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Sauer LASERTECH 40 Planning Documentation

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Planning documentation LASERTEC 40
Documentation for preparatory measures for installation,
commissioning and operation;
including transport and installation instructions
LASERTEC 40

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Summary of Contents for Sauer LASERTECH 40

  • Page 1 Planning documentation LASERTEC 40 Documentation for preparatory measures for installation, commissioning and operation; including transport and installation instructions LASERTEC 40...
  • Page 2 The version in the manufacturer's language (German) is definitive for the technical content. Issue: 02/10 Ident no.: 2586320*PU*LT40*GB*8124 ©2010 SAUER GmbH LASERTEC 40...
  • Page 3 Ensure the manual is available at the machine. Nobody without the necessary training - whether provided internally, by a training organisation or directly by SAUER GmbH - is allowed to operate the machine, even for a short time.
  • Page 4 Effective utilisation of the machine Training courses SAUER provides training and further training for specialist personnel as a service. Whether the machine’s features are actually utilised depends on the user’s qualifications. For this reason, clarify in good time whether your staff has the necessary knowledge.
  • Page 5 Planning, transport, installation Symbols used Note Specific information on operating sequences, machine reactions and cost- effective usage of the machine. • Please pay attention to the related information. • Also pass on all notes to other operators. Attention Specific instructions, requirements and actions that are not allowed to prevent damage.
  • Page 6 Planning, transport, installation Hazard due electrical power Warning about hazardous electrical power, mortal danger! • Please pay attention to the related information. • Take particular care in these cases to prevent placing people at risk due to electrical power. • Also pass on all safety instructions to other operators.
  • Page 7 Planning, transport, installation Necessary preparatory measures Actions to be undertaken by the customer The customer is responsible for the following preparatory measures: Installation location • Preparation of installation location for the machine. See “Conditions for installation location”. • Ensuring the availability of: Supply of electricity, light, water, telephone Transport •...
  • Page 8 Planning, transport, installation Service / maintenance "As per and in addition to the general installation conditions, VDW 502 A and LMW 188 A, the operating organisation undertakes the obligation to provide technical support during installation and repair work, in particular the provision of suitable ladders, platforms, scaffolding, heavy tools, lifting gear etc.".
  • Page 9 The customer is entirely responsible for a suitable installation location. If problems should arise later due to failure to follow the information provided, SAUER cannot be held responsible. Ambient temperature The room must be evenly heated and the temperature should fluctuate as little as possible: •...
  • Page 10 Planning, transport, installation Corrosion prevention To prevent corrosion on the workpiece and machine, the installation location must be dry and free of aggressive vapours: • No soldering, welding, painting, pickling or electroplating systems in the same room. Foundation A suitable bearing plate approved by a structural engineer is required. •...
  • Page 11 Planning, transport, installation Load bearing capacity Ensure the floor has adequate load bearing capacity. • Have the load bearing capacity checked by a structural engineer. Have the structural engineer determine in a binding manner • That the load bearing capacity of the floor, the cellar roof or intermediate storey, including its substructure, is adequate (also in older buildings).
  • Page 12 Planning, transport, installation Cellar roofs, intermediate floors In case of installation of the machine on cellar roofs, intermediate floors or other load bearing structures: Have a structural engineer experienced in structural dynamics determine in a binding manner, as per DIN 4024 part 1: Flexible structures that support machines with rotating elements, •...
  • Page 13 Planning, transport, installation Access Adequately large access openings must be available for moving the machine to its installation location. Room height Ensure the room height is adequate so that installation and maintenance work can be performed unhindered. Machine area Ensure there are no pillars or other obstacles in the area of the machine that could hinder installation and maintenance work.
  • Page 14 • installation in potentially explosive atmospheres or areas containing potentially explosive substances consult SAUER GmbH. Information for machines with series transformer The cable connection between the overcurrent protection device (main fuse) and the separate series transformer depends on the operating voltage at the customer.
  • Page 15 Planning, transport, installation Installation dimensions Height Machine height ……………………………….. mm ………………. 2 370 ……………………………….. inch ………………. 93,30 Transport height ……………………………… mm ………………. 2 300 ……………………………… inch ………………. 90,55 Width Machine width …………………………………. mm ………………. 2 476 …………………………………. inch ………………. 97,50 Length Machine length ………………………………...
  • Page 16 Planning, transport, installation Installation area L x W ……………………….. mm …….. 4 250 x 3 876 ……………………….. inch …. 167,32 x 152,60 Mains connection In addition, escape routes and safety areas are to be maintained in accordance with local laws, regulations and stipulations. LASERTEC 40 Page 15...
  • Page 17 Planning, transport, installation Machine Standard LASERTEC 40 Page 16...
  • Page 18 Planning, transport, installation Weight Machine weight Machine ………………………………… Approx. kg …………….. 2 200 Installation weight Machine with max. weight for workpiece, oils and liquids ………………………… Max. kg ………………… 2 250 Load of foundation plates …………….. KN ……………………… 2 250 Machine supports Quantity + type ……………………………….
  • Page 19 Planning, transport, installation Installation data Electrical supply During the electrical installation attention is to be paid to ensuring EN 60 204, part 1, point 6.3.3 "Protection by automatic interruption of the power supply" is met. On this topic also see IEC 364-4-41 (DIN 57 100, VDE 0100, part 410). The machine is not allowed to be connected to mains with a residual current circuit breaker, see EN 50178, point 5.3.2.3 (old VDE 0160, point 5.5.3.4.2).
  • Page 20 Planning, transport, installation Connection ratings Machine connection: TN-S supply with 3 conductors (L1, L2, L3) as well as neutral conductor (N) and earth conductor (PE). Mains connection ………………… 3N/PE~50/60 Hz …….. 400/230 V Open cable length above floor …... m ………………………………...
  • Page 21 Planning, transport, installation Transport Transport instructions General instructions These transport instructions provide information on the attachment of transport equipment and tackle as well as on the safe transport of pallet, crate and machine. If a machine already installed is to be moved to a different place, the machine must be carefully prepared for the transport (see Transport preparation).
  • Page 22 Planning, transport, installation Transport machine, switch cabinet and accessories carefully! • Under no circumstance support or push using delicate parts such as the control panel, levers, trim panels or splash protection feature! • Fit lifting irons in the recesses in the machine base if necessary. Risk of accident due to pallet or crate falling or tipping! •...
  • Page 23 Planning, transport, installation What is the purpose of this documentation? This documentation is aimed at the people responsible for the transportation, positioning and installation of the machine and their staff. They will then be in a position to prepare the installation location and its surroundings so that the machine can be installed and connected immediately on delivery.
  • Page 24 Planning, transport, installation Delivery We deliver the machine • Either on a pallet with Plastic or aluminium (poly-cover) within Germany Aluminium sheeting across Europe • In a crate Accessories Standard accessories, tools and documentation are packed with the machine or in separate boxes. (Please unpack these boxes carefully) LASERTEC 40 Page 23...
  • Page 25 Check machine and accessories for transport damage and for completeness, using the delivery note. In case of damage • Report damage directly to SAUER service and in good time to the freight haulier. • Contact SAUER and your freight haulier immediately.
  • Page 26 Planning, transport, installation Transport in the packaging Only transport machine, switch cabinet and accessories to the installation location in the packaging - if possible. • It is imperative you observe the markings and instructions on the packaging. • Take into account the related transport weight and the transport dimensions (see shipping paperwork and "Technical information").
  • Page 27 Planning, transport, installation Transporting crate using a forklift truck Attach fork lift arms as wide apart as possible, as the centre of gravity is not necessarily in the middle of the packaging! Pay attention to the related markings for points for connecting tackle and the centre of gravity.
  • Page 28 Planning, transport, installation Transport equipment required If the tackle, lifting gear and tools stipulated by SAUER are not used, SAUER accepts no liability for damage or injuries. Machine The following transport equipment and tackle are required for transporting the machine without packaging: •...
  • Page 29 • If possible, take photographs of the damage. • Inform SAUER service about the damage. • Remove the fastenings that secure the accessories, peripheral equipment and the machine to the means of transport (lorry). Unload the accessories first and then the machine.
  • Page 30 Planning, transport, installation Transport data Transport weight Standard ………………………………. Approx. kg ………………. 2 560 Machine with pallet …………….……. Approx. kg ………………. 3 760 Machine with crate ………………….. Approx. kg ………………. 4 210 Exhaust system …………….………... Approx. kg ………………….. Chiller …………………………………. Approx. kg ………………... Transport dimensions, approx.
  • Page 31 Planning, transport, installation Transport using a crane Transport the machine, switch cabinet and accessories carefully. • Under no circumstances lift, support or push using delicate parts such as the control panel, levers, trim panels or splash protection feature! • Fit lifting irons in the recesses in the machine base if necessary. •...
  • Page 32 Planning, transport, installation Transport device • Open laser cover. • Install transport device no. 2406063 (already installed when machine is delivered). Avoid collisions with the laser under all circumstances! Fasten all threaded elements. • Tighten nuts. • Place plate with crane lug (crane lug ahead on the right) on the nuts with washers (keep distance between laser and plate).
  • Page 33 Planning, transport, installation Lifting machine Check whether all connections have been removed prior to lifting and transporting away. Lift machine carefully and ensure the machine is hanging straight. Balancing If necessary, set down machine and balance. Risk of accident due to material fracture! Fully screw in pins and shackles.
  • Page 34 The transport devices are included in the scope of delivery of the machine and are required whenever the machine has to be moved within the production site. Therefore, the device cannot be taken back by SAUER. After the transport, store the transport device at a safe place.
  • Page 35 Planning, transport, installation Transport using roller systems Carriages on rollers or similar roller transport systems are required to move the machine to a place that is inaccessible for crane. It is only allowed to use roller transport systems for transport on an even floor.
  • Page 36 Planning, transport, installation • The machine must not be lifted using the systems necessary for transport higher than absolutely necessary for inserting roller transport systems, i.e. max. height of steel rollers. • When working with the systems necessary for lifting the machine, the machine is to be appropriately secured against sudden lowering and sliding.
  • Page 37 Planning, transport, installation Shipping Safety Always use suitable packaging for transporting the machine by road, rail or sea. • Observe the applicable regulations. • If necessary, use a suitable freight haulier. • Note the transport weight (see "Technical information"). • In addition to the weight of the machine, also take into account the weight of the accessories included and the packaging.
  • Page 38 Planning, transport, installation Attaching moisture protection Protect machine and accessories against moisture using suitable means, e.g. using moisture absorbing agent, corrosion protection greases, covers, etc. Marking packaging Attach appropriate information about the centre of gravity, the attachment of tackle, etc. to the packaging. Risk of accident due to tipping machine, as the centre of gravity is not necessarily in the middle of the crate.

  • Page 39: Installation

    Planning, transport, installation Installation General instructions These installation instructions provide information on the initial and renewed installation, alignment and fastening of your machine. During lifting, moving and installation, also follow the instructions in this section. Provide the necessary space, connections and tools on-site. Installation, assembly, connection and commissioning can also be undertaken by our customer service.
  • Page 40 Planning, transport, installation Regulations As a matter of priority, the local regulations, laws and stipulations are to be followed during the installation of machines and switch cabinets, e.g. in Germany: Health and safety at work act, VDE accident prevention regulations, etc.. Maintain the stipulated safety areas and escape routes: In accordance with VDE 0100 part 729, e.g., escape routes must have a minimum width of 500 mm, 700 mm for flaps and doors.
  • Page 41 Type and number of levelling elements • Installation dimensions, fastening bolts Delivery ex-works In case of delivery by SAUER, the installation elements are in a separate package on the machine's pallet. Providing suitable measuring instruments • Provide spirit level (machine spirit level)
  • Page 42 Planning, transport, installation Installing machine, alternative 1 • Fasten machine supports (9) using threaded rod (2), conical washer (plate) (8), spherical washer (7), conical washer (6), spherical washer (5), washer (4) and nut (3) in recess (1) on the machine base. Follow order stated for the fastening elements! •...
  • Page 43 Planning, transport, installation Installing machine, alternative 2 • Align on the floor the machine supports (9) with fastened threaded rods (2), conical washer (plate) (8) and spherical washer (7) as per machine supports diagram: • See chapter “Technical Data”, section “Machine supports diagram”. •...
  • Page 44 Planning, transport, installation Aligning machine Fit spirit level parallel to the longitudinal and transverse axis on the work table or on the headstock. • Ensure measuring surface is clean. • Briefly push spirit level back and forwards on the measuring surface after fitting.
  • Page 45 Planning, transport, installation Connection, assembly General instructions These assembly instructions contain information on the assembly and connection of the machine. "As per and in addition to the general installation conditions, VDW 502 A and LMW 188 A, the operating organisation undertakes the obligation to provide technical support during installation and repair work, in particular the provision of suitable ladders, platforms, scaffolding, heavy tools, lifting gear etc.".
  • Page 46 Planning, transport, installation Removing corrosion protection Completely remove corrosion protection from bare metal machine parts such as guides, stop surfaces, bolted and clamping surfaces! Use suitable solvent or cleaning agent. Damage to lacquer by solvents! Do not use aggressive solvents: •...
  • Page 47 Planning, transport, installation Connection cooling plant (Design: Water-air cooler) Installation place Do not install the cooling plant in an area in which other facility plants cause a high ambient temperature. The cooling plant operates efficiently up to an ambient temperature of 40°C. At higher ambient temperatures the cooling plant does not provide the required cooling capacity, since the cooling agent cannot be cooled sufficiently.
  • Page 48 Planning, transport, installation Water feeder line (to laser) BLUE Water return line (from laser) RED • Install cooling water inlet and outlet below the service door and connect to the water-air cooler. Power switch Serial data cable Water feeder (to laser) BLUE Water return line (from laser) RED Voltage supply 3x 400V 50/60 Hz LASERTEC 40...
  • Page 49 Planning, transport, installation Electrical connections Connection of voltage supply The connection to the electrical supply is installed on the rear side by means of cable. Connect the plant by external disconnector with sufficient contact opening next to the plant which is marked as part of the plant. Besides secure the phase with a 16A fuse.
  • Page 50 Planning, transport, installation Connection for data exchange (SUB-D plug) The plug SUB-D 9 pol. for data monitoring is located at the rear side of the cooling plant. Plug allocation Signal exit Pin 1 Alarm Temperature Alarm Pin 2 Alarm Flow Pin 3 Remote start Pin 4...
  • Page 51 Planning, transport, installation Prepare cooling plant for transportation As far as the cooling plant consists of a multitude of sensitive electronic and mechanical components, observe the following preconditions and instructions for storage, installation and transportation of the plant. Transportation The transportation of the cooling plan must be performed as careful and shock-free and vibration-free as possible.
  • Page 52 Planning, transport, installation Connection of Cooling Plant (Special option: Water-water cooler) Guide fresh water inlet and outlet from underneath into the control cubicle and connect it to the planned places. See also ”Operating manual laser system”. LASERTEC 40 Page 51...
  • Page 53 Planning, transport, installation Machine to switch cabinet connection The switch cabinet is on the right side of the machine. Install the machine such that the switch cabinet is easily accessible. Ensure that the switch cabinet cooling is not impaired! Connection The connections between the machine and switch cabinet are already installed from the factory.
  • Page 54 Planning, transport, installation Connection of Suction Plant • Connect suction hose lead out underneath the service door from the machine and plug into the suction plant (either on the long or the short side). • Connect electrical cable from control cabinet to the suction plant. LASERTEC 40 Page 53...
  • Page 55 Planning, transport, installation Electrical connection Risk of accident due electrical power! • The electrical connection is only allowed to be made by an electrician. • The locally applicable regulations and directives are to be observed as a matter of priority. During work on electrical equipment, electronic components may be damaged by incorrect or faulty connection.
  • Page 56 Planning, transport, installation Connecting Switch off supply cable (power supply) and secure against switching back on or remove fuse for the supply cable and attach appropriate label. Mortal danger due to high electrical voltage! It is imperative you check the supply cable is isolated. Switch cabinet •...
  • Page 57 Planning, transport, installation Series transformer In case of connection using a series transformer, remove the cover from the transformer. • Undo ring bolts and fastening bolts on the cover and lift off cover. Do not damage earth conductor. Guide the supply cable through the cable gland and strain relief on the series transformer.
  • Page 58 Planning, transport, installation Cooling plant (for the design water-air cooler only) • Guide cable with terminal strip from cooling plant from underneath into the control cubicle and plug into terminal ”X 310” and X 301 (check for marking on the control cubicle). •...
  • Page 59 Planning, transport, installation Fluid connection for the CO -jet cleaning system option Compressed air Fluid condition: • oil-free • dry, pressure dew point -40°C or better • Pressure range 6 – 16 bar • Typical operating pressure and consumption: 15 bar and 550 l/min (approx.
  • Page 60 Planning, transport, installation Carbon dioxide Carbon dioxide supply (CO Carbon dioxide (CO ) in liquid form is required as cleaning fluid. Only CO supply systems that can deliver liquid fase are allowed for the operation (e.g. rising pipe bottle, rising pipe bottle set, tank, etc.). The supply pressure must be of min.
  • Page 61 Planning, transport, installation Commissioning the CO -jet cleaning system option The correct installation of the fluids must be completed! • Open the valve for compressed air supply. • Open the valve at the CO2 supply unit. Both pressure gauges (1) must show the corresponding system pressure. System pressure indicador for compressed air...
  • Page 62 Planning, transport, installation Stopping the CO -jet cleaning system option The CO -jet cleaning system must be placed out of service in order to replace the CO supply units (pressure bottles, bottle set, etc.). Procedure: • Close the valve on the CO supply unit (bottle, bottle set, liquid gas tank, etc.).
  • Page 63 Planning, transport, installation Checklist for electrical connection Mains voltage is sufficiently stable at the stipulated reactive power and does not vary from the rated voltage by more than the tolerance allowed. Correct mains voltage is available or appropriate voltage converter series transformer is available.
  • Page 64 Planning, transport, installation Final inspection It is imperative a final inspection is performed after the assembly of the machine. During this process follow the list of points and tick them off. • Check levels of all lubricants and top up as necessary. You will find necessary information Initial...
  • Page 65 Planning, transport, installation Splash protection feature are free of leaks. Clamping, fastening and connecting bolts are tightened. Documentation (safety instructions, machine manuals, control system manuals, circuit diagrams, etc.) is available. Documentation (safety instructions, machine, control system manuals) worked through. LASERTEC 40 Page 64...
  • Page 66 Planning, transport, installation Symbols in the lubrication schedule Lubricate with grease resp. oil Change filter Maintenance interval / operating hours See operating instructions Lubricants Only the use of suitable lubricants provides a safe machine operation. For spindle nuts and guides of X, Y and Z axes, use only the following lubricants: •...
  • Page 67 Planning, transport, installation Lubrication schedule LASERTEC 40 Page 66...
  • Page 68 Planning, transport, installation Lubrication requirements Follow instructions from the manufacturers of the peripherals! Item Location Activity X axis: 2 grease apply grease nipples (second approx. 3 cm grease nipple on the other side) Y-axis: 2 grease apply grease nipples (second approx.
  • Page 69 Planning, transport, installation Lubricant selection table Issue: 06/2004 Reliable operation of the machine will only be ensured if the correct lubricants are used. Lubricant approval Minimum requirements for following lubricating and hydraulic oils: DIN standard Lubricating oil CL 46 in accordance with DIN 51 517, part 2 Lubricating oil CLP 46 in accordance with DIN 51 517, part 3 Lubricating oil CLP 68 in accordance with DIN 51 517, part 3 Hydraulic oil HLP 10 in accordance with DIN 51 524, part 2...
  • Page 70 Planning, transport, installation Lubricating oil, hydraulic oil Lubricating oil Hydraulic oil HLP/ HLP/ HLP/ 51 502 HLPD HLPD HLPD ISO 6743 CKD 46 HM 10 HM 22 HM 46 HM 68 Viscosity at 40°C OSO 46 Precis Agip OSO 10 OSO-D 22 OSO 46 System...
  • Page 71 Planning, transport, installation Lubricating oil Hydraulic oil HLP/ HLP/ HLP/ 51 502 HLPD HLPD HLPD ISO 6743 CKD 46 HM 10 HM 22 HM 46 HM 68 Viscosity at 40°C Klüberoil Klüber 1-46 LAMORA COREX MOTOREX HLP 46 HLP-D 68 Hydranor Hydranor Hydranor...
  • Page 72 Planning, transport, installation Lubricating grease, liquid grease DIN 51 502 Lubricating grease Liquid grease ISO 6743 viscosity at 40°C AVIA LITHOPLEX 2 EP AVIA AVIALITH 2 EP Spheerol AP 2 Castrol Spheerol EPL 2 Nebula EP 2 ESSO Beacon EP 2 FUCHS RENOLIT S2 Klüber...