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1、Operational Manual of CNC Laser Cutting Machine28Machinery and Maintenance (SLCF-X Series)ChapterII LaserequipmentuseconditionsandequipmentinstallationI Use Condition of Equipment The use conditions of equipment may be slightly different if the equipment is equipped with different lasers. Please pre
2、pare corresponding conditions according to requirements in the chapter on the basis of corresponding laser. (A) ROFIN Fiber LaserTable 1 Use Condition of Equipment Provided with ROFIN Fiber LaserItem Requirements Remark Equipment Installation Foundation 1) It is required that the foundation should b
3、e constructed in strict accordance with the foundation drawing, and the cement strength level is higher than 42.5. Equipment Applicable Environment 1) Please ensure that the operating temperature of laser cutting equipment is between 5 and 400C. Laser Applicable Environment 1) Temperature: uniform h
4、eating between +5 and +40 ; 1) Relative air humidity: 10% -90 % (non-condensing) Small rooms should be set and equipped with air conditioners; Site Power Supply 1） Power supply capacity: 50 kVA2) Quality of power supply: three-phase voltage stability: 5%, three-phase power supply imbalance: 2.5%Thre
5、e-phase electronic stabilized power supply is recommended. Laser Cooling Water 1) Valves and pipelines All valves and pipelines are made of stainless steel or high-pressure hoses rather than galvanized materials, and stainless steel clips are adopted on pipe connectors. 2) External water pipe Rubber
6、 hoses with inner diameter of 1 (25.4mm), and outer diameter of 1.25 (32mm) or above, plastic (PVC) pipes, stainless steel or brass pipes; 3) External optical water pipe PU pipe with pressure resistance not less than 10kgf/cm2, please pay attention to sealing the pipe connectors. 4) Filter: filter p
7、ore diameter is 100m, and it should be preferably made of transparent plastic.5) Please see manual of laser; Auxiliary Gas Gas for Cutting Carbon Steel 1) One bottle of high purity oxygen (99.995%)Consumables 2) Three bottles of oxygen (99.6%)Gas for Cutting Stainless Steel 3) Three bottles of nitro
8、gen (99.7%) Compressed Air Source 1) Air quality: ISO8573-1 Maximum particle size: 5m Maximum condensate content: 5mg/m3 Maximum oil content: 0.1mg/m3 It is recommended that the equipment can be equipped with oil-free air compressor and freeze dryer (treatment capacity of 1 m3/min)Computer for Progr
9、amming 1) IBM PC compatible computer, CPU above PIII, memory greater than 512M, hard disk larger than 20G, operating system: Windows XPSheets for Debugging/Acceptance 1) Carbon steel: various specifications, it has smooth surface, black coating and none rust, and Baosteel SS400 is recommended. 2) St
10、ainless steel: various specifications; Gas Pressure Reducer for Gas Cylinder 1) Four oxygen pressure reducers for cylinder; 2) Two nitrogen pressure reducers for cylinder; Fire-fighting 1) Fire-fighting equipmentOthers 1) Acetone 500mL 2) Alcohol 500mFor maintenance II Equipment Installation(A) Hand
11、ling, Lifting and Positioning User should provide route for transporting the machine to the installation location and other information before delivery, specially, door dimension, pillar height, cable rack height, whether armored rollers can be used on the road or not, etc. Our company can transport
12、 the machine to agreed destination by vehicle.User should inspect damage condition of all equipment parts due to transportation after the equipment arrives in the destination, and record the condition on the shipping list signed by delivery drivers.The user is responsible for transporting the equipm
13、ent to the installation location, and pay attention to the machine scales marked on the drawing during transportation. Sizes of machine components related to transportation are shown in the following table. Table 3 Size of PartsComponent Name Length (mm)Width (mm)Height (mm)Remark Host machine 70001
14、1000 if workbench is included. 34003450Including machine body, cross beam, electric cabinet, gas path cabinet, light guiding system, machine casing, etc. Main workbench 45002800926Cutting zone base, partition dust collector, one cutting table and four bins; Workbench in feeding area 35002100950Laser
15、 support 11008001100Water cooler (including package) 14008001600Air compressor (including package) 13001000800freeze dryer (including package) 600400450Stabilized power supply (including package) 6005001200D series laser (including package) 220012001200Laser power supply (including package) 10008001
16、700CP4000 laser (including package) 350013001400Spare part wooden case7007006002 pieces Related information about lifting is described below: Trunk crane for lifting machine, switchboard and ancillary equipment; Recommended hoisting force: at least 30t. Forklift with capacity of 5t. Overhead crane w
17、ith capacity of 10t. Armored rollers, one is steerable, and two are solid. At least four hydraulic jacks with hoisting force of at least 5t (minimum regulating height: 40mm). Crowbar as long as 1 m, and extended part with enough strength; The machine should not be placed on the ground without floor;
18、 otherwise bottom of assembly can be damaged. The machine supporting pin bottom board must be higher than the ground by 80 mm. The distance to ground must be kept in the process of transporting the machine to the installation location. Laser power supply, cooling unit, stabilized power supply, freez
19、e dyer, laser support, dust collector (if it is available) and laser generator can be directly transported from the trunk to the installation location of the machine by forklift. The machine can be moved from outside environment to workshop by sheathed rollers, and further moved to the installation
20、location by overhead crane with considerable lifting capacity in the workshop or by the armored rollers continuously. Hydraulic jacks should be used in order to place the machine to the installation location and align it by armored roller. The machine host and workbench should be removed and placed
21、in appointed positions after the machine is transported to the site 1. If there is a vehicle or trunk crane with lifting capacity more than 10 tons, the other operator can operate as follows: Fixing blockSupport frameUpper cover boardLifting ringVertical lifting force greater than 10tFigure 1 Host L
22、ifting2. Workbench lifting: Four M24 lifting ring screws are tightened, note: the lifting ring screws should not be collided with the protective board; 3. The machine should be lifted and positioned in the workshop according to lifting criteria of heavy machinery. 4. The cross-beam support frame and
23、 fixing block should be removed after the machine is positioned. Otherwise, the machine should be moved by a jack and roller with carrying capacity greater than 10 tons: The machine should be lifted up by jack, and can be led to appointed location by certain force with the roller at the bottom of th
24、e machine. It is recommended that the machine should not be moved by forklift which can be tipped over due to instable center of gravity.(B) Installation ConditionsEquipment installation conditions are shown in layout figure provided by our company in advance.1. Field Space RequirementRequirements o
25、n layout of equipment parts and field space of equipment installation are shown in the equipment installation diagram (foundation drawing). Sufficient space should be left for opening doors of stabilized power supply, machine casing, electric cabinets, laser, dust collector, cooling device, freeze d
26、ryer, air compressor and other equipment for repair and maintenance in the future. 2. Ground RequirementsThe ground should be flat with certain carrying capacity as equipment foundation. The height different must be 5 mm in the range of host and switchboard. The height can be leveled by adjusting ho
27、rn during installation if it is slightly unlevel. A steel plate with sooth surface must be embedded in the part for supporting host base (machine body) and switchboard, which can be welded with horns. The iron pads should be produced and embedded according to requirements in foundation drawing, whic
28、h should be compact without suspension. Note Change in ground load in equipment surrounding area may form external effect on the equipment, thereby affecting the quality in cutting workpieces; Ground load is changed by the following factors: driving of vehicles, forklifts and land conveyers, install
29、ation or removal of other heavy machines around the equipment, operation of equipment causing vibration, such as punch, bender, shearing machine, etc. . 3. Foundation Bearing Concrete minimum thickness is 150 mm, and compressive strength is 1 N / mm (excluding iron mat region) within machine install
30、ation scope. Concrete depth in host region: 550mm. Foundation depth in workbench area: 300mm.Concrete shall meet the following requirements:Compressive strength: 20 N / mm .Payload: 100 kN / m.Note Please discuss with technicians from Shanghai UNITY PRIMA Laser Machinery Co., Ltd. if the above requi
31、rements can not be met. 4. Climate FactorsThe ambient temperature must be between +10 C and +40 C during equipment operation. The ambient temperature shall not be lower than +4 C when the equipment is turned off.Tips 1. Direct sunlight should be avoided; 2. There is no painting or degreasing equipme
32、nt near the laser. Rays with wavelength of 1.06 m can be absorbed by steam emitted during painting containing solvent, and steam of degreasing equipment. 3. The laser must be equipped with air conditioning device when the ambient temperature is 35 C. 4. The laser should not be operated in wet enviro
33、nment with relative humidity greater than 70%, otherwise, condensed water drips to corrode contactor and relay contacts, thereby making control system fail. Air conditioner can reduce temperature and humidity. (C) Weight Distribution of Machine ComponentsComponents of the machine are shown in layout
34、. The bearing capacity of the ground must be statically tested prior to installation. The weight of related equipment components and support points can be inquired from the following list. Table 4 Weight Distribution of MachineNo. Component Name Weight Distribution Total Weight (kg) 1Host (Including
35、 machine body, cross-beam,electric cabinet, gas path cabinet, light guiding system, etc.) 12 iron pads at the bottom of machine 90002 Main workbench (Base, cutting table, safety door, maximum workpiece weight) 4 iron pads at the bottom of base 40003Workbench in feeding area (Including weight of two
36、maximum workpieces) 4 iron pads at the bottom of base40004Cutting table 200kg (operation at workbench base) Single workbench 200Change workbench 4005Maximum workpiece weight 700kg distributed on cutting table 6Waste bin 420kg distributed on ground 807Laser and support 2 tie plates at the bottom 8Wat
37、er cooler (empty) 2 tie plates at the bottom of base 10009Air compressor Placed on flat ground 30010freeze dryer Placed on flat ground 555811Stabilized power supply (optional) Placed on flat ground600(D) Dust Removal Exhaust Pipe 1. Dust Removal System for Outward Exhaust by Common Axial Fan The dus
38、t removal pipeline is connected with the machine on one end, and is connected with the axial fan on the other end for exhausting the smoke of the machine outdoors. The pipeline must be fire-retardant with at most three bends, wherein the bending angle is 90 and bending radius is pipe diameter 1.5. T
39、he maximum pipeline length is 10 m. Pipe diameter: 220 mm for internal connection and 300mm for external connection. 2. Outward Exhaust by Environment-friendly Dust Collector Pipeline must meet the following requirements: Pipelines must be fire-retardant with at most two bends, wherein the bending a
40、ngle must be 90 , and the bending radius is pipe diameter 1.5. The maximum pipeline length is 10 m. The pipe diameter is 260 mm. Hard metal pipelines should be used as far as possible as middle-ware overlapped on the compact dust collector.Note If the dust collector is equipped by the customer, plea
41、se contact our technician or the supplier technician of the dust collector for installation and connection on the site. The duct collector should not exceed the maximum wind resistance 10daPa (= 100Pa), and our company does not guarantee dust collection effect.(E) Gas Pipeline (Line) Installation1.
42、Cutting Auxiliary Gas and Pipeline Installation(1) Cutting Gas Purity Requirements The purity of cutting auxiliary gas (hereinafter referred to as “auxiliary gas”) directly affects the cutting quality. General requirements on auxiliary gas purity are listed in the following table.Table 5 Auxiliary G
43、as PurityGas Category Purity Oxygen (O2 )99.95%Nitrogen (N2)99.6-99.999 %AirWater Oil Content 0.003ppm (2) Cutting Gas ConsumptionCutting gas consumption is related to the following factors: Nozzle diameter Material and plate thickness Auxiliary gas pressure Laser cutting duration The consumption of
44、 auxiliary gas during standard pressure cutting and high pressure cutting is listed in the following table, and the demanded cutting gas consumption can be estimated roughly according to the table. Table 6 Auxiliary Gas Consumption Gas Category N2O2 Consumption (Related to material and plate thickne
45、ss) 24 hours /15 cylinders (816 minutes/cylinder) 24hours/cylinder(3) High Pressure CuttingHigh pressure cutting is defined when the nozzle pressure is 6bar. High pressure cutting is adopted for processing stainless steel and aluminum alloy.Container frame is recommended when nitrogen is used as gas
46、 for high-pressure cutting. The secondary pressure of nitrogen cylinder is at least 30bar (when gas consumption is 85Nm3 / h, exit port is 2.5mm, and cutting gas pressure is 20bar).Secondary pressure of oxygen cylinder should be at least 20bar when oxygen is used as gas for high-pressure cutting (wh
47、en gas consumption is 20Nm3/h, exit port is 2.5mm, and cutting gas pressure is 10bar).(4) Auxiliary Gas PipelinePipelines must be installed in accordance with the connection positions marked by the symbols in the following installation drawing, please see the following drawing. Value containerFigure 2 Installation of Auxiliary Gas PipelinesConnected position should be away from the ground by about 300 mm, and the pipelines should be connected from the lower portion. Connec