Hardware and Machine Anatomy

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 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. 
 
 ← Safety Rules 

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