................................23
2.8 Environmental protection......................................................................................................24
2.9 Signage.....................................................................................................................................25
2.9.1 Mandatory Symbols...........................................................................................................25
2.9.2 Prohibition signs................................................................................................................25
2.9.3 Warnings............................................................................................................................26
2.9.4 Fire Safety Sign .................................................................................................................27
2.9.5 Safety Signs.......................................................................................................................28
3TECHNICAL SPECIFICATIONS.................................................................................29
3.1 General information...............................................................................................................29

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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3.2 Connected values....................................................................................................................33
3.3 Performance............................................................................................................................33
3.4 Service conditions...................................................................................................................33
3.5 Supplies ...................................................................................................................................34
3.6 Emissions.................................................................................................................................34
3.7 Nameplate ...............................................................................................................................34
4CONSTRUCTION AND FUNCTIONS.........................................................................35
4.1 Overview .................................................................................................................................35
4.2 Brief description of the scope of application........................................................................36
4.3 Description Assembly Group ................................................................................................37
4.3.1 X-axis.................................................................................................................................37
4.3.2 Y-axis.................................................................................................................................38
4.3.3 Z-axis.................................................................................................................................39
4.3.4 Z-axis 300mm (Option).....................................................................................................40
4.3.5 Z-axis 400mm (Option).....................................................................................................40
4.3.6 Toolholder .........................................................................................................................40
4.3.7 Central lubrication.............................................................................................................41
4.4 Operator terminal ..................................................................................................................43
4.4.1 Machine Controller............................................................................................................44
4.4.2 Connections on the Terminal.............................................................................................45
4.5 Connections on the machine..................................................................................................46
4.5.1 Tool length probe...............................................................................................................46
4.5.2 Compressed Air Supply Accessories (Optional)...............................................................46
4.6 HF Spindle ..............................................................................................................................47
4.7 Vacuum clamping system......................................................................................................48
4.7.1 Vacuum table.....................................................................................................................48
4.7.2 Side channel compressor (Option) ....................................................................................51
4.8 T-Slot plates (Option).............................................................................................................53
4.9 Minimal Lubrication (Option)..............................................................................................54
4.9.1 Dynacut MDE....................................................................................................................54
4.9.2 Noga Minicool...................................................................................................................56
4.10 Protective Fencing...............................................................................................................57
5WORKING AND HAZARDOUS AREAS.....................................................................58
5.1 Workspace...............................................................................................................................58

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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5.2 Danger zone ............................................................................................................................58
6INSTALLATION AND INITIAL COMMISSIONING .....................................................59
6.1 Safety instructions for installation and initial commissioning...........................................59
6.2 Preparations............................................................................................................................60
6.2.1 Setting up the machine ......................................................................................................60
6.2.2 Servomotor and control cable............................................................................................61
6.2.3 Install accessories ..............................................................................................................61
6.3 Installation ..............................................................................................................................62
6.3.1 Power up the controller......................................................................................................62
6.4 First installment......................................................................................................................62
7OPERATION...............................................................................................................63
7.1 Safety instructions for operation ..........................................................................................63
7.2 Activities before use ...............................................................................................................63
7.3 Turn on....................................................................................................................................64
7.4 Activities during operation....................................................................................................65
7.4.1 Operate the machine..........................................................................................................65
7.4.2 Change tool........................................................................................................................68
7.5 Switch off.................................................................................................................................68
7.6 Activities after use..................................................................................................................69
7.7 Shutdown Emergency............................................................................................................69
8MAINTENANCE..........................................................................................................70
8.1 Safety instructions for maintenance.....................................................................................70
8.2 Spares ......................................................................................................................................72
8.3 Schedule of Maintenance.......................................................................................................73
8.4 Maintenance work..................................................................................................................74
8.4.1 Machine cleaning...............................................................................................................74
8.4.2 Lubricate machine .............................................................................................................75
8.5 Measures after maintenance .................................................................................................76
9MALFUNCTIONS........................................................................................................77
9.1 Safety instructions for troubleshooting................................................................................77
9.2 Störungstabelle.......................................................................................................................79
9.3 Troubleshooting work............................................................................................................81

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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9.3.1 Unlock Emergency Stop....................................................................................................81
9.4 Commissioning after fault has been resolved......................................................................81
10 TRANSPORT, PACKAGING AND STORAGE........................................................82
10.1 Safety instructions for transport .......................................................................................82
10.2 Inspection before transport................................................................................................83
10.3 Packaging.............................................................................................................................83
10.4 Symbols on the packaging..................................................................................................84
10.5 Transport.............................................................................................................................85
10.6 Storage .................................................................................................................................86
11 DISMANTLING AND DISPOSAL.............................................................................87
11.1 Safety instructions for dismantling and disposal.............................................................87
11.2 Dismantling..........................................................................................................................87
11.3 Disposal................................................................................................................................88
12 ACCESSORIES .......................................................................................................89
13 CUSTOMER SERVICE ............................................................................................90

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
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1General
This manual allows the safe and efficient handling of the machine. The instructions are
part of the machine and must always be kept in the immediate vicinity of the machine
accessible to the personnel.
Staff must have carefully read and understood these instructions before commencing all
work. The basic prerequisite for safe working is compliance with all specified safety
instructions and instructions in this manual.
In addition, the local accident prevention regulations and general safety regulations apply
to the area of application of the machine.
Illustrations in this manual are for basic understanding and may differ from the actual
execution. In addition to these instructions, the instructions for the built-in components in
the appendix apply.
1.1 Description of Symbols
Safety instructions are marked by symbols in this manual. The safety instructions are
introduced by signal words that express the extent of the hazard.
HINT:
This combination of symbol and signal word indicates a potentially dangerous situation
that can lead to property and environmental damage if not avoided.
WARNING:
This combination of symbol and signal word indicates a potentially dangerous situation
that can lead to death or serious injury if not avoided.
CAUTION:
This combination of symbol and signal word indicates a potentially dangerous situation
that can lead to minor or minor injuries if not avoided.
DANGER:
This combination of symbol and signal word indicates an immediately dangerous
situation that leads to death or serious injury if not avoided.
Prohibition for people with pacemakers
This mark precedes activities in areas that are prohibited for people with pacemakers.
Warning of dangerous electrical voltage
This mark precedes activities on live system components.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Hot Surface Warning
This sign stands before activities in the handling of hot objects.
1.2 Limitation
All information and notes in this manual have been compiled considering the applicable
standards and regulations, the state of the art, as well as our many years of knowledge
and experience.
In the following cases, the manufacturer assumes no liability for damages:
•Failure to follow these instructions
•from improper use
•Use of non-trained personnel
•arbitrary conversions of any kind
•technical changes of any kind
•Use of non-approved spare parts or third-party accessories
The actual scope of delivery may deviate from the explanations and illustrations described
here in the case of special designs, the use of additional order options or due to the latest
technical changes.
The obligations agreed in the delivery contract, the general terms, and conditions as well as the
delivery conditions of the manufacturer and the legal regulations valid at the time of conclusion of
the contract apply.
1.3 Copyright
The contents of this manual are protected by copyright. Their use is permitted in the context of the
use of the machine. Any further use is not permitted without the written permission of the
manufacturer.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2Safety
This section provides an overview of all important safety aspects for the protection of persons as
well as for safe and trouble-free operation. Further task-related safety instructions are contained in
the sections on the individual phases of life.
2.1 Intended use
The CNC gantry system is used exclusively for the purpose of accommodating the tools
provided for this purpose, which are used for processing different materials and surfaces.
The intended use also includes compliance with all information in these instructions.
Any use that goes beyond the intended use or is otherwise deemed to be misuse.
WARNING:
Danger in case of misuse!
Misuse of the CNC portal milling machine can lead to dangerous situations.
•Operation outside the values specified in the "Technical Data".
•Bypassing and overriding safety devices.
•Conversion, conversion or modification of the construction or individual
pieces of equipment with the aim of changing the area of application or
the usability of the machine.
•Operation of the machine with flammable cooling lubricants.
•Machining of light metal alloys such as magnesium, aluminium and
titanium without suction device and appropriate safety measures.
•Operation of the machine if it is not in perfect technical condition.
•Operation of the machine within potentially explosive atmospheres.
Claims of any kind due to damage due to improper use are excluded.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.2 Basic dangers
The following section identifies residual risks that may arise from the machine even when used as
intended.
To reduce the risks of personal injury and property damage and to avoid dangerous situations, the
safety instructions listed here and the safety instructions in the further sections of this guide must be
observed.
2.2.1 D a ngers fro m e l ectri c a l e n e r g y
Electric current
DANGER:
Danger to life due to electric current!
In the event of contact with live parts, there is an immediate danger to life
due to electric shock. Damage to insulation or individual components can be
life-threatening.
•Work on the electrical system can only be carried out by qualified
electricians.
•In the event of damage to the insulation, switch off the power supply
immediately and arrange for repair.
•Before starting work on active parts of electrical systems and
equipment, ensure the voltage-free state and ensure it for the
duration of the work. Observe the 5 safety rules:
➢Unlock.
➢Secure against re-activation.
➢Determine freedom from tension.
➢Ground and short-circuit.
➢Cover or barrier adjacent live parts.
•Never bridge fuses or put them out of operation. When replacing
fuses, comply with the correct current specification.
•Keep moisture away from live parts. This can lead to a short circuit.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Stored charge
DANGER:
Danger to life due to stored charges!
Electrical charges can be stored in electronic components, which are
retained even after switching off and disconnecting from the power supply.
Contact with these components can lead from serious to fatal injuries.
•Before working on the components mentioned, completely disconnect
them from the power supply. Allow 10 minutes to ensure that the
internal capacitors are completely discharged.
2.2.2 D a ngers f rom me ch a nics
Rotating tools
WARNING:
Risk of injury due to rotating tools!
Clamped tools such as a milling spindle can lead to serious personal injury
or property damage.
•Before starting work, ensure that all covers, and safety devices are
installed and functioning properly.
•Do not reach into moving tools during operation.
•Before replacing the tools, always unplug the milling motor or switch
off the machine and secure it against reactivation.
Movement of the Axis
WARNING:
Risk of injury due to axis movements!
Collision of persons with components of the machine (Y-bridge, mobile unit,
rotary table with workpiece, tool) can lead to the most serious injuries.
•Do not hold body parts between the moving components and end
stops of the axles.
•Do not reach into a gap between the recirculating ball screw and
adjacent components.
•Do not reach into a column between the mobile unit and the Y-bridge.
•Carry out work on the machine only at a standstill.
•Wear personal protective equipment when working with the machine.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Falling materials
WARNING:
Injuries caused by falling materials!
During operation, chips, tools (or parts of them) can fall or be ejected
uncontrollably, causing serious injuries to the skin and eyes.
•Wear face protection or closed glasses, protective clothing, protective
gloves and safety shoes (PPE).
•If particles penetrate the eye, immediately seek medical attention.
Unexpected start-up of the machine
WARNING:
Risk of injury due to unexpected start-up of the machine!
The machine and the tools used with it can start unexpectedly, change
direction, or stop. This allows limbs to be detected.
•Make sure that no body parts get into the danger area of the
machine.
•Secure workspace from accidental access.
Tools
CAUTION:
Risk of injury due to negligent handling of tools!
Negligent handling of the tools can cause bruises or cuts.
•Handle tools carefully and as intended.
•When transporting tools, consider the weight.
•Wear protective gloves and safety shoes.
Sharp edges and pointed corners
CAUTION:
Risk of injury on sharp edges and sharp corners!
Sharp edges and pointed corners can cause abrasions and deep cuts onto
the skin.
•When working near sharp edges and pointed corners, proceed
carefully.
•If in doubt, wear protective gloves.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.2.3 Ha z a rds fro m h i gh o r low t e mpera t ures
Hot surfaces
WARNING:
Risk of injury due to hot surfaces!
Tools, workpieces, and chips can heat up strongly during operation. Skin
contact with hot surfaces causes severe burns of the skin.
•When working with tools, workpieces, and chips, always wear heat-
resistant protective clothing and protective gloves.
•Before all work, ensure that all surfaces have cooled to ambient
temperature
2.2.4 F i re ha z a rds
Highly flammable substances
WARNING:
Fire hazard due to highly flammable substances!
Organic dusts of coal or wood or inorganic dusts of magnesium, aluminum,
zinc, or titanium can catch fire and cause serious to fatal injuries.
•Do not smoke within the danger zone and in the immediate vicinity.
Do not deal with open fire or ignition sources.
•Have fire extinguishers ready.
•Avoid processing light metal alloys such as magnesium, aluminum,
zinc and titanium without suction device and appropriate safety
measures.
•In the event of a fire, stop work immediately. Leave the danger zone
until the all-clear is given.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.2.5 D a ngers f rom ra d i ati o n
Magnetic fields
DANGER:
Danger to life due to magnetic fields!
Magnetic fields from Servomotors can cause serious injury and even death,
as well as significant property damage.
•People with pacemakers should not be near the machine. The
function of the pacemaker could be impaired.
•Persons with metal implants must not be near the machine. Implants
can heat up or even be attracted by the magnetic field.
•Before maintenance work, place metal objects (jewelry, watches,
writing instruments, etc.).
•Do not bring electronic devices near the magnetic source. These
could be damaged.
•Do not bring storage media, credit cards, etc. close to the magnetic
source. Data can be deleted.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.2.6 Ha z a rds fro m ch e mi cal s u bstanc es
Cooling Emulsion
WARNING:
Risk of damage to health due to contaminated cooling emulsion!
Contaminated cooling emulsion can lead to inflammation when in contact
with the skin.
•Check cooling emulsion at regular intervals.
•When handling contaminated cooling emulsion, wear protective
clothing and chemical-resistant protective gloves.
•Avoid direct skin contact. Remove skin impurities immediately,
especially before breaks and after the end of work.
•Eat and drink exclusively in the designated break room.
CAUTION:
Risk of damage to health due to contact with cooling emulsion!
Contact with cooling emulsion can lead to damage to health.
•Avoid skin contact.
•Remove cooling emulsion from the skin immediately.
•Do not inhale vapors.
Oil and fat
CAUTION:
Risk of damage to health due to contact with oil and grease!
Contact with oil and fat can lead to damage to health.
•Avoid skin contact.
•Remove oil and fat from the skin immediately.
•Do not inhale vapors.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.2.7 G eneral ha za rds in th e workpl a ce
Noise
WARNING:
Risk of injury due to noise!
The noise level occurring in the work area can cause severe hearing
damage.
•Always wear hearing protection when working.
•Only stop in the danger zone if necessary.
Dirt and objects lying around
CAUTION:
Risk of injury due to falling over dirt and objects lying around!
Dirt and objects lying around form sources of slipping and tripping. In the
event of a fall, injuries can be caused.
•Always keep work area clean.
•Remove objects that are no longer needed from the work area and
especially from the ground.
•Mark unavoidable tripping points with yellow-black marking tape.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ 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 himself for commercial or economic
purposes or leaves it to a third party for use/application and who bears the legal product
responsibility for the protection of the user, the staff or third parties during operation.
Operator obligations
The machine is used in the commercial sector. The operator of the machine is therefore
subject to the legal obligations for occupational safety.
In addition to the safety instructions in this manual, the safety, accident prevention and
environmental protection regulations applicable to the area of use of the machine must be
complied with.
In particular, the following shall apply:
•The operator must find out about the applicable occupational health and safety
regulations and determine in a risk assessment additional hazard arising from the
special working conditions at the place of use of the machine. He must implement
these in as operating instructions for the operation of the machine.
•During the entire period of operation of the machinery, the operator must check
whether the operating instructions he has drawn up correspond to the current state
of the regulations and, if necessary, adapt them.
•The operator must clearly regulate and define the responsibilities for installation,
operation, troubleshooting, maintenance, and cleaning.
•The operator must ensure that all persons handling the machine have read and
understood these instructions. In addition, he must train the staff at regular
intervals and inform them about the dangers.
•The operator shall provide the personnel with the necessary protective equipment
and make it mandatory to wear the necessary protective equipment.
Furthermore, the operator is responsible for ensuring that the machine is always in
technically perfect condition. Therefore, the following applies:
•The operator must ensure that the maintenance intervals described in these
instructions are adhered to.
The operator must have all safety devices regularly checked for functionality and
completeness.

Operating instructions
T-Rex Servo-Series
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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2.4 Staff requirements
2.4.1 Q ualifi c ation s
The different tasks described in this guide require different demands on qualifications of
the persons entrusted with these tasks.
WARNING:
Danger in case of insufficient qualification of persons!
Insufficiently qualified persons cannot assess the risks of handling the
machine and expose themselves and others to the risk of serious or fatal
injury.
•Have all work carried out only by qualified persons.
•Keep insufficiently qualified people out of the work area.
For all work, only persons are allowed who are expected to carry out this work reliably.
People whose responsiveness is affected, for example by drugs, alcohol, or medications,
are not approved.
This guide identifies the following qualifications of the persons for the various tasks:
Operator
The operator has been instructed by the operator about the tasks assigned to him and
possible dangers in the event of improper behavior. Tasks that go beyond operation in
normal operation may only be carried out by the operator if this is specified in these
instructions and the operator has expressly entrusted him with this.
Electrician
Due to his professional training, knowledge, and experience as well as knowledge of the
relevant standards and regulations, the electrician can carry out work on electrical systems
and to independently recognize and avoid possible dangers.
The electrician is specially trained for the working environment in which he works and
knows the relevant standards and regulations.
Professionals
Due to their professional training, knowledge, and experience as well as knowledge of the
relevant standards and regulations, specialist personnel can carry out the work assigned
to them and to independently identify possible dangers and avoid hazards.
Manufacturer
Certain work may only be carried out by specialist personnel of the manufacturer. Other
personnel is not authorized to carry out this work. To carry out the work involved, please
contact our customer service.

Operating instructions
T-Rex Servo-Series
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2.4.2 Instruction
The operator must regularly instruct the staff. For better follow-up, a training protocol must
be created with the following minimum content:
•Date of instruction
•Name of the instructor
•Contents of the instruction
•Name of the instructor
•Signatures of the instructed and the instructor
2.5 Personal protective equipment
Personal protective equipment is used to protect people from adverse effects on safety
and health at work.
Personnel must wear personal protective equipment during the various tasks on and with
the machinery, which will be referred to separately in the various sections of this manual.
Description of personal
protective equipment
The personal protective equipment is explained below:
Protective Clothing
Protective clothing is tight-fitting workwear with low tear resistance, with
tight sleeves and without protruding parts.
Chemical-resistant protective gloves
Chemical-resistant protective gloves are used to protect hands from
harsh chemicals.
Hearing protectors
Hearing protection is used to protect against hearing damage caused by
noise exposure.

Operating instructions
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2.6 Safety
WARNING:
Danger to life due to non-functioning safety devices!
In the case of non-functioning or suspended safety devices, there is a
risk of the most serious injuries up to death.
•Before starting work, check whether all safety devices are
functional and correctly installed.
•Never override or bridge safety devices.
•Ensure that all safety devices are always accessible.
Safety Helmet
Industrial safety helmets protect the head against falling objects,
oscillating loads and bumps on fixed objects.
Eye Protection
The goggles are used to protect the eyes from flying parts and liquid
splashes.
Gloves
Protective gloves are used to protect the hands from friction, abrasions,
punctures, or deeper injuries as well as from contact with hot surfaces.
Protective Hair Cover
The protective cover is used to protect the hair from being pulled in by
moving and rotating parts, such as example when drilling.
It is mandatory to wear protection if hair lengths are longer than the
circumference of the movable shaft.
Safety shoes
Safety shoes protect the feet from bruises, falling parts and slipping on
slippery surfaces.