CNC BARON XL TABLE TOP MILLING MACHINE
Contents
1. a cal al wl ml a 9 a ol S ol X ol N S N a o y o PART NO JB T7273 2 94 JB T270 4 94 GB T77 85 XZ32G 30 01 1 GB T70 85 GB T70 85 XZ32G 30 009 XZ32G 30 008 GB T276 94 XZ32G 30 007 JB T7271 1 94 JB T7271 6 94 XZ32G 30 006 XZ32G 30 004 XZ32G 30 005 GB T1096 79 XZ32G 30 001 GB T68 85 XZ32G 30 003 GB T70 85 XZ32G 30 002 GB T6182 86 GB T1162 2 89 GB T93 87 GB T5782 86 XZ32G 20 001 GB T276 94 XZ32G 20 024 GB T1096 79 XZ32G 20 019 GB T276 94 GB T893 1 86 GB T9877 1 XZ32G 20 032 XZ32G 20 012 GB T118 86 GB T1096 79 HEADSTOCK ASSEMBLY DESCRIPTION HANDLE M6X32 HAND WHEEL 12x100 SCREW M5X8 DIAL SEAT SCREW 6 14 SCREW 5 14 COVER BEARING SPACER BEARING 6202 WORM SHAFT BALL KNOB 12 40 HANDLE LEVER 12 160 LOCK BOLT WITH KNOB SPRING BASE SPRING KEY 8X22 GEAR SHAFT SCREW M5X8 WORM SCREW 8 20 FEEDING BOX LOCK NUT M16 FLUID LEVEL INDICATOR 27 1 5 SPRING WASHER 16 BOLT M16X65 HEAD BODY BEARING 6003 GEAR KEY 5X25 SHAFT COVER BEARING 6007 RETAINER RING EXTERNAL 62 OIL SEAL B35X62X12 OIL FILLER PLUG HEAD BODY COVER TAPER PIN 10X50 KEY 6X35 QTY 24 9 0 Q ay ai a ai Ga OT O1 Ga Oo OI Hy gt A B GB T96 87 GB T5781 86 PART NO XZ32G 20 014 XZ32G 20 016 GB T70 85 GB T893 1 86 GB T276 94 GB T894 1 86 XZ32G 20 020 GB T2089 84 GB T308 84 XZ32G 20 021 XZ322. 82 550 0 75 19 05 31 5 x 9 5 800 mm x 240 mm R8 Collets 2 HP 208 220 240vac single phase 60 HZ 1680 4500 RPMs approx 50 HZ 1360 3640 RPMs approx 42 1060 mm 30 760 mm 42 1067 mm 46 1067 mm 900 Ibs 15 SEC 11 Operations and Parts List NOTICE CHECK ALL PARTS AND SAFETY PRECAUTIONS FOR PROPER CONDITION BEFORE OPERATION 1 USE OF MAIN MACHINE PARTS 1 Raise and lower headstock on it rack and pinion mechanism by using the head crank When the desired height is reached tighten the bolts to avoid vibration 2 Head may be rotated 360 degrees by loosening the same bolts mentioned above Adjust the head to the desired angle and then tighten the heavy duty head lock nuts 3 The knob is set for MILLING amp DRILLING AND STOP The mushroom head red push button for emergency stop while milling and drilling and the green push button is for starting 4 Feed the spindle using the spindle feeding handle micro feed the spindle using the spindle micro feeding handle 5 Move the table from side to side by using the lengthwise table feed wheel and from front to back using the cross table feed wheel 6 Adjust the positive depth stop gauge according to working depth 7 Adjust the scale size according to working need 2 DRILLING OPERATION 1 For drilling a blind hole which does not pass through he work piece turn off the knob loosen the taper body of worm gear and spring bas
3. 5 Level the surface of the worktable on both lengthwise and crosswise by using a precision level 6 Use medium weight oil for the oil can on the left side of the machine base Squirt oil in between the grooves of the Z axis spline to keep the bearings inside the spindle lubricated Oil may leak out at the bottom of the spindle Pump oil on the ways of the machine every day you plan to machine an application Grease ball screws monthly by rubbing grease along the shaft under the X table To get to the Y ball screw jog the saddle to the front remove one side of the back way cover Use a putty knife to spread grease on the shaft below the base Bolt the CNC BARON XL Mill on either the optional machine stand or a sturdy workbench with four 3 8 or 1 2 diameter bolts It is recommended that the workbench height be about 30 inches high depending upon the operator s preference SEC 2 Setting up Your CNC BARON XL Milling Machine Your CNC BARON XL has been completely tested at the factory before shipment to ensure all features are functional Damage or components may go out of adjustment during shipment so it is recommended that all components be checked and adjusted as necessary prior to connecting the CNC BARON XL to a power source CAUTION YOU WILL NEED TO REMOVE SHIPPING MATERIAL INSIDE THE CONTROL UNIT BOX BEFORE PLUGGING IN FACING THE FAN OF THE CONTROL UNIT WITH THE TWO PORT CONNECTORS AND POWER CABLE SOCKET SHOWING AT THE BOTTOM OF T
4. SPINDLE ASSEMBLY oy A N 7 SPINDLE ASSEMBLY PART NO DESCRIPTION XZ32G 03 001 SPINDLE 2 GB T858 88 STOP WASHER 30 3 GB T810 86 NUT M30 X 1 5 GB T5780 86 BOLT M6 X 50 XZ32G 03 003 GRADUATE ROD BASE GB T41 86 NUT M6 7 XZ32G 03 002 ANTI DUST COVER 8 GB T297 94 BEARING 30208 P6 XZ32 03 002 RACK SLEEVE 1 1 1 0 1 3 10 XZ32G 03 004 RUBBER FLANGE GB T297 94 BEARING 30206 P6 12 GB T879 86 SPRING PIN 3 X18 XZ32G 03 010 HANDLE XZ32G 03 009 SUPPORT 1 1 1 5 6 7 15 GB T6172 86 THIN NUT M16 16 XZ32G 03 006 GRADUATE ROD 17 GB T818 85 SCREW M4 X 6 XZ32G 03 008 INDICATOR PLATE XZ32G 03 007 SET POSITION 19 TABLE ASSEMBLY 20 9 gt al 2 4 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 TABLE ASSEMBLY PART NO DESCRIPTION GB T7270 4 HANDLE BM10X80 XZ32G 10 001 HAND WHEEL GB T73 85 SCREW M6X10 XZ32G 10 002 DIAL CLUTCH GB T879 86 SPRING PIN 5X40 XZ32G 10 044 DIAL RING GB T70 85 SCREW 8 16 XZ32G 10 003 SQUARE FLANGE GB T118 86 TAPER PIN 8X30 JB T7940 4 95 OIL CUP GB T301 94 THRUST BEARING 51103 XZ32G 10 004 CROSS LEAD SCREW XZ32G 10 005 BASE XZ32G 10 008 ANTI DUST PLATE GB T810 88 NUT M16X1 5 GB T858 76 STOP WASHER 16 XZ32G 10 037 SQUARE COLUMN XZ32G 10 028 TAP GEAR SHAFT GB T301 94 THRUST BEARING 5
5. crate Using partner carefully lift crate box over the machine and inspect for damage or short shipment If damage has occurred during shipment contact both the carrier and CNC MASTERS in writing within the next business day Follow the procedure for the BARON XL regarding the lift of the machine 1 Be sure to lower the machine head as close to the machine body as possible by cranking the right side handle on the lower part of the column A screw on handle is supplied with this order Be sure to loosen the two hand screws on the left side of the machine head when cranking head into position Tighten at desired level of the machine head Use an engine hoist if a forklift or stacker is not available to pick up with fork under machine head between column and quill Also use the four large bolts located at the left and right side the base of the machine to lift from there as well While moving the CNC BARON XL make sure to keep it balanced 2 Do not place the CNC BARON XL in direct sunlight to avoid warping the machine which can cause lack of accuracy 3 Mount the CNC BARON XL to a sturdy table or a solid concrete foundation it is advisable that the base you choose be constructed well to avoid any vibrations during the operation 4 Thoroughly clean the machine and then coat all bright metal with a light lubricant to prevent corrosion CAUTION DO NOT USE flammable cleaners to clean your machine Any spark from machining can cause a fire
6. HANDLE FORK PIN SHAFT LEVER SPRING PIN 4X12 LEVER lt 26
7. Unit is powered off Motor connector can only go in one direction into the pins located on the bottom of Control Unit Be sure to place the connector accurately on all five pins WARNING Not placing the connector accurately on all five pins will result in the damage of the motor driver in the Control Unit when powering on This action will not be covered in the CNC MASTERS WARRANTY WARNING In the event a cable is pulled from the control or partially pulled off a connector IMMEDIATELY POWER OFF Plugging in a cable or fixing it from a partial pull can damage the control unit if the control unit is powered on If damage does occur as a result of this action the warranty does not cover service or replacement of parts For Tech Support You can reach us at 626 962 9300 or email us your questions at sales cncmasters com A reply will be given in step by step format to help you solve your problem by email SEC 6 Accessories and Options 4th Axis Coolant Control Quick Tool Change A Fourth Axis Rotary Table The CNC Baron XL has true 4 axis capabilities using the rotary table option Mount the rotary table to mill table with T nuts The rotary table can be controlled by the MASTER software using W commands IMPORTANT Do not carry the fourth axis by the bracket or motor alone Carry the fourth axis by its table only Oil the rotary table as needed Adjustment to remove backlash on the rotary table has already been made Do not try to adjus
8. is still under warranty and a surge protector has been used Contact CNC MASTERS if you would like to purchase another CPU card S6 BARON XL It may be possible that after time your Z axis belt has worn down the z motor has loosen lightening the tension on the belt For Z axis backlash or inaccurate travel check for the following 1 Extend quill as far down as it can go Power off controller Unplug controller and unplug spindle motor for safety for all check points below Check the rack teeth behind the quill and remove any build up of debris between the teeth Using a flashlight also examine the pinion for debris build up between the teeth as well and remove Debris build up will contribute to the in accurate movement or extra movement in the quill as the rack and pinion over compensate for the debris lodged between the teeth 2 Examine the belt behind the Z bracket Make sure the belt is tight If it is loose or appears to have broken teeth a belt replacement is necessary If it is loose go to the front of the bracket Use a Phillips screw driver to loosen all three screws that secures the axis motor to the bracket Have another person pry up the loose motor to tighten the belt against two sprockets and tighten the three screws on the motor A loose or broken belt can cause steps to be lost during travel 3 If inaccurate travel still exists then remove the Z bracket from machine for further examination There are two cap screws tha
9. spindle motor is the same ground connection used for your control unit at your electrical service panel Three Phase 220 Power If you only have 220 240 three phase power use only two leads from two pole circuit breakers 15 amps along with ground for single phase power It is recommended to use a licensed electrician to safely make this connection to your spindle motor SEC 4 Hand Held Remote Conirol with Joystick Option The Hand Held Remote Control is used to control jogging jog speed spindle speed and micro positioning It is plugged into the top port of the Control Unit and secured to the flat of the Z Axis Bracket with Velcro for easy removal and placement on your BARON XL Mill Operation Spindle Speed Control From the off position turning the speed knob to the right will turn the spindle on As the knob is turned to the left or right the speed will change accordingly Feed control should be done first before jogging with the joystick Feed on the fly may cause the hand held to malfunction Jog Speed Control Turning this knob to the left or right will set the jog speed accordingly In the micro setting turn the knob to the left to where it reads MICRO position jogging will then be disabled and micro positioning is enabled Feed control should be done first before jogging with the joystick Feed override or on the fly may cause the hand held to malfunction Jogging Joy Stick Moving the joystick positive or negative
10. to Local Disc C drive on left side of pop up window 5 Look for Program Files under the C drive 6 Look for CNC Masters under Program Files 7 Look for Master XU under CNC Masters 9 Open Master XU folder 10 Look on the right side of the pop up window You will find several small files that makes up Master XU 11 Look for ConfigXU cn3 which you can find toward top of the list of files 12 Highlight and delete the file There is only one config file that you will find under Master XU 13 Close all windows Power off computer Plug in USB cable and re boot computer Test and see if everything is functional again What we ve done here is an internal refreshing of the software which de bugs any stored temporary information in the config file The config file regenerates after using the Master software S3 There are times when a user s computer is faulty and not the control unit or software Do not forget to press RESET CONTROL and PORT ON before controlling the BARON XL with the Master program Try re booting computer If it still fails try another computer to ensure that the problem is the control unit If it is please contact CNC MASTERS for repair If you are using the Hand Held Remote only and receiving this problem please refer to the Hand Held Remote Control section in this manual to make sure all protocol is being followed S4 Power off control unit Be sure to manually move the axes away from making contact with their ho
11. 1102 GB T5782 86 SCREW 16 60 GB T93 87 SPRING WASHER XZ32G 10 031 BRACKET GB T70 85 SCREW 6 20 XZ32G 10 030 HEAD HANDLE GB T70 85 SCREW 5 14 GB T70 85 SCREW 8 25 XZ32G 10 006 LONGITUDINAL NUT GB T70 85 SCREW 8 45 XZ32G 10 011 ADJUSTABLE SCREW XZ32G 10 007 CROSS LEAD NUT XZ32G 10 013 GIB STRIP SHORT GB T5781 85 SCREW M8X12 XZ32G 10 043 MOVEABLE FIXED BLOCK XZ32G 10 012 2 HANDLE XZ32G 10 012 1 LOCK SCREW XZ32G 10 020 PIN XZ32G 10 014 CENTER BASE 21 NO 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 PART NO GB T119 86 7326 10 021 7326 10 041 7326 10 032 GB T276 94 GB T894 1 86 GB T1096 79 7326 10 022 GB T67 85 XZ32G 10 039 GB T70 85 XZ32G 10 023 XZ32G 10 038 XZ32G 10 026 GB T77 85 XZ32G 10 016 XZ32G 10 015 XZ32G 10 017 XZ32G 10 009 GB T70 85 XZ32G 10 018 XZ32G 10 019 XZ32G 10 042 XZ32G 10 020 DESCRIPTION PIN 8X20 SUPPORT CONNECTIVE PLATE TAPER GEAR BEARING 6204 2RS RETAINER RING 20 KEY 5X12 SCREW SCREW 5 10 COVER SCREW M8X40 CONNECTIVE BASE NUT GIB STRIP SCREW M10X8 DIAL CLUTCH SQUARE FLANGE LONGITUDINAL LEAD SCREW SQUARE FLANGE SCREW M6X15 MOVEABLE FIXED RING FIXED BLOCK TABLE GIB STRIP LONG QTY Pol DPI NP N 22 HEADSTOCK ASSEMBLY 23 N ww co w o o rm S N pi s
12. EM WITH THE CNC BARON XL CANNOT BE SOLVED WITH THESE TROUBLE SHOOTING TIPS CNC BARON XL PROBLEM P SOLUTION S P1 Backlash or error is found on the x and or y P2 Wrong Construction Error keeps popping up The Master refuses to read the tool path correctly or is buggy on a PROVEN program that has worked well before on the machine P3 Cannot seem to operate the Master program on my computer or no communication between the Master program and the Control Unit of the CNC BARON XL Mill P4 Turn the Control Unit ON and Master program is ON PORT is ON and motors are disengaged they do not run P5 Receiving erratic behavior when running the BARON XL with computer control variable spindle P6 Backlash or error is found on the z of the CNC BARON XL P7 Backlash or error is found on the x y z or w and the error is repeatable P8 If you are an international customer and the Master software is not responding on your computer 51 Be sure to adjust the strips making sure that the is not too tight nor too loose Refer to machine manual to determine the location of the gib strips If the problem persists after the gib strips have been adjusted be sure to oil table and block ways prior to start of every job Make sure that any locking screws are removed from the table and block At times users forget to unlock these screws Next check to see that the large jam nuts are secured to the endplates of the x and y It may be possibl
13. FOR BETTER AND DO NOT OPERATE THE CNC BARON XL WHILE UNDER THE INFLUENCE OF DRUGS USE THE RIGHT TOOL FOR THE JOB DO NOT ATTEMPT TO FORCE A SMALL TOOL OR ATTACHMENT TO DO THE WORK OF A LARGER INDUSTRIAL TOOL ENSURE THE CNC BARON XL IS PROPERLY GROUNDED SECURE WORK PIECE TO KEEP WORK PIECE FROM ROTATING WITH THE DRILL BIT REMOVE HANDLES OFF X AND Y HANDWHEELS DURING CNC OPERATION TO AVOID 10 ACROSS RUNNING MACHINES 11 SAFER PERFORMANCE 12 ALCOHOL OR ANY MEDICATION 13 14 15 OR CUTTING TOOL 16 CONTACT TO CLOTHES OR HAIR 17 WARNING DO NOT USE PAINT THINNER ACETONE OR ANY OTHER FLAMMABLE LIQUID TO CLEAN YOUR MACHINE ANY SPARK FROM MACHINING OR SPARKS FROM SHORT IN THE CONTROLLER CAN CAUSE SEC 10 Specifications Model X Axis Left Right table travel Y Axis Front Back saddle travel Z Axis Spindle Up Down travel Maximum Distance from Spindle nose to table Swivel Angle of Headstock at Perpendicular direction Drilling Capacity Face mill capacity End mill Capacity Working area of table Spindle taper Spindle Motor and Power Spindle 2 Speeds Machine Height without machine stand Machine Stand Height Overall length left end of table to right end of X motor handle Overall width back of machine to front end of Y motor handle Weight CNC BARON XL ZAY7045FG 21 5 546 mm 10 5 266 7 mm 5 127 mm 18 450 mm 90 Degrees 0 75 19 05 3 25
14. G 20 022 GB T73 85 XZ32G 20 018 GB T1096 79 GB T1096 79 XZ32G 20 025 XZ32G 20 017 GB T1096 79 XZ32G 20 007 XZ32G 20 003 GB T1096 79 GB T1096 79 XZ32G 20 006 XZ32G 20 005 XZ32G 20 004 GB T893 1 86 XZ32G 20 013 XZ32G20 011 XZ32G 20 010 GB T1096 79 GB T9877 1 88 GB T70 85 XZ32G 20 008 XZ32G 20 009 XZ32G 20 038 MOTOR WASHER 8 SCREW 8 25 DESCRIPTION ARBOR BOLT COVER CAP SCREW 8 55 RETAINER 35 BEARING 6202 INNER RING 18 GEAR SPRING STEEL BALL 8 GEAR GEAR SCREW M5X8 SHAFT KEY 5X60 KEY 6X12 GEAR GEAR KEY 6X28 GEAR SHAFT KEY 6X75 KEY 5X50 GEAR GEAR GEAR RETAINER RING EXTERNAL 35 SPACER GEAR SPINDLE SLEEVE GEAR KEY 6X18 OIL SEAL 5 45 10 SCREW 5 14 LEVER GASKET RING SCREW KNOB lt 25 cO O cO O Qo A SI Y N oy A O NN N oy By N o CO N XZ32G 20 039 XZ32G 20 036 XZ32G 20 037 GB T70 85 XZ32G 20 040 PART NO XZ32G 20 042 GB T77 85 GB T79 85 XZ32G 20 041A XZ32G 20 041B GB T3452 1 92 GB T70 85 XZ32G 20 029 GB T894 2 86 GB T9877 1 88 GB T879 86 XZ32G 20 031 XZ32G 20 026 XZ32G 20 027 XZ32G 20 028 GB T879 86 XZ32G 20 030 WASHER SPRING COVER SPRING SCREW 5 10 SPRING BASE DESCRIPTION LOCK HANDLE SCREW M10X10 SCREW M10X25 FIXED TIGHTENING COLLAR A FIXED TIGHTENING COLLAR B GASKET RING 9 8X2 65 SCREW M12X1 5 LEVER SHAFT SHORT RETAINER RING EXTERNAL 12 OIL SEAL 12 22 7 SPRING PIN 3X22
15. GING MACHINE SPEED 1 Turn the power off 2 To select proper speed move the speed lever to the desire position Refer to chart on face of machine USA is 60 Hz 3 If the gears not engaged remove the arbor bolt cover Rotate the spindle slightly to engage the gears and then replace the arbor blot cover 4 Recheck the lever setting and then turn the power on 6 INSTALLING AND CHANGING TOOLS WARNING BE SURE THE POWER IS TURNED OFF AND THE CNC BARON XL IS UNPLUGGED BEFORE INSTALLING OR CHANGING TOOL BITS 1 To remove arbor bolt draw bar remove arbor bolt cover Lock spindle by changing gears to the lowest setting L 1 Loosen the arbor bolt at the top of the spindle shaft 16 approximately 2 turns with a wrench In some cases if more torque is needed to loosen or tighten arbor bolt use thin rubber on a wrench to prevent damage and hold the spline of the spindle Tap the top of the arbor bolt with a rubber mallet After taper has been broken loose holding the chuck arbor on one hand and turn the arbor bolt with the other hand 2 To install face mill or cutter collet Insert cutter and cutter collet into the taper of spindle Tighten arbor bolt securely but do not over tighten ORDERING REPLACEMENT PARTS Complete parts list is attached if parts are needed contact CNC Masters by phone at 626 962 9300 or by email at sales cncmasters com CNC BARON XL BENCH MILLING amp DRILLING MACHINE PARTS LIST 17
16. HE CONTROL USE A PHILLIPS SCREW DRIVER TO SLIGHTLY LOOSEN THE TWO LARGE PANHEAD SCREWS ON THE LEFT SIDE OF THE CONTROL BOX SWING OPEN THE CONTROL COVER BOX TO THE RIGHT SLOWLY IF THE POWER CABLE USB CABLE AND OPTIONAL HAND HELD REMOTE CABLE ARE PLUGGED IN YOU WILL NEED TO UNPLUG THESE CABLES FIRST BEFORE OPENING COVER YOU WILL SEE TWO THREE PIECES OF CARDBOARD AND RUBBER BAND CAREFULLY REMOVE THESE MATERIALS FROM THE CONTROL UNIT WITHOUT TOUCHING THE PINS WHERE THE MOTOR CONNECTORS ARE PLACED OR THE CIRCUIT BOARD CARDS PLEASE TOUCH GROUND FIRST TO DISCHARGE ANY EXISTING STATIC YOU MAY HAVE IN YOUR BODY BEFORE REMOVING THE SHIPPING MATERIALS FROM THE INSIDE OF THE CONTROL UNIT ANY HUMAN STATIC THAT DISCHARGES INTO THE MAIN CPU CARD OR DRIVERS MAY CAUSE DAMAGE TO THE ELECTRONICS ALSO IMPORTANT MAKE SURE EACH SMALL BLACK BOX DRIVER WITH HEATSINK FOR EACH AXIS IS SECURED WELL TO ITS OWN BLUE OR BLACK COLORED STRIP CONNECTOR DO THIS BY LOOKING UNDERNEATH OF EACH DRIVER AND MAKING SURE THAT THE CIRCUIT BOARD INSIDE THE DRIVER IS FLUSH AGAINST THE LEFT SIDE OF THE BLUE OR BLACK CONNECTOR IF NOT TAKE ONE FINGER AND APPLY PRESSURE FROM THE RIGHT SIDE OF THE BLUE OR BLACK CONNECTOR AND WITH OTHER HAND APPLY PRESSURE TO THE BACK SIDE OF THE DRIVER S HEATSINK UNTIL THE CIRCUIT BOARD IN DRIVER IS FLUSH AGAINST THE LEFT SIDE OF THE BLUE OR BLACK CONNECTOR MAKE SURE ALL ORANGE CONNECTORS FROM EACH AXIS MOTOR ARE PLUGGED IN WELL ON IT
17. L NEED TO GO TO YOUR MASTER PROGRAM AND RE START YOUR PROGRAM To unlock the E Stop press the center button at the bottom of the hand held pendant that reads RES Unlock the E Stop AFTER you press STOP at the Master software If you decide to program your CNC Mill through the Master software and the software seems not to be functional be sure that only one red indicator light is on the hand held Both lights turned on locks the operation of the machine CAUTION The CNC BARON XL cannot be operated by the hand held remote if the USB cable from the control unit is not plugged into the computer and the Master program is not running However by removing the USB cable to the computer at the control unit this will allow you to have functionality of the BARON XL exclusively with the hand held remote Remove the cable only while the control unit is OFF If there are any questions call CNCMASTERS at 626 962 9300 or email us with your questions at sales cncmasters com We will reply promptly with step by step answers to help you resolve your problem SEC 5 Connecting Motor Cables to Control Unit Connect power cable USB port cable hand held remote control cable if purchased and motor cables to control unit box Looking at the control box and centering on the fan the order of motor cables go from left to right W if purchased Z Y X X is to the far right Installing motor cable orange connectors into the Control Unit Make sure Control
18. S OWN SET OF PINS BEFORE CLOSING CONTROL COVER AND POWERING UP CLOSE THE BOX AND TIGHTEN THE TWO PANHEAD SCREWS For shipping purposes the X and Y axis motors are not mounted The X and Y motors are already connected to the Control Unit but need to be mounted on each axis accordingly The brackets and motors are labeled with matching colors Next using a 5 32 Allen wrench loosen the collar clamps at the end of each axis until collar clamp rotates freely Do not loosen or remove large nut next to the clamp Align each motor with the cable pointing down and work the motor all the way into the bracket and clamp First wipe any oil off motor shaft CAUTION SECURE MOTOR FIRST WITH ITS FOUR PAN HEAD 10 SCREWS NEXT TIGHTEN THE COLLAR CLAMP THE COLLAR CLAMP MUST BE EVEN OR NEAR EVEN WITH THE OPENING OF THE BALL SCREW AND THE COLLAR CLAMP MUST BE TIGHTEN HARD If backlash or error is ever found on your X or Y axis it may be due to improper tightening of the collar clamp over the motor shaft Be sure to fit shaft key through one of the slots at ball screw opening Next check and adjust the belt tension on the spindle motor by opening the top cover of the CNC BARON XL There are two cap screws you will need to loosen at the top cover first You can then keep them loose for easy access to the top You can select the desired RPM by moving the belts to their proper position as indicated on the speed chart located at the face of the
19. Wy a ASS MASTERS Inc CNC BARON XL TABLE TOP MILLING MACHINE CNC MASTERS INC 16031 ARROW HWY STE J IRWINDALE CA 91706 PH 626 962 9300 sales cncmasters com www cncmasters com February 2011 THANK YOU FOR YOUR PURCHASE OF THE CNC BARON XL MILL WE WISH YOU MUCH SUCCESS IN THE MANY APPLICATIONS THIS CNC SYSTEM CAN ACCOMPLISH IMPORTANT PLEASE READ ALL INSTRUCTIONS IN THIS USER MANUAL TO BECOME FAMILIAR WITH YOUR CNC BARON XL Mill NOT FOLLOWING THE INSTRUCTIONS MAY RESULT IN THE DAMAGE OF YOUR PRODUCT AND VOID OUT YOUR WARRANTY WITH CNC MASTERS IT MAY ALSO CAUSE SERIOUS INJURY OR UNNECESSARY DOWNTIME SINCE YOU MAY NOT BE COMPLETELY FAMILIAR WITH THIS PRODUCT TABLE OF CONTENTS SEC 1 Receiving and Unpacking your CNC BARON XL SEC 2 Setting up your CNC BARON XL Milling Machine SEC 3 Connecting Electrical Power SEC 4 Hand Held Remote Conirol with Joystick Option SEC 5 Connecting Motor Cables to Control Unit SEC 6 Accessories and Options 4th Axis Coolant Control Quick Tool Change SEC 7 Self Help Support Trouble Shooting Tips SEC 8 Maintenance SEC 9 Safety Warnings SEC 10 Specifications SEC 11 Operations and Parts List MASTER SOFTWARE MANUAL Installation of the Master Software and instructions on how to use it SEC 1 Receiving and Unpacking your CNC BARON XL It is best to remove the crate box by unscrewing the bottom row of screws around the perimeter of the
20. cast housing and re tighten hard the two cap screws Your intent is to get the teeth on the worm gear to mesh well with the teeth on the worm screw There may be space between the teeth among the two parts This will cause backlash on the quill Adjusting the cast housing allows the for teeth to mesh up against each other If the worm screw feels too tight to rotate then you will have to compensate on the adjustment until you get the desired outcome the worm screw easily rotates by hand both ways and at the same time the quill should respond by moving up and down as you rotate the worm screw Please call or email us should you have more questions or need replacement parts S7 Go to your setup on the Master program You will then see the scales and the value for each of the axes Enter a very small value to compensate for the error on that axis and re test Adjust the value on the scale as needed until the error is compensated If this does not resolve the problem please refer to other solutions regarding backlash or errors of the axes S8 It may be possible that the regional setting on your Windows program may not be supported by the Master software Go to the control panel then click on regional settings and switch your regional settings to USA or America 1 The machine doesn t run when the power switch is turned ON a The knob is in the STOP position b A fuse has burned out Check in the switch box and replaces it if neces
21. e This will give you access into the quill and bearings for lubrication Control Unit Maintenance Clean filters on the control unit as needed and keep debris away from control unit as you blow out debris from machine DO NOT BLOW IN THE DIRECTION OF THE CONTROL UNIT Any metal debris could create an accidental short in the control unit Any wood dust that builds up over time inside the control unit could also absorb moisture and create an accidental short in the control unit It is recommended to open the control unit and air blow debris away from circuitry and electrical components if cnc machine is being used in high production To do this properly FIRST TOUCH GROUND OR USE ANTI STATIC 13 DEVICE TO KEEP STATIC AWAY FROM CONTROL UNIT AND COMPUTER Next power off control unit Unplug cables except for axis motors and optional spindle cables at bottom of control unit Open the control unit by slightly loosening the two large pan head Phillips screws on the left side of the control box Swing cover to the right Air blow any debris build up from the fan and inside the cover Blow out debris away from circuitry Next blow the circuitry in the control unit in the DOWN DIRECTION ONLY This will prevent metal fragmentation from accidentally lodging between electrical components and creating a short Be mindful of your computer as well Be sure to periodically air blow and clean the inside of a desktop computer Build up of dust can keep the computer fro
22. e that the jam nut has loosened causing backlash and inaccurate results Re tighten the jam nut but do not over tighten Over tightening will cause the ball screw not to rotate smoothly You can get to the jam nut by removing the axis motor off the bracket Place a Y bolt into the ball screw and secure with collar clamp Use a wrench to hold the bolt This will keep the ball screw from rotating Use another wrench to secure the jam nut If you have loc tite loosen the jam nut and place a few drops of loc tite on the threading to help secure the jam nut S2 Read this manual in its entirety It may very well be a problem in how you are writing your tool path program There may be G codes in your tool path that are not supported by the Master program You may have a letter o instead of number 0 in your program Also double check your MATH at each line of your program Be sure that your each line in your program does not contain lettering that does not pertain to the instructions manual or are not even shown in the examples or sample files After double checking that the program appears to be accurate or this is a PROVEN PROGRAM that has worked before on the machine then you may need to internally refresh the Master software to de bug Here s how Close down all softwares on computer Do the following 1 Power off controller and unplug USB cable at the computer side 2 Go to Start Right Click over Start 3 Go to Explore 4 Go
23. e then adjust the positive depth stop gauge so that the distance from the tip of the drilling bit to the end of the blind hole is equal to the desired depth 2 Fordriling a pass hole which passes through the work piece set the positive depth stop gauge in its uppermost position 3 MILLING OPERATION 1 Adjust the positive stop gauge top its uppermost position 2 Using the spindle feeding handle adjust the cutter to approximately the correct height turn off the knob and tighten the taper body of the worm gear and spring base 3 Set the working depth by using the micro feeding handle 4 Lock the rack sleeve at the height with the fixed bolt 5 When longitudinal feed milling it is a good idea to lock the across feeding table to ensure the accuracy of your work To do this tighten the two screws located on the right side of the table base 6 When cross feed milling lock the longitudinal feeding travel do this by tightening the two screws on the front of the table base 4 ADJUSTMENT 1 Adjustable moveable fixed rings are mounted on the front of the table to limit cross travel 2 The CNC BARON XL is equipped with gib strip adjustment to compensate for wear and excess slack on cross and longitudinal travel 3 Rotate the gib strip bolt slightly clockwise to tighten the gib trip Rotate it slightly counter clockwise to loosen the gib trip 4 Adjust the gib trip bolt until very slight drag is felt when moving the table 5 CHAN
24. ger micro positioning knob to the left or right will increment or decrement the motor in small steps By pressing the corresponding axes button again the motor will increment by 10 times By pressing the button a third time the motor will increment by 100 times The indicator lights will show which one of the three speeds are active One flash x1 Two flashes x4 Three flashes x10 The micrometer is ONLY intended for detailed positioning or fine machining of a part It is not intended to replace the joystick Swiftly turning the micrometer wheel back and forth several times will cause the Hand Held Remote to malfunction until you reset it again with the large red button and bottom center button After using the micrometer is best to reset the hand held remote before using the joystick Pressing the panic button once and then the center button will reset the hand held Go Button Pressing this button will begin to run the program on the host computer If the port is OFF it will turn the port ON and then it will have to be pressed again to start running the program Zero Button Pressing this button will zero the selected axis Large Red Panic Button Pressing this button once will stop the control from running Both indicator lights will turn on to indicate that operation is locked However it is imperative that you also PRESS STOP on the program that the computer is running THIS IS NOT A PAUSE FEATURE THIS IS AN EMERGENCY STOP AND YOU WIL
25. hat a heavy work piece that is held is balanced A work piece out of balance may shift while being machined b A hammer has been used on the work piece Never strike the work piece with a hammer c The table may not be level Check the table with a level to be sure that it is level on both side to side and front to back d The machine may not be stable on the floor Be sure the machine is firmly mounted to the floor SEC 8 Maintenance The proper maintenance of the CNC BARON XL is vital to a long life of the machine Lubricate the axes ways with oil prior to the start of a new job Manually grease the ball screws on the X and Y of the CNC BARON XL and squirt a medium weight oil into the bearings of the quill by raising the Z axis and squirting oil in between the grooves of the draw bar spline The Y ball screw can be greased by removing the black plastic anti dust cover and jogging the Y axis to the front It is recommended however that a vacuum be used instead of air blowing the machine to keep debris from lodging into ballscrews in between ways and the control unit CAUTION Regarding the CNC BARON XL Z Axis Quill If you do use air to blow out debris keep debris away from the rack part of quill the back of the quill when fully extended Debris build up on rack of quill could create backlash errors during travel Also for the CNC BARON XL Z axis remove the small red arrow indicator and sheet metal front faceplate off the machin
26. he tip of spring where the inside of the spring depresses in Press gas spring against a table and depress and release spring several times until the spring feels lubricated Attach the top of spring before attaching to the bottom Gas springs are also available should you need a replacement 11 7 If the problem still persists be sure to examine the slotted key on the left side of the quill after extending it all the way down Rub your finger along the surface of the key groove up and down If you feel a slight burr or bump use a crystal file to gently remove This burr or bump can cause the quill to bind at that point as it rubs against the casting on the machine head 8 Lastly if the problem persists it may either one of two things left the black cast piece called the handle base against the gray colored tubular piece called the worm gear may be loose The handle base must be rigid and tight to the worm gear If it is loose you will have to loosen the small set screw in the plastic handle Then unscrew plastic handle adjust the handle base and re tighten the plastic handle Having a loose handle base keeps the worm screw at the front where the small sprocket is on loose against the worn gear The other possibility is that the cast housing on the worm gear needs to be adjusted Slightly loosen only the two cap screws that secures the cast housing around the worm gear gray colored tubular piece Use a rubber mallet and tap either down or up the
27. ll damage the control unit during transportation CNC MASTERS WILL NOT BE HELD LIABLE FOR CONTROL UNIT DAMAGED WHEN SHIPPING TO US The X and Y ball screws are made for precision machining In the event the user rotates the ball screw into its ball nut the bearings may fall out The warranty will be voided on the ball screws as this will damage the ball screw s performance Also never hold the second ball nut with a wrench The second ball nut is the nut further away from the brass fitting Adjusting the second ball nut with a wrench will damage the ball nut assembly and void your warranty Adjusting of the ball nut can only be done to the ball nut next to the brass fitting SEC 9 Safety Warnings READ ALL INSTRUCTIONS BEFORE USING THE CNC BARON XL KEEP GUARDS IN PLACE AND IN WORKING ORDER KEEP WORK AREA CLEAN CLUTTERED AREAS INVITE INJURIES KEEP CHILDREN AND VISITORS AWAY FROM WORK AREA DRESS PROPERLY NO LOOSE CLOTHING GLOVES NECKTIES OR OTHER JEWELRY THAT CAN GET CAUGHT IN MOVING PARTS WEAR PROTECTIVE HAIR COVERING TO CONTAIN LONG HAIR 6 ALWAYS WEAR EYE PROTECTION ALSO USE FACE OR DUST MASK IF OPERATION IS DUSTY 7 REMOVE ADJUSTING KEYS AND WRENCHES FROM TOOL BEFORE STARTING BE SURE DRILL BIT OR CUTTING TOOL IS SECURELY LOCKED IN THE CHUCK AVOID UNINTENTIONAL STARTING NANA 14 KEEP PROPER FOOTING AND BALANCE AT ALL TIMES DO NOT REACH OVER OR MAINTAIN TOOLS WITH CARE KEEP TOOLS SHARP AND CLEAN
28. m properly connecting to the control unit HIGH HUMIDITY IN THE SHOP CAN CAUSE A DISTURBANCE IN THE PERFORMANCE OF THE YOUR COMPUTER AND CONTROL UNIT AS A RESULT OF DUST BUILD UP As a result a pop up note may appear on the Master software that USB line is not found In this case both control unit and computer should be powered off cleaned and re booted Power Off the Control Unit of the CNC BARON XL in between jobs DO NOT LEAVE IT IDLING Remember to close down the Master Software first before powering off control unit Allow the Control Unit and motors to cool off for 20 minutes if the machine is operating for more than six hours at one time The axis motors do get hot and remain constant This is normal WARNING DANGER IF IT IS NECESSARY TO OPEN THE CONTROL UNIT BLOW OUT DEBRIS OR OTHER PURPOSES USE CAUTION IF THE CONTROL UNIT IS PLUGGED INTO A POWER SOURCE THE CONTROL UNIT WILL CAUSE SHOCK POSSIBLE INJURY OR DEATH TO ANYONE TOUCHING THE INSIDE OF THE CONTROL UNIT UNPLUG CONTROL UNIT WHEN NEEDING TO SERVICE IT After initial testing and during operation of the CNC BARON XL periodically adjust gib strip bolts to remove table slack following the directions in the operator s manual for the mill SERVICING If the control unit ever requires service please ship back the Control Unit according to UPS or FedEx shipping instructions if you are having CNC MASTERS repair it Not adding sufficient padding on ALL SIDES of control unit wi
29. machine You can adjust the belt between the two step pulleys on BARON XL Mill by loosening the levers counter clockwise located at top right side next to the motor Move the motor to the front to loosen the belt tension to make the adjustment Push the motor back to tighten the belt tension IMPORTANT NOTE REGARDING MOTION IN X Y and Z MOTORS When operating the machine manually be advised that resistance from motors may be felt if turning the hand wheels fast Resistance can be avoided by turning the hand wheels slow or removing the motor connectors from the Control Unit while having the Control Unit powered down ALSO BE ADVISED that circular movement of the motor body is normal during the jogging of the X and Y Axis The circular movement in the motor removes the stress on the motor shaft Please allow for this flexibility in the motors which is why you will note the rubber grommets and shoulder washer spacers serving as a cushion between the motor and the motor bracket on the X and Y If this circular movement is excessive on one axis more than the other you may be able to reduce this motion with this action remove the axis motor from motor bracket Slightly loosen the two bolts that secure the motor bracket to the machine Place back motor Tighten the four pan head screws back on Tighten the collar clamp Rotate the motor hand crank until the motor finds its own center with its bracket and ball screw bore Re tighten hard the two bolts that sec
30. me limit switches Now power ON If motors still do not operate then the problem may lie in the actual home switch mechanism found at each axis bracket Begin by doing the following test Power off control unit Remove the x axis motor cable from the control unit Power on reset control Port On and run the y and z motors If the problem persists power off Now remove the y axis motor cable from the control unit Power on reset control Port On and run the z motor If the problem persists the problem could very well be on the z axis home switch Remove the pink terminal quick connect with the yellow line at the z axis home switch You may need to use a needle nose pliers to pull out Now power on and re test the z motor If the z motor runs then we know the problem is the z home switch Plug in the x motor cable back into place making sure it goes on all six pins and in the correct position Re test the x and the y motors to see if it runs If not the problem may rest in the x axis switch as well Remove the pink terminal quick connect at the x axis home switch and re test Both the z and the x should now run If yes please do the same test with the y to determine if the y switch is bad or not If the y home switch is plugged in and the three motors run then you have determined that the y motor switch is not bad The problematic home switch that is not 100 isolated from the rest of the machine is causing the control unit to disengage the powe
31. r in the axis motors Perhaps overtime or by applying too much pressure to switch has made the switch move internally causing a contact between the switch and the bracket The contact may be too small to determine with a continuity check on your voltmeter Check for continuity by reading the ohms on the voltmeter Unplug the motor cable at the control unit first be measuring continuity Remove the switch and place two new 6 nylon shoulder washers to and tighten back into position or re adjust the existing shoulder washers and limit switch assembly Take a voltmeter and make sure there is there absolutely no contact between the tip of the switch and the screw that secures the switch into place The only two parts should make contact is the tip of the switch and the terminal male spade for the quick connect yellow wire The BARON XL is still operational without plugging in the home switches pink terminals The home switch feature will be the only thing not operational You can use the BARON XL this way until you obtain new parts through CNC MASTERS or other hardware vendors for the home switches S5 Have you used a surge protector on the control unit Surges could indeed damage the microprocessor in the control unit causing this behavior A warning has been given in this manual to protect the control unit with a surge protector If a surge protector was used CNC MASTERS will honor its warranty with a replacement CPU card But first let us determine if it i
32. s another problem causing this behavior The spindle motor must be isolated from the rest of the machine Unplug control unit and spindle motor from power source and ground Unplug the cable at the control unit that connects the 10 inverter to the control unit Do this by opening the control unit with its two large pan head screws on the left of the control unit Loosen the two screws and swing open the cover to the right Use a voltmeter and check for continuity between the motor and the machine body If there is continuity this may cause the erratic behavior Double check the bolts that secure spindle motor Through time it may very well be that the bolts have come out of alignment with its isolation The CNC BARON XL should come with nylon shoulder washers and flat washers on each of the four bolts which should keep the motor isolated Check for missing parts The inverter mounted on the BARON XL should also remain isolated from the rest of the machine which explains the plastic plate between the machine and the inverter Take a voltmeter and do a continuity check between the machine and a securing nut on the inverter mounting If there is a connection re adjusting the inverter will be needed to ensure isolation If after trying these troubleshooting solutions then we can safely determine that the CPU card is no longer operational and a replacement card will be needed from CNC MASTERS Contact CNC MASTERS for an RMA number if your BARON
33. sary c If there is a surge in current the circuit breaker may have opened Press the circuit breaker back if it is in the open position d The gear may not be engaged Adjust the speed lever to be sure it is engaged 2 The motor overheats or there is insufficient power a The machine is over loaded Reduce the load of the feed b The voltage supply is too low provide stable power with a reliable power supply c The switch may have burned out or it may have a broken contact point Replace the switch d The contact relays may be broken Replace it e There may be a poor electrical connection Have a qualified electrician check the working and power supply f The motor is faulty Replace with a new one 0 The drill bit or cutting blade be worn Sharpen or replace the bits as needed 3 The spindle bearing is very hot a There is insufficient lubrication Turn off the power and check the bearing for lubrication If necessary apply bearing grease b The spindle bearing is worn or fixed too tight Turn off the power unplug the electrical connection and rotate the spindle by hand Be sure it rotates freely If not adjust the bearing If after adjusting the bearing the spindle still does not rotate freely you will have to replace it c The spindle has been turning at high speed for a long time After long use turn the machine off for a while to give it a rest and allow it to cool off 12 4 Table tra
34. t an acceptable range to give you the power protection you need for the control unit If your control unit is wired at 220 240 use a line conditioner if your voltage is 233 or higher Your voltage should not exceed 240 Q CAUTION BEFORE POWERING ON CONTROL UNIT ENSURE THAT EACH AXIS MOTOR CABLE IS PROPERLY PLUGGED INTO THE CONTROL UNIT POWERING ON CONTROL UNIT WHILE MOTOR CABLES CONNECTIONS ARE SLIGHTLY UNPLUGGED MAY CAUSE DAMAGE TO THE AXIS DRIVER IN THE CONTROL UNIT THE WARRANTY DOES NOT COVER THIS TYPE OF DAMAGE TO DRIVER You may need to unplug power cable USB cable and optional coolant and hand held cables from the bottom of control unit before opening Slightly loosen the two large Phillips pan head screws on left side and swing cover open to the right to check Q CAUTION DO NOT USE A HIGH FREQUENCY WELDER IN THE SAME AREA YOUR CNC MACHINE IS IN OPERATION AS THIS MAY CAUSE A DISTURBANCE IN THE CONTROL Radio CB antennas military aviation equipment or anything that emits of high frequency near the operation of your CNC machine may cause a disturbance during the operating your tool path program Take necessary steps to shield the machine if necessary When powering the control unit WARNING Axis motors do get very HOT during operation and remain constant This is normal Keep small children away from machine and especially axis motors during operation if this machine is used in a home environment When not in use unpl
35. t power cable The 110 or 220 output for the spindle motor and output for the control unit should not be placed next to each other If so you will need to properly shield and ground the shield the control unit power cable from the spindle motor cable Use a DEDICATED circuit for the control unit Do not share this circuit with other electrical devises or machinery as this can cause a disturbance during running of a tool path program If AC voltage is close to 122 at outlet use a minimum 600 watts line conditioner to maintain voltage at 110 115 A good recommendation for a low cost line conditioner is to visit this site http www apc com resource include techspec_index cfm base sku LE1200 Please check with your electrical supply company if your supply is on the high end Electrical companies may adjust voltage seasonally to compensate for amount of usage which may over power the control unit if voltage was found to be on the higher end previously Voltage can swing up and down throughout the day especially in most rural country areas So if your voltage is already deemed on the higher end around 121 123 a line conditioner is required to avoid damaging the control unit should the voltage swing higher The CNC MASTERS warranty on the control unit does not cover high voltage damage Keep in mind certain battery back up surge protectors are ONLY surge protectors and NOT line conditioners Be sure the tolerance level of the line conditioner is a
36. t secures the bracket to the side of the machine head Place bracket on table Examine the sprocket on the motor shaft and check to see that the sprocket is not loose Rotate the smaller sprocket on the worm screw at the machine head Check to see if it is loose as well Rotating the sprocket by hand back and forth should give you a good feel and visual indication of the quill The quills movement should move accurately in accordance to the rotation movement of the worm screw with your hand Keep in mind that more force is required to turn the sprocket in the direction that moves the quill up as you are dealing with the force of the extended gas spring 4 Next remove the face plate off the machine head Begin by removing the red arrow indicator and save small parts by placing them in the side pocket of table Slightly loosen the nut on the top left side of face plate Unscrew the bottom left side screw Remove face plate 5 Examine the gas spring the connection at the top and make sure there the spring s bracket is not loose 6 It may also be possible that the gas spring may be a little dry and getting stuck at certain points when being depressed and released Pop gas spring off its two ball studs Remove the safety clip at the bottom first Pop spring off ball stud Position spring in the horizontal position to easily remove the top safety clip and remove spring from machine Using some hydraulic fluid or any type of light thin cutting oil rub at t
37. t the table if it does not need to be adjusted for backlash error The W axis must be checked and saved at the SETUP window in the Master Software to function correctly with the Master program The center sleeve of rotary table is a MT 2 B Coolant Supply WARNING For your protection always unplug the control unit or coolant pump from its power source before installing or servicing Should the pump appear not to be working do not reach for it remove or disassemble before you disconnect power Do not use pump for oil solvent or gasoline or warranty will be voided Always make sure pump is submersed Running pump outside of submersion will burn out and warranty is voided on the pump The pump s motor will burn out in a moment s time when not submersed and is operating This in not covered under the warranty So be sure to check that pump is fully submerged before operating each job The coolant option has an electrical pump which is submerged in the built in tank inside the machine s base This tank can hold up to five gallons Pour four five gallons into the exposed strainer which is located under the knee Install 3 coolant hose from the U clamp located next to the strainer to the barb nozzle on the X table Plug the pump into the 115 VAC outlet labeled Coolant in the Control Unit This cable will come out the right side of the machine s column Warning Do not use this outlet to drive a load larger than 0 7 amps or the Con
38. trol Unit will be damaged THIS ACTION WILL NOT BE COVERED UNDER THE WARRANTY The COOLANT ON and COOLANT OFF commands will turn this pump on and off on your Master Software display and can also be controlled with G code commands Be sure to always have between 4 5 gallons of liquid coolant to ensure the pump in the tank remains submersed Periodically inspect the pump by first unplugging the control unit removing the cover plate which you can find on the bottom back of the machine column Remove the sponge filter and clean off trapped debris Coolant can also be drained through the drain plug located below the cover plate C Easy Change Quick Tool System This system uses a master tool holder which features an R8 taper design Tools can be easily secured and removed Tool setup can be entered in the tool length compensation section under Setup of MASTER software The Quick Tool Change system is a worthy investment which will cut downtime if the user needs several tool changes during the machining of a part SEC 7 Self Help Support Trouble Shooting Tips Please refer to this part of the instructions for problems regarding the CNC BARON XL Most problems can be fixed with a simple solution saving you downtime Please refer to these TROUBLE SHOOTING solutions that should be attempted before contacting CNC MASTERS ALSO BE SURE TO READ THIS MANUAL IN ITS ENTIRETY TO AVOID COMPLICATIONS PLEASE CONTACT CNC MASTERS BY EMAIL OR PHONE SHOULD YOUR PROBL
39. ug the control unit Do not shut down system at a circuit breaker Powering up at circuit breaker can cause a brief surge while the system is resetting itself which may cause damage If powering up at circuit breaker is needed be sure system is unplugged first The Spindle Motor Follow each check box to avoid damages and complications below Q Computer Variable Spindle Control 208 220 240 Volt single phase with ground 60Hz 50Hz is acceptable 15 amp service Q Computer Variable Spindle Control Note A Be sure to unplug the spindle motor after the day s use or install a manual ON OFF power switch at the power source for the spindle motor This will prolong the life of the inverter Q Computer Variable Spindle Control Note B The spindle motor label will read that it requires three phase 220 The mounted inverter ONLY requires 208 220 240 single phase power The inverter will output three phase into the spindle motor So you will only need single phase to power up the spindle motor through the inverter Q CAUTION Proper ground earth is important and dangerous without Be sure ground is connected at your outlet before plugging in Use a licensed electrician if you are not sure about your grounded line Plugging in the spindle motor without a proper ground may cause shock or injury CNC MASTERS is not responsible for users not taking proper safety precautions to avoid electrical shock Be sure this ground connection for the
40. ure the motor bracket to the machine NOTE BREAKAGE OF THE MOTOR SHAFT WILL NOT BE COVERED UNDER THE CNC MASTERS WARRANTY BREAKAGE OF THE MOTOR SHAFT IS A RESULT OF NOT ALLOWING THE MOTOR THE FLEXIBILITY NEEDED TO ABSORB THE STRAIN ON ITS SHAFT If you hear any clicking sounds in the movement of the X and Y that is normal The clicking sound are the ball bearings moving inside the ball nuts of your X and Y SEC 3 Connecting Electrical Power Three components of your CNC BARON XL require electrical power These components are the e Control Unit e Spindle Motor e Your host computer The Control Unit Follow each check box to avoid damages and complications below Requires standard 110 115 with true ground 60Hz power 50Hz for most countries outside of the USA Upon request at time of ordering your control unit can also be rewired for 220 240 single phase with true ground Q USE 600 MINIMUM BATTERY BACK UP SURGE PROTECTOR FOR THE CONTROL UNIT OF YOUR CNC MILL THE CONTROL UNIT IS AS SENSITIVE AS A COMPUTER A BATTERY BACK UP SURGE PROTECTOR WILL ALSO KEEP ELECTRICAL POWER CONSISTENT TO AVOID ANY BRIEF POWER INTERRUPTION DURING A PROGRAM RUN OF YOUR CNC MACHINE The CNC MASTERS warranty on the control unit does not cover high voltage damage Q Separate the control unit power cable from the spindle motor cable as physically apart as possible to prevent spikes from the spindle motor power cable to the control uni
41. vel is not balanced a The gap of the table guide is too wide or you feel a heavy drag when moving the table Adjust strip in proper b The locked bolts may be loose Check and tighten them if necessary c The feed is too deep Reduce the depth of cutting make several passes to reach the required depth 5 There is vibration and roughness of working surface during performance a The gap of the spindle bearing is too wide Adjust the gap or replace the bearing with a new one b Spindle loosening up and down Check the adjustment of the two inner bearing covers Adjust them so there is no free play in the taper bearing and the taper bearing must turn freely Tighten them against each other to save this adjustment c The gap of the taper sliding plate is too wide Adjust the bolt tension d The chuck is loose Tighten the chuck e The drill bit or cutter is dull Sharpen or replace it Be sure to use cutting fluid to preserve tool life f The work piece is not held firmly Check the clamps or vise you are using and make sure to tighten the work piece 6 The micro feed does not work smoothly a clutch may be loose Check this and tighten if necessary b The worm gear or worm shaft may be worn Check these and replace if necessary c The hand wheel fixed screw may be loose Check it and tighten if necessary 7 The work piece is not machined accurately a Imbalance of a heavy work piece Check to see t
42. will jog the axis accordingly For micro positioning select the axis by first pressing the button and then move the joystick to that axis To avoid confusion between POS and NEG directions always look at your axes movement from the point of view of the cutter The joystick positioning is designed to be operated in the direction of the cutter not the movement of the axes Change the axis with the micrometer by again moving the joystick to the other axis To disable the micrometer move the jog speed by turning the knob away from the MICRO position CAUTION DO NOT FLICK THE JOYSTICK TO OBTAIN SMALL MOVEMENTS OF AN AXIS ON A RAPID FEED AS THIS WILL FREEZE OR CONFUSE THE SYSTEM Instead when need to jog a small distance on an axis lower the feed knob first to a low feed rate and then gently toggle the joystick to that position DO NOT QUICKLY ALTERNATE OR TOGGLE REPEATEDLY IN THE SAME DIRECTION THE JOYSTICK WITHOUT ALLOWING THE AXIS MOTOR TO FINISH ITS COMMAND YOU GAVE IT ON THE JOYSTICK X Y Z W Selection Buttons Pressing these buttons will select which axes are activated by jogging the joystick The indicator lights will show which axes are active Micro Positioning Control To operate the micro positioning the jog speed control must be in the micro position turning knob completely to the left If the axis is not already selected by use of the joystick press one of the axes buttons and then move the joystick to select the axis Turning the lar
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