StoneyCNC STEPCRAFT User manual

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Operating
Instructions
Original Instructions
Date: 31/05/2014
Industrial HF spindle | STEPCRAFT version

StoneyCNC
DCU ALPHA CAMPUS
OLD Finglas Road
Glasnevin
Dublin 11
Tel (mobile): [phone]
Tel : [phone]
E-mail: [e-mail]
Website: www.stoneycnc.co.uk
Please read these instructions completely before you use your CNC system and only
operate your machine when you are confident you understand its operation and also
the potential dangers associated with its use.
Before starting, powering on and operating, the machine should be inspected to
ensure all parts and connections are functioning as expected.

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TABLE OF CONTENTS
1 Introduction .....................................................................................................................6
1.1 Preface.....................................................................................................................6
1.2 Meaning of the related symbols................................................................................7
1.3 Unboxing and identification of parts..........................................................................8
1.4 Storage ....................................................................................................................8
1.5 Liability and guarantee.............................................................................................9
1.6 Warranty ..................................................................................................................9
2 SAFETY........................................................................................................................10
2.1 General..................................................................................................................10
2.2 Obligations of the operator.....................................................................................11
2.3 Recommended Use................................................................................................12
2.3.1 Typical Application Materials...........................................................................12
2.4 Work piece Clamping.............................................................................................13
2.5 Machine isolation when you interact with the machine ...........................................13
2.6 Cutting tool specification and Loading....................................................................14
2.7 Sources of Dangers................................................................................................14
2.7.1 Cutters............................................................................................................14
2.7.2 Keep away from Spindle systems when in operation.......................................14
2.7.1 Freshly Cut Materials ......................................................................................15
2.7.2 Spindle Wind down .........................................................................................15
2.7.3 Management of Particulates and Swarf around the control PC........................15
2.7.4 Manage the USB cables connected to the machine........................................15
2.7.5 Eye Ear and Dust protection............................................................................16
2.7.6 SAFETY circuits..............................................................................................17
3 Setup.............................................................................................................................17
3.1.1 System setup ..................................................................................................17
3.1.2 Resetting the software before touching the spindle.........................................19
3.1.3 SAFETY circuits..............................................................................................21

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Do NOT Interfere
with the machine
when under CNC
control
NEVER LEAVE
THE MACHINE
WORKING
UNATTENDED

5
Ensure You understand
the safety considerations
of a machine provided
in the open configuration
without a safety
enclsoure
WARNING
Read & understand
operators manual before
usingthis machine.
Failure to follow operating
instructions could result in
death or seriousinjury

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1 INTRODUCTION
SPECIAL NOTICE
Please note that on older STEPCRAFT control boards when the UC100 module powers
down during use the spindle can start up if left on and in CNC mode. This has been
rectified in more recent versions of the STEPCRAFT mainboard.
Therefore when in CNC mode it is imperative that you act with extreme caution when
using your industrial CNC spindle.
1.1 PREFACE
Dear Customer
Congratulations on your purchase of the HF industrial spindle system.
If you, the purchaser, intend to set up and use the machine yourself, then you must read and
fully understand this booklet describing the correct and safe procedures for set up and use of
your spindle.
This document will serve as a reference document for operation and safety and must be in
the vicinity of the spindle at all times. As an operator and user of this spindle, you are obliged
to read and to understand these operating instructions carefully.
Additionally, as you are the person who has taken responsibility for the safety aspects of the
spindle use and you are responsible to make sure every person who uses the spindle or
comes into contact with the spindle is aware of the safety aspects and the dangers
associated with the spindle and any extras or additional tools supplied with the spindle.
The images or sketches in these instructions serve as illustration only and may deviate
therefore from the actual installation configuration.
If you have any questions regarding the use of the spindle please contact StoneyCNC.
It is assumed that this spindle will be used on a CNC router system. Therefore the safety
aspects of this operators manual are aimed at users with a CNC router. If you intend on
using this spindle on any other device than a CNC router please contact usfor more details.

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1.2 MEANING OF THE RELATED SYMBOLS
DANGER
Symbols and texts, that are marked with the addition "DANGER”, warn
against a specific threatening/dangerous hazard (serious injury, long term
damage, death)
Unconditional attention must be given to these references!
WARNING
Symbols and texts, that are marked with the addition "WARNING, "warn
against a possibly threatening danger (serious injury, long term damage,
death)
Unconditional attention must be given to these references!
CAUTION
Symbols and texts, that are marked with the addition "CAUTION, "warn
against a possibly threatening danger (possible injuries, risk of damages)
Unconditional attention must be given to these references!
Where the manual refers with this symbol (shown left) it contains very
important references. Compliance is unconditional in order to avoid damage
to people and property.
Unconditional attention must be given to these references!
Danger through electric shock.
Danger through mechanical movements –danger of crushing and pinching
.
Danger through flying particles ejected by the machine system. Carry
unconditionally visibility protection –ALWAY WEAR EYE PROTECTION –
READ THE MANUAL –and have the manual to hand at all times near the
machining area.
DANGER spindle cutting edge

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1.3 UNBOXING AND IDENTIFICATION OF PARTS
Figure 1: Identification of parts
Figure 1 shows the contents of the industrial spindle box
- Main drive system housing with cable umbilical
- Spindle motor
- Interface cable
- ER11 collet spanners
Carefully unbox all parts and inspect for any damage.
1.4 STORAGE
In the case where the spindle is stored and not used for extended periods of time (greater
than 3 days) the system must be placed in an atmosphere free from moisture and from
excessive changes in temperature.

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1.5 LIABILITY AND GUARANTEE
All statements in these operating instructions serve the certain and
undisturbed business of the cutting spindle.
The operating instructions are an important component of the spindle, its safe use, and the
long term reliability of the system. These instructions must be read and studied carefully by
ANY operator of the machine system before use.
Improper handling Always take care when handling a rotating cutting spindle. The spindle
itself is robust and not easily damaged but cables and connections must be managed
carefully to avoid damage and danger of electric shock.
1.6 WARRANTY
The spindle system is guaranteed with a 12 month warranty from the date of delivery on site
at the customer location.
The warranty covers all hardware aspects of the machine use within the 12 month warranty
period provided the spindle operation and use meets the following requirements:
The spindle is used by trained operators only or those who are fully aware of the
contents of this operators manual. The use of the spindle by untrained persons
will immediately void the warranty as well as putting the spindle and the
untrained operator in serious risk of injury or damage.
The spindle is used within the application scope recommended/discussed. The
spindle can operate between 5000-24000rpm. With max power between 18,000
and 24,000..
The environment where the spindle is kept does not expose the spindle to
excessive moisture or thermal changes.
The AC electrical supply to the machine is reliable and free from excessive noise
–if necessary a dedicated MCB/RCD switch may be required.
The AC electrical system has a reliable and professionally installed earth
connection.
The cables to the spindle and associated controls are managed and protected.
Damaged cables can cause short circuits and can damage the machine’s

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sensitive electronics. Machine damage due to cable damage voids the warranty
terms.
2 SAFETY
2.1 GENERAL
The operator and user of the CNC router system and associated spindle must
inform themselves of the potential dangers prior to machine use. Please
carefully read the instructions before operating the machine and always act with
due diligence towards the safety considerations. The operator must be over 18
and be an able bodied person.
The machine operator must pay special attention to the following:
Remember and note all safety references and important aspects of the
machine use
Keep this manual to hand in the machine working area at all times
Disorder and clutter in the machine area significantly increases the
possibilities of dangerous situations. Keep the machine area tidy.
Do not let others work in close proximity to (or in the field of work of) the
machine without proper supervision and training
Always use appropriate guarding of the cutting tool when in use.
Do not overburden the machine. Use the machine within the indicated travel
area and within the application limits of the CNC system.
Always use the correct tool. Do not use low quality or weak tools for heavy
machining applications. NEVER USE A TOOL OUTSIDE OF ITS
RECOMMENDED OPERATING ENVELOPE.
Always wear suitable work clothing when using the machine. DO NO WEAR
JEWELERY OR LOOSE CLOTHES e.g. hoodies or loose fit jumpers. Loose
clothes can get caught in the moving parts of the machine and cause serious
risk of injury or damage to the operator and the machine.
Always wear eye protection such as safety spectacles or goggles to protect
the user from airborne waste/particles from the CNC cutting process.
Please ensure that all connection cables and connectors are secure and
safely managed before using the machine in order to avoid any damage or

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risk of exposure to electric shock. In the event of any damage only allow a
qualified person remedy the problem. Keep all connection cables within the
machine area and managed appropriately.
Always ensure that the work piece is securely fastened and clamped to the
machine bed. Failure to clamp the work piece securely can lead to a
dangerous and potentially lethal situation to the operator.
Always be comfortable when using the machine. Do not over-stretch in the
working area during operation. Avoid abnormal body bearing especially when
loading the work piece of moving the machine.
Only change the spindle cutter when the spindle has been disabled –See
Section3.1.2 for more details.
Always be attentive. The machine is potentially very dangerous when not used
by a trained operator. Pay attention to your work and always be attentive to
the machine at all times. Expect the unexpected. Build confidence slowly.
In the case where injury has occurred to people who have used the machine
improperly and outside of the machines applicable operational range, the
manufacturer/provider of the machine is not liable to any damage so caused.
In the case where interlocks are provided on machine enclosures - always
check safety Interlocks after first switching on the machine. For example, turn
on the spindle manually and then test the safety systems operation to
verify it works. Do not just assume it does.
2.2 OBLIGATIONS OF THE OPERATOR
The operator of the CNC router MUST explicitly train and inform all users (or people working
in close proximity to the system) of the relevant risks and dangers associated with using the
CNC router machine. Please ensure no unqualified people or children can obtain access to
the machine. The operator MUST insist on proper instruction and training for ALL USERS.
The operator must do the following
Operation of the router must only be carried out when the system is in a mechanically
sound and reliable operational condition.
Must use suitable protection arrangements and security arrangements in order to
minimize the dangers associated with the machine use.
Must make sure the guarding of the spindle and cutter when in operation is
appropriate and safe for the job being carried out.
Inspect the machine periodically (optimally on a daily basis) to ensure the machine is
in perfect working order prior to use.

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If outside of warranty, use only original spare or replacement parts to maintain the
same level of performance.
Pay special attention to all recommendations outlined in this manual.
2.3 RECOMMENDED USE
TYPICAL APPLICATION MATERIALS2.3.1
The industrial HF spindle system when used on a CNC router is suitable for milling, boring,
engraving the following materials:
Wood.
Plastics.
Aluminium and other NE metals (under certain very specific conditions)
Fibre composites e.g. GFK or CFK (with specific attention to the dust generated from
cutting)
The above list of materials is appropriate if the following conditions are met
Appropriate tooling is used for the job requirement
The tools have been installed correctly in the collet mounting system in the provided
spindle. Never use a tool outside of its operating parameters.
The spindle speed and feed rate are appropriate for the job
In the case where you are machining aluminium some extra care is required to
maintain good chip development. If necessary a cold airline will improve chip
generation.
Coolant may be required in some cases where aluminium is the main application.

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2.4 WORK PIECE CLAMPING
Extra care must be made to
ensure that the materials/work
pieces are secured firmly with
suitable clamp means on the
machine table. Failure to clamp
the work properly can lead to
extremely dangerous and
uncontrollable situations.
ALWAYS ensure your work is
clamped down securely.
NEVER use your hands or manually hold down the work piece when the machine is working.
This can cause severe injury to the operator.
FAILURE to clamp down the work securely can cause machine and spindle damage.
2.5 MACHINE ISOLATION WHEN YOU INTERACT WITH THE MACHINE
When you need to interact with the machine to move clamps,
reposition clamps/work pieces, change tools, or come into the
machining area in any way –it is important you de-activate the
control software. If the “reset” button is activated in either
Mach3/UCCNC and the machine can be controlled then it is
possible for unexpected start-ups to occur. For example
items/tools/parts falling onto the keyboard could result in an
unexpected start-up. Before you interact with the spindle or any aspect of the machine
working area you must de-activate the software. Resetting the software before touching the
spindle. Section 3.1.2 shoes how to disable the software. Once the reset button is pressed in
the control software and the estop software logic is “Active” then
- In order for the spindle to turn on
- Or in order for the machine to be moved
- The reset button must be pressed again
- And then an unintended interaction with the machine must then occur.
- Isolation of the control software pre pressing the “reset button” before interacting with
the machine is best practice.
Do NOT Interfere
with the machine
when under CNC
control

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2.6 CUTTING TOOL SPECIFICATION AND LOADING
If the machine is used for milling or boring, the cutter should not exceed diameter 8mm. The
maximum RPM range as indicated by the provider of standard or special tools must be
adhered to at ALL TIMES. Always check the tool specification and do not allow a tool to
rotate at a speed in excess of its recommended maximum speed.
When using the industrial spindle it is very important to use the correct collet to mount your
tools. For example –its best to use a tool specified exactly for the cutter. So use a ¼ inch
collet for a ¼ inch tool. Its very important to load the tools correctly and make sure they are
tight in the spindle.
2.7 SOURCES OF DANGERS
CUTTERS
2.7.1
CAUTION Milling machine tools and cutters have
extremely sharp cutting edges and cutting tips.
Improper contact with the sharp tool cutting edges
can easily lead to sometimes severe cuts and trauma.
Even with the spindle system off the cutting tools are
still very dangerous if touched or handled improperly
KEEP AWAY FROM SPINDLE SYSTEMS WHEN IN OPERATION
2.7.2
DANGER Keep away from the spindle during operation as the
rotating cutter is extremely dangerous. Additionally –when loaded
with a sharp cutter touching the spindle even with no power
connected can lead to serious injury due to the sharp cutting
edges. Where required spindle guarding systems should be used
to prevent access to the rotating cutter.
CAUTION
Rotating Cutter

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FRESHLY CUT MATERIALS
2.7.1
CAUTION Freshly milled/drilled work piece material that has not
be de-burred can have sharp edges. Care should be taken to
avoid injury when handling recently machined work piece
material. This is equally relevant for plastics and timbers as
small splinters or small pieces of plastic left over from the
machining operations can cause injury when handled
SPINDLE WIND DOWN2.7.2
The spindle systems will “wind down” to a stop after they have been turned off. The operator
must be aware that no contact should be made with the spindle until the cutter has come to a
complete stop.
MANAGEMENT OF PARTICULATES AND SWARF AROUND THE CONTROL PC2.7.3
It is very important to be careful about how you manage the generation of swarf and dust
from the machine when in operation. Propagation of chips and swarf onto the control PC
system can cause issues with the PC operation. Particles can get stuck behind the keyboard
keys for example and cause uncontrolled keyboard signals being sent to the machine. Use of
appropriate guarding of the control PC from swarf –or getting a sealed industrial keyboard is
a good solution to this. It can be worth considering purchasing an industrial PC with full dust
protection as standard.
MANAGE THE USB CABLES CONNECTED TO THE MACHINE2.7.4
CAUTION Your CNC system is controlled using a USB
connection between the UC100 motion controller and the
machine control electronics. An example of a USB cable
connection as shown in the Figure here to the right. The
control software Mach3/UCCNC, is continuously
communicating with the machine down the USB cable.
Therefore IT IS IMPERATIVE that you do not touch or

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interfere with the USB connection under normal operation. This is ESPECIALLY important
when using a laptop as often the USB cable is close to where the user is interacting with the
machine. The laptop can also be moved around. Any movement of
interference with the USB port connection when the machine is in use is
EXTREMELY DANGEROUS. EXTREME care must be taken to ensure the
USB connection to the PC is not snagged, pulled, touched or moved in
any way when the machine is under Mach3/UCCNC control. Where
appropriate route the cables in ducting or management system to prevent
trip hazard.
EYE EAR AND DUST PROTECTION2.7.5
DANGER Eye (safety goggles) and ear (safety ear muffs) protection must be worn at all
times. The spindle. system can produce noise levels in excess of 80dB and machining
causes the generation of chips and swarf that can easily enter a person’s eye and cause
injury. All persons in the vicinity of the machine tool during its operation must have
appropriate levels of eye and ear protection at all times. The noise levels are reduced
significantly when the machine is operating with a full safety enclosure. In addition to the
extraction system configured at the cutting zone –it is highly recommended that you use the
correct dust mask system for the materials you are machining.
ALWAYS WEAR EYE PROTECTION, EAR PROTECTION AND APPROPRIATE DUST
MASK PROTECTION
CAUTION
Protect USB
connection
Eye protection
must be worn
Ear protection
must be worn
Wear Face
Mask

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SAFETY CIRCUITS2.7.6
Please note that on older STEPCRAT control boards when the UC100 module powers down
during use the spindle can start up if left on and in CNC mode. This has been rectified in
more recent versions of the STEPCRAFT mainboard.
Therefore when in CNC mode it is imperative that you act with extreme caution when using
your industrial CNC spindle.
3 SETUP
SYSTEM SETUP3.1.1
Plug the interface cable into the back of the STEPCRAFT and into the back of the Industrial
spindle control box. See Figure 2 for how this is carried out.
Figure 2: Interface cable connection

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Figure 3: Plug cable into the spindle connector
Figure 4: Operation and control
Plug cable into spindle connectos as shown in Figure 3.
When in Manual mode the spindle can be controlled as shown in Figure 4.
When in CNC mode the spindle will be controlled by the UCCNC controller.

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Figure 5: UCCNC settings for idustrial HF spindle control
NOTE: if you are changing settings
- Click in box to change setting
- Type in value
- Press ENTER key on keyboard to register value
- Click apply
- Click save
RESETTING THE SOFTWARE BEFORE TOUCHING THE SPINDLE3.1.2
DANGER Before you change the tool in the spindle and before you handle any of the spindle
components in any way, you must de-activate the spindle system to avoid accidental spindle
start-up during handling.
Mach3/UCCNC Isolation (Software Estop) The first stage in disabling the
spindle system is to hit the reset button in Mach3/UCCNC. This will help
in preventing unexpected startup of the machine spindle.

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