www.cronsrud.

com

C. R. ONSRUD INC.
OSAI 5 AXIS
F/G-SERIES
CNC ROUTERS

DATE MANUFACTURED: 01/2014

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Table of Contents
Cover Page -
Table of Contents -
Section - Introduction -
Section - Safety Rules
-Lock Out/ Tag Out 1
- Employer/ End User Responsibility 2
-Machine Stickers 3
- Safety Rules 9
Section - Machine Set Up & Components
- Machine Set Up 1
- Electrical Components 5
- Spindle Head 10
- Servo Motors 11
Sensors, Valves & External Components 12
Section – OSAI- Controls & Operations
- CR Onsrud OSAI Operation's Manual 1
- Error Codes 25
Section - Machine Power Up and Functionality
- Functionality 3
Section - Machine Misuses
- Known Misuses 2
Section - Maintenance & Spare Parts
- Maintenance 2
- Cutter Recommendation 6
- Spare Parts 9
Section - Warranty 1

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Getting Started with the C.R. Onsrud CNC Router

Welcome to C.R. Onsrud’s getting started guide. These points are intended to ensure that our customers have all
needed information, and have met all compliances for the full integration and running of the new CNC Router.

Disclaimer: Changes to Equipment:

The following documentation is intended for personnel
properly trained by a Certified C.R. Onsrud
Representative only! Any use by untrained personnel can
result in machine damage or personal injury. This
document is intended to provide additional information,
guidance and/ or direction on a number of common issues
and questions that have been raised over time. This
document and its content is for informational purposes
only; it is not intended to, and should not be, used as a
substitute for proper Factory Training or Services.
WE AT C.R. ONSRUD HAVE STRIVED TO ENSURE THE
ACCURACY OF THE CONTENT IN THIS DOCUMENT TO BE
CORRECT AT THE DATE OF PUBLICATION BUT WE MAKE
NO WARRANTIES OR REPRESENTATIONS IN REGARDS TO
THE CONTENT. C.R. ONSRUD EXCLUDES LIABILITY, FOR
ANY INACCURACIES IN THIS DOCUMENT, HOWSOEVER
ARISING.
Logos and Trademarks:
C.R. ONSRUD and the Router Bit emblem used in the
C.R. ONSRUD logo are trademarks of C.R. ONSRUD,
INC. and are not to be reproduced without the written
consent of C.R. ONSRUD.
C.R. ONSRUD, INC reserves the right to change
equipment specifications without notice.
CNC Machine Operation:
All models of C.R. ONSRUD CNC Routers must always be
operated by fully trained personnel in accordance to the
manufacturer’s instruction.
All operators must be trained by a C.R. ONSRUD
representative and must follow all safety regulations in
accordance to the employer’s and OSHA’s standards.
All operators must read and follow all health and safety
guide lines. Please read and follow all MSDS sheets for
materials being cut on the CNC router. You should be able
to obtain these from your supervisor.
Machine Care:
The C.R. ONSRUD CNC Machine is a precision tool and
should be treated as such. Keep the machine clean and
free of any debris or obstructions. The operator should
follow the maintenance schedule for proper machine care.

All other names whether they be brand or product names,

used in this document are brand names, trade names,
service marks, trademarks, or registered trademarks of
their respective owners.
Warranty:
All equipment requiring attention under warranty must
have a RMA (Return Merchandise Authorization) number
attached, and must be returned to C.R. Onsrud for
investigation. No claims will be considered where C.R.
Onsrud’s equipment has been misused, or where
adjustments, modification, or repairs have been attempted
or performed by any unauthorized person(s). Prior consent
must be obtained in instances where recommended C.R.
Onsrud parts are to be substituted or omitted. Failure to
comply will void the warranty of the machine.

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FG-SERIES C.N.C Router

MODEL# F309G20 SERIAL # 309G140101
DATE MANUFACTURED: 01/2014

Thank you for the confidence you have shown in our product by choosing the 5 Axis MOVING GANTRY
C.N.C Router by C. R. ONSRUD, INC.!

PLEASE READ THE MANUAL THOROUGHLY

We believe this manual to be concise and to the point. The time required to read it will greatly enhance your
safe, effective and efficient use of this machinery.

PROPERLY MADE, QUALITY holding fixtures or effective flow through vacuum are crucial to the safe and
efficient operation of any CNC Router. For a fixture to be adequate, it must hold the work piece securely
enough so that cutting forces cannot separate the work piece from the flow through board or work fixture(s).

THE MANUAL INCLUDED WITH YOUR MACHINE IS NOT A COMPLETE SAFETY TRAINING PROGRAM
IT IS AN OWNER'S MANUAL. THE MANUAL IS NOT YOUR PILOT'S LICENSE RATHER IT IS YOUR
CERTIFICATE OF PURCHASE.ONLY FACTORY CERTIFIED TRAINING FROM A C.R. ONSRUD
TECHNICIAN WILL QUALIFY PERSON(S) TO PROPERLY AND SAFELY OPERATE THE EQUIPMENT.

Operators and maintenance personnel must additionally be trained in industrial safety principles, machining
fundamentals and general machine operation safety practices! If you have not had this training, contact your
plant safety officer or supervisor for this training before continuing!

After you have absorbed this basic knowledge, call C. R. Onsrud Inc. at 1-(704)-528-4528 or toll-free in
the U.S: 1-(800)-638–8185 if you are still even slightly uncertain of any details concerning the safe and proper
operation of your machine. If it is a CNC machine emergency the customer can contact our technical support
line for 24hr/ 7 days support at 1-866-ONSRUDS (1-866-667-7837).

We routinely provide phone consultation with customers regarding tooling, operation, and safety tips,
and troubleshooting. We encourage your calls.

CUSTOMERS ARE PROVIDED WITH MACHINE AND SOFTWARE TRAINING UPON PURCHASE OF A
CNC ROUTER MACHINE. ANY ADDITIONAL MACHINE TRAINING IS AVAILABLE TO CUSTOMERS AT
THEIR EXPENSE. ADDITIONAL MACHINE TRAINING WILL BE DONE AT THE CUSTOMERS FAUCILITY.
SOFTWARE TRAINING CAN BE DONE IN OUR NORTH CAROLINA FACILITY, OR ON LOCATION AT
THE CUSTOMER'S SITE.

C R Onsrud, Inc offers 24/7/365 technical support to the original CNC Router purchaser’s factory trained
personnel. After the regular business hours of 8:00 am (ET) to 5:00 pm (ET), CNC machine technical support
can be reached by calling the Emergency After Hours Support Line at 866-667-7837. (866-ONSRUDS)
This service is intended to be used for machine related issues as software and training are available at our
North Carolina facility or on-site at the customer’s facility as prearranged training sessions.

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LOCK OUT/ TAG OUT PROCEDURE

For C.R. Onsrud Moving Gantry CNC Routers
C.R. Onsrud CNC Routers use Electricity and Compressed Air as their Two Energy Sources.
WARNING!! It is the employer’s responsibility to provide energy isolation devices for this equipment and
ensure that all potential service and maintenance personnel follow lockout/ tagout procedures developed by
the employer in accordance with the Occupational Safety and Health Administration’s (OSHA) control of
hazardous energy standard 29 CFR 1910.147
RESIDUAL ENERGIES which may be present after energy sources have been removed per the above
standard include:
 Cutting Spindle Rotation could continue to rotate for several seconds after removal of electrical
energy source. Once spindle rotation has stopped this residual energy is dissipated.
 The cutting spindle and spindle mounting plate may fall under force of gravity if the pneumatic
energy source (compressed air) has been removed and the Z axis drive belt is removed. Once the
cutting spindle and spindle mounting plate are in the full down position, this residual energy is
dissipated.
 Inertia of Moving Gantry could lead to a condition under which the Gantry could continue to move for
several seconds after removal of energy source. Once table motion has stopped, all residual energy in
the Gantry is dissipated.
 Inertia of the spindle and spindle mounting plate moving along the Y axis could lead to a
condition under which the spindle and spindle mounting plate could continue to move for several
seconds after removal of energy sources. Once the spindle and spindle mounting plate movement has
stopped this residual energy is dissipated.
WARNING!!: The Variable Speed Spindle Drive Unit (Frequency Inverter) and the Axis Servo Drive units
contain capacitors which remain charged with dangerous electrical voltages for up to ten minutes after turning
off the main circuit power supply. DO NOT touch motor drive components before allowing these components
to discharge.

After removing power source(s) from the equipment, wait at least ten minutes before touching or disconnecting
sections of the equipment that normally carry electrical charges (i.e. capacitors, contacts, screw connections).
To be safe, measure the electrical contact points with a meter before touching the equipment.
Refer to Frequency Inverter instruction manual and Servo Drive instruction manuals for specific information
NOTIFY: All affected employees that the Lock Out is to occur and why.
SHUTDOWN: Disconnect Electrical and Pneumatic power by turning the isolation devices to the “OFF”
position. Test by attempting to restart the machine. Return all switches to the OFF position.
LOCK: the machine with approved locks from your lockout/ tagout station. Apply tags.
AFTER ALL SERVICING IS FINISHED: Make sure all tools are removed from the area. Replace all guards.
Remove the locks and tags from the energy isolation devices. Clear area of bystanders and restore power
sources.
C.R. Onsrud CNC Routers use two power sources, please follow all OSHA
Standards Lock Out/ Tag Out procedures when servicing these machine.
Each Energy Source will need to be isolated independently from the other.

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Employer / End User Responsibility

From the ANSI Standard for CNC equipment
5.2 Employer

The employer shall be responsible for the overall workplace safety of

personnel (e.g. acoustics, housekeeping, adequate lighting and ventilation).
The user shall review the machine and its associated equipment including
installation, setup and any modifications as provided by the supplier(s) to
ensure their compliance with this standard. The user shall ensure that:

a) The recognized hazards for the tasks to be implemented on the machine are
identified;

b) The protective measures required for the tasks identified are provided and
used in accordance with this standard;

c) The safeguarding required to eliminate or control the identified hazards as

provided by the supplier is used and maintained;

d) A procedure for the inspection and maintenance of the machine is established

to ensure that its parts, safeguarding and other protective devices are in safe
operating condition and adjustment;

e) Correct and safe working procedures are being followed;

f) Maintain accurate machine maintenance records that can be reviewed by

maintenance personal during service and inspection calls;

g) Shall obtain the skill standard from the Manufacturer and review with
employee to ensure employee is qualified.

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 SAFETY: STICKERS AND INFORMATION

1 !!WARNING!! - Crush, cut and fall hazards. FIG 1
 Do NOT climb on this machine.
 Always Lock out/ Tag out before
servicing
There are (2) Crush, Cut, Fall, Hazards Stickers
(Part# H6145-TAWHPJ). They are placed on the
front side of Y axis Ball Screw cover (See Fig 1.1)
Please see close up picture (Fig 1.2).

2 !!WARNING!! - Machine Starts FIG 2

Automatically.
There are (2) Stay Clear stickers (Part# H6008-
KDWVPJ) that should be located on either side of
the Machine’s dust hood. They should be placed
just inside the front air cylinder of the dust
brushes.

3 !!!DANGER!!! - HIGH VOLTAGE - FIG 3

Disconnect power before servicing
machine or panel.
There are (2) High Voltage Stickers (Part# 775-2)
located at the rear side of the bridge on the
electrical cabinet doors. They should be placed
on the bottom corners of both doors.

4 !!!DANGER!!! - HIGH VOLTAGE - FIG 4

Disconnect power before servicing
machine or panel.
On the machine’s Base Support Tubes there will
be (2) CAUTION Do NOT step or stand on this
surface (Part# H5080-CYCHPJ) safety stickers.
There will be (1) sticker on each support tube.

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 SAFETY: STICKERS AND INFORMATION

5 !!WARNING!! – Read and understand the FIG 5
operator’s manual before using this machine.
Failure to follow the operating instructions
could result in injury or damage to equipment.
The Read Manual sticker (Part# 775-6) is located
in two locations one on the Console and the other
is on the dust hood transition of the machine.
Please ensure that the sticker is in place on the
console.

6 !!WARNING!! – Potential respiratory hazard. FIG 6

Wear approved respirator in this area.

The Respiratory Warning sticker (Part# C38-06)
is located in two locations one on the Console
and the other is on the dust hood transition of the
machine. Please ensure that the sticker is in
place on the console.

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 SAFTEY SECTION: SAFETY RULES

AS WITH ALL MACHINERY THERE ARE CERTAIN HAZARDS INVOLVED WITH OPERATION AND USE
OF THIS MACHINE. USING THE MACHINE WITH RESPECT AND CAUTION WILL CONSIDERABLY
LESSEN THE POSSIBILITY OF PERSONAL INJURY.
- HOWEVER, IF NORMAL SAFETY PRECAUTIONS ARE OVERLOOKED OR IGNORED, PERSONAL
INJURY TO THE OPERATOR, MAINTENANCE PERSONNEL OR BYSTANDERS MAY RESULT.
- THIS MACHINE WAS DESIGNED FOR CERTAIN APPLICATIONS ONLY. C. R. ONSRUD, INC.
STRONGLY RECOMMENDS THAT THIS MACHINE NOT BE MODIFIED AND/OR USED FOR ANY
APPLICATION OTHER THAN FOR WHICH IT WAS DESIGNED.
- WARNING: FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY!
1. IT IS VERY IMPORTANT TO READ AND 5. REMOVE ADJUSTING KEYS AND WRENCHES.
UNDERSTAND THIS ENTIRE MANUAL BEFORE Form the habit of checking to see that all adjustment
INSTALLING, STARTING OR OPERATING YOUR and set-up tools and wrenches are safely removed
ROUTER! Learn the tool's application and limitations before turning the machine "on".
as well as the specific hazards peculiar to it.
CAUTION!! It is the employer's responsibility to 6. KEEP WORK AREA CLEAN. Cluttered areas
ensure that all potential operators and maintenance and benches invite accidents. Dirt and debris can also
personnel read and understand this manual and that cause unnecessary premature damage to moving
they are adequately trained to ensure safe interaction components.
with this equipment.
CAUTION!! Persons untrained in routing 7. DO NOT USE THE MACHINE IN DANGEROUS
fundamentals and C.N.C Router operation and safety ENVIRONMENTS. Don't use machinery or power
practices should not use this machine! Operations tools in damp or wet locations, or expose them to rain.
and maintenance training is available to new Avoid combustibles. Keep work area well lighted.
customers at no charge upon purchase of a new
8. KEEP VISITORS AND CHILDREN AWAY. All
machine, any additional or enhanced training will be
visitors and children should be kept a safe distance
at the customer's expense.
from the work area.
2. KEEP ALL GUARDS IN PLACE AND IN 9. DON'T FORCE TOOL. Bits and cutters will do the
WORKING ORDER. Do not start or run any machine job better and more safely at the feed rate for which
with the doors open or guards out of place. they were designed.
3. DO NOT DEFEAT ANY SAFETY DEVICES OR 10. USE THE RIGHT TOOL. Don't force a tool or
INTERLOCKS. Tampering with safety devices can attachment to do a job for which it was not designed.
create unnecessary hazards.
4. GROUND (EARTH) MACHINE 11. USE PROPER SIZE TOOLS. Don’t use tools that
It is strongly recommended that an 8 ft. grounding rod exceed weight and size specifications of the spindle
be attached to the machine, at the grounding block manufacturer. This information can be found in the
where main power connects, and driven into the spindle owner’s manual. RUNNING TOOLS OF
ground. EXCESSIVE WEIGHT AND SIZE OF CAN RESULT IN
MECHANICAL DAMAGE AND SERIOUS PERSONAL INJURY!!

Recommended also is a continuous copper wire from
the three phase power barrier strip (located at the rear
service panel) to the center tap of the isolation
transformer, and on to the main machine disconnect.
DANGER!! Hazard of fatal electrical shock!
Electrical connections and adjustments should be
made by a qualified electrician only.
12. WEAR PROPER APPAREL. No loose clothing,
gloves, neckties, rings, bracelets, or other jewelry
which may get caught in the machine should be worn.
Non-slip footwear is recommended. Wear protective
hair covering to contain long hair.

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13. ALWAYS USE SAFETY GLASSES. Wear
safety glasses which comply with ANSI Z87.1.
Everyday eyeglasses only have impact resistant
lenses; they are not safety glasses.
14. WEAR HEARING PROTECTION where noise
levels exceed OSHA standards.
15. WEAR RESPIRATORY PROTECTION where
wood dust is not totally controlled.
WARNING! The dust created by certain woods,
wood products and certain other products which may
be processed on this machine can be injurious to your
health. Always operate machinery in a well ventilated
area. Provide adequate dust collection. Wear
respiratory protection where appropriate.
WARNING! Aluminum Dust can be highly explosive in
dust collection systems. Aluminum powder is used in
the launching of the space shuttles booster rocket.
Please use caution when cutting Aluminum.
WARNING! Some research links lengthy exposure to
the sawdust from some kinds of wood to some
specific types of cancer. There is conflicting research.
Other respiratory problems may result from exposure
to sawdust. The risks and the necessary precautions
will be different for different materials being cut.
To reduce the risk of these cancers and other
respiratory problems:
• Always be sure that the sawdust removal system is
operating properly.
• Whenever working with or near this saw, wear a
mask or respirator appropriate for whatever material
the saw is cutting.
• Review the current MSDS for the wood, wood
composite or other material being cut on this saw for
the up-to-date information and details on the hazards
created by its sawdust and how best to deal with
those hazards.
16. DON'T OVERREACH. Keep proper footing and
balance at all times.
17. MAINTAIN MACHINERY IN TOP CONDITION.
Keep tools sharp and clean for best and safest
performance. Follow instructions carefully when
lubricating, maintaining the machine.
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18. DISCONNECT POWER SOURCES BEFORE
SERVICING OR CHANGING TOOLS AND
ACCESSORIES. Only properly trained and qualified
persons should perform these functions.
WARNING!! It is the employer's responsibility to
provide energy isolation devices for this equipment
and insure that all potential service and maintenance
personnel follow lock out/ tag out procedures
developed by the employer in accordance with the
occupational safety and health administration's
(OSHA) control of hazardous energy standard 29
CFR 1910.147. RESIDUAL ENERGIES which may be
present after energy sources have been removed per
the above standard.
* Inertia of belts, pulleys and spindles could lead to a
condition under which belts, pulleys and spindles
continue to rotate up to several minutes after removal
of energy source. Once rotation has stopped, this
residual energy is dissipated.
WARNING!!: The Variable Speed Drive Unit
(Frequency Inverter) contains capacitors which
remain charged with dangerous electrical
voltages for up to several minutes after turning off
the main circuit power supply. Do not touch
motor drive circuit components until the “charge”
lamp is extinguished.
When disconnected from the electrical power
source with the “charge” lamp extinguished, the
machine stores no residual energy.
Refer to Frequency Inverter instruction manual for
specific information.
19. NEVER STAND ON A MACHINE. Serious injury
could occur if the machine is not properly locked out
or powered down.
20. CHECK FOR DAMAGED OR MISSING PARTS.
Be certain that guards, labels and other important
equipment is in place and able to perform it's intended
function before using any machine. Check for proper
alignment and smooth operation of moving parts,
broken or damaged parts, and proper mounting of
tools and accessories.
If you do not know how to recognize proper operating
condition, consult your plant safety officer, supervisor
or call C. R. Onsrud at 1-(704)-528-4528 or toll free in
the U.S: 1-(800)-638-8185.
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21. NEVER LEAVE A RUNNING MACHINE 23. FOLLOW PROPER TOOL AND TOOL HOLDER
UNATTENDED. Turn machine "off" or trip an MAINTENANCE. Large Tools, Insert Profile Tooling,
emergency device, then allow it to come to a Tool Holders should all be properly maintained and
complete stop before leaving work station (except balanced regularly to ensure tool integrity. Improper
under emergency circumstances). maintenance can create structural instability of the
tool while running and may result in mechanical
damage, personal injury, or fatality.
22. EXCESSIVE HEAT CREATED BY DULL 24. DRUGS, ALCOHOL, MEDICATION. Do not
TOOLS AND/OR IMPROPER MACHINING operate, repair, set-up, or perform maintenance on
METHODS CAN CREATE A FIRE HAZARD. Basic this or any other machine while under the influence of
good practice for avoiding heat build-up include: drugs, prescription or otherwise, alcohol, any
Always use sharp cutting tools. Make sure to medication, or mental condition which might impair
always ramp into your cuts. Always machine at motor processes, clarity of thought, or in any other
proper chip-load to avoid heat build up. way interfere with safe interaction with this equipment.
IF YOU ARE NOT THOROUGHLY FAMILIAR WITH THE SAFE OPERATION OF CNC ROUTERS OBTAIN
ADVICE FROM YOUR PLANT SAFETY DIRECTOR, SUPERVISOR, OR CALL C.R. ONSRUD, INC. AT: 1-
(704)-528 4528 OR TOLL-FREE IN THE U.S. AT 1-(800)-638-8185.
Please also refer to the American National Standards Institute ANSI 01.1 1992 Safety Requirements for
Woodworking Machinery and the U. S. Department of Labor OSHA 1910.213 Regulations.

DANGER!! DO NOT LIFT THIS MACHINE BY THE BRIDGE!

IMPORTANT: THIS MACHINE REQUIRES ADJUSTMENTS WHICH ARE NOT

NECESSARILY PRE-SET AT THE FACTORY.

START-UP ASSISTANCE: CAN BE OBTAINED FROM C. R. ONSRUD, INC. BY

TELEPHONE, (704)-528-4528, OR TOLL FREE IN THE U.S: 1-(800)-638-8185.

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Section – Machine Set Up and Components
MACHINE SET UP
GW SERIES CNC ROUTERS
 GUARDS
This is a very versatile machine which may be
equipped with a wide variety of user-supplied tooling.
Because C.R. Onsrud Inc. can not anticipate the
extensive variety of tooling which may be employed,
IT IS THE USER'S RESPONSIBILITY TO
ASSURE THAT THE TOOLING WHICH THEY
INSTALL ON THE C.R. ONSRUD CNC
ROUTER IS PROPERLY GUARDED TO OSHA
STANDARDS!
C.R. Onsrud, Inc. urges you to contact the factory at
1-(704)-508-7000, or toll-free In the U.S:
1-(800)-638-8185 to discuss appropriate guarding for
YOUR particular application and tooling selection.
 ELECTRICAL CONNECTION
 MACHINE VOLTAGE
C.R. ONSRUD ROUTERS are shipped from the
factory pre-wired for a SPECIFIC voltage. The C.R.
Onsrud, Inc. nameplate (which can be found on the
machine's Left Bridge Support) and also an orange
sticker (on the control panel cover) identify this
voltage. If you have any questions about how to
identify the operating voltage for a specific machine,
please call our Technical Department: 1-(704)-528-
4528, or toll-free in the U.S.1-(800)-638-8185, and for
business after hours call: 1-(866)-667-7837.
All control manufacturers strongly recommend an
isolation transformer on the 3phase input. If you
have ordered an Isolation Transformer with your
machine, it is very important that the customer has
provided us with the proper voltage of the building so
the Isolation Transformer can be tapped properly. The
taps can be checked and verified by a qualified
electrician.
www.cronsrud.com
DANGER!! HAZARD OF FATAL ELECTRICAL SHOCK!
ELECTRICAL CONNECTIONS AND
ADJUSTMENTS SHOULD BE MADE BY A QUALIFIED
ELECTRICIAN ONLY.
WARNING!! THIS MACHINE MUST BE
GROUNDED IN ACCORDANCE WITH LOCAL AND
NATIONAL CODES. Make ground connections to the
appropriate points indicated by the ground symbol
inside the control box in accordance with local and
national codes.
Appropriate 440 VAC three phase power is required
for connection to the input power barrier strip provided
inside the service box located on the machine base
where the console cable connects.
IF PLANT POWER HAS A HIGH
LEG IT MUST BE CONNECTED TO
L3. IF IT IS CONNECTED TO L1
OR L2 SEVERE DAMAGE MAY
RESULT!
WARNING!! IT IS THE EMPLOYER'S
RESPONSIBILITY TO PROVIDE ENERGY
ISOLATION DEVICES FOR THIS EQUIPMENT AND
INSURE THAT ALL POTENTIAL SERVICE AND
MAINTENANCE PERSONNEL FOLLOW LOCK
OUT/ TAG OUT PROCEDURES DEVELOPED BY
THE EMPLOYER IN ACCORDANCE WITH THE
OCCUPATIONAL SAFETY AND HEALTH
ADMINISTRATION'S (OSHA) CONTROL OF
HAZARDOUS ENERGY STANDARD 29 CFR
1910.147. Once disconnected from the electrical
power source the machine stores no residual
electrical energy.
WARNING!! THE CONTROL SYSTEM IS BUILT TO
RUN ON 440 VAC THREE PHASE POWER, AND IT
SHOULD NOT EXCEED FLUCUATIONS PAST 450
VAC
EXCEPTION: Capacitors in variable speed drive
units can take several minutes to discharge. If
your machine is so equipped, follow the drive
unit’s instructions carefully when servicing.
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Section – Machine Set Up and Components
 OVERLOAD PROTECTION
Each of the motor starters is
equipped with overload
protection for the motors and
machine wiring. If tripped, the
overload may be reset by
pushing the reset button on the
overload module (under the
contactor, it is the bottom
portion of the "starter").
There will be a motor starter for A) Drive Power, B)
Frequency Inverter, & C) Indicates a Time Delay
Relay for Emergency Circuit.
The overload does not take the place of a properly
sized circuit breaker or fused disconnect which
should be installed on the incoming power line by
a qualified electrician in accordance with local
and national codes
DANGER!! HAZARD OF FATAL ELECTRICAL
SHOCK! ELECTRICAL CONNECTIONS AND
ADJUSTMENTS SHOULD BE MADE BY A
QUALIFIED ELECTRICIAN ONLY.
 FUSES
The machine’s control voltage
transformer has primary and
secondary side fusing which protect
the machine control wiring from
over current hazards.
 DUST COLLECTION
On 5 axis machine’s the use of a Dust Hood can
reduce the travel distance of the machine’s spindle
head, and there for is optional. C.R. Onsrud still
strongly recommends that the customer keep the
machine free of dust, debris and waste, as this can
cause premature wear and damage to the machine’s
mechanical and electrical components.
www.cronsrud.com
 CONNECTION
Onsrud CNC Routers require approximately 3500-
4000 cfm of dust collection flow for machines
fitted with a 12 inch dust outlet, and 1500-2000
cfm for machines fitted with an 8 inch dust outlet.
Make connection with flex hose to the outlet at the top
of the Cutting Spindle hood. Use as little "flex hose"
as possible as the flow characteristics are inferior to
smooth wall pipe. If a blast gate is installed on the
Router's dust outlet to reduce suction, be careful not
to reduce suction excessively or machine
performance and safety could be impaired (see
above). Consult the factory or contact your C. R.
Onsrud distributor.
WARNING: SAWING, SANDING OR MACHINING
WOOD PRODUCTS CAN PRODUCE WOOD DUST
WHICH CAN CAUSE A FLAMMABLE OR
EXPLOSIVE HAZARD.
WARNING: WOOD DUST MAY CAUSE LUNG,
UPPER RESPIRATORY TRACT, EYE AND SKIN
IRRITATION. SOME WOOD SPECIES MAY CAUSE
DERMATITIS AND/OR RESPIRATORY ALLERGIC
EFFECTS.
* Avoid dust contact with ignition source.
* Sweep or vacuum dust for recovery or disposal.
* Avoid prolonged or repeated breathing of wood
dust in air.
* Avoid dust contact with eyes and skin.
WARNING! Aluminum Dust can be highly explosive
in dust collection systems. Aluminum powder is used
in the launching of the space shuttles booster rocket.
Please use caution when cutting Aluminum.
IMPORTANT: IT IS THE EMPLOYER’S
RESPONSIBILITY TO ENSURE THAT NOT ONLY
ALL MACHINE OPERATORS, BUT ALSO ALL
OTHER PERSONS EXPOSED TO ENVIRONMENTS
WHERE WOOD DUST MAY BE PRESENT ARE
INFORMED OF WOOD DUST HAZARDS AND ARE
PROPERLY TRAINED IN COMPLIANCE WITH
OSHA 29 CFR 1910.1200 HAZARD
COMMUNICATION STANDARDS!
FIRST AID: If inhaled remove to fresh air. In case of
contact, flush eyes and skin with water. If irritation
persists, call a physician. For additional information,
see the Material Safety Data Sheet provided by your
safety director.
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Section – Machine Set Up and Components
 COMPRESSED AIR
WARNING!! IT IS THE EMPLOYER'S
RESPONSIBILITY TO PROVIDE ENERGY ISOLATION
DEVICES FOR THIS EQUIPMENT AND INSURE THAT
ALL POTENTIAL SERVICE AND MAINTENANCE
PERSONNEL FOLLOW LOCKOUT/TAG OUT
PROCEDURES DEVELOPED BY THE EMPLOYER IN
ACCORDANCE WITH THE OCCUPATIONAL SAFETY
AND HEALTH ADMINISTRATION'S (OSHA) CONTROL
OF HAZARDOUS ENERGY STANDARD 29 CFR
1910.147.
 CONNECTION
Connect a non-fluctuating
compressed air line capable
of delivering at least 8 cfm at
100 pounds per square inch
to the 3/8" pipe-thread inlet
located at the control box on
the Rear of the machine.
RESIDUAL ENERGIES which may be present after
pneumatic energy source has been removed per the
above standard include:
Once disconnected from the compressed air line at the
incoming filter regulator the machine stores no residual
pneumatic energy
 AIR SYSTEM ADJUSTMENTS
A knob on top of the incoming
filter-regulator adjusts the
pressure of the air supplied to the
machine. Rotate this knob left or
right until the pressure gauge on
the incoming filter-regulator
reads 100 psi.
 PRESSURE SWITCH
The machine is equipped with 2 pressure
switches located in the right main
electrical box. 1st provides 100 psi at 8-12
cfm while the 2nd provides 100 psi at
bursts of 40 cfm for counter balance.
Note: If the machine does not have proper
pressure the machine will not allow the
machine to run.
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CLEAN AIR IS ABSOLUTELY ESSENTIAL!
THE ROUTER USES YOUR COMPRESSED AIR
TO OPERATE PRECISION EQUIPMENT. THE
INTEGRAL FILTER IN THE INCOMING FILTER-
REGULATOR PROVIDED WITH YOUR
MACHINE WILL REMOVE PARTICLES AND
MOISTURE FROM REASONABLE QUALITY AIR.
HOWEVER, IF YOU KNOW THAT YOU HAVE
ANY OF THE FOLLOWING:
*EXCESSIVE MOISTURE IN YOUR AIR LINES.
*PIPE SCALE OR OTHER DEBRIS IN YOUR AIR
LINES.
*MORE THAN 150 FEET BETWEEN YOUR
ROUTER AND YOUR AIR DRYER SYSTEM.
THEN WE STRONGLY RECOMMEND THAT
YOU ADD ADDITIONAL FILTRATION THAT
ENSURES CLEAN DRY AIR.
 LUBRICATION
 SPINDLE BEARING LUBRICATION
The spindle motor bearings are permanently
lubricated for the life of the motor.
 SLIDE LUBRICATION
Each Linear Guide Rail has bearing blocks or
“trucks” that slide along the match profile of the
rail. Each truck has at least one standard Zerk
fitting that should have one pump of grease
injected into it approximately once every two
weeks under high production, and two pumps
once a month under low or medium production.
The Zerk fitting will also lubricate the ball screws
of the axes also. Note: See the above pictures as
examples of our grease points. (See the Maintenance
Section of this manual for location.)
Page 3 of 15
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Section – Machine Set Up and Components

 TOOL HOLDER & COLLET ASSEMBLY:

The tool holders used on your machine are HSK 63 type taper that is a machined match for the taper inside
your machines variable high speed spindle. The tool holder has four components:
A) Tool Arbor, B) Chuck Nut, C) Collet, and D) Router Bit

All parts are machine matched and balanced. The Collets are
available in virtually any size, ranging up to one inch
maximum capacity. Normal wear, as well as sawdust and/or
rosin build-up in the collet, chuck-nut or taper of the chuck
assembly will cause bit breakage and/or poor cut finish.
Inspect these components regularly. Clean with fine scotch
brite (NOT SANDPAPER) and ethyl alcohol replace
components as necessary.
IMPORTANT NOTE ABOUT CHUCK AND COLLET ASSEMBLES: Collets must be assembled to the
clamping nut before inserting collet into the tool holder.
To assemble collet to nut, (1) Hold the nut in one
hand with the threads visible, now place the collet into
the center of nut at a slight angle the face of the collet
should face the threads of the nut. (2) Now apply a
small amount of downward pressure snapping the
collet into place.

To remove collet from nut, (3) Hold the nut firmly in

one hand, and grasp the collet with the other. (4)
Apply a small amount of pressure pushing side-ways
until nut separates from collet.

NOTE: OVER TIGHTENING OF THE NUT CAN OCCUR WITH USE OF TOOL SET UP STAND!! THE
TOOL'S CLAMPING NUT SHOULD HAVE NO MORE THEN 90-95 Ft POUNDS OF TORQUE APPLIED.
SPECIALIZED TORQUE SPANNER WRENCHES CAN BE OBTAINED.

 SPINDLE TAPER & CLAMPING GROUP

The electro spindle of the machine needs to have the clamping group and nose cone taper cleaned and
lubricated a minimum of one a month. Debris should not be allowed to build up in this area as it can cause tool
clamping issues resulting in damage to the machine and/or personal injury. Using a clean dry rag and the
recommended lubricant(s) this can be accomplished. Below are the recommended types of lubricants:

METAFLUX-Fette-Paste Nr.70-8508
METAFLUX-Moly-Spray Nr.70.82

For further explanation please see the manufacturer’s maintenance section in the manual.

Page 4 of 15

Section – Machine Set Up and Components
 ELECTRICAL COMPONENTS
(Left Hand Cabinet)
A) X - Axis (Big X or X) Servo Drive - Servo drive
controlling the X axis movement of the machine.
This is the Master Drive for the axis commanding
both master and slave drives to drive the servo
motors.
B) U - Axis (little x or U) Servo Drive - Servo drive
controlling the U axis movement of the machine. This
is the Slave Drive for the axis responding to the
commands given by X axis to drive the servo motors.
C) Y - Axis Servo Drive - Controls the movement of
the head along the bridge of the machine. The motor
turns a ball screw with a pulley and belt located In the
bridge above the tool tray.
D) Z - Axis Servo Drive - Controls the up and down
motion of the spindle head. This axis should always
be raised 1st before moving any other axes, when
the machine is stopped.
E) P - Axis Servo Drive - Controls rotation of the
tool tray during the tool change commands, and
Machine Datum.
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F) C – Axis Servo Drive - Controls rotation of the
spindle head during machine operations.
G) A – Axis Servo Drive - Controls the pivoting of the
spindle head during machine operations.
H) Teach Pendant Connection - Connection for a
remote hand pad to be used with OSAI controls. The
Teach Pendant is a payable option and will need to in
tale changes to the system for it to work.
I) Blue Fast Wire Console Connection - This is the
Fast Wire cable that goes to the Computer Console.
Connecting the Servo Drive to the Console where the
chain will be terminated by a terminator.
J) Orange Fast Wire Drive Connections - These are
the Fast Wire connections for the OSAI system. The
system uses these connections as a monitor for
diagnosing communications status between the
system components.
K) Main 440V Drive Supply Power – This is where
the servo drives main supply comes in before daisy
chaining supplying all the drive from this location.
Page 5 of 15

Section – Machine Set Up and Components
 ELECTRICAL COMPONENTS
(Left Hand Cabinet)
L) E C Coupler - This device controls the directional
travel of the Inputs and Outputs for the machine. The
coupler is configured for the specific amounts of
Inputs and Outputs for the machine.
M) Ground Terminal - This is one of the machines
grounding bar.
N) ASI Terminal - A terminal converting the 32 pin
connection from the Circuit Board into individual
connection terminal points for different circuits of the
machine.
O) Pneumatic Manifold - Manifold holding the
Pneumatic solenoids which activate and deactivate
different pneumatic functions of the machine.
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P) Cooling Fan - Used to keep the Electrical Boxes
and the components cool. Computers and
precision electrical controls are not designed to
operate at EXTREME temperatures. Most
component manufacturers do not certify their
electrical components for operation below
freezing or above 120 deg. F!
Q) I/O Blocks - These are the Inputs and Outputs
controlling different functions of the machine. The
configuration of the I/O Blocks will vary slightly
between machines. The amount of options that are
purchased with a machine determines the amount
of I/O Blocks a machine needs.
R) Heat Exchange Unit – This unit work in
conjunction with the fans ensure that the cabinet
stays within an optimal operating temperature..
Computers and precision electrical controls are
not designed to operate at EXTREME
temperatures. Most component manufacturers
do not certify their electrical components for
operation below freezing or above 120 deg. F!
Page 6 of 15

Section – Machine Set Up and Components
 ELECTRICAL COMPONENTS
(Right Hand Cabinet)
A) OSAI 10/ 510 Control - This is the control unit for
the machine. The controller Interfaces with servo
system and variable speed inverter.
B) Circuit Board - The Electronic circuit board traffics
the machine signals to the proper terminal points.
C) Finder Relays - These Ice Cube relays have three
separate functions, the first is a status of the
emergency circuit, the second is for the optional drill
head contactor, and the last is for spindle reverse.
D) Three Phase Motor Starter - Thermal overload
protection for the Multi - drill head motor starter with
manual reset. (Note: This feature is optional and not
standard on machines.)
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E) Main Air Solenoid - Supplies machine with
compressed air, and is in line with the air pressure
switch located in the left electrical box.
F) +24 VDC Power Supply - Takes the 120 VAC
supply from the transformer and converts it to a +24
VDC signal for the input/ output circuits.
G) Thermal Overload Protection - Each motor
starter on the machine will be equipped with thermal
protection. These can be reset if tripped.
H) Time Delay Relay - Disengages three phase
power upon activation of an Emergency Stop.
I) Air Pressure Switches – These switches ensure
that the machine is operating with the proper
recommended pressure. The machine will fault with
an error if pressure falls below 95 psi. The switches
are for the machine’s main supply and counter
balance
Page 7 of 15

Section – Machine Set Up and Components
 ELECTRICAL COMPONENTS
(Right Hand Cabinet)
J) 120 VAC Terminal Strip - This is the terminal strip
for 120 VAC coming from the Transformer (M) for 120
VAC supply to the PC Console of the machine.
WARNING!! THE CONTROL SYSTEM IS BUILT TO
RUN ON 440 VAC THREE PHASE POWER. We
recommend that the power levels be as close to
440 VAC as possible.
K) Ground Terminal - This is a grounding strip for
the machine.
L) Frequency Inverter - Unit controls the variable
high speed router spindle, using control signals from
the OSAI 10/ 510 Control system.
M) Three Phase Power Barrier Strip - Brings the
main 440 VAC three phase power into the cabinets
from the front service panel.
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N) 150 VAC Transformer - Unit transforms the main
three phase 440VAC power into a 120 VAC signal to
the +24 VDC Power Supply.
O) Braking Resistors - Absorbs discharged power
from the inverter during the braking cycle of the high
speed router spindle.
P) Circuit Breakers - The machine’s control voltage
transformer has primary and secondary side circuit
breakers which protect the machine control wiring
from over current hazards.
Q) Flow Meter – This device monitors the spindle
coolant, to ensure that the spindle can be operated
safely and effectively. If meter doesn’t detect coolant
the spindle will not start.
R) Cabinet Support Shock – This shock is used to
support the cabinet door holding it open when
needing to be inside the cabinets.
Page 8 of 15

Section – Machine Set Up and Components
 ELECTRICAL COMPONENTS
(Service Box on Machine Base)
A) Main Three Phase Barrier Strip - The main
440VAC three phase power from the isolation
transformer hook up. The cables should be feed
through the 2 inch gray tube at the rear of the
machine base (See Preliminary Installation
Instructions for picture). This terminal should be
equipped with a 30 amp breaker.
NOTE: IF PLANT POWER HAS A HIGH LEG IT MUST BE
CONNECTED TO L3. IF IT IS CONNECTED TO L1 OR L2
SEVERE DAMAGE MAY RESULT!
(Service Box on Machine Base)
D) Vacuum Table Electrical Access – This
designates the location of the vacuum signals for the
ball valve activation, pressure switch, and the manual
push buttons activation.
E) Operator Console Electrical Access – Carries
power, and signals between the Operator Console
and the machine’s OSAI control.
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B) Ground Lug – The electrician will connect the
main power ground at this lug. We recommend that
the customer connect an 8 foot ground rod at the
transformer tying the grounds together at the lug in
the transformer casing.
C) Networking Hub - Used to Network the Machine
to the customers office Network.
F) Electrical Access to Rear Cabinets – This
designates the power and I/O signals being carried to
the machine’s electrical cabinets on the rear of the
bridge.
G) Main Power Access – This is where the customer
will feed the main power from the transformer to the
main connection see letter A above.
H) Chiller Contact – This is a dry contact for the
chiller to power on when the machine is powered on.
This is an option and the customer will need to
provide connections.
Page 9 of 15

Section – Machine Set Up and Components
 SPINDLE HEAD (A-Axis)
A) HSK 63F Router Spindle - This is the machine's
main spindle or, "cutting head" used in part
manufacturing.
B) A - Axis Motor Pulley - This drive pulley is what
causes the A - Axis to rotate when commanded by the
A Drive inside the First Cabinet.
C) A - Axis Belt & Pulleys - This belt and pulley
respond to the motor pulley sweeping the spindle in a
pivoting motion about the Z - Axis.
 SPINDLE HEAD (C-Axis)
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D) Three phase power - Power connection for the A
axis motor. This is a high voltage connection proper
lock out/ tag out procedures need to be followed.
E) A - Axis Terminal Strip - Connection for the
different home and over travel switch signals.
F) A - Axis Home and Over Travel Switch - These
switches signal when the A - Axis is home and when it
may be in a hard over travel.
G) A - Axis Energy Chain - Protecting the different
cables and wires for operation of the A - Axis.
H) C-Axis Motor - This motor is controlled by the C
Drive inside the First Cabinet. When commanded this
motor will cause the spindle head to rotate about the
Z axis.
I) Home and Over Travel Switches - Two of these
three switches are for the C axis positive and negative
over travel. The third is used during the Homing cycle
to home out the C axis.
J) C - Axis Belts - These belts are used to rotate the
C axis when the motor is commanded to rotate during
a movement.
K) Pneumatic Manifold - This is a pneumatic
manifold for the different pneumatic needs of the
spindle head.
Page 10 of 15

Section – Machine Set Up and Components
 SERVO MOTORS
 Y - AXIS SERVO MOTOR:
A) Y - Axis Servo Motor - Located behind the rear
spindle plate. The motor power and encoder cable
connection can be found here also.
B) Motor and Ball Screw Pulleys - Pulley system
the drives the head along the bridge left to right when
facing the front of the machine.
C) Y - axis Belt - To drive the head along the bridge, a
belt is used in between the pulleys. As the motor
rotates the pulley will in turn spin the ball screw.
 X - AXIS SERVO MOTOR:
NOTE: ON G-SERIES MACHINES THE RACK NEEDS TO BE
CLEANED EVERYDAY!!
A) X - Axis Servo Motor - This motor is set up for
Rack and Pinion it is located in the Tool Tray Column
of the Gantry. This is the Master Motor in the slave
circuit that drives the gantry motion.
B) X axis Gear Box & Pinion – This is the gear box &
pinion that the motor uses (with the machine rack) to
move the Gantry down the length of the machine
base.
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 Z - AXIS SERVO MOTOR:
A) Z - Axis Servo Motor - Motor controls the vertical
up and down movement of the head. Connections for
encoder and power are located here also.
B) Z - Axis Pulley Box - Location of the pulleys for
the motor and ball screw to allow the spindle head its'
up and down vertical motion.
C) Z - Axis Belt - The belts that connects the two
pulleys is located here. This is a wearable Item and
will need to be routinely.
 U - AXIS SERVO MOTOR:
NOTE: ON G-SERIES MACHINES THE RACK NEEDS TO BE
CLEANED EVERYDAY!!
A) U - Axis Servo Motor - This motor is set up for
Rack and Pinion it is located in the Non Tool Tray
Column of the Gantry. This is the Slave Motor in the
slave circuit that drives the gantry motion.
B) U axis Gear Box & Pinion – This is the gear box &
pinion that the motor uses (with the machine rack) to
move the Gantry down the length of the machine
base.
Page 11 of 15
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Section – Machine Set Up and Components

 P - AXIS SERVO MOTOR: (TOOL TRAY)  VACUUM GAUGES AND BUTTONS:

A) Vacuum Pressure Gauge - Reads vacuum

pressure on zones, if pressure falls below certain
value the machine will have a machine fault stopping
the machine.

B) Vacuum Activation Button – Operator’s manual

activation/ de activation of vacuum ball valves under
the table.
A) P - Axis Servo Motor - Tool Tray rotation is  OVER TRAVEL LIMIT SWITCHES:
controlled through this motor. Connections for Encoder
and power are located at the bottom of motor.
B) Tool Tray Gear Box - Make sure not to lose the
key in the shaft during machine placement or
offloading.
C) Tool Tray Mount Plates - Air actuated for sliding
into and out of tool change position. Solenoid In the
rear electrical cabinet activates air cylinder during tool
change commands.
D) 12 Position Aluminum Tool Tray – The Aluminum A) X - Axis Over Travel Switch - Located on the
tray and HSD Tool Clips for holding the HSK 63F tool bottom of the Gantry Column with the tool tray. When
holders of your machine. tripped that switch will put the machine into an
emergency status.
 VACUUM BALL VALVE: B) Y - Axis Over Travel Switch - Located on the rear side
of the back plate (can be seen from the tool tray side of
machine). When tripped the switch puts the machine into an
emergency status.

C) Z - Axis Over Travel Switch - Located in between

the back plate and the spindle plate. When tripped that
switch put the machine into an emergency status.

A) Pneumatic Ball Valve Assembly - Applies the

suction to the table or fixture to hold the part in place.
Ball valve is activated through the manual vacuum
activation valve.
B) Solenoid Valve – Pneumatic solenoid valve used
to actuate the ball valve open and closed. Can be
activated through Console screen, manual push button
or M- Code activation.

Page 12 of 15
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Section – Machine Set Up and Components

 TOOL TRAY COMPONENTS:  DATUM SENSORS:

A) Tool Tray In Position Sensor - When the tool tray

is in the forward position the sensor lets the machine
know it ok to continue with the tool change.
B) Tool Tray Clip - Top and Bottom clip hold the HSK
63 style tool holder (used on our machines) in the tray
during rotation of tool change and also during
production runs.
C) Rotational Adjustment Bolt - These bolts are A) X - Axis Datum Switch - Located on the inside of
used when the tool tray is out of rotation side to side. the right column (between table and column) datum
Please call our technical department for proper switch for the encoder of the X Axis Servo Motor. This
procedural steps. sensor references the "0" position, or home during the
datum cycle.
D) Center Locking Nut - Used to lock the tool tray B) U - Axis Datum Switch - Located on the inside of
into place for consistent Z - axis pick up position. This the left column. This sensor references the "0"
lock nut and the set screw can also be used to adjust position, or home during the datum cycle.
the height of the tool tray under certain
circumstances. Please call our technical department
for proper procedural steps.
E) Linear Guide Block (Truck) - These trucks are C) Y - Axis Datum Switch - Located on the behind
located on all of the profiled Linear Guide Rails. the back plate on the bridge of the machine. This
These "Trucks" need to be greased regularly, in sensor references the "0" position, or home during the
accordance with maintenance of the machine (see datum cycle.
Maintenance section).
F) Pneumatic Cylinder - Initiates the sliding into and D) Z - Axis Datum Switch - Located between the
out of position of the tool tray during the tool change spindle plate and the back plate, references "0"
cycle. position of the Z axis during the datum cycle.
G) Tool In Slot Sensor - Senses whether a tool is in
a pocket or not during a tool change sequence. Used
to avoid parking a tool into a pocket with that has a
tool in it.
H) P - Axis Datum Sensor - Used to sense the
"home" position of the tool tray during a Datum cycle.

Page 13 of 15

Section – Machine Set Up and Components
 EXTERNAL CABINET COMPONENTS:
A) Power On Button - This button enables the
System for operation. This brings power into the
cabinets, and boots the WinMedia panel.
B) Limit Override - This button allows the machine to
be moved after an Axis Over travel Switch has been
activated. By holding this button and cycling power
the system will "override" the Emergency Status of
the machine.
C) Vacuum Override Switches - Switches to
override the vacuum failure alarms. Also used when
parts are held with some type of clamping system.
NOTE: We do not recommend that the machine be
run with these overrides on. Doing so is unsafe
and may cause personal injury or machine
damage.
D) Drives Enable - This will turn the Servo Drives on
enabling system to be Homed, and ready for machine
operations.
E) Spindle Load Meter - This meter shows the
amount of load on the spindle when running, and can
be used in troubleshooting possible issues.
F) HPG (Hand Pulse Generator) - After choosing the
HPG function this dial moves the selected axis, by the
designated amount.
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G) Mode Selection - These buttons will select
specific modes for machine functionality. Manual,
Single Axis Home, Single Block, Auto, MDI, and
Incremental Jog are the selections.
H) Feed & Speed Overrides - These dials can be
used to speed up or slow down any of the following
three functions: Spindle Speed (rpm), Program Feed
(ipm), and the Jog Mode Feed (ipm).
I) Reset/ Rewind – This key will rest the machine part
program to the beginning, and will also reset Fault
messages from the control.
J) Cycle Start - These keys help control certain
operation functions inside and outside of program
running.
K) Cycle Pause/ Feed Hold - These keys help
control certain operation functions inside and outside
of program running.
L) OSAI Keyboard - Computer keyboard used in
entering, selecting and editing data going into the
system.
M) WinMedia Panel - This will show you the Onsrud
Control screens, for operating the CNC machine.
These screens are specific to the Onsrud machine,
and are different then the default OSAI screens.
Page 14 of 15
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Section – Machine Set Up and Components

 EXTERNAL COMPONENTS:
 Counter Balance & Z axis Ball Screw –
The machine is equipped with a counter
balance system on the Z axis.
A) Z axis Ball Screw – This drives the
machine’s head up/ down. The Z axis will
vary between different machines due to
customer’s requirements for travel stroke
of the axis.
B) Counter Balance Cylinders – These
cylinders help to counter balance the
weight of the machine head taking the
strain off of the motor.
C) Z axis Linear Rails – Assist in the motion
of the Z axis head.
SEE PHOTOS BELOW
D) Heat Exchanger – This unit assists in keeping
the internal temperature of the cabinets down.
E) Counter Balance Main Pressure – This is the
main pressure for the counter balance system.
This should be set to 60 psi and should not
fluctuate.
F) Counter Balance Regulator – This regulates
how much pressure to apply to the counter
balance system.
G) Pressure Gauge – This gauge monitors the
fluctuation of the air pressure during motion.

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C.R. ONSRUD
OSAI MACHINE CONTROL MANUAL

Fig. 0-1 - OSAI Boot Controller

Fig. 0-2 - OSAI Process Controller

This manual is an introductory overview on the operation of a C.R. Onsrud OSAI CNC Router. This manual will
walk the operator through all basic operations of the machine from machine power up through the cutting of a
2-D 3-axis part. By no means does this manual substitute one’s need for factory certified training; just reading
this manual does not qualify one as a machine operator.

Page 1 of 42
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 Section 1 - OSAI Process Controller - Screen Breakdown

Fig. 1-1 CNC- Machine’s Serial Number- e.g. NC19371003
PROCESS – Shows the process in use on machine (Applies to Dual
Process machines only)
MODE- Function that machine is currently from the Mode Selection on the
Operator Panel (see Fig. 7-1). (e.g. MANJOG (Manual Jog))
STATUS- The current state of the machine. (e.g. IDLE- not running)
UNIT- Type of measuring system the machine will use to measure distance
traveled- (e.g. Inches)

Fig. 1-2
Active Tool- Gives Tool number and offset address of Tool in the spindle-
(e.g. 1.1 = Tool #1, Offset #1 from the Offset Table)
Next Tool- Displays the next tool called in program
Diameter- Displays the diameter of Active Tool
Tool Length- Shows length offset of Active Tool

Fig. 1-3
POS. - This area will display the machine’s
positioning information for each axis. It will provide
Work Position, Programmed Position, Machine
Position, Absolute Position, Distance to Go,
Following Error, and the active Origin number from
the Origins Table.
X- Y- Z- A- C-
-NOTE: Axes P (& Q) is designated for Tool
tray(s) and not shown in the display.

To activate a particular axis the operator needs to simply touch the corresponding letter on the screen. For
example, if the operator wanted the Y axis to move, one would press the Y under the POS button (highlighted in
above picture), select the Manual button from the Operator panel, and then press and hold the Cycle Start
button. This will move the Y axis in the direction indicated in the Jog Inc. The operator would then release the
Cycle Start button to stop the axis motion.
Fig. 1-4 PROGRAMMED - PERCENT - ACTUAL
Prog. Feed- Controls feed rates in the active
program being run.
Man. Feed- Controls feed rates in Manual
Mode.
Spindle- Controls spindle rpm’s +/- 25% of
the programmed rpm’s.
Rapid- Controls the machine’s automatic
rapid traverse rate.
In this area the operator can monitor the different feeds and speeds of the machine. The controller will monitor
the programmed machine rates, the percentage of the rate that is changed, and calculate the actual rate the
machine is moving. The percentage is controlled by overrides on the Operator Panel.
-NOTE: All selections on the screen are activated by left clicking on the touch pad, or touching of the
display screen with a stylus.

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 Section 1 - Screen Breakdown (continued)

Fig. 1-5
HPG- This selection activates the Hand Pulse Generator wheel found to the right of the
Process Control screen.
JOG RET- Allows the operator to return to the last machine position.

Fig. 1-6
Jog Dir- Indicates the direction a selected axis will move during Manual Jog.

Fig. 1-7
Jog Inc.- Selects distance used by HPG per mark on the dial, and also the distance
traveled when using Incremental Jog.

Fig.1-8
Set Z Shift – This function will shift the Z axis by the amount displayed when running a
program. The value is based on the final depth of the program. (A Z shift is used when the
operator is “Dry Running” a program)

Fig. 1-9
Table Mode- This selection allows the operator to change which table(s) to run the needed
job(s) on. This feature is only on Multi Table machines and works in conjunction with C.R.
Onsrud Program Select Software and the document “Functional Design Spec for
Program Select”.

Fig. 1-10
[G]- Displays G-Code commands that have been used by the
operator, or in the present (or last) program run.
[M]- Displays M-Code commands being used.
Selected Prog.- Displays program selected to run on the
machine.
Subprogram- Displays the subprogram being run inside the
main program.
CYCLE RUN- Displays the actual run time of the active (or
last) program being run.
CYCLE IN HOLD- Displays how long the active (or last)
program was in Cycle Hold (or Cycle Pause).
PROGRAM MESSAGE: Displays a line by line read out of the
G-Code program being run on the machine. This gives the
operator the ability to find an exact point in the G-Code for
editing if necessary.

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 Section 2 - OSAI Process Controller – PROCESS MACHINE CONTROL

Fig. 2

Fig. 2-1 The LOAD/ AUTO button is only for machines with Table Mode option. This gives the
operator the choice of pendulum processing (continuous machine cutting) multiple
programs on the machine. The operator only needs to press the button to toggle between
the two states of LOAD or AUTO. Please see the section on running jobs in table modes
and refer to the document “Functional Design Spec for Program Select”.
Fig. 2-2
T/P Enable is active only when the Teach Pendant option is purchased with the machine. This
device is NOT designed for running part programs on the machine.

Fig. 2-3
Retract Z will retract the Z axis to its Park Position. Operators can use this button when stopping
a “Dry Run” program and to move the Z axis up to a safe position.

Fig. 2-4
Table Load will send the machine’s tables or gantry to the set load position. This allows the
operator to load the machine table with material to process.

Fig. 2-5
Brushes Up/ Down will allow the operator to manually put the Dust Brushes in the up or
down position. The button toggles between the two states shown.

Fig. 2-6
Message Reset will reset the Yellow error message when displayed in the middle of the Process
Control Screen.

Fig. 2-7 Auto Home will set the Machine X, Y, & Z axes to absolute zero position upon power up of the
machine. The machine should not be run until this step has been executed.
Fig. 2-8
Diagnostics will allow the operator to visually observe the input and output signals of the
machine. This button will change the appearance of the Process Control Screen (see section 4).

Fig. 2-9 Table Set Up allows the operator to set up the table vacuum zones. Zones can be turned on and
off independently or simultaneously. This is also where the operator would manually activate and
deactivate pop up pins for the machine if so equipped. This button will change the appearance of
the Process Control Screen (see section 3).

Fig. 2-10 Tool Set Up allows access to machine functionality that deals with the main router spindle, tool
tray, or Multi Spindle Drill Head. This button will change the appearance of the Process Control
Screen (see section 5).

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 Section 3 - OSAI Process Controller – Table Set Up Screen

Fig. 3-1 Fig. 3-2

The operator will press the button to gain access to the Vacuum Zone Control screen (see Fig. 2-9). Here
the operator can activate and deactivate vacuum on the machine table(s). The operator can activate all zones or
individually select zones to apply vacuum to. The material being processed will dictate which zone(s) should be on
and which should be off. For example, if the operator is running a job that is 39” x 52” and his material is 48” x 60”
the operator will only need to activate one individual zone rather than all zones. Machine Model and options
purchased will dictate how many zones a specific machine will have. The operator will then press

 Section 4 - OSAI Process Controller – Diagnostic Screen

Fig. 4-1
The operator can access the Diagnostics screen by
pressing on the main Process Controller
screen (see Fig. 2-8). This gives the operator a visual
representation of the input and output signals of their
machine. The number of input and output units a
given machine has is determined by what options
were purchased on the machine. The operator can
find a complete list of inputs and outputs for a specific
machine inside the machine Owners Manual. To
return to the main Process Controller Screen the
operator will press the button.

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 Section 5 - OSAI Process Controller – Tool Setup Screen

Fig. 5

Fig. 5-1 Drill Head Set Up allows the operator to access the Drill Head Set Up screen for the machine. This
button will change the appearance of the Process Control Screen (see Fig. 6-1).
Fig. 5-2 Tool Tray In/ Tool Tray Out allows the operator to activate and deactivate
the Tool Tray In solenoid. The actual tray position is indicated by the color
green. When deactivated the button will be red.
Fig. 5-3 Clamp Tool/ Release Tool allows the operator to actuate the spindle’s draw
bar for manual loading or unloading toolholders into the spindle. The green
button indicates the present state of the spindle’s draw bar.
Fig. 5-4 Park Tool allows the operator to park the tool into the tool tray. If there is an Active Tool in the
machine spindle, the button will be Blue.
Fig. 5-5
T/P Enable enables the Machine’s Hand pad if this machine option was purchased.

Fig. 5-6
Z axis Retract retracts the Z axis to its Park position.

Fig. 5-7
Table Load places the machine tables or gantry into the pre-set load position.

Fig. 5-8 Brushes Up/ Down allows the operator to activate and deactivate the solenoid for the Dust
Brushes on the dust hood.
Fig. 5-9 Message Reset resets the Yellow error messages when displayed in the middle of the Process
Control Screen.
Fig. 5-10
Load (please see Fig. 2-1 of this manual).

Fig. 5-11
Air Blast On activates the Tool Clean air blast of the spindle.

Fig. 5-12
Index Carousel allows the operator to manually rotate the Tool Tray of the machine.

Fig. 5-13
Return brings the operator back to the main Process Control Screen.

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 Section 6 - OSAI Process Controller – MSB Drillhead Set Up Screen

Fig. 6

The Drill Head is a machine purchased option, and is not on all machines. To access it, the operator will press

the button (see Fig. 2-10) then the button (see Fig. 5-1). The screen will change and show an
image of the machine’s head. The image will have a router spindle on the right and a drill head on the left. This
screen allows the operator to manually fire individual or multiple drill spindles. The operator will also be able to

turn the drill head motor on and off. By pressing the button the operator can drop the drill head into down
position, and activate the Drill Head functions. Please see images below.

Fig. 6-1
The operator now has the choice of selecting which drill spindles to call. Numbers
left of the yellow arrow indicates the tool numbers for individual drills. These
numbers will differ with drill head options (e.g. 9 spindle, 13 spindle, & 15 spindle
are common configurations). The green buttons above the number indicate the
spindles are in the up position. By pressing All Drill Heads Down all of the drill
spindle will fire into the down position. All Drill Heads Up will retract them back up
into the block, and the block will still be down. To retract the Drill Head Up the
operator needs to press the button. The screen will return to the image shown
above.

Fig. 6-2 To activate individual drill spindles the operator will press the gray button below the
tool numbers, the spindle will fire down and the button will turn green. All Drill
Heads Up will bring all spindles back up, or the operator can press the button
above the tool number to retract the individual spindle. Note: Only when there is
one or more spindles down can the Drill Motor be turned on. To turn on the
motor, (e.g. to check rotation of the bit) the operator presses the light blue
button then presses it again to shut the motor off. When done with
drill head the operator will first press , then press this will return the
operator to the Tool Set Up Screen (please see page 6).

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 Section 7 - OSAI Operator Panel & Keyboard

Fig. 7

The machine console has an interacting Keyboard and Operator Panel that work together with the WinMedia
screens shown in the previous pages. These components together are the Control Console. This section will
break down each of these components for the console. When using the OSAI Controller, the operator will need
to make sure that the Caps Lock is turned on on the Keyboard.

Fig. 7-1 Fig. 7-2 - Mode Selection

1. Incremental Jog - Jogs a selected axis a designated distance for
incremental movements by pressing the Cycle Start.
2. Manual - Mode selection for manually moving the machine.
3. Single Axis Home - Will home one axis at a time by selecting the axis to
home and then pressing the Cycle Start.
4. Single Block - Allows the operator to Cycle through a program line by line.
5. Auto - Mode selection for running programs.
6. MDI - (Manual Data Input) - Allow operator to manually input G-Codes into
the machine.
NOTE: The operator can tell what mode the machine is in be looking at the Mode
field in the Process Controller screen (see Fig. 1-1).
Fig. 7-2 Fig. 7-3 - Over rides & Cycle Functions
1. Machine Overrides - These dials control the feed & speed overrides for the
machine. By setting the percentage of the programmed rate, the control can
calculate the actual machine rate.
2. Reset - Resets alarm codes, messages, and Part Programs on the display
screen.
3. Cycle (Start) - Executes commands to start a program, initiate machine
movement, and for MDI input data.
4. Cycle Pause (Feed Hold) - Pauses the current program or command that
the machine is running.
The overrides allow the operator to manually control the machine feed and speed rates. By turning the
corresponding dial, these overrides work in conjunction with the PROGRAMMED - PERCENT - ACTUAL
section of the Process Control Screen (please see page 2). The Man Feed, Prog Feed, and Rapid can have
percent rates from 0 to 100%. The Spindle percent rates can go to +/ - 25% of programmed speed.

In example: Programmed Percent Actual or Programmed Percent Actual

Spindle: 18000 125 22500 or 18000 75 13500

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 OSAI Operator Panel & Keyboard (continued)

Fig. 7-3 Fig. 7-4 - Control Power
1. Emergency Stop- Disables the machine’s drives. WARNING: The machine will
still have power in the electrical and control screen functionality.
2. Spindle Load Meter - Monitors the spindle load percentage, this should be
checked frequently by the operator.
3. Computer Power- Supplies the 110 VAC to the computer. Turns on machine
power.
4. Drives On - Enables the machine’s drives once the OSAI Boot Control has
properly booted and machine is not in an Emergency State.
5. Hand Pulse Generator (HPG) - Once the option is selected on the display
screen, this dial is used to move the machine the distance input in the Jog Inc.
field on the Process Control screen.
6. Limit Over Ride - When an Over Travel Switch is activated on any axes, this
allows the operator to “release” the alarm and jog the machine off the switch. The
button needs to be held down in order to activate any axes movement.

Fig. 7-4 Fig. 7-5 - Vacuum Zone Overrides

These switches override the vacuum pressure switches on the machine.
Configuration of the switches is determined by the machine model and
vacuum specifications.

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 Section 8 - C.R. Onsrud OSAI Boot Up Procedure

The Operator is responsible for following proper machine power up and safety steps:

1. Turn on the main power disconnect for the machine. This will be the main three phase supply of power for
the machine.

2. Make sure the machine has proper air pressure at the Main Air Regulator of the machine. The
recommended amount of air supply to the machine is 100 psi (7 bar). If pressure drops below 85 psi the
machine will have a Low Air Pressure alarm message.

3. Check the machine for any tools, debris, and or obstructions blocking any of the axes movements.

4. Turn Computer Power switch to the On position (see Fig. 7-3) - Wait for the computer to Boot.
Fig. 8-1

5. The OSAI Boot Controller window will appear, allow this to boot
completely (see Fig. 8-1).

Fig. 8-2

6. Once the OSAI Boot Controller completely boots, the OSAI

Process Controller will open (see Fig. 8-2). The OSAI Process
Controller will display an error of 001 MACHINE IN E-STOP.

7. Pull the Emergency Stop (see Fig. 7-3) button out. This will complete the emergency circuit allowing the
machine to power up when Drives On (see Fig. 7-3) is pressed.

8. Press the green Drives On button (see Fig. 7-3). The OSAI Process Controller will display a message
Waiting on M/C powering up. Once the machine finishes powering up the screen will display a message
032 AXES NOT REFERENCED.

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 Section 9 – Machine Orientation and Warm Up

After the machine has been powered on, the operator will need to perform two procedures to prepare the
machine for operation. These two procedures must be done with every machine power cycle.

Section 9.1 – Auto Home

The first procedure will needed to be preformed whenever the machine is powered off from the main three
phase power. This procedure is referred to as Homing the machine. Homing the machine orientates the
machine to an Absolute Machine Zero for all axes, also known as Machine Home. Once performed the
machine will then base all of its movements off of this point unless otherwise commanded by the operator.
Step 9.1-1 Fig. 9.1-1
To set the Machine Zero the operator will need to press the Auto Home button from the
OSAI Process Controller screen (see Fig. 2-7 and Fig. 9-1). The machine begins with
Homing the Z axis, once Z axis is homed the machine will then proceed to home the
remaining axes. Standard configurations would be in the following order X, x (U), Y,& P.

Besides setting the Absolute Machine Zero the machine also activates the preset software positive and
negative over travel limits for each axis. This step is very important for machine operation. At power up of the
machine, the OSAI Control has not referenced the physical location of the machine’s axes; therefore the
machine does not know where the physical limits are on the machine base. Any manual or rapid movement on
the machine before Auto Home can allow the machine to run into the physical Over Travel Blocks also called
Hard Stops. It is possible to damage the machine by hitting the Over Travel Blocks.

Section 9.2 – Spindle Bearing Warm Up

This step is very important. The spindle has two sealed Ceramic Bearing sets at the top and bottom of the
spindle. These bearings are sealed with grease that needs to be loosened up to proper viscosity. If not
properly warmed up each morning, the bearings can be prematurely damaged causing the spindle to break
down and result in machine down time. A tool needs to be loaded into the spindle for warm up.

Step 9.2-1 Fig. 9.2-1

To load a tool, the operator will want to select the MDI (Manual Data Input) button (see Fig.
7-1) from the operator panel, and a prompt window will open on the OSAI Process
Controller.

Step 9.2-2 Fig. 9.2-2

In the prompt window the operator will type M6 T1 into
the provided field (provided that there is a tool in
pocket position one on the tool tray), press Enter on
the Keyboard, or Confirm in the prompt window (see
Fig.9.2-2).
Step 9.2-3 Fig. 9.2-3
To execute the command, the operator will need to press the Green Cycle (Start) button
from the Operator Panel (see Fig. 7-2). At this time the machine will proceed to load the
selected tool from the Tool Tray into the router spindle.

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 Section 9 – (continued)
Step 9.2-4 Fig. 9.2-4
The operator will need to position the machine to the
middle of the machine table for safety. While still in the
MDI mode (see Fig. 7-1), the operator will type the
coordinates for the middle of the table (this value is
different depending on machine model). Then press
Enter on the Keyboard of the machine (see Fig. 7).
Step 9.2-5 Fig. 9.2-5
To execute the command the operator will need to press the Green Cycle (Start) button from
the Operator Panel (see Fig. 7-2). At this time the machine will load a tool from the Tool Tray
into the router spindle.

Step 9.2-6 Fig. 9.2-6

With the machine in a safe position and while still in
MDI mode (see Fig. 7-1) the operator will need to start
the router spindle. The operator will type in M3 S9000
into the prompt window and press Enter on the
Keyboard (see Fig. 7).

Step 9.2-7 Fig. 9.2-7

Press the Cycle (Start) button (see Fig. 7-2) on the Operator Panel. Once the
spindle starts, the operator will be able to see the Spindle Load Meter register a
very small percent to confirm spindle starts up (see Fig. 7-4).

The operator should warm-up the spindle for a minimum of 10 minutes every morning. Failure to warm-up the
spindle prior to cutting can damage the spindle bearings resulting in premature failure. NOTE: The operator
must understand that the order of the procedures in this section is important. The machine axes must be
referenced before performing the spindle warm up. It must also be noted that the spindle will not start unless
there is a tool in the spindle. (Additional spindle care information is provided in the spindle manufacturer’s
manual.)
Step 9.2-8 Fig. 9.2-8
After warming up the spindle for 10 minutes the operator can press the Cycle Pause (Feed
Hold) button (see Fig. 7-2) to stop the spindle.

Step 9.2-9 Fig. 9.2-9

The operator can press the Table Load button (see Fig. 2-4) and load the machine with
material for that day’s production run.

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 Section 10 – Machine Manual Mode

After the machine has been Homed, the operator can manually move the machine axes around. There are
three methods that the operator can use to move the machine:

 Manual Jog (see Step 10.1-1) - The selected axis will move while the operator presses and
holds the green Cycle button. Once released the axis will stop moving.

 Incremental Jog (see Step 10.2-1) - In conjunction with Jog Dir (see Fig. 1-6) and Jog Inc. (see Fig.
1-6) when selected the machine will move only the distance equal to the amount indicated in Jog Inc. (see
Fig. 1-6).

 HPG (Hand Pulse Generator) (see Step 10.3-1) - Works in conjunction with the Hand Pulse
Generator (see Fig. 7-4) and Jog Inc. Fig. 1-6). When selected a full revolution of the hand wheel will move
the selected axis the distance equal to the amount indicated in Jog Inc. Fig. 1-6).

Step 10.1-1 Manual Jog Fig. 10.1-1

Select Manual mode (see Fig. 7-1) and the desired axis
from the OSAI Process Controller screen (see Fig. 1-4)
that the operator chooses to move.

Step 10.1-2 Fig. 10.1-2

The operator will need to select the desired positive or negative direction from the
Jog Dir (see Fig. 1-6).
Step 10.1-3 Fig. 10.1-3
The operator will press and hold the Green Cycle button to move the axis and release it to
stop the axis motion. The axis will move as long as the button is pressed.

Step 10.2-1 Incremental Jog Fig. 10.2-1

Select Incremental Jog mode (see Fig. 7-1) and the desired
axis from the OSAI Process Controller screen (see Fig. 1-4)
the operator chooses to move.
Step 10.2-2 Fig. 10.2-2
The operator will need to select the desired positive or negative direction from the
Jog Dir (see Fig. 1-6).

Step 10.2-3 Fig. 10.2-3

The operator will need to select the desired distance the axis will move in the Jog
Inc. field. This value ranges from 0.00001 to 1.00000, most common values are
1.00000, 0.10000, 0.01000, and 0.00100, as is changed by pressing the [ - ]
button or [ + ] button.
Step 10.2-4 Fig. 10.2-4
The operator will press and hold the Green Cycle button; the axis will move the determined
distance in Jog Inc. and then automatically stop. The axis will move as long as the button is
pressed, once released the axis will stop moving.

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 Section 10 – (continued)
Step 10.3-1 HPG (Hand Pulse Generator) Fig. 10.3-1
Select HPG (see Fig. 1-5) and the desired axis
from the OSAI Process Controller screen (see
Fig. 1-4). A yellow message window 092 HPG
ENABLED will appear letting the operator know
that the HPG is activated. To exit the HPG mode
the operator can press the Manual mode button

Step 10.3-2 Fig. 10.3-2

The operator will need to select the desired distance the axis will move in the Jog
Inc. field. This value ranges from 0.00001 to 1.00000, most common values are
1.00000, 0.10000, 0.01000, and 0.00100, as is changed by pressing the [ - ]
button or [ + ] button.
Step 10.3-3 Fig. 10.3-3
The operator will then use the Hand Pulse Generator dial (see Fig. 7-4) to move the
selected axis. One full revolution of the dial will cause the axis to move the distance
indicated in the Jog Inc. field. If the increment was 1.00000 the one revolution equals a
full inch of travel, where as one click would move only 0.01 of an inch.

Step 10.4-1 Single Axis Home Fig.10.4-1

This mode allows the operator to Home one axis of the machine. The operator will select the
Single Axis Home button from the Operator Panel (see Fig. 7-1).

Step 10.4-2 Fig.10.4-2

The operator will need to select the desired axis to home
from the OSAI Process Controller screen.

Step 10.4-3 Fig.10.4-3

The operator will need to press the Green Cycle button (see Fig. 7-2) to execute the Home
sequence. The axis selected will move to its zero position. This process is similar to Auto Home
(see Step 9.1-1) except that only one axis will be moving.

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 Section 11 – Tool Length Offsets

Section 11 – Setting Up Tool Length:
The tool length offset is a variable the machine uses to offset the spindle position, so that the tip of the tool will
position at a predetermined program Z zero position. In combination with the User Origin these values can
offset the machine’s Absolute Zero position to match the program zero position.
This manual will show the operator three methods of entering tool lengths into the machine’s Offset Table.
 First there is Manual Tool Set. (see Steps 11.1)
 Second is measuring the tools “Off Line” with a measuring device. (see Steps 11.2)
 Third is using the Auto Tool Set method (see Steps 11.3) (this method is an option and must be purchased).
Step 11.1-1 - Manual Tool Set – Fig. 11.1-1
Load a tool into the spindle. Go to MDI, type in M6 T# (enter the
desired tool number needing to be entered), press Enter on the
keyboard, and then the Green Cycle (Start) button (see Step
9.2-2 & 9.2-3 for details). This will load the first tool to be
measured into the router spindle. Look in the Active Tool field
on the main Process Controller screen (see Fig. 11.1-1). In
example, 1.1 may be displayed referencing tool tray position 1
and length offset 1.
Step 11.1-2 Fig. 11.1-2
The operator will need to press the Table Set Up button (see Fig. 11.1-2) to access the
vacuum activation. Activating vacuum in Zone 1 (see Section 3 for details), then press
Return.
Step 11.1-3 Fig. 11.1-3
The operator will need to select the
MANUAL mode button (see Fig. 7-1) from
the Operator Panel, and select the X axis
from the OSAI Process Controller screen.
The selected axis, will high light in black (see
Fig. 11.1-3 where Y axis is selected).
Step 11.1-4 Fig. 11.1-4
The operator will need to position the X axis at approximately 6 inches
using the Jog Dir and pressing the green Cycle button (see Steps 10.1-1
to 10.1-3).
Step 11.1-5
The operator will need to repeat Steps 11.1-3 and 11.1-4 to position the Y axis.
Step 11.1-6 Fig. 11.1-6
The operator will need to select the Z axis (see Fig.
1-3) from the OSAI Process Control screen.

Step 11.1-7 Fig. 11.1-7

The operator will need to select the HPG button (see
Fig.1-4) from the OSAI Process Control screen.

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 Section 11 – (continued)
Step 11.1-8 Fig. 11.1-8
The operator then needs to set the Jog Inc. to 1.00000 (or the highest
setting) (see Fig. 1-7) by pressing the [ + ] on the screen.

Step 11.1-9 Fig. 11.1-9

Begin rotating the Hand Pulse Generator in a counter clockwise direction to bring the Z
axis down toward the machine spoil board. When the tip of the tool is approximately ½ to 1
inch above the table stop axis motion, and change the Jog Inc. to 0.10000 by pressing the
[ - ]. Begin bringing the tool tip down closer to the spoil board. At approximately 1/8 to 1/4
of an inch above the spoil board, change the Jog Inc. to 0.01000 and finish bringing the tip
of the tool down until it touches the spoil board top.
NOTE: The above step (11.1-9) is setting the Program Z zero position to the bottom of material. If the
operator desires the Program Z zero to be the Top of material repeat the same steps as above (11.1-8 &
11.1-9), except bring the tip of the tool to the top of the material while it is on the machine table.
WE RECOMMEND SETTING PROGRAM Z ZERO TO THE BOTTOM OF MATERIAL.
Step 11.1-10 Fig. 11.1-10
Once the tip of the tool is on the top of the spoil board the operator will press the Tool
Setup button (see Section 2 – Tool Setup Screen).

Step 11.1-11 Fig. 11.1-11

When inside the Tool Setup screen the operator needs to press the Man. Tool Set
button from the middle of the screen. A prompt window will open called Tool offset prest
– NCxxxxxxxx – Proc. #1 – [INCH] (this may differ due to machine options and model).
Step 11.1-12 Fig. 11.1-12
The operator will need to fill in the required fields with information
so the machine knows where to go to retrieve the information. The
fields are:
 Offset Number: Type the number of the tool that was load into
the spindle (i.e. if Tool 1 was loaded then 1 should be typed).
 Reference Axis: This is the axis that the offset value will be
applied to and should be Z.
 Tool tip position: This field is used in direct relation to the use of
UAO’s (User Absolute Origin’s – see Section 13). If UAO’s are
not used this field is left at 0,0.
Once the operator has filled in these fields press the OK button in the prompt window, or press the Enter
button on the keyboard. This will enter the value into the offset address for that tool, and the operator can look
at the Tool Length field of the Process Controller screen (see Fig. 1-2) to see the value entered. NOTE: The
machine will not move any axes after the value has been entered.
Step 11.1-13 Fig. 11.1-13
The operator will press the Z axis Retract brining the Z axis into its raised position. The
operator will then repeat Steps 11.1-1 to 11.1-13 for all tools needing to be touched off.
This method if used will need to be done if the spoil board is surfaced or if a tool is
changed.

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 Section 11 – (continued)
Step 11.2-1 – Measuring Tool Length Off Line – If the operator chooses Fig. 11.2-1
this method of entering Tool Lengths the operator will also need to work with
the use of UAO’s (User Absolute Origins) (see Section 13).
This method of entering tool length offsets is done with a Digital Bench Top
Tool Setter (see Fig. 11.2-1) that can be purchased by the customer. Turn
power onto the device and bring the indicator to the top face of the base and
press the ZERO/ ABS button to zero out the device. Once zeroed the device
will be ready to use. NOTE: The operator will want to have all router bits,
placed in collets, and locked down in the Tool Holder (see the Maintenance
section of the Owner’s Manual for proper steps in changing and loading tools).
Step 11.2-2 Fig. 11.2-2
Bring the indicator up away from the base of the device ensuring that there is
enough room to place the tool holder under the indicator tip (see Fig. 11.2-2).
Now place the Tool Holder that needs to be measured into the device, and
bring the indicator back down to the tip of the tool. Verify this number by
checking it more then once.
Record this value on a piece of paper and also note in what tool tray pocket
position the tool will be placed. Repeat Steps 11.2-1 and 11.2-2 for all tools
needing to be measured.

Step 11.2-3 Fig. 11.2-3

The operator will select the Utility button (see Fig. 11.2-3) from the bottom right
of OSAI Process Controller screen. When the menu appears select the option
of Table Editor. This will open a new window called OSAI Table Editor (see
Fig. 11.2-4).

Step 11.2-4 Fig. 11.2-4

Once in the OSAI Table Editor window, the operator will select
the Tables button from the bottom of the screen opening a menu.
 Offset
 Origin
 User
 Tools
The operator will select Offset from the menu opening the Offset
Variables Table (see Fig. 11.2-5).

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 Section 11 – (continued)
Step 11.2-5 Fig. 11.2-5
Inside the Offset Variable Table the operator will use the
directional arrow keys on the keyboard to select the desired offset
number. The offset number and the tool pocket number should
match. (i.e. If the operator changes the bit in tool pocket position 1,
then performs Steps 11.2-1 & 11.2-2, the operator (in this screen)
will select Offset 1 to enter the value.)

The measurement recorded in Step 11.2-2 will be entered into the

field labeled Length 1 and press Enter on the keyboard.

NOTE: The operator can also enter any diameter value if Tool
Compensation is used in the programs. The diameter field will
accept positive and negative values.
The operator will need to stay in the OSAI Table Editor screen and repeat Step 11.2-5 for all tool lengths
needed. These values do not need to be changed unless the operator takes the router bit out of the tool holder
and replaces it with a different bit (e.g. a new tool, or a replacement bit).
Step 11.3-1 – Auto Tool Set
NOTE: This method of setting tool length is NOT a standard feature, and would need to be purchased as an
option on your machine. It must also be stated that this method CAN NOT be used with large diameter tools
and profile tools. The large diameter tools and profile tools would need to use the method of measuring tools
offline (see Fig. 11.2-1 to 11.2-5).
Step 11.3-1 Fig. 11.3-1
The operator will begin by removing all Large tools from the Tool Tray. After this is completed
press the Tool Setup button from the OSAI Process Controller screen.

Step 11.3-2 Fig. 11.3-2

The operator will then select the AUTO mode button from the Operator Panel (see Fig. 7-1)

Step 11.3-2 Fig. 11.3-2

From the Tool Setup screen the operator will press the Auto Tool Set which will open a
prompt window on the screen.
Step 11.3-3 Fig. 11.3-3
In the prompt window the operator will be asked to Enter a letter
for what it is to be touched off. The letter O stands for only one
tool and a letter A stands for all tools in the tool tray (large tools
have been removed from the tray).
The operator will type a letter O into the box and then press
Enter on the key board.

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 Section 11 – (continued)
Step 11.3-4 Fig. 11.3-4
The operator will then type the tool number of the tool that
needs to be set. Standard machines will have 8 to 12
positions. In example, the operator will want to type in 2 if
the tool in position 2 needs to be set, and press Enter.

The machine will perform the following actions:

 Rotate the tool tray into position.
 Pick up the desired tool.
 Position itself over the digital touch pad mounted on the machine (note this position is set into the machine
parameters).
 The machine will then position the Z axis to activate the pads sensor.
 Finally raise Z axis to park position and enter value into the tool offset table (see Steps 11.2-3 to 11.2-5).
Step 11.3-5 Fig. 11.3-5
The operator may want to run all the tools in the tool tray with the
Auto Tool Set option. In that case the operator will enter the letter
A into the box mentioned in Step 11.3-3. The operator will then
press Enter on the Keyboard.

The machine will perform the following actions:

 The machine will begin by rotating the tool tray. The machine will use the Tool In Slot sensor to check each
pocket position of the tray sensing whether or not the pocket has a tool in it.
 When the machine finishes a complete rotation of the tray it will load the first Tool into the machine.
 Position itself over the digital touch pad mounted on the machine.
 Touch off the Tool and continue the same steps for each tool sensed in the tray.
NOTE: Tools with a diameter larger then 1 inch or tools with profiles must be removed from the tool
tray before beginning this method of measuring tool lengths! Tools with profiles and diameters larger
then 1 inch will damage the Automatic Tool Touch Off device.

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 Section 12 – Drill Head (MSB) Length Offsets

The MSB or Multi Spindle Block is an option that is purchased and built onto the machine. This section is
for machine’s that have this option. If the operator’s machine does not have a MSB option on the
machine Drill lengths will be measured using one of the methods in Section 11.
Step 12.1 Fig. 12.1
The operator will need to set up the Drill Head tool lengths for
the machine before running jobs. The operator will need to go
to the Drillhead Set Up screen (see Section 6, Fig. 6) and
press the MSB Down button on the screen. This will lower the
drill head into place.

We offer 3 standard configurations of drill heads

9 spindle (all vertical)
13 spindle (all vertical)
15 spindle (11 vertical and 4 horizontal)
Step 12.2 Fig. 12.2
Once the MSB unit is down the operator will fire all the
spindles down in the drill block by pressing the All Drill
Heads Down button on the screen. All the drill spindles in the
head will fire. All drills will be measured at the same time
using the same tool length.

We recommend using standard line boring drills of a 70 mm

length and a shank diameter of 10mm.
Step 12.3 Fig. 12.3
With all of the drill spindles in the down position the MSB unit
is ready to have the offset lengths set by the operator. The
operator will need to activate vacuum on the table.

The operator will go to the Table Set Up screen

and turn On vacuum to Zone 1, and then press Return.

Step 12.4 Fig. 12.4

The operator will now select the MANUAL
mode button (see Fig. 7-1) from the Operator
Panel, and then select the X axis from the
OSAI Process Controller screen. The
selected axis, will high light in black (see Fig.
12.4 where Y axis is selected).
Step 12.5 Fig. 12.5
The operator will need to position the X axis at approximately 6 inches
using the Jog Dir and pressing the green Cycle button (see Steps 10.1-1
to 10.1-3).

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 Section 12 – (continued)
Step 12.6
The operator will need to repeat Steps 12.5 and 12.5 to position the Y axis. The operator needs to make sure his
MSB head is entirely over the spoil board of the table.
Step 12.7 Fig. 12.7
The operator now needs to select the Z axis (see Fig.
1-3) from the OSAI Process Control screen.

Step 12.8 Fig. 12.8

The operator will select the HPG button (see
Fig.1-4) from the OSAI Process Control screen.
Step 12.9 Fig. 12.9
The operator then set the Jog Inc. to 1.00000 (or the highest setting)
(see Fig. 1-7) by pressing the [ + ] on the screen.

Step 12.10 Fig. 12.10

Begin rotating the Hand Pulse Generator in a counter clockwise direction to bring the Z
axis down toward the machine spoil board. When the tip of the drills are approximately ½
to 1 inch above the table stop axis motion, and change the Jog Inc. to 0.10000 by
pressing the [ - ]. Begin bringing the drills down closer to the spoil board. At approximately
1/8 to 1/4 of an inch above the spoil board, change the Jog Inc. to 0.01000 and finish
brining the drills down until the tips touch the spoil board top.
NOTE: The above step (12.10) is setting the Program Z zero position to the bottom of material. If the
operator desires the Program Z zero to be the Top of material repeat the same steps as above (12.1 to
12.10), except bring the tip of the drill to the top of the material while it is on the machine table.
WE RECOMMEND SETTING PROGRAM Z ZERO TO THE BOTTOM OF MATERIAL.
Step 12.12 Fig. 12.12
When inside the Drillhead Set Up screen the operator needs to press the Man.
Tool Set button from the middle of the screen. A prompt window will open called
Tool offset prest – NCxxxxxxxx – Proc. #1 – [INCH] (this may differ due to
machine options and model).
Step 12.13 Fig. 12.13
The operator will need to fill in the required fields with information so
the controller knows where to go to retrieve the information. The fields
are:
 Offset Number: The operator will type in the number of the
intersecting bit 36 into this field. All the drills will look to this offset
number for tool length.
 Reference Axis: This is the axis that the offset value will be applied
to and should be Z.
 Tool tip position: This field is used in direct relation to the use of
UAO’s (User Absolute Origin’s – see Section 13). If UAO’s are used
the value entered into Axis 3(Z) of the origin is the same value
entered in Tool Tip Position. If UAO’s are not used this field is left at
0.0. The operator will then press the OK button.

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 Section 12 – Drill Head (MSB) Length Offsets

Step 12.14 Fig. 12.14
Once the length has been set the operator will need to retract the drills and the MSB
unit. From the Drillhead Set Up screen the operator will press the All Drill Heads Up

button from the screen.

Step 12.15 Fig. 12.15

After the drill heads are retracted the operator will now press the MSB Up Button
from the screen. Retracting the entire unit to its parked position. Then press the
Drillhead Set Up button to return to the Tool Setup screen.

Step 12.16 Fig. 12.16

From the Tool Setup screen the operator will need to press Z axis Retract button to retract Z
to its park position.

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 Section 13 – Origins & UAO’s (User Absolute Origins)

In this section the operator will learn about the use of Origins in the OSAI Control. An Origin is a variable used
by the control system to “shift” one or more of the machine’s axes from a known position. This shift can be
done as an Incremental move or as an Absolute move. In this manual we will discuss the use of User
Absolute Origins or also known as UAO’s, and how they are used to “shift” the machine’s Absolute Zero
position to match the Program Zero position. There is a table with ten absolute origins the programmer or
operator can use in the program.

To use the UAO’s (User Absolute Origins) there are two criteria:

1.) The G-Code program to be run must have a line of code that calls out the use of an Origin and which
Origin to be use. The value is 1-10, and must be in the following format – (UAO,x) (note: x represents a
value of 1-10).
2.) The operator must set up and enter the values to be use by the origin. These values are entered at the
machine. Step 13.2 will show the operator how to get to the tables.
Steps 13.1 will give an example of how and where the origin is called in the program. Steps 13.2 will show the
operator how to access the Origin Table and enter the values.

NOTE:
As a CNC manufacturer we will not discriminate as to what CAD/ CAM software a customer uses with our
machine. We will work with any software company to assist them in creating proper code for our machine to
run. The examples given in this step are from the software that we distribute and support.
Step 13.1-1 Fig. 13.1-1
To the right is some example G - Code showing the ;FILENAME EXAMPLE
beginning of a program. Highlighted in red shows how ;MACHINE CONFIGURATION = 0, 0, 148., 1, 1, 0, 1, 0, 0, 1
;(ESTIMATED CYCLE TIME = 0MINS 14SECS)
the UAO is called out before the machine performs a G70
tool change. When the machine reads this line of code G27
it will go look at the value(s) inside the Origin Table G90
number 1. This is a very common UAO call for nested G80
base processing. G40
MOV= 72
VFF= 1
FCT=.0001
Note: Please see Section 15 for an over view G00 G79 Z(@ZPARKP1)
explanation of basic G – Code. (UAO,1)
;OPERATION CHANGE
M06 T1
Step 13.1-2 Fig. 13.1-2
To the right is more example of G - Code showing the ; EXAMPLE2
beginning of a program. Like the example above the ;*** TOOL LIST ***
; TOOL - 01 DIA. - .5 T1 -
UAO call is highlighted in red. When the machine ;*****************
reads this line of code it will activate the value(s) N5 MOV=72
inside the Origin Table number 2. N10 VFF=1
N15 FCT=.00001
Note: Please see Section 15 for an over view N20 G00 G79 Z(@ZPARKP1)
explanation of basic G – Code. N25 (UAO,2)
;( TOOL - 01 )
N30 M06 T1

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 Section 13 – (continued)
Step 13.2-1 Fig. 13.2-1
The operator will need to access the machine’s origin tables in order to enter the desired
values to be used. From the main OSAI Process Controller, the operator will press the
Utility button in the bottom left corner. From the menu that appears, select Table Editor
(see Fig. 13.2-1), this will open the OSAI Table Editor window.

Step 13.2-2 Fig. 13.2-2

From the bottom of the OSAI Table Editor the operator will need to select
the Tables button (Fig. 13.2-2) to open the menu. From this menu the
operator will select Origin. This will open the Origin Table which is where
the operator will enter his values.

Step 13.2-3 Fig. 13.2-3

With the Origin Table open the operator will use the directional arrow keys
on the Keyboard to highlight the desired table number. In the image to the
right (see Fig. 13.2-3), Origin Table 1 is highlighted. By pressing the Enter
button on the keyboard, the operator will be able to access the table to enter
new values.

Step 13.2-4 Fig. 13.2-4

The operator will enter the desired values into the corresponding axes. In this
example we will be shifting the X axis .5 inches, Y axis .5 inches, and the Z
axis .73 inches. Once the values are entered and verified the operator will
press OK, and see the values in the Origin Table under table 1.

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 Section 13 – (continued)
Step 13.2-5 Fig. 13.2-5
Using the directional arrows, the operator will select the next Origin that needs
to be set up. The operator will repeat Steps 13.2-3 to 13.2-4 for all desired
origins as needed. Fig. 13.2-5 shows origins 1 and 2 with values.

To review this section, in Steps 13.1-1 in the program EXAMPLE the program calls out the use of (UAO,1). In
Steps13.2-1 to 13.2-4 the operator entered the desired values into Origin 1 to shift the machine. When the
program executes the UAO call in the program the control will look at the values in Origin and shift the Machine
Absolute Zero by the amounts designated in the table. The program will believe it is running at X0, Y0, and Z0,
but physically the machine will be running it at X0.5, Y0.5, and Z0.73. This is referred to as an Origin Shift or
Work Shift.
 Section 14.1 – Part Program Management
Once the CAD/ CAM software has produced the G – Code program to be run on the machine, the operator will
need to load that program into the UPP Directory (User Part Program Directory). The operator will have two
different ways in which program(s) can be loaded into the UPP Directory.

1.) Connect the machine to the network of the company and create a shared folder in which to place the
program into, so that the operator can access them from the OSAI Operator console.
2.) Place the program(s) onto a USB memory device, then bring the device to the machine and copy the
program into the OSAI Operator Console.

This manual will instruct the operator how to load the programs into the UPP Directory and then call them up to
be run. The instructions will be for the loading of programs off of a USB Memory Device into the UPP.
Step 14.1-1 Fig. 14.1-1
The operator will plug the USB Memory Device into the OSAI WinMedia Panel (the
port is labeled on the right side of the screen) and the Windows operating system
should Auto Play the device opening a prompt window. The operator will select the
option Open folder to view files using Windows Explorer (see Fig. 14.1) from the
screen.

Step 14.1-2 Fig. 14.1-2

The operator will see the prompt window for the device appear. Inside the
window will be a list of jobs that need to be run. The operator will need to
select the job(s) to run on the machine. If this method is used, it is
recommended to keep the Memory Device clean to avoid confusion in
choosing the job to be run.

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 Section 14.1 – (continued)

Step 14.1-3 Fig. 14.1-3
The operator will need to select all the jobs to be run. To do this the
operator will press Ctrl & A to highlight all the jobs blue (see Fig 14.3).

Step 14.1-4 Fig. 14.1-4

The operator will need to cut the jobs off the USB Memory Device by
pressing Ctrl & X on the keyboard (see Fig. 14.4).

Step 14.1-5 Fig. 14.1-5

The operator will click on the Start button (at the bottom left of screen) then select
the My Computer icon from the list on the right. The My Computer window will
open (see Fig. 14.5).

Step 14.1-6 Fig. 14.1-6

The operator will need to open the UPP Drive that should appear in the My
Computer window. This drive should be mapped out, in the example shown the
designation is Upp on ‘NC14580101’ (Z:). The operator will double click on the Upp
icon in order to gain access to the UPP folder.

Step 14.1-7 Fig. 14.1-7

The operator will then select the UPP Folder and double click it to open the folder.
This gives the operator access to the storage area for the part programs (jobs) to
be run.

Step 14.1-8 Fig. 14.1-8

The UPP Directory will open. The operator will press Ctrl & V this will paste the
programs in the UPP. The operator will see the new programs highlighted in the
screen. This is the storage area that the operator will store the programs in. The
operator can create sub directory folders inside the UPP to help organize the UPP
directory. The programs stored in this area can have one of three extensions those
extensions are:
.txt
.nc
.anc
NOTE: The operator can close the windows discussed in the previous steps (see Steps 14.1 to 14.8)
and Maximize the OSAI Process Controller.

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 Section 14.2 – Activation and Running Part Programs

Step 14.2-1 Fig. 14.2-1
With the OSAI Process Controller open, the operator will need to access the part
programs. Press the Part Program button and from the menu, the
operator will want to select Part Program Management. If the operator is finished
running a program, select Deactivate Part Program and the active program will
disengage.

Step 14.2-2 Fig. 14.2-2

The Part Program Management prompt window will open. The operator
will want to select the desired program to run. The program will highlight
as in Fig. 14.2-2 showing that the program EXAMPLE.ANC is the
selected program. The operator has some functionality in this window; for
example, one can rename a desired program, delete a previously run
program, deactivate an active program, and so on. Outside of activation
and deactivation of a program, all functionality is a form of editing the
existing programs or directory.
Step 14.2-3 Fig. 14.2-3
Once the desired program is selected, the operator will need to activate
the program in order to run it on the machine. The operator achieves this
by pressing the Activate button on the side of the Part Program
Management window. The operator will see the program code appear in
the bottom left of the OSAI Process Control Screen under PROGRAM
MESSAGE. Once activated, the operator needs to press the Exit button
to close the Part Program Management window.
Step 14.2-4 Fig. 14.2-4
The program is activated and can be run. The operator will need to put
the machine in Auto mode, make sure the work area is clear of debris
and personnel, turn on dust collection, apply vacuum to the table, and
check to make sure the proper Z shift is entered (if a Dry Run is used) in
order to cycle the program.
NOTE: For operator’s whom are not familiar with running and programming a CNC
router we recommend that the operator “Dry Runs” the program at the beginning to
become comfortable and familiarize themselves with the CNC machine and it
motions.
NOTE: Prior to running a job the operator will want to ensure all variables are entered into the control
and that all safety measures are taken. Below are 7 steps that the operator can take to ensure prior
running:
1.) Tool Length: Ensure tool lengths are correct and entered into the control
2.) Origins: Ensure that Origin (Fixture Offsets) are correct for the program being run
3.) Z Shift: Ensure that the proper Z Shift (Material Offset) is set for a Dry Run or set to Zero for
actually cutting material
4.) Program: Check and ensure that the program is loaded in the control and Activated to run
5.) Overrides: Ensure that all the overrides are in the correct position for running the program
6.) Vacuum: Ensure vacuum is on and applied to the work piece and overrides are in correct safety
position
7.) Dust Collection: Ensure Dust Collector is on and blast gates are open

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 Section 14.3 – Program Dry Run

Step 14.3-1 Fig. 14.3-1
To “Dry Run” or to run the program in the air, the operator will need to set the Z
axis Shift. Press the Set Z Shift on the screen.

Step 14.3-2 Fig. 14.3-2

The Z axis Material Offset window will open. The operator will enter the
“shift” needed into the Enter Z value on the screen. This shift value will
change based on the material thickness being run. The shift is based off of
the Z axis final depth in the part program. This value should be larger then
the material thickness.

Step 14.3-2
In example, if the material to be cut is 1 inch thick, then the Z shift value should be 1.25 inches or greater.
When the program runs, the tip of the tool will be .25 inches off the top of the material. Once the “Dry Run” is
completed (it is recommended to run through all tool changes in the program) the operator will need to change
the Z Shift back to 0.0 (zero) in order for the tool to cut the material.

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 Section 15.1 – General NC Code explanations

G-Code FUNCTION M-Code FUNCTION
G00 Machine Rapid Move M00 Program stop/ Pause
G01 Program Feed Move M01 Program stop optional
G02 Clockwise Interpolation of an arc M02 End of Program
G03 Counter clockwise Interpolation of an arc M03 Spindle Rotation CW
G16 Free Interpolation Plane Selection (used for M04 Spindle Rotation CCW
interpolation of slave axis)
G17 XY Interpolation Plane M05 Spindle Stop
G40 Cancel cutter compensation M06 Tool change/Offset Activation
G41 Enable cutter comp. on the left side of M30 End of Program, reset and rewind
geometry
G42 Enable cutter comp. on the right side of M98 Brushes Down
geometry
G70 Inch units M99 Brushes Up
G71 Metric units
G79 Absolute (in ref. to home position)
G90 Absolute (in ref. to current origin)
G91 Incremental (in ref. to previous move)
 Section 15.2 – Onsrud Specific NC Code explanations
Specific FUNCTION Specific FUNCTION
G-Code G-Code
G200 Automatic Vacuum On & Pop-Up Down by G331 Enables the X axis in Process 2 when launched
Table by Process 1
G201 Automatic Vacuum Off & Pop-Up Up by G350 Enables U axis in Process 1 and Releases X axis
Table in process 2
G300 Disable the X axis in Process 1 G351 Enables U axis in Process 2 and Releases X axis
in process 1
G301 Enables the X axis in Process 1 G352 Process 1 puts all axes back to normal
G302 Enables Process 2 X axis in Process 1 and G353 Process 2 puts all axes back to normal
calls it U
G310 Disable the X axis in Process 1 when G500 Motion Filtering Macro
launched by Process 2
G311 Enables the X axis in Process 1 when G600 Tool Change Routine for Multi-Spindle m/c
launched by Process 2
G320 Disable the X axis in Process 2 G699 Resets the retractable Probe (Probe retracts then
Z retracts)
G321 Enable the X axis in Process 2 G700 Work surface probing routine (Modal), collected
values are stored in E101 to E199
G322 Enables Process 1 X axis in Process 2 and G999 Cancel G700 to G998 Macro’s
calls it U
G330 Disable the X axis in Process 2 when
launched by Process 1

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 Section 15.2 – (continued)

Specific M- FUNCTION Specific M- FUNCTION
Codes Codes
M18 Tool Clamp w/o Tool (Single spindle) M130 All Vacuum Zones on
M20 Tool Clamp (Single spindle) M131 Vacuum Zone 1 on
M21 Tool Release (Single spindle) M132 Vacuum Zone 2 on
M22 Cone Air On (Single spindle) M133 Vacuum Zone 3 on
M23 Cone Air Off (Single spindle) M134 Vacuum Zone 4 on
M24 Head Up (Single spindle) M135 Vacuum Zone 5 on
M25 Head Down (Single spindle) M136 Vacuum Zone 6 on
M34 Pull Spindle from Process 2 into Process 1 M137 Vacuum Zone 7 on
Release spindle from Process 1 back to
M35 Process 2 M138 Vacuum Zone 8 on
M66 Tool in Spindle Preset M139 Vacuum Zone 9 on
M70 Raise All Vacuum Pods M140 All Vacuum Zones off
M71 Raise Vacuum Pod 1 M141 Vacuum Zone 1 off
M72 Raise Vacuum Pod 2 M142 Vacuum Zone 2 off
M73 Raise Vacuum Pod 3 M143 Vacuum Zone 3 off
M74 Raise Vacuum Pod 4 M144 Vacuum Zone 4 off
M75 Raise Vacuum Pod 5 M145 Vacuum Zone 5 off
M76 Raise Vacuum Pod 6 M146 Vacuum Zone 6 off
M77 Raise Vacuum Pod 7 M147 Vacuum Zone 7 off
M78 Raise Vacuum Pod 8 M148 Vacuum Zone 8 off
M79 Raise Vacuum Pod 9 M149 Vacuum Zone 9 off
M80 Lower All Vacuum Pods M154 Request RESET mode
M81 Lower Vacuum Pod 1 M155 Request FOLLOW mode
M82 Lower Vacuum Pod 2 M156 Request TORQUE mode
M83 Lower Vacuum Pod 3 M157 Request HOLD mode
M84 Lower Vacuum Pod 4 M158 Change OS3 max. current
M85 Lower Vacuum Pod 5 M159 Restore OS3 max. current
M86 Lower Vacuum Pod 6 M200 All Heads Up
M87 Lower Vacuum Pod 7 M201 Head 1 Up
M88 Lower Vacuum Pod 8 M202 Head 2 Up
M89 Lower Vacuum Pod 9 M203 Head 3 Up
M90 Raise Moveable Probe M204 Head 4 Up
M91 Lower Moveable Probe M205 Head 5 Up
M100 Dual Process Slaving Enable M206 Head 6 Up
M101 Dual Process Slaving Disable M207 Head 7 Up
M110 All Roller Clamp Zones enabled M208 Head 8 Up
M111 All Roller Clamp Zones disabled

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 Section 15.2 – (continued)

Specific M- FUNCTION Specific M- FUNCTION

Codes Codes
M210 All Heads Down M300 All Tools Clamp
M211 Head 1 Down M301 Head 1 Tool Clamp
M212 Head 2 Down M302 Head 2 Tool Clamp
M213 Head 3 Down M303 Head 3 Tool Clamp
M214 Head 4 Down M304 Head 4 Tool Clamp
M215 Head 5 Down M305 Head 5 Tool Clamp
M216 Head 6 Down M306 Head 6 Tool Clamp
M217 Head 7 Down M307 Head 7 Tool Clamp
M218 Head 8 Down M308 Head 8 Tool Clamp
M220 All Brushes Up M310 All Tools Release
M221 Head 1 Brushes Up M311 Head 1 Tool Release
M222 Head 2 Brushes Up M312 Head 2 Tool Release
M223 Head 3 Brushes Up M313 Head 3 Tool Release
M224 Head 4 Brushes Up M314 Head 4 Tool Release
M225 Head 5 Brushes Up M315 Head 5 Tool Release
M226 Head 6 Brushes Up M316 Head 6 Tool Release
M227 Head 7 Brushes Up M317 Head 7 Tool Release
M228 Head 8 Brushes Up M318 Head 8 Tool Release
M230 All Brushes Down M320 All Cone Air on
M231 Head 1 Brushes Down M321 Head 1 Cone Air On
M232 Head 2 Brushes Down M322 Head 2 Cone Air On
M233 Head 3 Brushes Down M323 Head 3 Cone Air On
M234 Head 4 Brushes Down M324 Head 4 Cone Air On
M235 Head 5 Brushes Down M325 Head 5 Cone Air On
M236 Head 6 Brushes Down M326 Head 6 Cone Air On
M237 Head 7 Brushes Down M327 Head 7 Cone Air On
M238 Head 8 Brushes Down M328 Head 8 Cone Air On
M240 Open Tool Rack Cover / Tray #1 Out M330 All Cone Air off
M241 Close Tool Rack Cover / Tray #1 In M331 Head 1 Cone Air Off
M242 Tray #1 Down M332 Head 2 Cone Air Off
M243 Tray #1 Up M333 Head 3 Cone Air Off
M250 Tray #2 Out M334 Head 4 Cone Air Off
M251 Tray #2 In M335 Head 5 Cone Air Off
M252 Tray #2 Down M336 Head 6 Cone Air Off
M253 Tray #2 Up M337 Head 7 Cone Air Off
M290 Enable X axis +ve s/w limit M338 Head 8 Cone Air Off
M291 Disable X axis +ve s/w limit

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 Section 15.2 – (continued)

Specific M- FUNCTION
Codes
M340 Raise All Vacuum Pop-ups
M341 Raise Vacuum Pop-up 1
M342 Raise Vacuum Pop-up 2
M343 Raise Vacuum Pop-up 3
M344 Raise Vacuum Pop-up 4
M345 Raise Vacuum Pop-up 5
M346 Raise Vacuum Pop-up 6
M347 Raise Vacuum Pop-up 7
M348 Raise Vacuum Pop-up 8
M349 Raise Vacuum Pop-up 9
M350 Raise Vacuum Pop-up 10
M351 Raise Vacuum Pop-up 11
M352 Raise Vacuum Pop-up 12
M353 Raise Vacuum Pop-up 13
M354 Raise Vacuum Pop-up 14
M355 Raise Vacuum Pop-up 15
M356 Raise Vacuum Pop-up 16
M360 Lower All Vacuum Pop-ups
M361 Lower Vacuum Pop-up 1
M362 Lower Vacuum Pop-up 2
M363 Lower Vacuum Pop-up 3
M364 Lower Vacuum Pop-up 4
M365 Lower Vacuum Pop-up 5
M366 Lower Vacuum Pop-up 6
M367 Lower Vacuum Pop-up 7
M368 Lower Vacuum Pop-up 8
M369 Lower Vacuum Pop-up 9
M370 Lower Vacuum Pop-up 10
M371 Lower Vacuum Pop-up 11
M372 Lower Vacuum Pop-up 12
M373 Lower Vacuum Pop-up 13
M374 Lower Vacuum Pop-up 14
M375 Lower Vacuum Pop-up 15
M376 Lower Vacuum Pop-up 16

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 Section 16 – EE Fault Codes for C.R. Onsrud OSAI Control

EMERGENCY MESSAGES (User Manual, DAC DAM Sercos Manual)

Code Message Description Remedial action

Positioning or following error

greater than the configured
EE001 Servo error axis Exit with reset.
value. Non-locking error
(ERRO status).

Split axes positioning or

following error greater than the
EE002 Skew Error Axis Exit with reset.
configured value. Non-locking
error (ERRO status).

Erroneous encoder
Encoder phase
EE003 configuration. Non-locking Exit with reset.
error
error (ERRO status).
The axis is out of tolerance after
Timeout tolerance
EE004 the specified time. Non-locking Exit with reset.
error
error (ERRO status).
The axis is out of tolerance.
Inpos tolerance
EE005 Non-locking error (ERRO Exit with reset.
error
status).
Broken wire detected in the
Broken wire
EE006 transducerr cable. Locking error Switch off the system.
detection
(EMERG status).

The axes boards have not been

EE007 Watch dog axis refreshed in the specified time. Switch off the system.
Locking error (EMERG status).
Calculation error (division by
Divide by zero
EE008 zero). Locking error (EMERG Switch off the system.
axis
status).
Invalid command Request not valid for this board.
EE009 Switch off the system.
axes Locking error (EMERG status).

Coprocessor error. Locking

EE010 Escape found axis Switch off the system.
error (EMERG status).

This emergency is given by the

Software
axis board when the axis Jog the axis in the
EE011 overtravel limit
reaches the software travel limit. opposite direction.
with HPG
Non-locking error.

The axis board generates this

HPG software message to indicate that the axis
EE012
overtravel exit has returned within the software
travel limit.

CANOpen I/O devices have not

WatchDog - CAN beenrefreshed within the
EE013 Switch off the system
I/O module allotted time. Lockingerror
(EMERG status)
CAN
Transmission or reception error Check connections and
EE014 communication
hasoccurred on CAN Open bus turn off the system
error
FastWire I/O devices have not
WatchDog -
been refreshed within the
EE015 FastWire I/O Switch off the system
allotted time. Lockingerror
module
(EMERG status)

Page 33 of 42
 www.cronsrud.com

Transmission or reception error

on the FastWire bus. The field
DEVICE indicates the node (*)
causing the error. The field
ERROR provides further
FastWire Check the bus
information useful for
EE016 communication connections and the
debugging and is of no
error termination.
importance to the end user.
(*) ‘node’ means any device
which can be connected to the
FastWire (e.g. drives, bridges,
I/Os, etc.).

Exit with reset.

Plus shutdown Machine shutdown request. Note: Not displayed as
EE020
request Non-locking error (ERRO). filtered from human
interface.
The logic board has not
responded within the hardware-
EE021 Plus watch dog Switch off the system.
set interval. Locking error
(EMERG status).
The logic task has divided by
Plus divide by
EE022 zero. Locking error (EMERG Switch off the system.
zero
status).
Request not allowed to the logic
Plus invalid op-
EE023 task. Locking error (EMERG Switch off the system.
code
status).

Plus I/O ring I/O ring failure. Locking error

EE024 Switch off the system.
failure (EMERG status).
Plus coprocessor
exception WinPlus/Coprocessor error in
EE025 or the logic task. Locking error Switch off the system.
WinPlus (EMERG status).
Exception
The logic task has not been
Plus realtime task assigned a sampling time
EE026 Switch off the system.
overrun interval. Locking error
(EMERG status).

This emergency is generated by

Axis hw the user logic when the axis 1) Exit with reset.
EE027 overtravel limit reaches the hardware overtravel 2)Jog the axis within
reached microswitch. Non-locking error the limits.
(ERRO).

This message is generated by

Exit over travel the logic task to indicate that
EE028 Note: It is a warning.
hardware the axis has returned within the
hardware overtravel limits..

Too many no wait

The logic has sent too many no Contact the Technical
EE029 requests from
wait requests. Assistance service
Logic
The system cannot interpret the
EE030 Ghost interrupt interruption. It is a locking error Switch off the system.
(EMERG status).

General front panel failure:

Front Panel watchdog, coprocessore, parity
EE031 Switch off the system.
anomaly error, etc. Locking error
(EMERG status).

This message indicates that a

Contact the Technical
EE032 False interrupt false interrupt has been
Assistance service.
detected.

Page 34 of 42
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An anomaly has been detected

Unrecoverable
during data
EE033 Remote I/O Switch-off the system.
reception/transmission on I/O
Failure
Ring.
Recoverable An anomaly has been detected Try to remove the
EE034 Remote I/O during data anomaly cause and
Failure reception/transmission on RIO. reset the system.
EE46 Bit Description - Error code in S129
SERCOS DRIVE ERRORS EE47 Bit Description
IDN

0203, 0206,xxxx.
Indicates one or more of the
following errors:
Power supply error (PSU)
Code Message Description Remedial action 15 15 Parameter 495 Bit 15
Blocked motor
EEPROM error
Op System Error
Drive Error

Over signal An excessive distorsion of the

Switch off and then on
EE040 distorsion on optical fiber signal has been 14 14
again.
optical fibre detected.
The optical fiber signal has been
Interrupt
interrupted. Check the optical Switch off and then on
EE041 trasmission on 13 13
fiber cable and all the again.
optical fibre
connections.
Switch off and on
again; if the anomaly
AT Telegram Data loop communication with
EE042 persists, contact the 12 12
missing D.S.I. driver missing.
Technical Assistance
service.
D.S.I.
Contact the Technical 0601,0602
EE043 Initialization Error during initialisation phase. 11 11
Assistance service. Excessive position Error
phase error
Anomaly when sending
Anomaly on
EE044 commands from Master to System reset. 10 10
service channel
D.S.I. driver.
Anomaly on Reset the system and
Anomaly during command
EE045 D.S.I.command remove the cause of 9 9
execution.
execution the error.

0201,0205
Drive shut down: Error coming from "class 1 See the D.S.I. drive
EE046 8 Bus Overvoltage, or Power group 8
class 1 diagnostic diagnostic" drive. documentation.
overtemperature

Shut down Anomaly signal non-locking

See the D.S.I. drive 0202
EE047 warning: class 2 coming from D.S.I. "class 2 7 7
documentation. Overcurrent
diagnostic diagnostic" driver.
Switch off the system
D.S.I. Fault:
Locking error, when handling and contact the 0207 > 020D
EE048 anomaly during 6 6
an anomaly caused by the drive. Technical Assistance Power Transistor Error
anomaly
service.

The request to enable an axis

reaches the system while it is
already performing the
Axis enable calculations for the movement 0300>0304,0800>0808,0A00>0A08
Eliminate the error by
EE049 request not of the axis that has not yet been 5 Error in encoder 1 (X24) and/or 5
executing a Reset
allowed enabled (e.g. the request to Encoder 2 (X25)
enable the axis by PLUS arrives
after "consent for the
movement")

0204
4 4
Interference on the 24v PSU

Page 35 of 42

MECHATROLINK ANOMALIES
EE050 Axis board Mechatrolink axis board not
memory failure detected by hardware
diagnostics at CNC power up,or
board failure.
EE052 Communication Communications with the drive
error have been broken off. If the
ALARM code is ‘FFFF’ a
synchronisation error has
occurred, otherwise it is a drive
related error (see drive
documentation)
EE053 Drive alarm The drive has notified an error.
For the ALARM codes, see the
drive documentation.
EE054 Command The drive failed to perform or
timeout accept a command within the
maximum allotted time (five
seconds). The value of the
ALARM code is not significant.
Fastwire
Axes Board At start-up the CNC hardware
EE055 Memory Test diagnostics found that the
Failed OS8531 axes board was faulty.
At start-up the CNC did not find
a drive under the address
Drive/Bridge not
EE056 configured in AMP for the
Connected Axis n
indicated axis on the FastWire
bus.
Drive Command Error while executing a
EE057 Error Axis n command during the operation
Error:eeee phase.
Code eeee Description
1000 invalid axis ID
1001 Timeout on a command issue
1002 communication channel
engaged
1003 axis inhibited because of severe
error
www.cronsrud.com
3 3
0501 Parameter 151 bit 7 Motor
2 2
Motor overtemperature overtemperature
Parameter 115 bit 6 Power
1 1 supply temperature >80
deg.
Parameter 93 bit 4 Sftware
0401
protecion: motor
0 Software motor temperature 0
temperature > alarm level
protection
(P088)
Check drive addresses
for axis
characterisation in
AMP.As an
alternative, fit a new
board.
Check drive integrity
and parameters. Check
Mechatrolink
communication wiring
harness and the
communication cable
termination (plug).
Check drive
parameters and, if it is
a dynamics problem,
extend check to AMP
dynamic parameters.
Eliminate drive alarm
cause and RESET
system.
Check drive integrity
and parameters. If the
anomaly persists,
contact the Technical
Service.
Replace the board.
check if the address on
the drive corresponds
to the one configured
in AMP; check the
cable connections.
2 (Drive Off), 3 (Drive
On), 4 (Hold)
Possible causes
internal CNC error
drive does not respond
internal CNC error
The axis has been
inhibited earlier
because of a severe
error
Page 36 of 42
 www.cronsrud.com

1004 non digital axis attempt to work with

an analog axis

1005 invalid request application error

1006 invalid command Internal CNC error

2002 command failed Internal CNC error

2003 invalid drive ID Internal CNC error

2004 Drive engaged Internal CNC error

2005 invalid request Internal CNC error or

application error

2007 wrong monitoring data CNC or drive error

during monitoring

2101 command cannot be executed illegal operation

2102 monitoring table overflow request to monitor

more than 16 variables

2103 Monitoring already active Monitoring already

active
2104 No variable to be monitored No variable to be
monitored
2105 error during transmission Malfunctioning on the
internal serial port

2106 timeout error in transmission Malfunctioning on the

internal serial port

2107 timeout error in reception Malfunctioning on the

internal serial port

2108 checksum error Malfunctioning on the

internal serial port

2109 echoing error Malfunctioning on the

internal serial port

2110 Hyperface error Malfunctioning on the

encoder serial port

2111 feedback table overflow too many feedback

variables
2112 wrong variable ID non existing variable

2113 parameter table overflow too many parameters

selected for the
command
2114 wrong parameter ID non existing parameter

2115 Inconsistent Dry state parameter

write

2116 invalid memory address

2117 inconsistent data in sequencer

2118 inconsistent power board size

data

2119 Point2Point command not

available
2120 offset identification not
available
2121 synchronisation timeout on
ROTC
2122 wrong FPGA register ID reprogram FPGA

2123 location number overflow

Page 37 of 42
 www.cronsrud.com

2124 Qep counter release timeout DSP malfunction

2125 external Qep TD counter release DSP malfunction

timeout

2126 no encoder interface connected

2127 power error power board

malfunction
EE058 Drive Alarm Axis Drive alarm during operation. Eliminate the cause
X and Reset
Alarm:aa
Alarm: aa Description Possible causes Type
of Recommended action
stop
30 (Models B & Brake resistor circuit faulty brake resistor Check the resistance of the brake
C only) malfunction either too low or short IGBT
jumper or check the earth
circuit, Open
connections.
31 DSP Watchdog Firmware version IGBT
Reload drive firmware
error. Open
32 NMI triggered Firmware version IGBT
Reload drive firmware
error. Open
33 24V power supply fault faulty drive

34 Initial position error. Motor moving, from

SYNCHS error (QeP and external causes, during IGBT
Cycle the power
SinCos not congruent). the initialization phase. Open
.
40 Drive overheat duty cycle too heavy,
Ramp Reduce the acceleration or cool the
Cycle is using too
Down heat sink.
much current.
41 Motor overheat or thermal duty cycle too heavy or RAMP DOWN The drive
protection fault thermal sensor not continues to check the
connected, or sensor movement of the motor,
not cooled after high and it decelerates
temperature rise. Ramp Reduce the acceleration or cool the according to the value in
Down motor. parameter 37 (Maximum
acceleration of the motor),
up to the complete stop of
the motor. If fitted the
motor brake is applied.
42 (A) Drive overcurrent or short overcurrent in the Check the motor phasing. Check the DYN. 0 VEL. The drive,
circuit drive. drive earth connection. . without checking velocity
IGBT module overcurrent. Check the connections to the brake and position of the motor,
Over current in the resistor. . it applies the declared
braking resistance Dyn. Check cooling and reduce the current in parameter 66
0 Vel dynamics of the operating cycle (Value fixed terna of
IGBT module Anomaly in PSU control ramp) to arrest the
overtemperature movement, up to velocity
zero. If fitted the motor
brake is applied
42 (B & C) Drive overcurrent or short Drive overcurrent. Check the motor phasing. Check the
circuit Dyn. drive earth connection. .
0 Vel

43 (B & C) Brake resistor overcurrent brake resistor too small

Overcurrent in brake Ramp Check the brake resistor and drive
resistor. Down earth connection.

44 (B & C) Brake resistor not connected brake resistor faulty or IGBT

not connected Check brake resitor connections
Open
45 HW over/undervoltage supply voltage out of
protection (380V)/(400V) tolerance or not
Ramp
connected.
Down
Missing phase (Only
Model A)

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46 Target position not reached Point 2 Point command

(Mov 01) failed

47 Bus overvoltage Bus voltage too high.

Duty cycle too heavy Dyn.
or brake resistor too 0 Vel
big or open circuit
48 Bus undervoltage Bus voltage too low. 400V supply insufficient
Ramp
Input mains voltage
Down
too low
49 I2T Motor triggered Duty cycle too high. Ramp Lower the acceleration of the
Motor overheated. Down programmed movement.
50 I2T Brake resistor triggered Duty cycle too high.
Ramp Lower the acceleration use a more
Overheated brake
Down powerful resistance.
resistor.
51 I2T Drive triggered Duty cycle too high. Ramp Lower the acceleration use a more
Drive overheated. Down powerful resistance.
52 Rapid Halt Requested As the drive is enabled
Ramp Check the emergency string and the
the Rapid Halt signal
Down wiring of the Rapid Halt input.
becomes active.
53 Encoder Faulty or not connected Encoder faulty or not DYN. 2 SEC. The drive,
(causes automatic RESRIF) connected without checking velocity
and position of the motor,
applies the current
declared in parameter 66
Dyn.
(Value of fixed terna of
2 Sec.
current) for 2 seconds.
After this time it interrupts
the braking current, and
enables the motor brakeif
fitted.
54 Time out on emergency stop The axis failed to stop
within 2 seconds after Dyn. Check the setting of the feedback
emergency stop. Check 2 Sec. loop.
control loops.
55 Following error out of range max. position error Ramp
Check the setting
exceeded Down
56 Velocity error out of range max. speed error Ramp
Check the setting
exceeded Down
57 Mov01 Movement detected in hold state movement detected in Ramp
or command HOLD state Down
58 Power board alarm Power board alarm not
recognized. Excess
Ramp
noise present. Poor or
Down
missing Earth
connection or screen.
59 Wrong parameter Parameter 42 or 45 has IGBT OPEN The drive
value 0. Some loses control of the motor,
IGBT
parameters are wrong. Check the parameters. and activates the brake if
Open
fitted. If no brake is fitted
the motor coasts to a halt.
60 Power Lost Unrecognized alarm Ramp Check the drive and motor earth
the power card. Down connections.
61 SinCos Error Sine and cosine Dyn.
Information from the 2 Sec. Re-enable the drive.
drive incoherent.
62 Tuning limit During the tuning Ramp
movement the motor Down
has exceeded the
maximum planned
move.

Page 39 of 42
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63 Timeout of brake IGBT Brake IGBT stays Ramp

(only B & C) closed for more than Down
0,5 seconds. IGBT
fault. Brake Resistance
fault.
64 External Safety Device Enabling while the ramp
activated device “External down
Safety Device” (ESD)
is active and it is short-
circuiting the phases of
the motor; this alarm
can be verified only if
it controls the ESD.
65 Requested current unobtainable Error current too high ramp
down
66 Motor position uncontrolled Excessive position Dyn.
error 0 Vel
67 Motor velocity uncontrolled Excessive velocity Dyn.
error 0 Vel
68 Collision Maximum admissable IGBT
current is applied and Open
motor does not move
for 0.5s
69 External position error Position measured with Ramp
external transducer Down
different to motor
transducer.
EE059 Drive Fault Axis Severe drive failure during Check whether the
X operation drive is damaged;
Fault:ff replace the drive.
Fault:ff Description Possible causes IGBT
Open
01 Flash Checksum Hardware logic board IGBT
faulty Open
02 External Data Hardware logic board IGBT
faulty Open
03 Block B0 Program Hardware logic board IGBT
faulty Open
04 Block B0 Data Hardware logic board IGBT
faulty Open
05 Block B1 Hardware logic board IGBT
faulty Open
06 Block B2 Hardware logic board IGBT
faulty Open
07 Block SARAM Hardware logic board IGBT
faulty Open
08 Dualport Hardware logic board IGBT
faulty Open
09 SCI Timeout in transmission Hardware logic board
IGBT
faulty or encoder
Open
malfunction
10 SCI Timeout in reception Hardware logic board
IGBT
faulty or encoder
Open
malfunction
11 SCI error in echo comparison Hardware logic board
IGBT
faulty or encoder
Open
malfunction
12 DSP SPI fault Hardware logic board IGBT
faulty Open
13 DSP Timer fault Hardware logic board IGBT
faulty Open
14 E2PROM Hardware logic board IGBT
faulty Open

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15 Power board not recognized Hardware power board IGBT

faulty Open
16 Emergency Clear Emergency request.
The CNC has
Ramp
generated an
Down
Emergency Clear
(broadcast) message
17 Transmission error or FastWire FastWire cable fault or
Ramp
cable broken terminator not
Down
connected or CNC off.
18 WatchDog CN_DSP communication with Ramp
the CNC interrupted Down
19 Buffer CNC target empty no target from CNC Ramp
Mov 01 Down
20 Sequencer Error configuration file not
Mov 01 compatible

EE060 Drive Drive initialisation failed during Check whether the

Initialisation start-up. drive is damaged;
Error Axis X check parameters,
Error:eeee replace the drive.
Error: eeee Description Possible causes

1000 invalid axis ID internal CNC error

1001 Timeout on a command issue drive does not respond

1002 communication channel internal CNC error

engaged
1003 axis inhibited because of severe The axis has been
error inhibited earlier
because of a severe
error
1004 non digital axis attempt to work with
an analog axis

1005 invalid request application error

1006 invalid command Internal CNC error

2002 command failed Internal CNC error

2003 invalid drive ID Internal CNC error

2004 Drive engaged Internal CNC error

2005 invalid request Internal CNC error or

application error

2007 wrong monitoring data CNC or drive error

during monitoring

2101 command cannot be executed illegal operation

2102 monitoring table overflow request to monitor

more than 16 variables

2103 Monitoring already active Monitoring already

active
2104 No variable to be monitored No variable to be
monitored
2105 error during transmission Malfunctioning on the
internal serial port

2106 timeout error in transmission Malfunctioning on the

internal serial port

2107 timeout error in reception Malfunctioning on the

internal serial port

Page 41 of 42
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2108 checksum error Malfunctioning on the

internal serial port

2109 echoing error Malfunctioning on the

internal serial port

2110 Hyperface error Malfunctioning on the

encoder serial port

2111 feedback table overflow too many feedback

variables
2112 wrong variable ID non existing variable

2113 parameter table overflow too many parameters

selected for the
command
2114 wrong parameter ID non existing parameter

2115 Inconsistent Dry state parameter

write

2116 invalid memory address

2117 inconsistent data in sequencer

2118 inconsistent power board size

data

2119 Point2Point command not

available
2120 offset identification not
available
2121 synchronisation timeout on
ROTC
2122 wrong FPGA register ID reprogram FPGA

2123 location number overflow

2124 Qep counter release timeout DSP malfunction

2125 external Qep TD counter release DSP malfunction

timeout

2126 no encoder interface connected

2127 power error power board

malfunction

Page 42 of 42

MACHINE POWER UP & FUNCTIONALITY
 MACHINE POWER UP
Your machine is equipped with interlocks which are
designed to prevent the machine from starting under
the following circumstances:
(1.) Bumper-bar Tape-switches are depressed.
(2.) If any of the red (Emergency Stop) mushroom
buttons are pushed in.
(3.) If none of the enable buttons have not been
pushed or power switch is not in the on position.
(4.) If the machine’s pressure switch senses
inadequate air pressure.
(5.) If any of the Axes are on an Over Travel
Switch.
WARNING: The machine’s interlocks DO NOT
guarantee a safe start-up or operating situation:
PROPER MACHINE INSTALLATION, MACHINE
MAINTENANCE, AND THOROUGH OPERATOR
TRAINING ARE CRUCIAL TO THE SAFE, EFFICIENT
AND CORRECT OPERATION OF THIS SYSTEM.
IF YOU HAVE ANY QUESTIONS ABOUT THE
ADEQUACY OF ANY ONE OF THESE VERY
IMPORTANT REQUIREMENTS, STOP NOW AND
CONTACT YOUR SUPERVISOR OR C.R. ONSRUD, INC.
AT: (704) 508- 7000, OR TOLL FREE IN THE U.S. AT:
(800) 638-8185.
MACHINE SHOULD NOT BE POWERED UP BEFORE
INSTALLATION TECHNICIAN ARRIVES. DOING SO
MAY CAUSE DAMAGE TO THE MACHINE.
A qualified electrician should verify voltage at the
transformer and at the main power barrier strip
located in the electrical box before power is applied to
the machine components. The power should match
what is shown on the machines name plate and
electrical cabinets, if it does not then serious injury or
damage can occur.
www.cronsrud.com
Make sure that the machine is clean and clear of
debris, bystanders, and other hazards that can
cause injury and/ or damage.
Check that the machine is not on any of the blue over
travel switches located on each of the three main
axes (X, Y, & Z).
Machine power on should been done In the
following steps:
o Make sure that the main power circuit breaker is
on.
o Turn on air pressure and verify it is at 100 psi.
o Pull Out the Red Mushroom switch on the panel
WARNING: THESE ARE NOT THE COMPLETE STEPS
TO ENABLE THE MACHINE FOR OPERATION.
THIS WILL BRING THREE PHASE POWER INTO THE
MACHINE THIS WILL NOT ENABLE THE DRIVE
SYSTEM.
 MACHINE POWER DOWN
Machine power down should been done In the
following steps:
o Press the Red Mushroom "stop" button next to the
green "enable" or Drives on button.
o Shutdown Controller and Computer
o Turn the power switch to Off
o Turn off the air compressor to the machine.
o Turn off main circuit breaker for the machine.
DANGER!! SUDDEN LOSS OF THREE PHASE POWER
TO THE MACHINE, DURING THE SPINDLE RAMP UP,
CAN CAUSE THE SPINDLE TO CONTINUE TO ROTATE
EVEN AFTER THE LOSS OF MAIN POWER.
 ADJUSTING SPINDLE SPEED DURING
CUTTING
All C.R. Onsrud CNC Routers are equipped with the
ability to adjust the spindle rpm during machine
operation. The operator will need to review the
operations section for specifics on this adjustment per
control system. This gives a customer the ability to
adjust the spindle rpm to achieve the most optimal
chip load.
Keeping in mind the spindle rpm is not the only
variable in the chip load calculation.
Page 1 of 2
 www.cronsrud.com

 LOAD METER DO NOT exceed the cutter manufacturer’s speed

(rpm) rating for any cutter used.
A load meter is located on the side panel of the DO NOT OPERATE THIS MACHINE UNLESS
electrical enclosure to give indication of current YOU HAVE BEEN TRAINED BY A CERTIFIED
operating load as a percentage of maximum drive C.R. ONSRUD TECHNICIAN.
(Frequency Inverter) output.
This meter is also an important maintenance indicator
for an operator. The meter can give an indication of a
dulling tool, or even possible damage to the spindle
bearings.
The meter can also indicate whether a material has
the proper feeds, and speeds in the program being
cut.

 ADJUSTING FEED RATES WHILE

CUTTING
Feed rates can be adjusted while in the cut, aka “on
the fly” with any of our CNC Routers. In conjunction
with the spindle speed adjustment this gives an
operator the ability to adjust the chip load for
maximum tool life and the best cut quality.
There will be either a potentiometer dial on the control
panel labeled Feed, or a key marked “Feed” is located
on the machine’s control pad. Using either of these
will allow the operator to change the feed rate of the
machine while cutting the material.
COMPLETE CONTROLLER OPERATIONS
INSTRUCTIONS ARE INCLUDED IN YOUR RINGED
MANUAL BINDER.

 ROUTING
WARNING!! DO NOT START OR RUN ANY
MACHINE WITH THE DOORS OPEN OR GUARDS
OUT OF PLACE.
WARNING!! WEAR EYE PROTECTION AND
HEARING PROTECTION WHEN OPERATING THIS
OR ANY OTHER WOODWORKING MACHINE.
WHERE WOOD DUST IS NOT TOTALLY
CONTROLLED, RESPIRATORY PROTECTION
SHOULD BE USED.

Page 2 of 2

KNOWN METHODS OF MISUSE
1. INADEQUATE FIXTURES: PROPERLY MADE,
QUALITY FIXTURES are crucial to the safe and efficient
operation of the Router. For a fixture to be adequate, it
must:
(a.) Hold the work piece securely enough so that cutting
forces cannot separate the work piece from the fixture,
(b.) Ensure that the machine has sufficient suction to hold
the work piece while machining
(c.) Adequately isolate the operator from the cutting tool
and machining scrap and debris.
2. REMOVAL OF GUARDS: KEEP ALL GUARDS IN
PLACE AND IN WORKING ORDER. Do not start or run
any machine with the doors open or guards out of place.
3. INTENTIONAL DEFEAT OF INTERLOCKS: DO NOT
DEFEAT ANY SAFETY DEVICE OR INTERLOCK.
Tampering with safety devices can create unnecessary
hazards.
4. INADEQUATE GROUNDING: GROUND ALL TOOLS
AND MACHINERY IN ACCORDANCE WITH APPLICABLE
CODES.
DANGER!! Hazard of fatal electrical shock! Electrical
connections and adjustments should be made by a
qualified electrician only.
5. FAILURE TO REMOVE ADJUSTING KEYS AND
CHUCK WRENCHES: Form the habit of checking to see
that all adjustment and set-up tools and wrenches are
safely removed before turning machine "on".
6. FAILURE TO KEEP WORK AREA CLEAN. Cluttered
areas and benches invite accidents.
7. USING USE THE MACHINE IN DANGEROUS
ENVIRONMENTS. Don't use machinery or power tools in
damp or wet locations, or expose them to rain. Avoid
combustibles. Keep work area well lighted.
8. FAILURE TO KEEP VISITORS AND CHILDREN
AWAY. All visitors and children should be kept a safe
distance from the work area.
9. FORCING THE TOOL: DON'T FORCE TOOL. Bits
and cutters will do the job better and more safely at the
feed rate for which they were designed.
www.cronsrud.com
10. FORCING ATTACHMENTS: USE THE RIGHT TOOL.
Don't force a tool or attachment to do a job for which it was
not designed.
11. INAPPROPRIATE APPAREL: WEAR PROPER
APPAREL. No loose clothing, gloves, neckties, rings,
bracelets, or other jewelry which may get caught in the
machine should be worn. Non-slip footwear is
recommended. Wear protective hair covering to contain
long hair.
12. FAILURE TO WEAR SAFETY GLASSES: ALWAYS
USE SAFETY GLASSES. Wear safety glasses which
comply with ANSI Z87.1. Everyday eyeglasses only have
impact resistant lenses; they are not safety glasses.
13. FAILURE TO USE HEARING PROTECTION: WEAR
HEARING PROTECTION where noise levels exceed
OSHA standards.
14. FAILURE TO WEAR RESPIRATORY PROTECTION:
WEAR RESPIRATORY PROTECTION where wood dust is
not totally controlled.
WARNING! The dust created by certain woods, wood
products and certain other products which may be
processed on this machine can be injurious to your health.
Always operate machinery in a well ventilated area.
Provide adequate dust collection. Wear respiratory
protection where appropriate
15. OVERREACHING: DON'T OVERREACH. Keep
proper footing and balance at all times.
16. INADEQUATE MAINTENANCE: MAINTAIN
MACHINERY IN TOP CONDITION. Keep tools sharp and
clean for best and safest performance. Follow instructions
carefully when lubricating, maintaining and changing tools
or accessories.
17. FAILURE TO DISCONNECT POWER SOURCES:
DISCONNECT POWER SOURCES BEFORE SERVICING
OR CHANGING TOOLS AND ACCESSORIES. Only
properly trained and qualified persons should perform
these functions.
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WARNING!! It is the employer's responsibility to provide
energy isolation devices for this equipment and insure that
all potential service and maintenance personnel follow
lockout/ tag out procedures developed by the employer in
accordance with the occupational safety and health
administration's (OSHA) control of hazardous energy
standard 29 CFR 1910.147.
WARNING !!: The Variable Speed Drive Unit
(Frequency Inverter) contains capacitors which remain
charged with dangerous electrical voltages for up to
several minutes after turning off the main circuit power
supply. Do not touch motor drive circuit components
until the “charge” lamp is extinguished.
When disconnected from the electrical power source
with the “charge” lamp extinguished, the machine
stores no residual energy.
Refer to Frequency Inverter instruction manual for
specific information.
18. STANDING ON MACHINE: NEVER STAND ON A
MACHINE. Serious injury could occur if the machine is
tipped or if the cutting tool is accidentally contacted. Or the
machine is started.
19. OPERATING DAMAGED OR INCOMPLETE
MACHINE: CHECK FOR DAMAGED OR MISSING
PARTS. Be certain that guards, labels and other important
equipment is in place and able to perform it's intended
function before using any machine. Check for proper
alignment and smooth operation of moving parts, broken or
damaged parts, and proper mounting of tools and
accessories. If you do not know how to recognize proper
operating condition, consult your plant safety officer or
supervisor or call C. R. Onsrud at 1-(704)-508-7000 or toll
free in the U.S: 1-(800)-638-8185.
20. EXCESSIVE HEAT CREATED BY DULL TOOLS
AND/OR IMPROPER MACHINING METHODS CAN
CREATE A FIRE HAZARD. Basic good practice for
avoiding heat build-up include: Always use sharp cutting
tools, and always ramp into your cuts. Always machine
at proper chip-load speeds to avoid heat build up.
21. LEAVING RUNNING MACHINE UNATTENDED:
NEVER LEAVE A RUNNING MACHINE UNATTENDED.
Turn machine "off" and allow to come to a complete stop
before leaving work station (except under emergency
circumstances).
www.cronsrud.com
22. USE PROPER SIZE TOOLS. Don’t use tools that
exceed weight and size specifications of the spindle
manufacturer. This information can be found in the spindle
owner’s manual. RUNNING TOOLS OF EXCESSIVE
WEIGHT AND SIZE OF CAN RESULT IN MECHANICAL
DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH!!
23. FOLLOW PROPER TOOL AND TOOL HOLDER
MAINTENANCE. Large Tools, Insert Profile Tooling, Tool
Holders should all be properly maintained and balanced
regularly to ensure tool integrity. Improper maintenance can
create structural instability of the tool while running and
may result in mechanical damage, personal injury, or
fatality.
23. USING MACHINE WHILE IMPAIRED BY DRUGS,
ALCOHOL OR MEDICATION: Do not operate, repair, set-
up, or perform maintenance on this or any other machine
while under the influence of drugs, prescription or
otherwise, alcohol, any medication, or mental condition
which might impair motor processes, clarity of thought, or in
any other way interfere with safe interaction with this
equipment.
IF YOU ARE NOT THOROUGHLY FAMILIAR WITH THE
SAFE OPERATION OF ROUTERS, OBTAIN ADVICE
FROM YOUR PLANT SAFETY DIRECTOR,
SUPERVISOR, OR CALL C. R. ONSRUD, INC. :
LOCAL: 1-(704)-508-7000
Or TOLL-FREE IN THE U.S.: 1-(800)-638-8185.
Questions?
If you have any questions concerning your C.R. Onsrud
Routers, please contact our factory at the address or one of
the phone numbers listed below:
C. R. Onsrud, Inc
P.O. Box 419 / 120 Technology Dr
Troutman, NC 28166-0419
1-(704)-508-7000
1-(800)-638–8185
We routinely provide phone consultation with
customers regarding tooling, operation, and safety
tips. We encourage your calls.
ANY ADDITIONAL, OPERATIONS, SAFETY AND
MAINTENANCE TRAINING IS AVAILABLE AT OUR NORTH
CAROLINA MANUFACTURING FACILITY OR ON SITE AT THE
CUSTOMER'S FACILITY PLEASE CONTACT OUR SERVICE
DEPARTMENT FOR A QUOTE.
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DAILY MAINTENANCE
 The operator should perform a “walk around the machine” before powering it up. Check to make sure there
are no obstructions in the path of any of the axes strokes that would hinder machine movement or cause
damage to the machine.
 The machine’s air pressure should be checked daily. In the morning, check to ensure that the machine has
proper air pressure at the regulator, and also check the filter indicator. If the indicator is green, then the filter
is OK; if the filter is turning red, try cleaning the filter or order a new filter for the air regulator.
NOTE: The filter in the machine’s Eliminizer should be replaced every 6 month(s).
 The operator is required to warm the spindle every morning prior to cutting any material. Your router spindle
can run at 24,000 rpm! In the morning, or whenever the machine has not been run for several hours: load
a tool, start the spindle at a speed of 9,000 rpm (assuming this does not exceed the recommended rpm
of the tool), let the spindle run at this “warm up speed” for 15 minutes to allow the bearing grease to loosen
up. Once warmed up, stop the spindle rotation and park the tool. Note: The morning warm up should
only be done after the machine has been homed.
DO NOT LEAVE THE MACHINE UNATTENDED WHILE THE SPINDLE IS WARMING UP!!
 Check that the tool tray appears to be in proper alignment with the spindle as tools are being loaded and
parked. Keep the tool tray and tool holders clean of debris. Observe that the dust brushes are going up and
down properly.
 Tool holders should be broken down and cleaned thoroughly whenever a bit is changed. Whether the bit is
being changed due to dulling of the bit or breaking of the bit. Tighten bits in the tool holder securely, but do
not tighten so tightly that the collet is forced down into the taper of the tool holder, thus distorting the collet
and causing uneven gripping of the shank of the bit. Over tightening can also cause damage to the bearing
ring located in the clamping nut. Collets wear out! Replace a collet at least every month of “running time.”
(Worn collets WILL cause bit breakage. New collets are less expensive than most router bits.)
 The operator should also clean off the machine of any debris, dust, or chips at the end of each working shift.
 The operator should closely inspect the spindle taper, clean and lubricate as needed. The operator should
not allow any debris or contaminants to build up in this area as it may cause premature damage to the
spindle. See the spindle manufacturer’s manual for further details.
 The operator should wipe down the ends of the linear rail on the machine. The operator should only need to
wipe the accumulation that appears at the ends of each of the axes stroke. Throughout the shift when the
machine is idle the operator will want to check the rails to make sure grease is being applied. By running a
finger along the face of the rail the operator should feel a fine greasy film on the rail. If the film can’t be felt
immediately, grease the machine.
 On Moving Gantry machine’s check the rack on axes with rack for build up and or debris.
Clean / Remove, any build up, as this will cause premature wear and inaccuracy.
 The operator should check and observe the machine movements throughout each shift that the machine
runs, noting and investigating any unusual noises, loose and/ or odd moving components, also
any inconsistencies the machine might be creating or experiencing (i.e. inconsistent cutting depth).
 Operator should always park tool at the end of the day. As the hot spindle cools it may tighten up on the
taper of the tool holder making it VERY difficult to remove the tool holder from the spindle.

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WEEKLY MAINTENANCE
 Perform all daily maintenance checks on the machine mentioned in the Daily Maintenance section.

 Clean and blow out the filter(s) on the vacuum pump(s).

 Check that the machines cooling fans are operating. There is a fan on the top of the spindle, and
inside the electrical cabinet.
 Check the nose of the spindle and clean the spindle nose of any debris or build up.

 Check the spindle’s Bullet distance as it protrudes out of the spindle. Extend the bullet from the
spindle and using a depth micrometer measure the distance this should be approximately .414
inches (+/- 0.002) refer to the spindle manual for an exact value. Ensure that the bullet is not loose.
 Check the dust brushes and dust hood components ensure that the up/ down travel is not binding
cause trouble with the motion of the hood and also ensure that the brushes are not mangled, curled
inward, or deformed due to debris.
 Grease the machine at the models standard greasing points. For grease point locations please refer
to the components section of your machine owner’s manual. NOTE: The spindle motor bearings
are permanently lubricated for the life of the motor.
 Linear Bearings: The Linear Bearing Block (“Trucks”) should be greased every 40 hours that the
machine runs. You should put in 2 pumps of the recommended NLGI #1 Lithium based grease into
each zerk fitting.
 Ball Screw & Nut: The Ball Screws should be greased every 40 hours that the machine runs. You
should put in 3 - 4 pumps of the recommended NLGI #1 Lithium based grease into each zerk fitting.
 Below are some examples of grease points on a machine. Please refer to the Components Section
of the manual for the specific grease points for your machine model.

 X – These 4 grease points are located behind the Column  Y & Z – These 7 grease points are located from under
that the Tool Tray is mounted. the machines bridge on the bottom of the back plate.
 U – These 4 grease points are located behind the Non Tool  Z & Y – These 7 grease points are located along the
Tray Column where the Black Energy Track is located. side of the Z axis. 4 are located below the Y axis
billows, and 3 are located above the billows
 Tool Tray – Finally there are 2 grease points located
on the linear blocks for the Tool Tray.
Note: All grease points should be greased with the proper Multifak EP1 grease every 40 working hours. The proper
grease can be ordered from our parts department. Part #: 274502 - Description - Multifak EP1.

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MONTHLY MAINTENANCE
 Perform all daily maintenance checks on the machine mentioned in the Daily Maintenance section.

 Perform all weekly maintenance checks on the machine mentioned in the Weekly
Maintenance section.
 Check the emergency circuit to ensure each emergency device is working properly and resetting correctly.

(WITH MACHINE POWER OFF)

Perform these steps after turning off all the machine power and performing proper OSHA regulated
lock out procedures!!
 Check axes strokes by manually pushing each of the axes (with power off to the machine) the full stroke of
the axis. Check for any type of noticeable resistance during the travel.
 Open the machine’s electrical cabinets located on the rear of the bridge (see the machine Owner’s
Manuals Component Section for reference). Using a Shop Vac, or Dust Buster clean the dust out of the
cabinets. NOTE: DO NOT USE ANY TYPE OF COMPRESSED AIR TO CLEAN THE CABINETS.
COMPRESSED AIR HAS MINUTE AMOUNTS OF MOISTURE THAT CAN CAUSE EXTREME DAMAGE
TO YOUR ELECTRONICS INSIDE THE CABINETS!!
 Check the electronic devices for dust build up. Use a proper electronics cleaner to remove the dust
(computer, and electronics stores carry these cleaners) if dust is evident clean the components with the
fore mentioned cleaner.
 Check and clean the rack along X axis of moving gantry machines, checking both the tool tray and non tool
tray side of the axis. The rack should be cleaned of debris on a regular basis in between each tooth of the
rack to clean out the debris.
 Lubricate, clean, and verify the adjustment of the spindle bullet and clamping group on the router
spindle(s). Proper care and adjustment of these components is vital for safe and accurate use if the electro
spindle. Refer to the manufacturer’s manual for further details.

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C.R. Onsrud Tooling and Accessory Recommendations: Per Application

It is not possible for us to recommend a tool that is "best" for a particular material. In natural wood, variables such as growth rate,
acidity, and moisture content will greatly affect tool life. Bonding agents and fillers used in composite materials such as plywood,
particleboard and medium density fiberboard vary widely in hardness and abrasiveness thereby affecting its machining. When routing
plastics and aluminum, the thickness, hardness and melting temperature of your particular material will all have to be considered when
selecting a tool.
Although experimentation will be required, the following list includes tools which customers of ours have used successfully in
many of their machining applications. This list should help guide your choices:
Tooling Accessories:
200 TH Torque Wrench Helps ensure the user is following the manufacturer’s torque specifications for collets &
clamping nuts.
03690-25 HSK 63F SYOZ25 Collet Key for Torque Wrench 200TH
90-002 GLC 2.5 inch Surface Cutter Used for resurfacing the machine’s spoil board – ¾ inch shank.
91-125 10 pk Inserts 10 pack Solid Carbide inserts for the 90-002 GLC cutter.
91-130 Replacement Screws for Extra torque screws for the 90-002 GLC cutter.
Insert
91-136 Torque wrench Torque wrench for insert screws on the 90-002 GLC.
33-10 Collet Brush Kit Contains 4 brushes ranging from ¼ in to ¾ in for proper cleaning of tool holder collets.
33-21 Collet Cleaning Kit Cleaning kit for tool holders and collets includes a T-9 lubricant and cleaner.
33-66 Spindle Wiper for HSK 63F Used for properly wiping out the taper of the spindle nose.
Clamp Tool Spindle Clamp Group Used for proper maintenance of the spindle clamp group.
Maintenance Tool
Bullet Gauge (390-2) Bullet Distance Verification Used for proper maintenance of the spindle bullet.
Tool
VTM-2525 Vacuum Gasket ¼” x ¼” closed cell vacuum tape.
XM3150 Rubber Gasket Cord 5/16” Round PVC cord used with NEMI grid vacuum.
BOF.HSK63F09813 High Speed Drill Chuck for Capacity: 1/16mm High Speed Drill Chuck – Balanced to 24,000 rpm.
63F series HSK spindles
BOF.HSK63A10013 High Speed Drill Chuck for Capacity: 1/16mm High Speed Drill Chuck – Balanced to 24,000 rpm.
63A series HSK spindles
HSK63-F Tool Arbor & Clamping Nut Std (78mm) Tool holder (SYOZ) W/Chucknut (24RPM)
HSK63-A Tool Arbor & Clamping Nut HSK63-A ER40 Toolholder with Nut
727-CROHSK63 Digital Tool measuring Device Using in tool preparation for measuring the tool length. Helps to increase cycle time by
Bench Top Tool Setter lower downtime on the machine for tool maintenance.
SYOZ25 (RDO 35) Tool Holder Collets Collets for HSK 63F(SYOZ25) Tool Holders range from 1/8 in to 1 in and various metric
sizes
**** Please ensure that the appropriate SYOZ25 collet sizes are ordered for each shank diameter size of cutters ordered for the machine
production. It is also recommended to have 1 extra of each size. For our first time customers these should be ordered and arrive PRIOR to
the technicians arrival!! ****
TOOLING APPLICATIONS:
LAMINATED WOOD MATERIALS: Melamine, Veneer, Laminates, and Plywoods
OC 60-100 SERIES DE SC COMPRESSION
OC 60-100C SERIES DE SC CHIPBREAKER/ FINISHER COMPRESSION
OC 60-100MW DE SC MAX LIFE COMPRESSION
VT Series 3100 DE SC COMPRESSION
VT Series 3100M DE SC MORTISE COMPRESSION
VT Series 3100XP DE SC “XTREME PERFORMANCE” COMPRESSION
AE DD05070 5mm x 70mm x 10mm shank line boring drills. Available in 57mm length for Brad & Thru Points in line boring
applications.
AE DD08070 8mm x 70mm x 10mm shank line boring drills. Available in 57mm length for Brad & Thru Points in line boring
applications.

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C.R. Onsrud Tooling and Accessory Recommendations: Per Application

PLYWOODS: Recommendation for general purpose cutting and for most grades of plywood
OC 48-000 SERIES CARBIDE TIPPED STRAIGHT
OC 48-700 SERIES CARBIDE TIPPED STRAIGHT (MDF & HARD PLYWOODS)
VT Series 4000 SC DE STRAIGHT FLUTE
SOLID WOOD: Recommendation for general purpose wood routing
OC 52-200 SERIES DE SC UP CUT
OC 57-700 SERIES DE SC DOWN CUT
VT SERIES 1200 TWO FLUTE UP CUT
VT SERIES 1300 TWO FLUTE DOWN CUT
CRO CRO SERIES DE SC UP CUT – CRO-280 (1/4”), CRO-320 (3/8”), CRO360 (1/2”)
CRO CRO D SERIES DE SC DOWN CUT – CRO-280D (1/4”), CRO-320D (3/8”), CRO360D (1/2”)
PLASTICS: Recommendations for hard and soft plastics: see OC catalog for PCD for Acrylic Edge Finish bits
OC 63-700 SERIES SE SC UP CUT O FLUTE – Hard plastics for smooth finish
VT SERIES 5600 SE SC O FLUTE UP CUT – Hard Plastics with smooth finish
OC 63-750 SERIES SE SC UP CUT O FLUTE – Soft Plastics for smooth finish
VT SERIES 5600S SE SC O FLUTE UP CUT – Soft Plastics with smooth finish
OC 52-700 SERIES DE SC UP CUT SPIRAL – for Pocketing Application where bottom finish is not vital
OC 66-300 SERIES DE SC UP CUT – for Pocketing with improved bottom finsh
OC 52-200 B SERIES DE SC BALLNOSE UP CUT
VT SERIES 2200 TWO FLUTE SC BALLNOSE
OC 37-00 SERIES Solid Carbide V - BOTTOM BITS
VT SERIES 3800 Solid Carbide V-Point Bits
ALUMINUM: Recommendations for Aluminum applications
OC 63-600 SERIES SINGLE FLUTE SC UP CUT O FLUTE– most general aluminum applications
VT SERIES 5600A SC SE UP CUT O FLUTE – most general aluminum applications
FOAM: Recommendation for cutting foam
OC 52-700 SERIES SC DE DOWN CUT -
COMPOSITE: This encompasses many different materials, please consult your local tool rep for special applications
OC 54-200 SERIES 3E & 4E SC SPIRAL for Fiberglass & Composites (Coated against abrasive characteristics)
OC 66-800 SERIES DFC COMPRESSION FOR COMPOSITES (Diamond Film Coated)
OC 66-900 SERIES HIGH PERFORMANCE COMPOSITE (Coated with AlTiN)
VT SERIES 6100 3E SC UP CUT Phenolic/ Composite Spirals
AEROSPACE/ AUTOMOTIVE: For general applications in Aluminum Grade 6000 & 7000 see the OC AMC series catalog. Also see the EMC
Series catalog.
OC 34-000 SERIES MODULAR TOOL – used for application where potting of precut slots in panels is needed.
HONEYCOMB: Recommendations for application of cutting Honeycomb materials
OC 29-050 SERIES DIAMOND GRIT HOGGER – Used on abrasive cores (graphite, phenolic, or fiberglass).
OC 29-100 SERIES SC HONEYCOMB HOGGER (Coated) – Coated with ZRN for increased tool life.
OC 30-700 SERIES REDUCED WEIGHT HONEYCOMB CUTTER – 35% weight reduction for better performance on 3 & 5 axis
applications.
ENGRAVING:
OC 37-00 SERIES SE SC ENGRAVING TOOLS – 60 DEGREE ANGLE
OC 37-20 SERIES SE SC ENGRAVING TOOLS – 30 DEGREE ANGLE
OC 37-50 SERIES DE CARBIDE TIPPED FOLDING TOOL – Dibond/ Alucobond
**For more details please reference your Catalog (OC) from Onsrud Cutter or your Catalog (VT) from Vortex Tooling. Also note that CRO
SERIES bits are designed by C.R. Onsrud and have been tested in many soft material applications outside of wood and wood composites.**

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AGGREGATES & LARGE PROFILE TOOLS:

Depending upon a customer’s machine model The C.R. Onsrud CNC Router can use aggregates. The C.R.
Onsrud machine has been designed with a Tool Tray that will accommodate many styles of aggregates.
Depending upon the type of aggregate purchased some tool positions adjacent to the aggregate may be
unusable to accommodate the size of the aggregate.
C.R. Onsrud CNC Routers can also use an assortment of custom tools to achieve profiles in the materials
being cut. These tools can become extremely large and must be used with extreme care. Your router spindle
manufacturer has provided some recommendation on tool sizes that can been used on the machine. These
recommendations are based on the weight of the tool and tool holder and it’s the center of gravity. Please refer
to the spindle’s manual to gain access to the charts for reference. Note: Exceeding the limits of this spindle
can cause instability in the tool being used and can create a hazardous work environment resulting in
machine damage or personal injury and in some cases fatality!!

Aggregate programming and set up is viewed as Advanced Machine Training, and will not take place during
the initial machine install. It is our recommendation that a customer become familiar and comfortable running
the C.R. Onsrud machine before moving into aggregate machining. Please contact our office at (704) 508-
7000 for more information about aggregates and their use.

 NOTE: C.R. Onsrud does not "endorse" any Moulder Aggregates of any kind, due to safety
concerns!!

 Moulder Aggregates should NEVER be used without "OSHA" approved Guarding.

It is the expressed opinion of C.R. Onsrud Inc.:

A moulder head should not be used on any machine, of any model, without a protective
enclosure around the machine! Many moulder aggregates are physically too large and
heavy to be used on machines that have not been custom configured!

WARNING: Any customer that chooses to use moulder aggregates, after the above mentioned opinion,
does so at their own risk. Any modifications to the machine’s tool tray, tool clips, or machine set up in
order to accommodate such a large aggregate will void the machine’s warranty. C.R. Onsrud Inc. will
not take any responsibility for damage to the machine, tool, or personnel.

WARNING: Customers using Large Profile Tools must follow the spindle manufacturer’s
recommendations along with the tool manufacturer’s recommendations for weights, center of gravity,
spindle speeds and feed rates. It is the customer’s responsibility to maintain the tools integrity and
balance failure to do may cause catastrophic failure of the tool resulting in machine damage, personal
injury or death!!

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SPOILBOARD REPLACEMENT:
Here are some guide lines for replacing the spoilboard(s) on the machine table of a C.R. Onsrud CNC Router.

NOTE: Soilboard(s) material should consist of LDF, Ultralight MDF, or Trupan. These materials allow the
most vacuum to access the material’s surface area on the machine table. This in turns results in better hold
down of the sheet stock being cut. We do not recommend using MDF due to vacuum restriction.

1.) Place the material on top of existing spoilboard(s). Surface the top of the material removing between 0.005”
- 0.015” from the top. It is important to remove this material, due to the “glaze” that the manufacturer applies
during manufacturing. By removing this “glaze” on the top and bottom surface the vacuum will produce better
flow to the surface area of the sheet stock.

2.) Flip the newly surfaced material over. Machine the material to desired length and width (X&Y) dimensions
to fit the machine table. Finish the material off by drilling or routing the holes and countersinks for bolt down.

3.) Remove the new spoilboard(s) and seal the four edges of the board(s). This is step is to ensure that there
is no vacuum loss around the edge of the new spoilboard(s) and all the vacuum is directed at the surface area
of the sheet stock.

4.) Remove the old spoilboard(s) from the machine table. Inspect the gasket around each of the zones of the
machine table. Replace the gasket in areas that are cracked, twisted, and/or squashed.

5.) Place the new spoilboard(s) on the machine table, align, and then bolt them down to the machine table.

6.) Once bolted down surface the top side of the new spoilboard(s) to flatten the material and also to remove
the “glaze” as done in Step 1. Once the new board has been surfaced the machine is ready for production.

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Quarterly Maintenance on the Clamp Group for HSK63 F: Using the Clamp Tool
Items Needed:
 4mm T Handled Allen Wrench
 Adjustable Wrench
 Needle Nose Pliers
 Bullet Gauge Block/ Depth Micrometer
 Spindle Wiper
 C.R. Onsrud Clamp Tool
 Extra Fine Scotch Brite Pad & Clean dry rags
 Blue Loc-Tite
 MetaFlux grease
NOTE: The procedure shown can be done with the spindle mounted on the machine. In the following document the steps shown are done
on a spindle that was removed from a machine. The spindle DOES NOT need to be removed from the machine to perform this maintenance.

1.
Begin by wiping down the spindle nose to eliminate possible
contamination when doing this procedure. Use a lint free rag to
wipe the exterior of the spindle nose. Check the status of the
spindle bullet, in the figure to the left the bullet is in the retracted
state.

**NOTE: DO NOT USE COMPRESSED AIR TO BLOW OUT OR CLEAN THE SPINDLE
NOSE!! DOING SO CAN CAUSE DAMAGE INTERNALLY TO THE SPINDLE!!**

2.

Using the machine control, activate the output to extend

the bullet. This will put the machine spindle in the state of
Tool Release and the bullet state will be extended. The
spindle will not be able to be turned by hand.

3.

Using an Adjustable Wrench hold the Bullet stationary, place the 4mm
Allen Wrench inside the center of the Bullet and loosen the set screw
inside the Bullet.

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4.
Remove the set screw from the spindle
bullet. Clean the set screw with an extra
fine piece of Scotch Brite.

**NOTE: Place set screw to the side as it will be

used to set the bullet distance later in the
procedure.**

5. Once the Bullet is broken loose, remove the Bullet from the spindle nose. See images below of the
Bullet being removed.

6. Using a pair of Needle Nose Pliers, remove one of the Clamp Group fingers from the spindle nose.
Once the first finger is removed, continue removing the remaining fingers from the nose using the same
technique.

7. Once the Bullet and the Clamp Group are out of the
spindle nose, use the Needle Nose Pliers to remove
the Clamp Group Hub from inside the spindle nose.

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8.

Ensure that both the white Ceramic Spring Bushing

(A) and the Clamp Group Hub (B) come out of the
spindle. Clean both by wiping of any build up and
debris that may be on them. Once clean place them
to the side.

9.

Using a clean lint free rag, clean the inside of the spindle nose
removing any debris from inside the spindle nose.

10. Inspect and clean the Clamp Group Fingers, the Bullet, The Clamp Group Hub, and the Ceramic
Bushing. Inspect for any damage such as dings, burrs, scratches, and such, on the surfaces of the
clamp group fingers, clamp group hub and the Bullet. Use a small amount of Metaflux grease to the
contact points between the clamp group hub and the clamp group fingers. Wipe down all components
of any excess grease.

11.

Once everything is clean, slip the

Ceramic Bushing and the Clamp
Group Hub back up inside the
spindle nose.

12.

Using the Clamp Tool, place the Clamp Group Fingers into
the recess at the bottom of the guide shaft.

**NOTE: If doing this procedure while the spindle is on the machine,

combine steps 11 & 12 by placing the Clamp Group Hub & Ceramic
Bushing on top of the fingers, then proceed to the next step.**

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13.
Guide the Clamp Tool into the spindle nose and gently slide
the all the way up into the nose. Once the Clamp group is all to
the top of the spindle nose, give the Clamp Tool a slight push
upward to seat the Clamp Group (there will be a minor click as
the group seats into the recess inside the spindle nose).

**NOTE: If you followed both steps 11 & 12 be sure to align the Clamp Group
Fingers with the Clamp Hub in order to seat everything properly.**

14.

Once the Clamp Group has been seated in the spindle

nose, look up and check the spindle nose before
proceeding to the next step.

15.

Slide the Spindle Bullet into the center of Clamp Group

and begin screwing the bullet on to the end of the draw
bar shaft.

16. At this point the Bullet distance will need to be set. It is important to set this distance
correctly for the proper functionality of the spindle. Using either the aluminum Gauge Block,
or a Depth Micrometer set the distance of the Bullet.

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17. Once the distance is set, place a small drop of Blue Loc-Tite on to the Bullet Set Screw.
Using the 4mm Allen Wrench and gently holding the Bullet still, re insert the set screw into
the Bullet and snug the set screw down. Ensure to verify that there was no change in the
Bullet distance and tighten down the set screw using an Adjustable Wrench and the 4mm
Allen Wrench.

Once the procedure is finished, you will want to follow the steps to verify the spindle sensor
activation. If you do not have this procedure please contact the C.R. Onsrud Technical
Support Department at 704-508-7000 Mon. through Fri. 8:00 am to 5:00 pm (EST) or via
email at techsupport@cronsrud.com to obtain the procedure. Also contact Technical
Support with any questions our concerns regarding performance of the above steps.

Please contact C.R. Onsrud’s Parts Department at 704-508-7000 or via email at

parts@cronsrud.com to purchase the specialty tools mentioned in the above procedure:
 Clamp Tool
 Bullet Gauge Block
 Spindle Wiper
 Metaflux

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SPINDLE BEARING REPLACEMENT - TRY OUR WAY FIRST

Your CNC Router spindle is capable of speeds up to 24,000 rpm. It is, consequently, an extremely high-
precision device. Clearances and tolerances are measured in tenths of thousands of an inch. IF YOU ARE
UNFAMILIAR WITH CLOSE-TOLERANCE WORK ON HIGH SPEED SPINDLES, WE STRONGLY
RECOMMEND THAT YOU SEND YOUR SPINDLE BACK TO THE FACTORY FOR BEARING
REPLACEMENT.

REMOVAL

Call our technical support line at 704-528-4528 for specific detailed instructions on the removal procedure.

!!DANGER!! - BEFORE PROCEEDING REMOVE AIR AND ELECTRICAL POWER PER YOUR
EMPLOYER'S OSHA CONTROL OF HAZARDOUS ENERGY STANDARD 29 CFR 1910.147 LOCKOUT/TAG
OUT PROCEDURE.

*Remove the flex pipe from your dust hood outlet.

*Disconnect air lines that feed the cylinders for retracting the dust hood brushes.

*Remove the dust hood. Now carefully pull the hood forward being sure not to catch any of the air or electrical
lines in the process.

*Disconnect all the air lines and electrical lines marking their locations (All the spindle sensor are connected to
the junction box located on the spindle plate in the upper left corner inside the dust hood.) MAKE SURE TO
MARK LOCATION OF CONNECTIONS!

*Carefully Mark all 3 phase power cables so they may be reconnected to the same terminals.

*Unbolt the spindle from the plate (do not lose the key located in the back of the spindle). It is good practice
to have the spindle blocked up when unbolting failure to do so may cause personal injury or damage
to the spindle.

This unit weighs 75 pounds, support it well!

Now the spindle can be carried to a work bench and carefully packaged for shipment back to C.R. Onsrud, Inc.

PACKAGING

When returning spindles to the factory, it is very important to package them properly. Damages due to
improper packaging can be time consuming and add unnecessary cost to repair. The spindle should be
isolated from shock and prevented from movement. A specially made reusable wooden box or expanded foam
pack is strongly recommended.

DO NOT! DO NOT! DO NOT! PACK YOUR SPINDLE IN A CARDBOARD BOX WITH NEWSPAPER OR
FOAM "PEANUTS"!! TO DO SO WILL VIRTUALLY GUARANTEE SHIPPING DAMAGE.
This spindle is worth $9,000.00 so pack it as appropriate for its value!

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SPINDLE REINSTALLATION
DANGER!! REMOVE AIR AND ELECTRICAL POWER PER YOUR EMPLOYER'S OSHA CONTROL OF
HAZARDOUS ENERGY STANDARD 29 CFR 1910.147 LOCK OUT/ TAG OUT PROCEDURE.

(Reverse the removal procedure on the previous page)

Be sure your tool holders are clean and your cutting tools are in balance.

ANY QUESTIONS? PLEASE CALL OUR TECH-SUPPORT HOT LINE:

(1)704-508-7000 or (1)866-667-7837

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C.R. Onsrud CNC Preventive Maintenance Check List

Company Name: Date:

Machine Model: Serial Number:

*This checklist contains routine procedures that a Certified C.R. Onsrud Technician will investigate while on a
Preventative Maintenance Service call. Any known specific machine issues and/or concerns need to be diagnosed prior
to arrival so that all parts that may potentially be needed are ordered and on site when the technician arrives.
PRIOR TO MACHINE POWER UP
1. Check for any visible damage to the machine:
 Stop block pads are in place and are not missing or damaged
YES NO Notes:

 Safety stickers are on the machine and have not been removed
YES NO Notes:

Additional Comments/Recommendations:

2. Check all axes datum switches (There is a minimum of 5 switches X, U, Y, Z, and V (Tool Tray). There may be more
switches depending on the machine model):
 Datum switches are clean
YES NO Notes:

 No visible damage on the sensing face of the sensor

YES NO Notes:

 Distance from the block is good and the connections are tight
YES NO Notes:

Additional Comments/Recommendations:

3. Check the X axis black energy chain:

 Notice any visible damage to the track, or to any hoses and cables inside the track
YES NO Notes:

 While observing the track when the machine is in operation, it lies properly in the J channel support
YES NO Notes:

Additional Comments/Recommendations:

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4. Manually check the X and U axis runner blocks by pushing the axes from one end of the stroke to the other.
 Are there noticeable tight spots where travel becomes difficult, or any grinding as the axis is traveling
YES NO Notes:

 The motion of the motor is free

YES NO Notes:

 Grease and lubricate all runner blocks.

Notes:

Additional Comments/Recommendations:

5. On Moving Gantry (G-Series) machine’s:

 The rack on both X and U are clear of visible build up and/or debris.
YES NO Notes:

Additional Comments/Recommendations:

6. Check the linear rails for the X and U axes:

 The X axis linear rail is free of visible damage (i.e. dings, gouges, missing caps, etc.)
YES NO Notes:

 The U axis linear rail is free of visible damage (i.e. dings, gouges, missing caps, etc.)
YES NO Notes:

Additional Comments/Recommendations:

7.  The X axis motor mounts, brackets, bolts, and cable connections are secure and free of visible damage.
(NOTE: On Fixed Bridge models, Check and tighten belt as needed, check that there are NO
missing teeth, cracks or fraying in the belt. Replace as necessary.)
YES NO Notes:

 The U axis motor mounts, brackets, bolts, and cable connections are secure and free of visible damage.
(NOTE: On Fixed Bridge models, Check and tighten belt as needed, check that there are NO
missing teeth, cracks or fraying in the belt.)
YES NO Notes:

Additional Comments/Recommendations:

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8. Y axis runner blocks and ball screw - Manually move the axis from one end of the stroke to the other by rotating the
ball screw pulley.
 Tight spots noticeable where travel becomes difficult, or any grinding as the axis is traveling
YES NO Notes:

 The motion of the motor is free

YES NO Notes:

 The lock nut on the pulley end of the ball screw is tight as well as the set screw for the lock nut
YES NO Notes:

 Grease and lubricate all runner blocks

Notes:

Additional Comments/Recommendations:

9.  Check the Ball Nut support Bolts going through the Back Plate to the Y axis Ball Nut Also check the
mounting bolts for the Ball Nut and Servo Motor carrier.
Notes:

 Check the mounting bolts for the Ball Nut and Servo Motor carrier
Notes:

Additional Comments/Recommendations:

10. Check the linear rails for the Y axis:

 The Y axis linear rail is free of visible damage (i.e. dings, gouges, missing caps, etc.)
YES NO Notes:

Additional Comments/Recommendations:

11.  The Y axis motor mount bolts, support bracket bolts, and cable connections are secure and free of visible
damage
YES NO Notes:

 Check and tighten belt as needed, ensure that there are NO missing teeth, cracks or fraying in the belt
Notes:

 Ensure the keys are in their keyways

Notes:

Additional Comments/Recommendations:

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12. Check the Y axis black energy chain:

 Notice any visible damage to the track, or to any hoses and cables inside the track
YES NO Notes:

Additional Comments/Recommendations:

13. Z axis runner blocks and ball screw - Manually move the axis from one end of the stroke to the other by rotating the
ball screw pulley.
 Tight spots noticeable where travel becomes difficult, or any grinding as the axis is traveling
YES NO Notes:

 The motion of the motor is free

YES NO Notes:

 The lock nut on the top end of the ball screw is tight as well as the set screw for the lock nut
YES NO Notes:

 Grease and lubricate all runner blocks

Notes:

Additional Comments/Recommendations:

14. Check the linear rails for the Z axis:

 The Z axis linear rail is free of visible damage (i.e. dings, gouges, missing caps, etc.)
YES NO Notes:

Additional Comments/Recommendations:

15.  Check the Ball Nut support bolts going through the front spindle plate to the Z axis ball nut
Notes:

Additional Comments/Recommendations:

16.  The Z axis motor mount bolts, support bracket bolts, and cable connections are secure and free of visible
damage
YES NO Notes:

 Check and tighten belt as needed, ensure that there are NO missing teeth, cracks or fraying in the belt
Notes:

 Ensure the keys are in their keyways

Notes:

Additional Comments/Recommendations:

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17. Check the Z axis black energy chain:

 Notice any visible damage to the track, or to any hoses and cables inside the track
YES NO Notes:

Additional Comments/Recommendations:

18. Tool Tray Assembly:

 Check that the Tool Tray has proper free rotation, ensuring that there are no tight spots in the gear box.
Notes:

 Ensure tool tray mounting is secure, and that the tray is level
Notes:

 Check all sensors and cable connections at the tool tray are secure and in place
Notes:

 Grease and lubricate all runner blocks

Notes:

Additional Comments/Recommendations:

19. Dust Hood Assembly:

 Ensure that the dust hood mounting bolts are secure
Notes:

 Ensure that the brush cylinders are secure

Notes:

 Note the condition of the brushes; check the back brush flap for proper mounting and proper motion
Notes:

Additional Comments/Recommendations:

20. Electrical Cabinets:

 The outside of the rear electrical cabinets are free of dust and/or debris
YES NO Notes:

 The inside of the rear electrical cabinets are free of dust and/or debris
YES NO Notes:

Additional Comments/Recommendations:

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21. Centralized grease fittings:

 All grease lines are connected properly and are free of visible damage
YES NO Notes:

 All runner blocks and ball screws are lubricated with Chevron NLGI No. 1 Grease
YES NO Notes:

Additional Comments/Recommendations:

UPON MACHINE POWER UP

22. With the Main Disconnect turned “ON”, verify the proper running voltage going into the machine before turning on the
machine power. Record Voltage Below:

23. Grounding:
 Machine is properly grounded
YES NO Notes:

 Isolation transformer is installed

YES NO Notes:

 Machine has a ground rod dedicated to the machine and transformer

YES NO Notes:

Additional Comments/Recommendations:

24. Fans:
 The spindle fan is functioning properly
YES NO Notes:

 The servo drive fans are functioning properly

YES NO Notes:

 The control units fans are functioning properly

YES NO Notes:

 The electrical box fan is functioning properly

YES NO Notes:

Additional Comments/Recommendations:

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25. Control System (depending on control unit in place, these steps may vary):
 The control system boots up properly
YES NO Notes:

 All datum switch signals are functioning properly

YES NO Notes:

 All vacuum overrides are activating properly

YES NO Notes:

 Tool tray in position functioning

YES NO Notes:

 Machine outputs are activating and deactivating properly

YES NO Notes:

 If applicable, document the total machine runtime hours here:

Additional Comments/Recommendations:

26. Emergency Stop Circuit:

 When all emergency bump bars are triggered, E-Stop is achieved
YES NO Notes:

 All Emergency Stop buttons are functioning properly (press & reset)
YES NO Notes:

 The Emergency Stop Cable is functioning properly (if applicable)

YES NO Notes:

 All Over Travel Switches are operating properly

YES NO Notes:

Additional Comments/Recommendations:

27. On Moving Gantry (G-Series) machine:

 Check the mesh on both the X axes and the U axes front and back of the column. Indicate each column at
the front (i.e. X 0”), middle (i.e. X 60” to 72”) and at the back (i.e. X 120” to 145”) of the machine. Adjust
mesh as needed.
Front:
Middle:
Back:
Additional Comments/Recommendations:

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28. Datum/ Home the machine ensuring proper homing direction and location. After cycle is complete verify the Machine
Zero position bringing a V-Bit down to the front corner.
*Note: Fixed Bridge machines will need to have Table 2 Machine Zero Position checked.
Additional Comments/Recommendations:

29. Manually Jog each of the axes to ensure smooth motion, and that there is no motor noise during the axes
acceleration, deceleration, and actual travel.
Additional Comments/Recommendations:

30. Check all tool holders & collets for rust, buildup or damage.
*If Needed: Clean with some fine grade scotchbrite and lacquer thinner.
Additional Comments/Recommendations:

31. Tooltray & Aggregate:

 Check tool tray pockets for wear and tear. Replace damaged clips as needed.
Notes:

 Check tool change alignment in both Y and Z axes.

Notes:

 Check pocket alignment in rotation of the tray. Adjust mechanically as needed.

*Note: If parameters need to be changed, please note the new value for future reference.
Notes:

 Aggregate Changer: Check and verify it’s change position (if applicable)
Notes:

Additional Comments/Recommendations:

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32. Spindle & Tool Sensors:

 Check the spindle cone for debris and clean and lubricate as recommended by the manufacturer.
*NOTE: Ensure that you use clean dry air.
Notes:

 Check the spindle drawbar bullet adjustment and adjust the distance if it is protruding from the nose of the
spindle cartridge if necessary.
Notes:

 Check spindle sensor activation during a tool change. Ensure that the sensors are activating and
deactivating in proper sequence.
Notes:

 Check the cone air blast to be sure that there is no restriction of airflow during tool change routine.
Notes:

 Check the Tool Release, Tool Lock, and Tool Capture sensors at the circuit board in the electrical cabinet.
Notes:

 Perform a preliminary field diagnosis of the spindle bearing by first checking the “free spin” of the spindle.
Then perform a spindle start up at 9,000 rpm listening for any bearing damage. Step the rpm of the spindle
up by 2,000 rpm every 2 minutes until reaching 18,000 rpm.
*Note: If a Spindle hour meter is present, record the reading below.
Hour Meter Reading:
Notes:

 Check the spindle for run out using a 12” Alignment Rod. Also perform a spindle tram check. Ensure that the
spindle is perpendicular to the table.
Notes:

 If applicable, verify Drill Head Offset Distance is correct for the intersecting bit of the drill block to the center
of the spindle. Adjust as needed.
Notes:

Additional Comments/Recommendations:

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33. Table Vacuum Zones & Components:

 Check vacuum table gasket tape for wear and damage.
Notes:

 Check all hoses for any possible wear or damage.

Notes:

 Verify ball valves are working properly and secured.

Notes:

 Check the vacuum PVC, plenum for any cracks or damage.

Notes:

 Totally seal one zone at a time to check vacuum gauges for a good pressure reading.
Notes:

 Verify that the vacuum zone overrides are working properly.

Notes:

 Check that the pressure sensors are working properly.

Notes:

Additional Comments/Recommendations:

34.  Send a program supplied by customer to the machine checking for proper communication in the download.
Verify that program was received at the controller, and run the job.
Notes:

 Check and make sure the finished part for square, edge finish quality, and if part is cut to size.
Notes:

Additional Comments/Recommendations:

35. Discuss options for additional control training, machine operation training, application’s training, and software training
(if it is software purchased from C.R. Onsrud) with the customer.
Additional Comments/Recommendations:

36. Perform a complete control system back up of any parameter changes made leaving one copy for the customer and
providing one for C.R. Onsrud, Inc.
Additional Comments/Recommendations:

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The items listed in this Preventative Maintenance Checklist have been completed as described above to the satisfaction
of the authorizing party.

Signed: Date:

Please Print
Name:
Additional
Comments:

C.R. Onsrud Service Technician

Signed: Date:

Please Print
Name:

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C.R. Onsrud, Inc. New Router Limited Warranty

1. TERMS AND CONDITIONS. At C.R. Onsrud, Inc. (the “Company”), we take great pride in the quality of our products and
carefully inspect and test our products prior to their sale. Subject to the terms, conditions and limitations set forth herein, we, therefore,
agree to correct any defects in our materials or workmanship which arise within two (2) years from the date of shipment from our
factory of any new, unused equipment, parts and machines provided that such equipment, parts and/or machinery are utilized in
conformance with the specifications for the same. However, this warranty does not extend to the repair or replacement of parts,
equipment or machines whose failure is caused, in whole or in part, from normal wear and tear, misuse, abuse, negligence, or willful
acts, either in installation or operation. In addition, this warranty does not extend to the repair or replacement of parts as part of
adjustments or routine maintenance. This Limited Warranty will be rendered null and void if the machine, or any parts thereto, has
been repaired or altered with parts and/or equipment not supplied or pre-approved by the Company. The Company further reserves
the right to decline responsibility where installations, repairs, maintenance or alterations have been improperly made or attempted by
others.
This Limited Warranty applies only to such new equipment, machines and parts manufactured by the Company. Any parts,
equipment, software, or machinery manufactured or supplied by other manufacturers shall be covered solely by the warranty, if any, of
such manufacturer and not by the Company. Moreover, this Limited Warranty shall extend only to the original purchaser from the
Company and may not be sold, assigned, conveyed or otherwise transferred, in whole or part, by operation of law or otherwise, to any
person, firm, corporation or other entity.
If your account payment status is not kept current and satisfactory, all technical support, software support and warranty
obligations, including those set forth herein, will be suspended. Any and all machines, equipment or parts requiring repair or
replacement under this Warranty Agreement shall be sent to the Company F.O.B. Troutman, North Carolina. Should the purchaser fail
to return to the Company the defective machine, equipment or parts within ten (10) days of its receipt of any replacement, then the
purchaser hereby expressly agrees to pay to the Company the full cost of such parts, equipment or machine, as if new and in good
working order, plus interest accruing until satisfied.

2. LIMITATIONS, DISCLAIMERS AND EXCLUSIONS. EXCEPT AS PROVIDED HEREIN, THERE ARE NO WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
THE MAXIMUM LIABILITY OF THE COMPANY ARISING FROM ANY WARRANTY CLAIM SHALL BE LIMITED TO THE REPAIR
OR REPLACEMENT OF THE COMPONENTS PROVEN DEFECTIVE. UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE
LIABLE OR RESPONSIBLE FOR ANY INCIDENTAL, SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, INCLUDING ANY
CLAIMS FOR ECONOMIC LOSS, LOSS OF PRODUCTION OR MATERIALS, PROPERTY DAMAGE, PRODUCT LIABILITY,
PERSONAL INJURY, OR ANY OTHER CLAIM BY THE PURCHASER, ITS AGENTS, EMPLOYEES, INSURANCE CARRIERS,
SUBROGATES, SUCCESSORS, ASSIGNS, OR THIRD PARTIES ARISING OUT OF THE USE OF THE PRODUCTS EXCEPT AS
EXPRESSLY PROVIDED HEREIN.

3. GOVERNING LAW, ARBITRATION AND FORUM SELECTION: This Limited Warranty agreement and the parties’
rights, obligations and performance under it are governed by the laws of the State of North Carolina excluding its choice of laws’
provisions and excluding the Convention for the International Sale of Goods.. Any controversy, claim or dispute arising out of or
relating to this Limited Warranty agreement shall be submitted to binding arbitration in Troutman, North Carolina in accordance with
the rules and law of the State of North Carolina, including the Revised Uniform Arbitration Act. The Parties shall each pay one-half of
the costs and expenses of such arbitration and each shall separately pay its counsel fees and expenses unless otherwise ordered by
the arbitrator(s). In the event that a dispute arises which requires arbitration or results in legal action, the prevailing party may recover
its reasonable attorney’s fees pursuant to N.C. Gen. Stat. § 6-21.6. Judgment upon any award rendered by the arbitrator(s) may be
entered in any North Carolina State Court having jurisdiction thereof. Further, the purchaser hereby irrevocably consents to and
confers personal jurisdiction upon the courts of the State of North Carolina, and waives any objections to the jurisdiction or venue of
such courts.

4. ENTIRE AGREEMENT AND MODIFICATION. The terms and conditions contained in this Limited Warranty agreement
shall constitute the entire and only agreement between the parties on the subject of the warranty of the products, superseding any and
all prior or contemporaneous oral or written agreements or communications between the parties as it relates to the warranty of the
products of the Company. This Limited Warranty agreement may not be modified or altered by sales agents or distributors of the
Company.

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