Hardware and Machine Anatomy
Hardware and Machine Anatomy
Manufacturer Specifications (Gen 2 Foreman)
- Cut area: ~49" × 49⅞" (1245 × 1248 mm)
- Z travel (Z-20 slider): ~165 mm (~6.5")
- Gantry clearance: up to ~160 mm depending on Z-slider mount height
- Motion: closed-loop steppers; 60 mm X rail / 50 mm Y rails
- Spindle: Redline 80mm 1.5kW air-cooled - ER20 collet (up to 1/2" shank); max ~1.5" bit diameter recommended
- Power: 110V spindle
Our Setup (Makerspace)
| Setting | Value | Implication |
|---|---|---|
| Z-20 mount position | Highest position | Maximizes gantry clearance (~160 mm) but reduces effective Z reach to the spoilboard - plan job thickness accordingly |
| Spoilboard | 3/4" (19 mm) | Include in Z-zero and max cut depth calculations; resurfacing removes material over time |
| Workholding | T-tracks | Use T-track clamps and fixtures (no vacuum table) |
| Dust collection | Not installed yet | Coming very soon - use shop vac / manual cleanup until installed |
Effective max work height also depends on spindle position in the mount and bit stick-out. Tall workpieces may eventually require lowering the Z assembly (trading gantry clearance for more Z reach).
TBD: Exact effective max cut height measurement for our current mount + spoilboard setup.
Bits and Collets
The spindle uses an ER20 collet system. Collet size must match your bit’s shank diameter exactly - using the wrong size collet is a safety hazard.
| Spec | Value | Notes |
|---|---|---|
| Collet type | ER20 | Standard ER20 collets; select size to match bit shank diameter exactly |
| Max shank diameter | 1/2" (12.7 mm) | Largest ER20 collet size; do not attempt larger shanks |
| Max bit diameter | ~1.5" | Larger bits have excess rotational mass and can fault the VFD - avoid |
| Installation | Two wrenches required | One wrench on the spindle flat, one on the collet nut; never run with a loose collet |
Install and tighten the bit before any spindle power. Always inspect the collet for wear or damage before use; replace if needed.
Component Glossary
| Component | What it is | Controlled by |
|---|---|---|
| Spindle | Motor that spins the cutting bit | VFD + RTS-X |
| VFD | Variable Frequency Drive - converts power and sets spindle RPM | RTS-X (must not be in manual/local mode during jobs) |
| Z-20 slider | Heavy-duty vertical axis assembly | RTS-X motion firmware |
| RTS-X controller | Real-time motion controller (closed-loop on Elite) | RTS-X firmware |
| Shop PC | Dedicated CNC computer at the makerspace | RTS-X Windows app (sole interface - no HMI touchscreen) |
| VCarve Pro | CAM/design software - creates toolpaths, does not run the machine | Separate from RTS-X |
Note: This machine does not have the optional Redline HMI touchscreen. All homing, zeroing, file import, simulation, and job execution happen through RTS-X on the dedicated shop PC.
TBD: Physical layout diagram - shop photos of spindle, VFD, e-stop, shop PC station, and work area. Link stock Onefinity manual diagram until then.
TBD: Shop-specific power outlet / breaker labeling.
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