manual grav32 gb

Engraving and Milling System

Manual

April 1998

Phoenix Contact GmbH & Co. Flachsmarktstr. 8-28 D-32825 Blomberg Telefon (05235) 300

Telefax (05235) 330199 Telex 935 863

User Manual CMS - GRAV 32 Directory I

1 Introduction............................................................................................................ 1

2 System configuration Engraving and Milling System ........................................ 2

3 Installation and Start Up........................................................................................ 3

3.1 Transport information............................................................................................... 3 3.2 Selection of the working area .................................................................................. 3 3.3 Removing the packaging.......................................................................................... 4

3.3.1 Removing the wood packaging............................................................................ 4 3.3.2 Removing the transport safety latch .................................................................... 4

3.4 Connections of the Engraving machine .................................................................. 5 3.5 Configuring the Software package .......................................................................... 6

3.5.1 Switching the Machine ON................................................................................... 7 3.5.2 Switching the machine OFF................................................................................. 7 3.5.3 Abort output......................................................................................................... 7 3.5.4 Opening the doors while operating ...................................................................... 8 3.5.5 Abort with the EMERGENCY-STOP.................................................................... 8 3.5.6 Interrupting the operation..................................................................................... 8

4 The Layout of the Engraving machine ................................................................. 9

4.1 The main unit of the GRAV 32 .................................................................................. 9 4.1.1 The main unit....................................................................................................... 9 4.1.2 Other supplied accessories ................................................................................. 9

4.2 The XYZ processing unit .......................................................................................... 10 4.3 The housing............................................................................................................... 10

4.3.1 The name plate.................................................................................................... 10 4.4 Operation keys, Display and connection elements ................................................ 11

4.4.1 The face plate of the control unit ......................................................................... 11 4.5 The remote control.................................................................................................... 12 4.6 Explanation of the individual keys........................................................................... 13

4.6.1 The Arrow keys.................................................................................................... 15 4.7 The Display................................................................................................................ 16 4.8 Setup Functions of the remote control ................................................................... 17

4.8.1 The Machine setup .............................................................................................. 17 4.8.2 The Tool Setup.................................................................................................... 19 4.8.3 Reseting all the Machine Parameters .................................................................. 19

5 The Engraving Spindle System ............................................................................ 20

5.1 The Engraving Spindle ............................................................................................. 20

User Manual CMS - GRAV 32 Directory II

5.2 Mounting of the Engraving Spindle ......................................................................... 21 5.2.1 Setting the Spindle holder higher......................................................................... 21 5.2.2 Exchanging the Spindle ....................................................................................... 22 5.2.3 Manual Tool change ............................................................................................ 23 5.2.4 Exchanging the chuck ......................................................................................... 24

5.3 Coolant Spray Fixture ............................................................................................... 24 5.3.1 Cooling with the Coolant Spray Fixture................................................................ 24 5.3.2 Connections of the Spindle and Coolant Spray Fixture........................................ 25 5.3.3 Assembly of the Coolant Spray Fixture................................................................ 26 5.3.4 Adjusting the Coolant Spray Fixture..................................................................... 26 5.3.5 Recommended Coolants ..................................................................................... 26

5.4 The Vacuum Fixture.................................................................................................. 27 5.4.1 The Components of the Vacuum Fixture ............................................................. 27 5.4.2 Assembly of the Vacuum Fixture ......................................................................... 27

6 The Tool Magazine................................................................................................. 28

6.1 The Components of the Tool Magazine................................................................... 28 6.1.1 The Tool Magazine.............................................................................................. 28 6.1.2 Installing the Tool Magazine ................................................................................ 28 6.1.3 Setting the Tool Magazine ................................................................................... 29 6.1.4 Test Run.............................................................................................................. 30 6.1.5 Setting the Tools according to Engraving Depth.................................................. 30 6.1.6 Fitting a Fixing Ring............................................................................................. 31 6.1.7 The Adjustment Block.......................................................................................... 31 6.1.8 Setting the tool depth with the adjustment block.................................................. 32

6.2 Operating Pressure................................................................................................... 33

7 The Control Cabinet............................................................................................... 34

7.1 The Control Unit ........................................................................................................ 35 7.2 Stepper Motor Control Card ..................................................................................... 36 7.3 The Interface Card..................................................................................................... 36

7.3.1 Exchanging a Plug-In Card.................................................................................. 36 7.3.2 Exchanging the EPROMS on the Interface Card ................................................. 37

7.4 Valves for the Pneumatic Control ............................................................................ 37 7.5 The Voltage module .................................................................................................. 38

7.5.1 Changing a fuse on a voltage module ................................................................. 38 7.6 Fuses of the Control Unit and Voltage Module....................................................... 39

8 Fixing System......................................................................................................... 40

8.1 The Vacuum Fixing System...................................................................................... 40 8.1.1 The Components of the Vacuum System ............................................................ 40

8.2 Vacuum Fixing Plates ............................................................................................... 40 8.2.1 Fitting a Vacuum Fixing Plate .............................................................................. 41

User Manual CMS - GRAV 32 Directory III

8.3 Vacuum Compressor ................................................................................................ 41 8.3.1 Vacuum Compressor W5 .................................................................................... 42 8.3.2 Installing the Vacuum Compressor ...................................................................... 42

8.4 Other fixing systems................................................................................................. 42

9 Various Engraving and Milling Methods.............................................................. 43

9.1 Engraving with Z-Tracking ....................................................................................... 43 9.2 Engraving without Z-Tracking.................................................................................. 44

10 Working with typical Workpieces....................................................................... 45

10.1 Engraving Single Schields ..................................................................................... 45 10.2 Engraving Multiple Shields .................................................................................... 46 10.3 Border Engraving.................................................................................................... 46 10.4 Engraving Front Plates with Script, Graphics and Break-outs............................ 47 10.5 Milling Printed Circuit Boards................................................................................ 47 10.6 Further Application Possibilities ........................................................................... 47 10.7 Feeding Speeds and Spindle Speeds .................................................................... 48

11 Care and Maintenance......................................................................................... 49

11.1 Daily Maintenance Tasks........................................................................................ 49 11.2 Expandable parts, Service and Service intervals ................................................. 49

11.2.1 Lubrication recommendations............................................................................ 50 11.2.2 Lubricating the X Axis ........................................................................................ 50 11.2.3 Lubricating the Y Axis ........................................................................................ 50 11.2.4 Lubricating the Z Axis ........................................................................................ 50

12 Errors and how to solve them ............................................................................ 51

13 Appendix............................................................................................................... 52

13.1 Pin layout of the V24 Cable .................................................................................... 52 13.2 Technical Data......................................................................................................... 53 13.3 Instruction list of the CMS Engraving/Milling System.......................................... 54

14 Index ..................................................................................................................... 55

Introduction Page 1

1 Introduction Congratulations on purchasing a PHOENIX CONTACT Engraving Machine CMS GRAV 32. With this high value quality machine you have a universal, modularly-built work station for engraving and milling tasks, as well as other processing possibilities. This manual is designed to assist you in working with the CMS Engraving/Milling system. All functions are described that work in conjunction with the system hardware. For a professional start up and operation of the entire system (in particular the software) please refer to the corresponding instruction manuals.

System configuration Engraving and Milling System Page 2

2 System configuration Engraving and Milling System For the operation of a CMS Engraving/Milling System requires the following components:

- Engraving machine GRAV 32 - Fixing system - IBM-compatible PC with a open serial interface (The requirement of the PC is depen-

dant to the software used. This is to be found in the instruction manual of the cor-responding software.) The following software packages are available:

CMS GRAVMASTER SOFT Vers. 3.1x Order number.: 50 66 31 1 CMS-GRAVUR-GC-SOFT Vers. 3.1x Order number.: 50 62 87 8 CMS-MARK Vers. 3.1x Order number.: 50 66 63 8

The above-mentioned components comprise a minimum configuration. It is possible to up-grade the system with the accessories listed at any time.

Installation and Start Up Page 3

3 Installation and Start Up

3.1 Transport information The Engraving/Milling machine CMS GRAV 32 is delivered in a solid wooden box. In this way it is protected from possible damage from the outside. Until located in its working area it must be transported on the wooden palet and may not be tilted or turned over.

Caution ! Do not drop the machine! Protect the machine from moisture! Even with visibly small crashes with minimum outer damage, the danger exists that either electrical or mechanical parts could be damaged or destroyed. With any visible outer damage please get in touch with PHOENIX CONTACT and the respective ship-ping agent.

3.2 Selection of the working area The working area of the machine must be in an industrial area. The engraving machine must be set up on a flat, fixed structure in a dry area. Recommended are e.g.:

- solid work benches - steel table consoles and so on.

Caution ! Never place the machine on an unstable table, chair, cupboard, slanted surface or trolley. Since very strong acceleration forces can occur, the machine could wobble on very unstable surfaces. In the extreme the machine could fall ! Furthermore sufficient lighting should also be present at the work place..

The device feet of the Engraving machine must be adjusted with a level to stand e-xactly horizontal (see Figure 3-1).

For the operation of the Engraving machine the following connections are required:

- 230 V / 50 Hz (115V / 60 Hz) alternating current with fused 16 A output. - A pneumatic hose with a working pressure of 5,5 - 6 bar. - A compressor with a volume performance of minimum 200 litre/min

The machine must be set up in such a way that it can be accessed from all sides. The PC should be placed in close proximity to the machine. The PC keyboard should be mobile e-nough to move close to the doors of the engraving machine, to control the position the engraving head. If on the machine table a surface is present for the keyboard, this will allow make the work a lot easier.

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3.3 Removing the packaging

3.3.1 Removing the wood packaging - Loosen the lower screws on all 4 sides of the base plate - Remove the wooden hood as one piece by raising it over the machine - Remove the the fixing screws of the machine to the palet. - Position the machine carefully on the required surface

Caution ! The surface must be dimensioned for both size and weight of the machine.

- Remove the protective foil of the the machine covers

3.3.2 Removing the transport safety latch The engraving machine may only be used once the transport safety latch (1) has been re-moved. If the machine is switched on with the safety latch still fastened, the stepper motors could be damaged.

1

2

3 Figure 3-1

(1) Transport safety latch (2) Main Lock Switch (for C-Lock) (3) Adjustable device feet

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Important ! The transport safety latch should be used everytime the machine is transported to a new location. The main switch can be secured with a C-lock, to prevent any unwanted used of the machine.

The machine is now ready for use. The start up is carried out (if ordered with the installation) by our Technical Support CMS team (TS). If a start up is carried without assistance of the Technical Support team, then the steps as listed in the following chapter should be carried out.

3.4 Connections of the Engraving machine

1 2 3

456

7

10

89

Figure 3-2

(1) 220 V supply for extraction unit with glass fuse rated 6.3 A / medium blow (2) 220 V supply for vacuum pump with glass fuse rated 6.3 A / medium blow (3) Machine supply cable 220 V with glass fused rated 6.3 A / medium blow (4) PC connection cable (5) Hose connection for cooling liquid (6) Air pressure connection for the control unit (7) Connection hose for vacuum cleaner (8) Air filter unit for the air connection to the spindle (1 bar) (9) Air pressure connection with air filter unit (min. 5.5 bar and min. 200 liter/minute) (10) Hose connection for vacuum pump (- 0.6 bar)

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Caution ! The power sockets (1) and (2) are powered even if the main switch is OFF !

The plug of the remote control is fitted in the round socket on the front side of the machine and is fastened with the safety thread. The power plug is inserted. Make sure that the the power supply is properly fused (see Technical Data). The pressure hose is connected at the rear of the machine. The air pressure is dried via a water filter. Either oiled or non-oiled air can be used. The PC is connected to the engraving machine with the V24 cable. Both devices must be switched off. The connection cable must be connected to the correct sockets on both ends (the ends of the connection cable are marked accordingly). Should the cable be connected incorrectly, the machine will not be correctly controlled. If the PC has only serial interfaces with 25-pole connectors, then the supplied adapter must be used !

Important ! The following points must be taken into account:

- Both connection plugs must have their fixing screws securely fastened. - The interface card must be properly secured and screwed in its slot in the PC. Cards that

are only slotted on to the mother board often have contact problems, particularly when the cable attached to the card is pulled. This can lead to an error function when operating the engraving machine.

- Use only the supplied connection cables. - Make sure that the socket is not subjected to the weight of the cable. Strain relief for the

cable is advisable at another point (i.e. on the table).

3.5 Configuring the Software package After the configuration of the Engraving machine, the Software package used to control the Engraving machine must also be configured. The following parameters must be the same as the settings in the SETUP program of the remote control: - Interface parameter of the COM - interface - Z - Tracking YES / NO - Manual tool change ON / OFF. (see chapter Setting the Spindle holder higher)

In the tool list of the software the correct tool settings must entered.

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3.5.1 Switching the Machine ON After the machine has been built up and connected as described, it can be switched ON. Proceed in the following sequence:

- Switch on the PC and wait until it has booted up. If the machine should be operated without a computer (i.e. when setting up the tool magazine), then ignore this point.

- Switch the main switch ON the machine. - The remote control will emit short tones. Now the tool number of the tool presently in-

stalled should be entered (0 for no tools). Display input tool-no in motor : press 1 .. 10 +<change> key

- After inputting the tool number and pressing the tool change key, the following message appears:

WARNING

>> Door open <<

- After the <Mains> key has been selected, the machine moves to the origin and is ready for use.

3.5.2 Switching the machine OFF After all work pieces have been worked on, the spindle moves to the origin of the work piece. Should no further work pieces be worked on, the GRAV 32 can switched OFF at the main switch.

3.5.3 Abort output The normal sequence is as follows:

- Abort the proceeding via the software (see the corresponding Software Instruction Ma-nual)

- The Engraving machine now completes the actual vector before coming to a halt. If this step is unwanted the machine can be stopped by pressing the <RESET> key.


3.5.4 Opening the doors while operating The opening of the doors can be used to halt the operation of the Engraving machine. The door switch is used as an emergency stop to protect the operating personnel from injury or danger. To once proceed with the operation of the machine, proceed as follows:

- Close the doors, press the <Mains>-key on the front of the machine - The machine saves the tool number and the position before the interruption. The ma-

chine now moves to this position once the doors are closed and the <Mains> key has been pressed.

3.5.5 Abort with the EMERGENCY-STOP Since the EMERGENCY-STOP is used to prevent a fatal mistake (e.g. a crash or other ) the procedure is as follows:

- Open the doors and remove the reason for the interruption, or use of the EMERGENCY-STOP (i.e. remove the part which caused the problem.)

- Close the doors. - Reset the EMERGENCY-STOP switch by pulling it out. - Press the <Mains > key on the machine front side. The Engraving machine moves to

the origin and then to the point where it was interrupted. The tool number and interrupti-on point are saved.

Important ! If the output is to be aborted entirely, then before resetting the machine, abort the output via the software.

3.5.6 Interrupting the operation By pressing the <PARK> key on the remote control, it is possible to interrupt the engraving / milling task. The machine moves to the park position. If a restart is required, a second pres-sing of the <PARK> key will cause the machine to continue.

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The Layout of the Engraving machine Page 9

4 The Layout of the Engraving machine

4.1 The main unit of the GRAV 32

1

2

3

Figure 4-1

4.1.1 The main unit (1) The XYZ-processing unit (2) The housing with connections and safety elements (3) The integrated control unit

4.1.2 Other supplied accessories - 1 remote control - 1 connection cable for the PC to the Engraving machine - 1 adapter D-SUB 9pole to 25pole - 1 storage box for all accessories - 1 tooth brush to clean all tools - 3 Allen keys - Fixing nuts for the coordinate table - Spindle accessories - 50 tool fixing rings


4.2 The XYZ processing unit The XYZ processing unit consists of a planed and machined XY coordinate table with integ-ral T-slots. The control of the three axis is achieved with three stepper motors. Free of play and easy running, the drive gears ensure a high processing speed and position repeatability on all three axis. 15 T-slots ensure a secure fastening method for the material to be worked on or any instal-led fixing system.

4.3 The housing The CMS processing unit is basically supplied in an enclosed housing. The housing fulfills the following tasks:

- Garantee optimal safety of the operating personnel - Reduction in machine noises - Containment of filings and dust

The safety features fulfill the requirements of the Accident Prevention Regulations. In the operating condition, all motors (inclusive the spindle motor) are switched off if the doors are opened. The EMERGENCY-STOP ensures an immediate stop of all functions. The wide swing doors allow an easy access to the working surface.

4.3.1 The name plate The name plate is to be found inside the working area of the machine, on the left-hand side below the door sensors.

Figure 4-2


4.4 Operation keys, Display and connection elements

4.4.1 The face plate of the control unit

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2

3

4

5

6

7

8

9

Figure 4-3

(1) Operating hour counter (2) Extraction switch ON / OFF (3) Mains ON switch (4) Main machine switch (5) Connection of the remote control (6) EMERGENCY STOP switch (7) Mains OFF switch (8) Vacuum pump ON / OFF switch (9) Interruption display


4.5 The remote control Using the remote control, the Engraving Machine can be manually controlled and configured.

Figure 4-4

It consists of a hand held unit with a 4 line display as well as 21 keys, which in part incorpo-rate double functions. Supplied with a two meter long connection cable, the remote control fulfills all the require-ments in the area of the entire machine with optimal input functions.


4.6 Explanation of the individual keys

1 2

3

0

4 5

6 7 8

9 10 11

12 13 14

15 16 17

18 19 20

Figure 4-5

(20) RESET Machine reset or SETUP abort After pressing the <RESET> key, the actual processing vector is interrupted, the machine goes thru a reference route (Same procedure step when switching ON the machine), and remains stationery in the left back corner. Procedure: 1. Data output interruption of the corresponding PC program (see also the software user

manual) 2. Press the <RESET> key

(19) SETUP After operating the <SETUP> key the machine goes into a SETUP-Mode. Here the system parameters of the Engraving Machine are displayed and can if needed be edited. The indivi-dual parameters can be viewed by selecting the key (13) <Parameter +> next Parameter respectively (10) <Parameter -> previous parameter. Values can be changed with the keys <+> and <->. By operating the <SETUP> key twice, the tool changer can be set up.


The meaning and standard settings of the single parameters are described in the chapter Setup Functions of the remote control. After the parameters are set, one presses the <ENTER> key to exit the <SETUP> and tool change-SETUP to return back to the Normal mode. (18) PARK ON / OFF After selecting the <PARK> key, the actual vector is still concluded. Thereafter the axis of the machine to the pre-defined park position (Left back corner). The display will show "Park position". In the park position there is no possibilty to use the control keys of the PC-keyboard. No further computer data is accepted by the machine. The door can be opened to inspect the result of the engraving task. After closing the doors, remember to push the <MAINS> button on the front plate of the machine! After pressing the <PARK>-button the engraving process continues with the next vector. (17) TOOL CHANGE With the <TOOL CHANGE >-key a manual tool change can take place. (16) Increment - With this key the increment of the feeding of the XYZ - axis can be manually reduced. (15) Increment + This key allows the increment of the feeding of the XYZ - axis to be manually increased. (14) VACUUM The valve for the <VACUUM> is set with this key to fix work pieces on the vacuum table. The display of the remote control shows whether the vacuum is switched ON or OFF. Symbol when ON [< (13) MOTOR ON / OFF The <MOTOR> key switched the spindle motor ON or OFF. With an opened hood, this key also opens or closes the tension chuck of the engraving spindle. In SETUP-Mode the next parameter is selected


(11) AIR ON / OFF The <AIR>-key switches the air valve of the coolant / spray unit ON or OFF. A symbol on the display shows the relevant setting. Symbol when ON [> (10) COOLANT ON / OFF Die <COOLANT> key switches the the coolant valve of the coolant/spray ON or OFF. A symbol on the display shows the switching condition. In the SETUP-Mode the parameter is selected Symbol when ON X (4) ENTER To exit SETUP and Tool SETUP By selecting the <ENTER> key, one returns to the normal mode.

4.6.1 The Arrow keys

4.6.1.1 Solid Arrow keys

<�> Key (0) half left down <�> Key (1) down <�> Key (2) half right down <�> Key (3) left <�> Key (5) right <�> Key (6) half left up <�> Key (7) up

These keys are used to move the engraving machine in the X and Y axis. The speed of mo-vement is dependant on the setup parameter 'INCREMENT'

4.6.1.2 The outline Z Arrow keys

<��> Key (9) Z direction down <��> Key (12) Z direction up

With these keys the engraving machine moves in the Z direction. The speed of movement is set by the setup parameter 'INCREMENT'


4.7 The Display Normally the display shows the position in which the engraving machine is to be found (ac-cording to the setting, the X, Y or Z position). In certain cases the following operational set-tings the following messages are possible:

Display Messages Remark *Error SZ

An invalid (i.e. too large) Z value Check the following parameters in the software: - Z-Height of the working surface - Length of the tool - Tool parameter with / without Z-Tracking - Traversing height, Engraving depth, Material thickness

*Error area XY

An invalid X or Y coordinate. Check the following parameter in the software: Shield width, Shield height, Origin.

*Error ?-Axis (? = X, Y oder Z)

After switching on the machine or after selecting the <RESET> key (see remote control) the corresponding axis cannot reach its zero point

*Error command ??

An invalid instruction. Possible cause: Machine reset without prior abort of the software output. False output device defined in the software

*Error Parity Displayed after switching on the machine before the PC Error ventilator

The air vent unit (Module A13) is not functioning correctly. Contact Customer Service immediately. Quit the error with the ENTER key. Machine can be operated, however under supervision

Error compressed air

When switching the machine ON and when changing a tool, the air pressure is measured until the preser air pressure is achieved. The preset minimum pressure has not been achieved. The air supply should be inspected and if required increased.

Operating system- Version CMS-GRAV (e.g. 5.14)

After every start and RESET of the machine

Machine system (e.g. GRAV 32)

After every start and RESET of the machine

Machine moves ... When using the remote control on traversing the X, Y or Z axis. Park position After selecting the <PARK> key on the remote control Door open The doors of the machine are not closed

The EMERGENCY-STOP was operated The key <Mains> on the machine was not selected

Comp. command The control unit of the GRAV 32 is receiving data from the PC.

* The designated errors could also be caused by data transmission errors. The errors can be

quitted by using the RESET key.


4.8 Setup Functions of the remote control Before the machine can be run by a PC, the operating system of the GRAV 32 must be con-figured.

4.8.1 The Machine setup By selecting the <Setup> key, the machine is ready for the Machine Setup. To get to the various menu items, press the <Parameter +> or <Parameter -> keys. The possible settings are achieved by pressing the <+> or <-> keys. To exit the Setup Menu at any time, press the <Enter> key. The selected values are then utilized. If you wish to exit the Setup mode, without taking the new values, then press the <Reset> key. Specific settings (RPM, Feed) are overwritten via software during normal ope-ration.

Important ! The transmission parameters of the COM interface to the CMS Interface Card of the GRAV 32 must be the same values as those entered in the corresponding Setup programs of the Software Package.

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The surest transmission integrity is achieved with the following interface settings Baudrate 19 200 Parity EVEN Data bits 7 Stop bits 1 Handshake Hardware

Display Default Possible Remark baudrate 9 600 1200..19200 Details must be the same as those of the para-

meters of the COM interface of the PC. parity

EVEN EVEN, ODDNONE

Details must be the same as those of the parameters of the COM interface of the PC.

data bits

7 7 8


stop bits

1 1 2


handshake Hardware Hardware Software


velocity x,y 1 cm/sec. 0.0-6.3 cm/s. Material and Tool dependant velocity z 1 cm/sec. 0.0-6.3 cm/s. Material and Tool dependant spindle turns r/min

60440 RPM 0-60440 RPM

Material and Tool dependant

end-frequency 5000 Hz 3500-5000 HZ

acceleration 16 HZ/ms 12-16 HZ/ms display mm mm, PU PU=Plot units (1mm=40 PU) orth-correction OFF ON

OFF

language German German English French

contrast REMOTE CONTROL

Stepless Setting with <+> and <-> keys


4.8.2 The Tool Setup After a second selection of the <Setup> key, one enters the Tool Setup.

Display Messages Remark measure single tool with <change>+<1-10>

Select any tool number and press the <Tool change> key, the spindle will collect the corresponding tool, measure the Z Height with the tool sensor and then return the tool to the corresponding tool holder.

measure all tools with <change>-key

By selecting the <Tool change> key, all the tools are measured with the Z sensor. The option should be used when the tool magazine has been modified. In this way you ensure that all tools are recorded and stored without any problems.

Tool tolerance +/- 0.100 mm

This setting defines the maximum tolerance that may occur with a tool change and the check of the Z sensor. If this value is exceded, the machine will halt and provide an error message. This function is only available with a reference route.

check tool at getting I putting Possible settings: none, getting, putting, getting and putting

This setting is used to define when the tool is to be measured by the tool sensor. „getting I putting“ means that every tool is measured by the Z sensor after getting and before the putting to the tool magazine. If the established value is exceeded at collection, the machine will halt and provide an error message.

tool change man. off Possible setting: ON / OFF

Is used to set whether the tools are to be changed manually or automatically. This menu item should be activated when the spindle is fastened in the upper fixing position. An automatic tool change is not possible in the upper fixing position

set tool posit. by pressing <change>-key

After the tool magazine has been modified, the position of the tools should be recorded anew. (see Setting of the Tool magazine)

After all machine and tool parameters have been set as required, they are recorded by se-lecting the <Enter> key and the Setup is concluded.

4.8.3 Reseting all the Machine Parameters With a Total Reset of the machine, all changed SETUP Parameters are lost. The SETUP is set back to the Default Parameters. To proceed with a Total Reset, do the following

- Select the <Reset> and <Setup> keys simultaneously. - Release first the <Reset> key and then release the <Setup> key. - The machine is once more set to the standard default values.

The Engraving Spindle System Page 20

5 The Engraving Spindle System The work with materials occurs with, in most cases, a rotating tool (Engraving bit, Milling bit, Drilling Bit). The exception is the cutter blade which fed without rotation across the work piece.

5.1 The Engraving Spindle The high frequency Spindle is a high precision processing tool which is also designed for an automatic tool change. The spindle motor is supplied fully fitted and connected. For optimal cooling, the spindle carrier is made of aluminium. A protective layer of air pre-vents cuttings or fluids (e.g. emulsions) from penetrating the bearings. In this way bearing damage can be prevented. The exiting air leaves the housing from between the front and the exiting washer. The spindle unit is made up of the following parts.

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34

5

7

89

9

10 11

12

6

Figure 5-1

(1) Z Tracking Sleeve (2) Fixing screw for the Z Tracking Sleeve (3) Lower spring with adjusting screw


(4) Fixing screw for the spindle holder (5) Fixing screw for the spindle carrier (6) Setting points for the spindle positioning (7) Upper spring with adjustment screw (8) Pneumatic holder for Z fixing (9) Fixing screw for the spindle holder block (10) Pneumatic connection for the Spindle Air Gap (11) High frequency spindle with electric connection plug (12) Air connection for the tool changer

5.2 Mounting of the Engraving Spindle The Spindle is supplied pre-fitted on the Z axis.

5.2.1 Setting the Spindle holder higher The possibility exists to raise the Spindle with holder by about 75 mm in the Z axis. This pos-sibility exists to work on, for instance housings. In the upper fixing position the vacuum con-nection is not available. Furthermore, an automatic tool change is not possible.

Caution ! In the Tool Setup the menu item Tool Change Manual must be set to ON.

To modify the Spindle position, proceed as follows:

- Loosen both upper fixing screws of the Spindle holder (see Figure position (9)) - The screws must not be fully turned out, since the fixing nuts could fall out. - Loosen and remove the third fixing screw entirely. The fixing nut can be positioned hig-

her through the small hole in the lower Z Axis cover plate. - Pull the Spindle holder forward so that the positioning pins (position (6)) come out of the

pin holes. - Lower the Spindle holder and unscrew the fixture of the vacuum vent on the rear of the

Spindle holder. - Move the holder upward in the Z direction, until the pins fit in the uppermost positioning

holes. - Tighten the upper fising screws (position (9)). - Now shift the lower fixing nuts of the fixing screws to the top and fasten the fixing

screws. - Change the Tool Setup Parameter accordingly.

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5.2.2 Exchanging the Spindle

5.2.2.1 Removing the Spindle To remove the Spindle from the holder, the following hoses and cable connections must be disconnected.

- Plug connector for electrical terminations - Air connection for pneumatic tool change - Air Gap connection

1

2

Figure 5-2

(1) - Fastening screw for Spindle holder sleeve (2) - Fixing screw for Spindle holder

Loosen then the fastening screw of the Spindle holder sleeve. Should the Spindle not be released, then it may be necessary to also loosen the front fixing screw of the Spindle hol-der. Now the Spindle can be lifted upward and out of the holder.

Important ! Before removing the Spindle the tool should be removed from the chuck and be replaced by the blunt transport pen (supplied with the machine). �


5.2.2.2 Installing a Spindle

Z

1

2

Figure 5-3

(1) - Z Tracking Sleeve (2) - Spindle adjustment block The installation occours in the reverse sequence to the removal. After the installation the Z height must be adjusted anew. The spindle must be fitted in the lowest position in the spindle holder sleeve and be fixed with the fastening screw. The spindle adjustment block must be positioned against the tensioning sleeve and fastened with the fixing screw. Then the screw of the spindle adjustment block must be loosened and the spindle must be moved by the Z length upward. After fastening the fixing screw, the spindle is set in the Z height.

Important ! If the Z sleeve is exchanged, the spindle must also be adjusted.

5.2.3 Manual Tool change To carry out a manual tool change procced as follows.

- Open the doors with a stationery spindle. - Press the <MOTOR> key on the remote control to open the chuck pneumatically. - Now remove the tool. - Put the new tool in the chuck. - Press the <MOTOR> key once more to close the chuck.

The spindle is now ready for operation

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5.2.4 Exchanging the chuck Before the chuck is exchanged, ensure that the bearings are not turning or moving.

- Remove the Z Tracking Sleeve by loosening both the fixing screws. - With the doors open, select the <MOTOR> key on the remote control. - Remove the tool from the chuck. - Using the supplied inner hex nut (supplied in the cleaning kit), remove the chuck by tur-

ning it anti-clockwise out of the axle. - If necessary clean the ball bearing in the axle with the supplied felt brush. - Clean the chuck with a brush. No dirt may be present in the chuck, and no dirt may en-

ter the chuck when cleaning it. - Lightly smear lubricant on the outside of the chuck. The inner side of the chuck must

remain fat-free. - Fasten the ball bearing by hand with the inner hex nut until it is secure in the axle. - Operate the <MOTOR> key on the remote control 2-3 times and inspect the seating of

the chuck once more. Comment: In the chuck you will find a sealed screw which holds the chuck in a pre-defined position in the axle.

5.3 Coolant Spray Fixture With the Coolant Spray Fixture the tools can be cooled during their operation. It consists of the following components

- Coolant Spray Jet - Hoses and adjustable valves for Coolant and Compressed Air - Coolant container with connection hoses

5.3.1 Cooling with the Coolant Spray Fixture While working on metallic material the use of a coolant is recommended on the tools. In this way the feeding speeds can be increased. Also the lifetime of the tools and the engraving result are improved. With some metals (especially aluminium alloys) cooling is essential, since a dry engraving can damage, or even ruin, the engraving result. The addition of a coolant can be done automatically with Coolant Spray Fixture. It assists in spraying the coolant on the tool during the engraving process. An Oil-Water-Emulsion is normally used as a coolant. An overview of possible coolants is shown in the table in the chapter Feeding Speeds and Spindle Speeds


5.3.2 Connections of the Spindle and Coolant Spray Fixture

1 2 3

4 5

6 7 8

9 10

11 12

Figure 5-4

(1) Coolant hose (2) Electrical connection of the Coolant Spray Fixture (3) Air hose for Coolant Spray Fixture (black hose) (4) Air brush connection (yellow hose) (5) Air connection for Z Feed (blue hose) (6) Air Gap connection (red hose) (7) Pneumatich connection Tool Changer (thick black hose) (8) Electric connection Spindle (9) Coolant hose with jet (10) Vacuum jet with hose (11) Cool air hose from valve to jet (12) Coolant hose from valve to jet


5.3.3 Assembly of the Coolant Spray Fixture The Coolant Spray Fixture is fitted above the Spindle holder. Should the unit be moved in its height, then the fixing screw should be loosened.

Caution ! The Sliding nut should not be allowed to fall behind the Spindle.

- The Coolant Spray Fixture should be fastened on the Z axis. - Connect the following on the distributor box:

- Insert the transparent hose (11) at 'Coolant'. - Fix the black hose (12) at 'Air Pressure'.

- Fill the coolant tank with the required coolant. - Connect the hose of the tank with the connection at the rear of the machine.

5.3.4 Adjusting the Coolant Spray Fixture Adjust the Flexi-Hose (9) so that the jet points directly at the tool. Press the <COOL> and <AIR> key on the remote control. With the initial operation air will first come out until the coo-lant is also under pressure. Only when the liquid coolant hose is completely full will the Coo-lant Spray Fixture start to function. If the coolant is only slowly exiting the jet then the coolant container should be raised to Spindle height. As soon as both air and liquid appear the mixture of air-liquid can be adjusted by the control valves on the side of the valve block. By turning the valve clockwise the corresponding out-put level is reduced. If the required ratio is adjusted, the valve setting can be fixed with the aid of the knurled screw. After setting the Coolant Spray Fixture, the operation can be swit-ched off by selecting the <COOL> and <AIR> keys on the remote control. The coolant air must always be switched on before the coolant liquid and after coolant liquid has been switched off to prevent any reversal of the coolant liquid in the hoses.

Caution ! When adjusting the Coolant Spray Fixture do not look into the jet, but rather turn a-way from the body !

5.3.5 Recommended Coolants As coolant for Aluminium we recommend the special oil ALUMAX 100 fro the preparation of the emulsion. Manufacturer: Steidle GmbH Präzisionwerkzeuge 40764 Langenfeld Tel.: 02173/17021 This oil is available in ratio 1:10 to 1:30 and with water is an excellent coolant.

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Also recommendable are pure cutting oils. These oils are however not sprayed with the Coo-lant Spray Fixture, but rather applied with an applicator before engraving on the work piece. Cutting oils can be purchased at most hardware stores. A common coolant used when engraving aluminium is a Methylated Spirits / Water mixture. Since the Engraving Machine is fully encapsulated, the air mixture is enhanced with alcohol within the machine.

� CAUTION - DANGER OF EXPLOSION ! Other non-flammable coolants, such as emulsions, should be used. Consider too the EU-Technical Safety Data Sheets.

5.4 The Vacuum Fixture With the help of an industrial vacuum cleaner connected to the machine the removal of dust and waste filings is possible. If the Spindle is positioned in the upper setting the use of a vacuum cleaner is however not possible.

5.4.1 The Components of the Vacuum Fixture - Vacuum hose with vacuum jet - Vacuum hose with connection adapter (Diameter 32 mm) to be connected with a stan-

dard vacuum cleaner to the vacuum hose of the GRAV 32.

5.4.2 Assembly of the Vacuum Fixture The vacuum jet is connected at the rear of the Spindle holder block with the corresponding fixing parts. The hose of your vacuum cleaner is connected with the adapter (supplied with the machine) with the vacuum hose. The mains socket for the vacuum cleaner is also at the rear of the machine. The Vacuum cleaner is switched ON or OFF with the switch (2) on the control unit (see The face plate of the control unit).

5.4.2.1 The Vaccum Cleaner Any industrial vacuum cleaner, preferably with a wet/dry function to vacuum up any liquids (important for use with the Coolant Spray Fixture).

Caution ! The vacuum cleaner should not exceed a power rating of more than 1000 Watt !

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The Tool Magazine Page 28

6 The Tool Magazine With the tool magazine the CMS Engraving/Milling System becomes a fully automatic pro-cessing station. The tool change is software controlled and requires no manual assistance. It is designed for use with tools of a diameter of 3 mm and a maximum shaft length of 36 mm, and controls up to 10 tools.

6.1 The Components of the Tool Magazine The Tool Magazine is supplied with the following components:

- Tool Magazine - Adjustment unit - Fixing rings

6.1.1 The Tool Magazine Up to 10 tools can be installed in the tool magazine. The tool holder block is installed within the operational area of the Engraving Machine.

2 3

1

1

Figure 6-1

(1) Tool Magazine (2) Tool Sensor (3) Tool Holder

6.1.2 Installing the Tool Magazine The Tool Magazine is supplied pre-assembled. According to requirement it can be installed either in the X or Y direction on the Machine table. The positioning must occur within the operational area of the Machine, although the position on the perimeter is recommended to allow the largest possible operating area. Furthermore the positioning close to the Machine Zero Point (Position after the RESET route) is advantageous, since optimized shorter ma-chine running times can be achieved.


6.1.3 Setting the Tool Magazine The position of the tool holder is saved in the operating system of the Engraving Machine. The positions must however first be recorded in the Teach-In-mode. Recording a new position is important under the following conditions:

- New installation of the Tool Magazine. - Exchange of the Interface Card. - After a change in the position of the Tool Magazine.

Before the Tool Magazine can be set, the Spindle in the Spindle holder must be adjusted in the Z dírection (see the Chapter Installing a Spindle). Therafter the Z Tracking Sleeve is removed and a tool is placed in the chuck of the Spindle.

- Loosen the fixing screw of the Tool Magazine. - Press the <Setup> key twice on the remote control and with the <Parameter -> key se-

lect the the menu item „Record Tool Position“. - Using the remote control move the Spindle in the Y axis (3) right to the back (see Figure

6-2). - Using the remote control now move the Spindle down in the Z axis and centrally over

the Tool Holder in the X axis (2). The Tool Magazine is now moved by hand in the Y a-xis (1) to adjust the position (see Figure 6-2).

- Now lower the tool in the Z axis in the Tool Holder until the Tool Holder moves slightly lower (see Figure 6-2). The Z height is now taken over by the Tool Number 1 (1.1). The display of the remote control now shows in the upper right corner the Tool Number (i.e. Tool 1).

- Now fasten the Tool Holder down. - Select the <Setup> key on the remote control. The Machine now moves upward in the

Z axis. - Move to the Tool Holder Number 10 (1.10) in the X and Y direction and slightly lower in

the Z axis. In the display of the remote control Tool 10 is shown. - Press <Enter> on the remote control.

3

2

1

1.10

1.1

Figure 6-2 The CMS GRAV 32 is now ready for operation.


Important : The recorded Position Coordinates can be seen on the display of the remote control. These Coordinates should be written down to save time in adjusting the position when, for instance, control card is replaced.

6.1.4 Test Run After setting the Tool Magazine the error-free operation of the Tool Changer System should be tested. Proceed as follows:

- Install tools in the Tool Compartments.

Caution ! The Tools must be positioned vertically in the Tool Holder !

- Press the <Setup> key twice to enter the Tool Setup menu - Then select the following menu item:

#Tool - Setup# measure all tools with <change>-key

- Press the <Change> key. All tools are measured one after another by the tool sensor.

The option should be selected when, for instance, the Tool Changer is reconfigured. In this way it is possible to ensure that all tools are collected without any problems and are correctly repositioned.

6.1.5 Setting the Tools according to Engraving Depth When working with the Z Tracking, all tools must be set according to engraving depth. Before a tool can be set to the required depth, the tool ( e.g. Engraving bit or Milling Bit ) must be fitted with a fixing ring.

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6.1.6 Fitting a Fixing Ring Every fixing ring may only be used once. If a tool is to be set to a new engraving depth the fixing ring must be exchanged.

- Put the adjustment block (3) with the wider opening facing upward on a solid work sur-face.

- Fit a fixing ring (2) in the adjustment block - Feed the required Engraving bit (1) vertically with the point facing downward into the fi-

xing ring and gently hit with a hammer until the point protrudes by about 3-4 mm.

1

2

3

Figure 6-3

6.1.7 The Adjustment Block The adjustment block is used to define the depth of the tool within the tool magazine. It consists of the following components:

1

2

3

Figure 6-4 (1) Depth gauge (2) Adjustment block (3) Adjustment block to insert the fixing ring on the tool


6.1.8 Setting the tool depth with the adjustment block An important requirement of an exact depth setting is a correctly set depth gauge for the adjustment block. The 0 of the scale of the depth gauge must be positioned under the indicated position (1). If this is not the case, then the adjustment can be made by adjusting the scale ring accordingly.

- Fit a fixing ring to the required tool so that it protrudes by about 3-4 mm. - Hold the adjustment block vertically with the depth gauge at the bottom and put the tool

point into the adjustment block (Warning !! Keep the engraving bit straight !). - Turn the sleeve carefully until a noticeable resistance is felt. - Continue to turn the sleeve until the needle of the depth gauge moves - Proceed with the turning of the sleeve until the required depth (2) is shown on the depth

gauge. - Remove the engraving bit and mark it or store it so that its set values are clearly visible.

1 2

Figure 6-5


6.2 Operating Pressure Make use of a compressor with a capacity of minimum 200 litre/minute. The supplied opera-ting pressure may not be lower than 5,5 bar, otherwise an automatic tool change cannot be guaranteed. The result is a badly held or inadequately tensioned tool. The tools could then be damaged or the workpiece may be incorrectly processed. The operating pressure of the Air Gap should be about 1 bar to prevent foreign matter from entering the spindle housing. The operation without air gap will mean an early breakdown of the Spindle. If a vacuum table is using as a fixing plate, then the vacuum pressure should be a minimum of -0.6 bar. The vacuum pressure can be actuated by pressing the <Vacuum> key (14) on the remote control. Any leakages should be avoided.

1

2

3

Figure 6-6

(1) Operating pressure Machine ( 5,5 - 6 bar ) (2) Operating pressure Air Gap of the Spindle ( 1 bar ) (3) Vacuum of the Vacuum plate (min. -0.6 bar )

The Control Cabinet Page 34

7 The Control Cabinet The Control Cabinet is integrated in the left-hand side of the Machine. It contains the control and power electronics. It forms the interface between the Computer and the XYZ Processing unit. In the control cabinet you will find the following elements :

1

2

3

45

67

8

9

10

Figure 7-1

(1) Pressure monitor (2) Control valve for Pneumatic connections (3) Connection box (4) 19“ Rack for the control cards (5) Voltage Supply modules (6) Safety module ( Module A 12 ) (7) Transformer T2 (8) Ventilator 220 V (9) Transformer T1 (10) Door sensor with control - LED The Control Cabinet door may only be opened by authorized personnel. Unqualified work on the integrated components will lead to extensive damage of the machine and incorporate a safety risk for the user. The Control Cabinet door can only be opened with the supplied control cabinet key. To open the door the key must be turned in the clock-wise direction.


7.1 The Control Unit Contained in the control unit are all control and interface cards. Work on the control unit should only be undertaken in coorporation with the technical customer service division of PHOENIX CONTACT.

2 3 4 5 67

8

9

8 8

1.1

1.2

1.3

1.4

Figure 7-2

(1.1) Voltage 5 V of the X,Y or Z axis (1.2) Voltage 24 V of the X,Y or Z axis (1.3) Overload Display of the X,Y or Z axis (1.4) Temperature error ( Temperature more than 75 °C) (2) Stepper motor control card of the X axis (Module A 1) (3) Stepper motor control card of the Y axis (Module A 2) (4) Stepper motor control card of the Z axis (Module A 3) (5) Interface Card (Module A 4) (6) Switching Interface (Module A 5) (7) SF Inverter (Module A 6) (8) Potentiometer Phase current (9) Ventilator unit (Module A 13)


7.2 Stepper Motor Control Card The three Stepper Motor Control Cards each control an X, Y or Z axis. Each has a rating of 160 VA and provides an adjustable current maximum 4 A per phase. The Phase current de-termines the torque of the stepper motor. The Potentiometer is used to adjust the phase current. It calibrated ex-factory and should only be adjusted by trained maintenance personnel. If the phase current is too low, the axes will not move (humming noise). If the phase current is too high, the axes will move with a whistling tone.

7.3 The Interface Card The Interface Card controls the Engraving Machine. Data entered via the remote control or the computer are converted into commands for the control card.

1

2

Figure 7-3

(1). EPROM 1 (2) EPROM 2

7.3.1 Exchanging a Plug-In Card Should an error be corrected by exchanging a corresponding Plug-In Card, then proceed as follows:

- Switch the Engraving Machine Main Switch OFF. - Wait about 10 seconds until all LED’s on the Cards are OFF. - Push the fixing lever at the bottom of the corresponding Card down. - Pull the Card out. - Insert the new Card in the slot. Make sure that the card is seated correctly in the rail. - Push the Card entirely in until it latches. - The fixing lever must snap in at the bottom of the Card.


7.3.2 Exchanging the EPROMS on the Interface Card The Operating System of the Engraving Machine is stored on the EPROMS of the Interface Card. Since this Operating System is systematically upgraded, it is possible to upgrade the Machine by exchanging both the EPROMS (see Figure 7-3). To do so, proceed as follows:

- Remove the Interface Card (see Figure 7-2 Position (4)) - Carefully lever the EPROMS out of their sockets with a small screwdriver. - Insert the new EPROMS in their corresponding sockets. Pay careful attention to the po-

larity of the EPROMS in their sockets (Both EPROM and socket have a notch denoting the first pin. Both the notch of the EPROMS and the socket must be in the same cor-responding position.).

- Fit the Control Card in its slot (see the chapter Exchanging a Plug-In Card )

7.4 Valves for the Pneumatic Control The valves for the pneumatic connections are arranged next to one another in the left upper corner of the Control Unit. These valves switch all pneumatic functions (some are software controlled).

1 2 3 4 5

1.1 1.2 2.1 2.2 3.1 3.2 4.1 4.2 5.1 5.2

Back wall

Control cabinet flap

Figure 7-4

(1) - Air Valve Coolant-Spray (black hose) (2) - Valve Air Gap Spindle (red hose) (3) - Valve Z Axis fixing (blue hose) (4) - Valve Free Air fixture (yellow hose) (5) - Valve Tool Change (thick black hose) Color Coding of the Connection cable : 1.1 brown 2.1 brown 3.1 brown 4.1 brown 5.1 brown 1.2 green 2.2 blue 3.2 white 4.2 pink 5.2 yellow


7.5 The Voltage module The following voltage modules are to be found in the Control Cabinet:

1 2 3 4 5

6

7

8

7 7

7

Figure 7-5

(1) - Intermediate circuit A7 SF Inverter (Module A 7) (2) - Power supply A6 24 V / 45 VA (Module A 8) (3) - Power supply A5 24 V / 10 VA (Module A 9) (4) - Power supply A4 5 V / 8 VA (Module A 10) (5) - Voltage module A3 for X Y Z Axis (Module A 11) (6) - Control LED`s (7) - Glass fuses (8) - Glass fuses ( of module A 12)

7.5.1 Changing a fuse on a voltage module Before replacing a fuse, the mains power cable must be removed from the power socket. In this way, the machine is then voltage-free. Open the fuse housing with the corresponding screwdriver. The cover can be lightly depressed and then turned to the left. A listing of all fuse types is also displayed on the inside of the control cabinet door. The exchanging of fuses on the control unit should only be undertaken in coorporation with the technical customer service division of PHOENIX CONTACT.


7.6 Fuses of the Control Unit and Voltage Module Table 1 shows all glass fuses (5x20mm) which are used within the control cabinet. The fuses of the power socket of the vacuum pump and the vacuum cleaner are accessible from the outside (see Figure 3-2)

Caution ! The power sockets could still be LIVE even if the Main Switch is OFF !

Module ( 5 * 20 mm )

A 5 500 mA / medium slow

A 6 6,3 A / slow-blo

A 7 6,3 A / medium slow

A 8 Primary 1 250 mA / slow-blo Primary 2 250 mA / slow-blo Secondary 2,5 A / medium slow

A 9 Primary 1 100 mA / slow-blo Primary 2 100 mA / slow-blo Secondary 500 mA / medium slow

A 10 Primary 1 125 mA / slow-blo Primary 2 125 mA / slow-blo Secondary 1,25 A / medium slow

A 11 X 4 A / medium slow Y 4 A / medium slow Z 4 A / medium slow

A 12 Primary 1 T1 2 A / slow-blo Primary 2 T1 2 A / slow-blo Primary 1 T2 1 A / slow-blo Primary 2 T2 1 A / slow-blo

Table 1

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Fixing System Page 40

8 Fixing System A fixing system is used to hold the workpiece on the operating table of the Engraving machi-ne. Basically all types of fixing systems can be used that are fixed and tensioned with the sliding nuts of the machine table (Holding blocks, small vices etc.).

8.1 The Vacuum Fixing System With the use of a vacuum fixing system all smooth materials can be processed on the Engraving Machine.

Important ! Make sure that enough vacuum is present to hold the work piece on the table. The vacuum is switched ON with the <Vacuum> key on the remote control. In the display the symbol ( [< ) will appear. The vacuum should always exceed -0.6 bar. (This can be seen on the manometer on the Z axis.)

8.1.1 The Components of the Vacuum System - Vacuum Compressor W5 - Vacuum plate VAC PL - Rubber fixing mat GHM

8.2 Vacuum Fixing Plates The material to be processed can be held securely on the vacuum plate. The vacuum plate has thin slits that fulfill the vacuum function. With individually punched rubber mats different shields can be prepared on the vacuum plate. For the positioning of the work piece to ad-justable stop-bars are also present. The following vacuum plates are available:

( L / B / H ) ( Length / Breadth / Height ) Vacuum plate 1: 250 x 150 x 28 mm Vacuum plate 2: 280 x 300 x 28 mm Vacuum plate 3: 500 x 500 x 28 mm

Other sizes are available on application.

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8.2.1 Fitting a Vacuum Fixing Plate The vacuum plate is fixed with machine screws in the longitudinal slots of the machine table. The fixing point ((Intersection of the two stop-bars) should be positioned close to the machi-ne-zero point (back left or as close as possible). All material can then be positioned against the stop-bar and be defined in the corresponding Software as the zero point. The connection hoses are fed through the holes in the back wall of the machine hood. Make sure that the hose does not obstruct the movement of the XY Unit. The vacuum hose should be fixed to the thread of the vacuum valve at the rear of the ma-chine. The valve may not be driven with compressed air. On the other side of the valve the vacuum hose of the vacuum compressor is connected. If the machine is used for milling work without the Z Tracking, it may be necessary to fix the vacuum plate on the coordinate table plan. Here a measure gauge is fixed on the Z Axis, and the measure head moves along the surface of the vacuum plate. If the gauge moves in the X or Y direction, then it may be necessary to fit thin sheets under the vacuum plate to align it better. This procedure can be repeated until the table is fixed and positioned within the required tolerances.

8.3 Vacuum Compressor For an error-free operation, we recommend the Phoenix Contact Vacuum Compressor W5. A similar compressor can also be used:


8.3.1 Vacuum Compressor W5 The Vacuum Compressor W5 creates sufficient tensioning force with the required vacuum. It consists of the following components:

1

2

3

4

5 6

Figure 8-1 (1) Vacuum Pump (2) Quick connection (3) Vacuum hose (4) Filter (5) Oil level window for oil check (6) ON-OFF switch

8.3.2 Installing the Vacuum Compressor The recommendations as regards setup and maintenance can be read in the operating in-structions as supplied by the manufacturer. The points should be adhered to, to ensure an error-free operation of the vacuum compressor.

8.4 Other fixing systems Basically any size fixing system (vice, tension block, holding fixture) can be used. It is impor-tant that the fixing system is itself fastened in such a way that is does not loosen during nor-mal operation. The fixing system can be fastened with machine screws and the sliding nuts in the machine table.

Caution ! Commonly the fixing system is far higher than the operating surface. Ensure then that the traversing height is set in such a way that the spindle does not crash into the fi-xing system. The traversing height should be greater than the height of the fixing sys-tem. Failure to consider this aspect could lead to considerable damage of both the fixing system as well the machine, and corresponding tool !

This should also be considered when the fixing system is fitted outside of the engraving area of machine. Here the collision can occur with spindle, and not the tool !

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Various Engraving and Milling Methods Page 43

9 Various Engraving and Milling Methods The engraving system can basically work with material in one of two ways. The only diffe-rence is the way in which the engraving / milling depth is achieved. The methods are :

- Engraving with Z-Tracking - Engraving without Z-Tracking

9.1 Engraving with Z-Tracking When engraving with Z-tracking the Z sleeve glides over the workpiece. The height of the engraving spindle is set so that the spring loaded spindle block has a pre-tension of about 0,5-2mm. This pre-tension strength can be adjusted by the adjustment screw (see Figure 5-1 position (3) and (7) ); the length of movement is adjusted via the software. Because the Z-Tracking Sleeve glides across the workpiece surface, the Spindle follows the surface con-tour. Any unevenness is therefore corrected. The tool protrudes a certain length beyond the sleeve (= engraving depth). In this way, an exactly defined penetration depth in the material surface takes place, even with material which is not exactly calibrated along the XYZ axis. Since the engraving bit point is conical, keeping the exact engraving depth is extremely im-portant. Only in this way can a consistent engraved line be achieved.

Figure 9-1

Various Engraving and Milling Methods Page 44

9.2 Engraving without Z-Tracking When engraving without Z-Tracking, the tool works without the Z-Tracking Sleeve. The ope-rating principle is the same as with standard milling machine. The disadvantage is that the workpiece must be correctly positioned to achieve a consistent engraving depth. The advantages of this principle are when one is engraving in areas of a workpiece that are difficult to access (a narrow channel), or when the tool is too long to work with Z-Tracking (long milling tool). The principle should be used when milling at greater depths, since once can mill in multiple steps. Furthermore, material surfaces that could be easily scratched can also be kept clean. The result without Z-Tracking is then satisfactory when the one works on small surfaces. On larger plates or workpieces, when the surface is uneven, the engraved lines could be incon-sistent.

Figure 9-2

Working with typical Workpieces Page 45

10 Working with typical Workpieces

10.1 Engraving Single Schields The engraving of already cut single shields can occur in a number of ways. Depending on which fixing method is used the possibility to engrave one or more shield. When using a vacuum plate both are possible. It is important to consider that a correspon-ding rubber mat is laid on the vacuum plate. All holes on the rubber mat must be covered, otherwise the vacuum could be insufficient to hold the material in position. The positioning of the workpiece should at best be against a stop-bar. Then it is not neces-sary to always define a new origin. If many single shields are to be engraved then these should be laid adjacent and below the first shield. The exact maintanance of the correspon-ding distances should also be considered. If this is too difficult, a frame can be milled with the Engraving Machine to always garantee an exact positioning.

1

1

2

34

4

Figure 10-1

(1) Shield (2) Frame (3) Rubber mat (4) Vacuum drill hole


10.2 Engraving Multiple Shields A more rational method to manufacture plastic shields in large numbers is the use of multiple engraving with milling of a large workpiece. In this way a matrix of multiple shields can be engraved on one plate. The number of single shields depends on the size of the shields and the size of the plate. After the engraving step the single shields are milled out of the plate with the Border functi-on. This means that as a rule about 0,1 to 0,05 mm material is left, so that the plate retains its integrity. After removing the plate, the single shields can then be removed from the plate. Together with the Border engraving, additional holes can also be drilled for future screw or rivet retention. It is therefore possible to create the entire shield completely. When drilling holes attention should be paid to the utilized rubbermat with corresponding holes. In no way should a corresponding hole in the rubber mat allow the vacuum pressure to be reduced ! Together with the relativels low effort in assembling the shields on the table, this method has one further advantage in that the shields need not be sorted, since one can engrave in the required sequence that the marking task will then take place.

Figure 10-2

10.3 Border Engraving Different tools can used for the Border Engraving. For the soft plastic plates, the simplest method is to mill the border with a correspondingly set engraving bit. Due to the conical sha-pe of the engraving bit, the face of the border is always the same. The engraving bit should have a small cutting thickness to keep the ridge as small as possible. If the face is not wanted, one can use a milling bit or a cylindrically polished engraving bit. Consider too the cutting direction (see also the Software Manual). For the drill holes a corresponding engraving bit or a drilling bit could be used. Bigger drill holes can be made by milling the circle in the corresponding diameter.


10.4 Engraving Front Plates with Script, Graphics and Break-outs Plastic or aluminium front plates can be produced entirely, including script, graphics, compa-ny logos, break-outs etc. The graphic-oriented GRAVMASTER-Software is optimally de-signed for these tasks. Since front plates are mostly made of aluminium, the break-outs should be created with shaft milling bits, since one is then able to achieve better vertical and smoother edges. If the front plate thickness is too large, then the break-out must be milled in multiple steps. Here the step widths can be entered in the GRAVMASTER Software, where the engraving depth is done step-wise (Example: Plate thichkness = 4 mm, Step width = 1.5 mm, Engraving depth = 4.2 mm. The break-out is milled in three steps). Since many different tools are required to produce a front plate, the tool change system can be particularly helpful. In this way the front plate can be completely produced without any assistance of the operator personnel.

10.5 Milling Printed Circuit Boards To mill prinetd circuit boards the Gerber Software is required to convert the Layout Program in Gerber format so that it can be outputted on the Engraving Machine. Single-sided and double-sided PCB’s can be produced. The following elements can be drilled or milled:

- PCB tracks and eyelets - all drill holes - Text, marking, graphics, which are incorporated on the PCB.

Important: The engraving of a PCB is considerably cleaner if cutting oil is used. This can be wiped off once the milling and drilling steps are concluded.

The description of the Gerber Software also contains further information as regards the en-graving of PCB’s.

10.6 Further Application Possibilities Together with normal engraving tasks the machine can also be used to manufacture simple tools. A typical application is the perimeter and milling of plates or the milling of pocket in a tool. For such operating steps all the points as for normal milling machines should be considered.

Caution ! Since the fixing force is relatively small, the processing data of the tool should be considered accordingly.

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10.7 Feeding Speeds and Spindle Speeds Feeding speeds and spindle speeds are important parameters which influence both the ope-rating time as well as the quality of the engraving. They are related in part to the material used. But other factors such as tool diameter, face angle, tool material, tool depth, tensio-ning force, lubrication etc. also need to be consired before selecting a feeding speed. Due to the multitude of factors, no exact formula can be given with which one could calculate the feeding speed. Here only emperical values can be given. In certain cases the optimum value can only be found with many tests. Since one as a rule only works with a few different materials, one can on the basis of the emperical values and due to experience gained make a table to record the working parameter for the corresponding engraving task. The values in the following table are to be seen as a guideline and can only be seen as a reference for which no accuracy or guarantee can be given. They are valid for a spindle speed of 30000 RPM. If possible a low speed should be utilized to prevent unnecessary noi-se. The setting of the operating depth can be done with the following rule-of-thumb: Operating depth Z = Tool Diameter / 10

Material

Strength (N/mm²)

Feed

(cm/sec)

Cooling

(YES/NO/Which ?)Engraving Bit 0,3 mm ; Engraving depth 0,1-0,3 mm ; RPM ca. 30000 RPM Gravoply 44 5-7 No Resopal 2-3 No Printed Circuit Boards 1-2 Oil Aluminium 200-300 0,5-2 Alumax 100 Aluminium, high impact 400-530 0,5-1 Alumax 100 Aluminium, Cast 180-330 0,5-2 Alumax 100 Brass 320-440 0,5-1 Oil or Emulsion Steel untreated 350-455 0,3-0,5 Oil or Emulsion Steel über 400 0,1-0,2 Oil V2A 0,1 Oil

Milling bit 2 mm / Milling depth 1 mm Gravoply 44 3 possibly Air Resopal 1 No Aluminium 200-530 1-2 Alumax 100 Steel untreated 350-455 0,5 Emulsion

Table 2

Care and Maintenance Page 49

11 Care and Maintenance

11.1 Daily Maintenance Tasks The daily care of the Engraving Machine is limited to the cleaning of the machine after any tasks are concluded. The Machine should be vacuumed and all accumulated filings, sha-vings and waste must be removed. Particularly important is the attention to the automatic tool changer, if installed. Here regular inspection and cleaning of the tool slots is necessary to garantee an error-free operation. When use is made of a Coolant-Spray Unit, it is advisable to wipe the machine regularly with a clean cloth.

Caution ! Before any cleaning tasks make sure that there is no tool in the Spindle to prevent any possible injuries. This or any other tools must be properly fitted after the cleaning is concluded. To clean the transparent covers, do not use any solvents ! The Machine may not be cleaned with compressed air since filings could be forced into very sensitive areas of the machine such as the tracks or bearings !

11.2 Expandable parts, Service and Service intervals The following Machine parts must be regularly serviced and if necessary be replaced:

- All Axis Guides - All Axis Drive Spindles - Filter mats in the Control

The service intervals are different for the various components. Axis Guides and Axis Drive Spindles: Service: Lubrication Interval: Every 500 hours (See the operating hours counter in the machine front plate)

Filter mats in the Control Service: Cleaning Interval: Every 500 hours, a minimum of once every year. (See the operating hours

counter in the machine front plate)

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Care and Maintenance Page 50

11.2.1 Lubrication recommendations The X and Y Axis and guides must be lubricated every 500 operating hours. The Z Axis is completely encapsulated and should be lubricated every 1000 hours. Leave this task to the Service Technician of PHOENIX CONTACT.

11.2.2 Lubricating the X Axis On the left-hand side of the fixing flange of the Z Axis, you will find the lubrication nipple of the X Axis. To lubricate the X Axis, drive the Z Axis to the right-hand side and use a grease gun.

11.2.3 Lubricating the Y Axis The lubrication nipple of the Y Axis is located behind the left-hand support of the XYZ Unit. To lubricate the Y Axis drive the Unit forward and use a grease gun.

11.2.4 Lubricating the Z Axis Before lubricating the Z Axis, this must be removed from the machine. Proceed in the follo-wing way:

- Remove the Spindle together with the Spindle holder, Coolant-Spray Unit and the Motor of the Z Axis.

- Loosen all four fixing screws with which the Z Axis is held. - Remove the rubber stops and then loosen the now visible fixing screw of the special

coupling. - Loosen the four screws of the stepper motor flange plate and remove this carefully from

the head plate. - Loosen the plug connectors of the limit switches. - Loosen the fixing screws M6 x 22 of the fixing plate as well as both the centre screws

M5 x 10 of the head plate side. - Remove the rubber lip seals. - Now by hand turn the bearing thread Spindle to achieve a moving of the cover plate.

This should be moved as far as possible to allow a lubrication of the Spindle. - After the lubrication the re-assembly of the Z Axis is done in the reverse order.

Errors and how to solve them Page 51

12 Errors and how to solve them The following table includes a selection of possible errors and how to solve them. If any unknown errors or defects occur, please call the Technical Support Division of PHOENIX CONTACT.

Error description Reason for error Remedy Machine does not respond to the PC, can however be driven by the remote control without errors.

- Interface cable loose. - Interface parameter do not

correspond software- and machine wise.

- Fasten the Interface cable properly at both ends. - Check the Setup, adjust

values if necessary.

Machine does not respond to either PC or to the remote control.

- Door open. - 5 V Supply voltage is not

present.

- Control card is defect.

- Close the door and operate the <MAINS ON> switch on the machine

.- Check the fuses. If all is OK, then call Technical Service.

- Replace the Control card.

Tool are incorrectly tensioned

- Position of the Tool Maga-zine is not correct

- Air pressure too low

- Record a new Tool Position use SETUP - Increase Pressure

Repetitive positioning errors. The stepper motors run with a whining tone.

- Step loss of the stepper motor.

- Reduce the parameters 'Acceleration' and 'Maxi- mum Frequency' in the SETUP Program on the remote control.

The vacuum or vacuum pump do not function correct-ly, although the control lamp is lit

- The glass fuses in the cor-responding sockets at the rear of the machine are de-fect

- Replace the corresponding glass fuses.

The work piece is not held firmly on the vacuum table

- Work piece is moved by the tool or lifted by the tool

Check the vacuum pressure (minimum - 0.6 bar) Seal any leakages

Appendix Page 52

13 Appendix

13.1 Pin layout of the V24 Cable Should there be any compatibility problems the pin connections of the Interface Cable should be compared to the layout as detailed here.

Figure 13-1

Caution ! Use only the original cable as supplied. �

Appendix Page 53

13.2 Technical Data Machine type CMS-GRAV 32 Maximum Fixing Area 850 x 750 mm Engraving / Milling Area 540 x 500 mm Movement of the Z Axis 75 mm Movement Accuracy < 1/40 mm (0.025 mm) Repeatable Accuracy < 1/100 mm (0.010 mm) Maximum Traversing Speed Positioning in the X,Y,Z Axis:

- max. 125 mm per second ( in every Axis ) Moving in the X,Y,Z Axis:

- max. 63 mm per second ( in every Axis ) Ambient Temperature 5 - 35 °C Relative Humidity 35 - 75 % Power Supply 230/110 V + 10%, 50/60 Hz Mains Fuse Protection 10/16 A Power Consumption Idle 240 W Spindle 170 W Connection Vacuum Pump max. 1000 W Connection Vacuum Cleaner max. 1000 W Noise Level Workplace defined Emmission value LEQ 70dB(A) Dimensions (B x W x H) with closed Hood 1250 mm x 1030 mm x 860 mm with open Hood 1230 mm x 1030 mm x 1500 mm Weight approx. 170 KG Interface V. 24 (RS 232 C serial)

Appendix Page 54

13.3 Instruction list of the CMS Engraving/Milling System

Command Syntax Parameter Function AS Automatic Spindle

AS Miller is switched ON with next PD and at PU with a pre-defined time delay switched OFF. After switching ON the device, AS is active.

CHR 127 Immediate STOP CL CooL

CL c c=0 Coolant OFF c=1 Coolant ON

Switching the Coolant ON or OFF

DP Digitize Point

DP The actual axis position in the syntax "x,y,z"

FZ Fasten-Z

FZ,s s=0 Fixing OFF s=1 Fixing ON

Switching the Fixing Z ON or OFF

ID Identify ID Machine returns Identify String IN Initialize IN Sets all Parameters to their default setting NS No Spind-le

NS The Milling bit is not switched ON with the following PD. This instruction is reset by AS. Should the Spindle be switched ON, it is switched OFF.

PA Plot Abso-lute

PA x,y x,y: Absolute Target Coordinate

Moves the Milling bit to the X/Y absolute given coordinate

PD Pen Down PD Sets the Tool down to Milling depth PR Plot Rela-tive

PR x,y x,y:target coordina-te relative to actual milling bit position

Moves the Milling bit along the vector, defi-ned by the x, y positions

PU Pen Up PU Raises or lowers the Milling bit to the Tra-versing Height

RS Rotation Speed

RS,s s: Rotation Speed in (RPM)

Setting of the RPM

SU Switch Up SU,k k:channel number Switches the the channel k of the Interface SY Spray SY s s = 0: Spray OFF

s = 1: Spray ON Switches the Spray ON or OFF

SZ Set Z-Parameter

SZ h,t h:Trav.-height(PU) t: Mill.-depth (PU)

Definition of Traversing Height and Milling Depth in PU

TO Turn Spindle Off

TO Switches the Spindle OFF

TS Turn Spindle

TS Switches the Spindle ON. If switched OFF with NS, then first set AS

VC Vacuum Clean

VC,s

s=0:Vacuum OFF s=1:Vacuum ON

Switches the Vacuum Cleaner ON or OFF

VS Velocity Select

VS,v v: Speed (cm/sec) Defines the speed in cm per second

ZS Z-Speed ZS,v v: Speed (cm/sec) Defines the sink speed in cm per second ZH Z-Height Tools

ZH,v v=Sleeve;W1,.,W10 Transfers the Z height of the sleeve and the tools

Index Page 55

14 Index

-A- Abort output.............................................7 Accessories .............................................9 Adjusting coolant spray fixture...............26 Adjustment block ...................................31 Air valve.................................................15 Arrow keys.............................................15

-B- Border engraving ...................................47

-C- Care ......................................................50 Check tool .............................................19 Chuck lubricant......................................24 Cleaning ................................................50 CMS-Interface card ...............................37 CMS-Tool magazine..............................28 Compressor...........................................34 Connection elements.............................11 Connections of the engraving machine....5 Control cabinet ......................................35 Control cabinet door ..............................35 Control unit ............................................36 Coolant spray fixture..............................24 Coolants .................................... 15; 26; 27 Cooling ..................................................24 Cutting oils.............................................27

-D- Depth adjustment ..................................33 Device feet ..........................................3; 4 Display elements ...................................11 Display-Messages .................................16

-E- EMERGENCY-STOP...............................8 Engraving depth ....................................30 Engraving spindle ..................................20 Engraving spindle system......................20 ENTER ..................................................15 EPROM 1 ..............................................37 EPROM 2 ..............................................37 Exchanging the chuck ...........................24 Exchanging the spindle..........................22 Exit SETUP ...........................................15 Expandable parts...................................50

-F- Face plate ............................................. 11 Feeding speeds .............................. 24; 49 Fixing plates.......................................... 41 Fixing ring ............................................. 31 Fixing system .................................. 41; 43 Front plates ........................................... 48 Fuse types ............................................ 39 Fuses .................................................... 40

-G- Glass fuse............................................... 5

-H- High frequency spindle.......................... 20 Housing................................................. 10

-I- Increment.............................................. 14 Industrial area ......................................... 3 Install tool magazine ............................. 28 Installing a spindle................................. 23 Instruction list ........................................ 55 Interface setting .................................... 18 Interrupt .................................................. 8

-K- Keys...................................................... 13

-L- Lubrication ............................................ 50

-M- Machine parameters ............................. 19 Machine Setup ...................................... 17 Main switch ................................4; 5; 7; 37 Main unit ................................................. 9 Maintenance ......................................... 50 Manual tool change............................... 23 Methylated spirits .................................. 27 Modules .......................................... 36; 39 Mounting of the engraving spindle......... 21 Multiple shields...................................... 47

Index Page 56

-N- Name plate ............................................10

-O- Opening the doors ...................................8 Operating pressure................................34 Operating pressure air gap....................34 Operating pressure machine .................34 Operating system ..................................29 Operation keys ......................................11

-P- PARK.....................................................14 Plug-In card ...........................................37 Pneumatic Control .................................38 Potentiometer ........................................37 Printed circuit boards.............................48

-R- Remote control .................................. 6; 12 RESET ..................................................13

-S- Service intervals ....................................50 Set the spindle holder higher .................21 Setting tool magazine ............................29 SETUP ..................................................13 Setup Functions............................... 14; 17 Setup tools ............................................19 Single shields ........................................46 Single tool..............................................19 Sliding nuts............................................41 Solve errors ...........................................52 Spindle motor ........................................14 Spindle speeds ......................................49 Stepper motor control cards ..................37 Switch OFF..............................................7 Switch ON ...............................................7 Symbol [< ..............................................14 Symbol [> ..............................................15 Symbol X ...............................................15

System configuration............................... 2

-T- Technical Data ...................................... 54 Test run................................................. 30 Tool change manual.............................. 19 Tool changing magazine ....................... 29 Tool magazine ...................................... 28 Tool parameters.................................... 19 Tool position.......................................... 19 Tool setup ............................................. 19 Total Reset............................................ 19 Transmission......................................... 18 Transport information.............................. 3 Transport safety latch.............................. 4

-V- V24 Cable ......................................... 6; 53 Vacuum................................................. 14 Vacuum cleaner .................................... 27 Vacuum fixing system ........................... 41 Vacuum fixture ...................................... 27 Vacuum of the vacuum plate................. 34 Vacuum-Aggregate W5......................... 43 Vacuum-Compressor W5...................... 43 Voltage modules ................................... 39

-W- Working area .......................................... 3

-X- X-Axis ................................................... 51 XYZ-Processing unit ............................. 10

-Y- Y-Axis ................................................... 51

-Z- Z-Axis.................................................... 51 Z-Tracking............................................. 44 Z-Tracking sleeve ........................... 20; 23

manual grav32 gb

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