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Cincinnati CL-7A Operation, Safety And Maintenance Manual

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OPERATION, SAFETY AND MAINTENANCE MANUAL
EM-474 (N-09/02)
CL-7A
LASER SYSTEM
with PC Control
C I N C I N N A T I I N C O R P O R A T E D
C I N C I N N A T I ,
O H I O
PRELIMINARY
C O P Y R I G H T
C I N C I N N ATI I N C O R P O R ATE D
(04/02)
4 5 2 1 1
ã
2002

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Summary of Contents for Cincinnati CL-7A

  • Page 1 OPERATION, SAFETY AND MAINTENANCE MANUAL CL-7A LASER SYSTEM with PC Control C I N C I N N A T I I N C O R P O R A T E D C I N C I N N A T I ,...

  • Page 2: Table Of Contents

    CL-7A LASER SYSTEM CONTENTS INTRODUCTION SECTION 1 IDENTIFICATION SECTION 2 INSTALLATION LIFTING AND MOVING FOUNDATION INSTALLATION OF MACHINE CHILLER LEVELING ELECTRICAL CONNECTION SAFETY DEVICES SECTION 3 SAFETY SAFETY IS EVERYONE’S JOB EXPLANATION OF LASER RADIATION HAZARDS NOMINAL HAZARD ZONES ASSOCIATED HAZARDS...
  • Page 3 (Continued) LASER MENU COMMANDS 6-30 VARIABLES MENU COMMANDS 6-35 POSITIONS MENU COMMANDS 6-36 MESSAGES MENU COMMANDS 6-36 WINDOW MENU COMMANDS 6-37 HELP MENU COMMANDS 6-37 MISCELLANEOUS WINDOW FEATURES 6-38 WINDOWS NT ADMINISTRATION 6-39 SECTION 7 OPERATION MACHINE START-UP CHILLER WARM UP CUTTING PROCEDURES BATCH MODE PROGRAM EXECUTION NORMAL SHUTDOWN...
  • Page 4 (Continued) OPTICS HANDLING AND CLEANING AUTO FOCUS CUTTING HEAD BEAM DELIVERY ALIGNMENT PURPOSE WHEN REQUIRED TOOLS REQUIRED COMPLETE SYSTEM ALIGNMENT RESONATOR WARM-UP 9-11 FIRST EXTERNAL MIRROR ALIGNMENT 9-11 COLLIMATOR BEAM ALIGNMENT 9-12 X-AXIS BEAM ALIGNMENT 9-12 Y-AXIS BEAM ALIGNMENT 9-14 Z-AXIS ALIGNMENT 9-15 FINAL ALIGNMENT CHECK...
  • Page 5 ✦ Quality and type of material CINCINNATI machines are designed to be rugged and durable. However, improper adjustment or lack of maintenance can reduce the quality of parts produced on the machine. The quality of a laser-cut edge depends on the combination of a uniform...

  • Page 6: Section 1 Identification

    SECTION 1 IDENTIFICATION CL-7A LASER SYSTEM 1. LASER RESONATOR 7. X-AXIS GUIDE (Covered) 15. LOAD FRAME 2. GANTRY LIGHT 8. X-AXIS BEAM TUBE 16. Y-AXIS MATERIAL STOPS Amber: High Voltage Warning Light ● 9. AWARENESS BARRIER & 17. SCRAP COLLECTOR / COOLANT Red: Laser Radiation Danger Light ●...
  • Page 7 Z-AXIS MOTOR 7. 5.0” / 7-1/2” LENS HOLDERS Z-AXIS HOME SWITCH 8. MAGNETIC BREAKAWAY COUPLING COUNTERBALANCE SPRING LATCHES (2) 9. LENS COOLING WATER LINES ASSIST GAS SCREEN STRAINER 10. ASSIST GAS INLET MATERIAL CONTACT SWITCH 11. FOCUS ADJUSTING RING PROGRAMMABLE ASSIST GAS FIGURE 1-2 Noncontact Head Assembly...
  • Page 8 SCRAP TRAYS (Fume Plenum hidden below Trays) MATERIAL SUPPORT GRID (Upper Pallet) SCRAP CART AND SCRAP TOTES PALLET DRIVE MOTORS (Covers removed) CUTTING COOLANT FILTER PALLET DRIVE CHAINS COOLANT PUMP FIGURE 1-3 Top View of Main Frame, Resonator End (4x8, 5x10 Models) Note: For 6x12 Models, Items 2, 3 and 4 are at the other end of the Main Frame.

  • Page 9: Section 2 Installation

    Instal- lations involving this type of equipment in close proximity to the machine require special consider- ations and CINCINNATI INCORPORATED must be consulted. A certified foundation plan drawing is provided 1.5” THICK when the machine is ordered.

  • Page 10: Installation Of Machine

    Installation consists of the following steps: drawing. Consult CINCINNATI INCORPORATED if an alternative chiller location is required. The 1. Remove lifting clevises.

  • Page 11: Electrical Connection

    Foundation DO NOT START MACHINE UNTIL THOROUGHLY Plan drawing. READING THE SAFETY SECTION OF THIS MAN- UAL AND A CINCINNATI INCORPORATED SER- 6. Repeat Step 3 as a final level check. VICE REPRESENTATIVE IS PRESENT. ELECTRICAL CONNECTION ❦...

  • Page 12: Section 3 Safety

    SECTION 3 SAFETY SAFETY IS EVERYONE'S JOB The CINCINNATI CNC Laser System operates in the far-infrared region, which is invisible and has high The CINCINNATI CNC Laser System manufactured heat energy. The beam emitted has a wavelength of CINCINNATI INCORPORATED been 10.6 µm (micrometers).
  • Page 13 Gamma rays 3x10 X-rays 3x10 3x10 Ultraviolet 3x10 rays 3x10 Visible light (380-780 nanometers wavelength) 3x10 3x10 Lasers CINCINNATI CNC LASER Infrared 3x10 rays 3x10 3x10 3x10 Microwave 3x10 FM broadcast band Radio -frequency (RF) waves AM broadcast band 3x10...
  • Page 14 CONTROL MEASURES developing laser safety standards. Of the standards that apply to users, the ANSI standard Z136.1 is The CINCINNATI CNC Laser System has been probably the most important and most often quoted. designed and manufactured using the highest engi-...

  • Page 15: Explanation Of Laser Radiation

    However, the duties of a service person do not necessarily include the duties The CINCINNATI CNC Laser System is a gas-type or responsibilities of a maintenance person. laser. Gas lasers use a gas or a mixture of gases as their light-amplifying substance.

  • Page 16: Nominal Hazard Zones

    CINCINNATI CNC Laser System. The downward to a spot as it exits to do cutting. type and style of eye protection to use should be...

  • Page 17: Associated Hazards

    Because of the high electrical energies used to gen- If your laser cuts only ferrous material, clean the erate the laser beam in the CINCINNATI CNC Laser fume box and duct after 5000 hours; if cutting only System, electrocution hazards are possibly a far aluminum, every 1000 hours;...

  • Page 18: Gas Storage

    The laser resonator requires a propri- purpose of such equipment should be understood etary laser gas premix available from CINCINNATI by operating personnel. This equipment should be INCORPORATED in a compressed cylinder that is provided to extinguish or control small fires only.
  • Page 19 ✦ Do not tamper with safety devices in valves or ✦ Open cylinder valves slowly. A cylinder not pro- on cylinders. vided with a handwheel valve should be opened with a spindle key or a special wrench or other ✦ When empty, cylinders are to be returned to the tool provided or approved by the gas supplier.
  • Page 20 ✦ High pressure oxygen dial gages should have additional precautions are necessary because of the special properties exhibited by fluids at cryogenic safety vent covers to protect the operator from temperatures. flying parts in case of an internal explosion. Each oxygen dial gage should be marked OXY- Both the liquid and its boil-off vapor can rapidly GEN - USE NO OIL OR GREASE.

  • Page 21: Precautions

    higher concentrations. Approximately 0.021 cubic ✦ Do not approach the gantry from the backside feet are released to the ambient atmosphere dur- of the machine while drive power is ON. Severe ing a normal laser gas exchange. This is done by injury can result from being trapped between the operator once every 72 hours when the system the machine frame and its moving members.

  • Page 22: Safety Signs

    See Figure 1-2. that may exist - unless specified procedures are fol- lowed - a number of warning signs are attached to CINCINNATI Lasers. Warning signs are not intend- AVOID EXPOSURE ed to be a substitute for reading and understanding...
  • Page 23 DANGER – TO REDUCE THE POSSIBILITY OF DANGER SERIOUS INJURY (911058) This sign is mounted on the operator side of the INVISIBLE AND/OR VISIBLE gantry. It warns against the dangers of climbing LASER RADIATION WHEN on the material support grids and the machine OPEN AND INTERLOCK frame, defeating the safety mat and the need to DEFEATED.

  • Page 24: Safety Guidelines

    DANGER - LASER SPECIFICATIONS / POISONOUS WARNING FUMES / ALIGNMENT BEAM (924594) The warning to avoid exposure to laser radiation DO NOT CLIMB ON and specifications for type, power and class of the laser is shown on the left side of this sign. The MATERIAL SUPPORT large, bold lettering cautions persons working GRIDS OR MACHINE...

  • Page 25: Safety Maintenance Check

    Know your controls, be familiar with emergency OPERATING MODES functioning properly. ✦ ✦ shutdown procedures. GANTRY and CUTTING HEAD positioning ✦ properly. Fume and dust control system operating properly. ✦ SAFETY SIGNS clean and easily read. Do not position any part of your body where it may ✦...

  • Page 26: Section 4 Specifications

    SECTION 4 SPECIFICATIONS DIMENSIONS WIDTH HEIGHT WEIGHT MODEL LENGTH COMPONENT SPECIFICATIONS MAXIMUM MATERIAL THICKNESS FOR CLAMP- ING: 0.63 (16 mm) GUARANTEED TYPICAL Note: The nozzle must be at least 0.80 inches (20 LASER POWER RANGE mm) above the material to avoid interference with the clamps.

  • Page 27: Piping Connections

    Maintenance instructions in SECTION 9. If tion is required. the above additives are not available, consult CINCINNATI INCORPORATED for approval of a BEAM DELIVERY PURGE: The gas manifold has a comparable product from another supplier. 1/4” NPT female port for the beam purge gas. An air dryer is supplied as standard with a 25 ft.,...

  • Page 28: Gas Requirements

    Helium (He), Carbon Dioxide one location and an “empty manifold seal” ), Nitrogen (N), Xenon (Xe) and Carbon (EMS) in the other location. Monoxide (CO) available from CINCINNATI INCORPORATED. Safety concerns with Car- WORKING EFFECTIVE bon Monoxide are addressed under “GAS...
  • Page 29 Tables 4-2 and 4-3 apply to single orifice noz- keeps the beam delivery enclosure free of air- zles. To estimate assist gas flow for nozzles with borne contaminants by maintaining a slight more than one orifice, contact CINCINNATI positive pressure. Note that paint fumes and INCORPORATED Laser Applications.

  • Page 30: Ambient Temperature

    90-125 PSI. The air supplied to the dryer must extend the ambient temperature limits. Contact be less than 100°F and free of oil and/or water CINCINNATI INCORPORATED Laser Technical Ser- mist. Excessive wet or oily air could overwhelm vices for more information.

  • Page 31: Contouring Accuracy

    CONTOURING ACCURACY a narrow strip of material is removed along the path made by the lens. Material is removed by vaporiza- tion and melting where the lens concentrates laser Contouring accuracy is a function of the feedrate power into a small spot on the workpiece. Assist gas and the curvature of the path.

  • Page 32: Loading Material

    Y = 0 stops can be cut: clamp head. ✦ LASER SETUP, ELECTRICAL (by CINCINNATI Load “YSTOP.cnc” program to scribe a line across Laser Service) specifically setting of Y-Axis Home the stop. The YSTOP.cnc program can be edited Offset.
  • Page 33 Unclamp the 3” (76mm) part and measure Note: Changing the home offset parameter can only be done by a CINCINNATI Service its width. The “Y” position error is: Representative. If the Y-axis home offset ERROR = 3” - part width - kerf...
  • Page 34 X-stop pin location. ✦ LASER SETUP, ELECTRICAL (by CINCINNATI Service), specifically setting of X-Axis Home Off- 3. The position of the X-stop pin is checked by set.
  • Page 35 6. In order to maintain the initial accuracy, this procedure will have to be repeated if: ✦ The X-axis ballscrew coupling is disconnect- ed from the screw or motor. ✦ The X-axis calibration limit switch or cam is removed and/or replaced. ✦...

  • Page 36: Section 6 Machine Controls

    SECTION 6 MACHINE CONTROLS DISKETTE DRIVE MACHINE OPERATOR PANEL EMERGENCY STOP BUTTON KEYBOARD MONITOR TRACKBALL CD-ROM DRIVE (Inside) FIGURE 6-1 Operator Control Station OPERATOR CONTROL STATION Diskette and CD-ROM Drives: A 3.5” diskette drive is provided for program/data storage and loading, including part programs, macros and The following descriptions are of the individual con- parameter libraries.
  • Page 37 FIGURE 6-2 Machine Operator Panel...
  • Page 38 DRIVES selector switch: When key is removed SHUTTER LOCK / ENABLED keyswitch: When from this keyswitch or in the LOCK/OFF (Left) key is removed from this keyswitch or in the position, the motor drives in the Laser System are LOCK/CLOSED (Left) position, the shutter within disabled.
  • Page 39 nozzle assembly is activated when this pushbut- of the pallets is not enabled until the PALLETS ton is depressed and will be noted by illumination NOT READY pushbutton/indicator is pushed and of the button. To stop the flow of gas, the illumi- the light extinguished.
  • Page 40 200 IPM times 75% = NOTE: THIS KEYSWITCH IS PRIMARILY INTENDED FOR USE BY PER- 150 IPM. The FEEDRATE OVERRIDE selector SONNEL TRAINED BY CINCINNATI INCORPORATED. switch is adjustable from 0% to 100%. Feedrate Override can also be used to vary the jogging...

  • Page 41: Remote Station

    a. Laser shutter will close and high voltage will be disabled. b. All axis motion will stop. c. All auxiliary functions such as assist gas flow and coolant flow will stop. When the key is in BYPASS (right) position, the nozzle assembly interlocks are defeated.

  • Page 42: Laser System Display Window

    STATION ENABLE keyswitch: When the key is functional only when the STATION ENABLE key is inserted and the switch is turned to the horizon- in the horizontal position. Motion will stop when the button is released. tal position and the CNC is placed in JOG mode on the Operator Console, the following occur: Y pushbutton: This pushbutton must be used in a.
  • Page 43 Menu Bar Tool Bar Process Status Bar Application Workspace Page 6-37 Page 6-37 Page 6-36 Page 6-10 Page 6-17 Page 6-18 Page 6-19 Page 6-30 Page 6-35 Page 6-36 Program Status Bar Main Status Bar FIGURE 6-4 Laser System Display Window (Red icon) Quickly open an existing file Open an edit window containing the part from the default directory.
  • Page 44 Rewind (Also keyboard key F3). Sets the first block of the part program as the next block to be executed when Cycle Start Application Workspace is pressed. Use this function to restart the program from the beginning when The Application Workspace is the initially blank area program execution is interrupted by a below the process status bar and above the program system alarm, pressing Cycle Stop, etc.

  • Page 45: File Menu Commands

    trackball or keyboard. The next section to the right Shortcuts is used to display the current CNC mode or opera- tor message notification. If a single operator mes- Toolbar: sage is pending (see FYI Messages Command), the Keys: CTRL+N or {ALT, F, N} sequence message text will be displayed in this area (the end of longer messages may be clipped).
  • Page 46 ically select the file to open. Selecting a file in the browser window will cause its name to appear in the File Name box. Files of Type: Lists the types of files to display in the browser. The choices are: NC Program Files (with .cnc extension) Process Parameter Files (with .lib extension) All Files...
  • Page 47 Shortcuts Keys: CTRL+F4 or {ALT, F, C} sequence Toolbar: Note: If you close a file without saving it, all Note: Only files with the extension listed in the changes made since the last time the file Files of Type box are shown here. was saved will be lost.
  • Page 48 3. In each row, enter the program filename in the Program column by typing it directly or using the browse button to select it with the mouse. Note: The operator cannot use the Laser System (Browse button) display window until the software finishes 4.
  • Page 49 If the program has no syntax errors, "Plot NC Pro- with the X and Y-machine coordinates of the start gram" opens a new window displaying a graphical and end. The small window also displays the radius plot of the tool path. The plot represents where the for a G02 or G03 arc.
  • Page 50 ✦ A part program can be restarted inside of a sub- routine as long as that subroutine is located in the same file as the main program. Note howev- er, if this is done, the program will restart at the first instance the subroutine is called.
  • Page 51 Shortcuts Keys: {ALT, F, R} sequence The Print Setup command opens the Print Setup dialog box. Use the controls in this dialog box to select a printer and printing options. Name: Lists the printers that are set up on your computer.

  • Page 52: Edit Menu Commands

    “Edit / Copy” Command Shortcuts Use this command to copy selected data onto the Toolbar: clipboard. This command is unavailable if there is no data currently selected. Copying data to the clip- “File / Exit” command board replaces the contents previously stored there. Use this command to shut down the CNC Laser Shortcuts Control.

  • Page 53: View Menu Commands

    “View / Process Status Bar” Command Replace dialog box Use this command to display and hide the Process Status Bar which shows the feedrates, current G- codes, laser system status, assist gas pressure and Z-axis standoff during program execution. A check mark appears next to the menu item when the Process Status Bar is displayed.

  • Page 54: Maintenance Menu Commands

    Chang- the window. ing configuration parameters by non- CINCINNATI personnel is restricted to the Zoom Extents shows the entire plot in the window. parameters specified in the EDIT button Zoom In magnifies the center portion of the plot.
  • Page 55 Print: Sends an image of the current page to print- Rapids (G00) Jerk: Specifies the servo “Jerk” value er, if connected. used during rapid (G00) moves. Smart Rapids Jerk: Specifies the servo “Jerk” value Edit: When the dialog is first opened, all parameter used during Smart Rapids moves.
  • Page 56 PMAC interface console window. al serial port. This is used only by CINCINNATI personnel for diagnostic purposes. Note: This option not available when the Automa- tion System option is “CINCINNATI Materi- Fault Logging: Enables automatic logging of system al Handling System”.
  • Page 57 For more description, Jog Speed in Clamp Zone: The speed to which the contact CINCINNATI Laser Service. axis is automatically limited within the rapid clamp zone. This value must be less than or equal...
  • Page 58 Z-Axis Jog Speed: The target speed when push but- Automatic Lube System (Check box): This box is tons are used to jog the Z-axis. checked when the laser system has an automatic lubrication system. If checked, the Auxiliary page Following Error Limit: The maximum magnitude the also displays parameters for "Lube Distance", Z-axis servo following error can attain before the "Lube Interval"...
  • Page 59 Cycle Duration: The maximum length of time the be configured. DPRNT statements required per pro- automatic bearing lube system will continue to gram specifies the minimum number of DPRNT operate during a single lube cycle. If the lube cycle statements a CNC program must contain in order complete limit switch does not trip within Cycle to be executed without errors.
  • Page 60 tance set below and retracts the head “on the fly”. As the X/Y decelerate at the end of the rapid move, the head is commanded down so it will be in posi- tion for the next cut. Z-Up Distance: The distance that the head retracts during Automatic Partial Z-Up moves.
  • Page 61 “Maintenance / Mirror Alignment” Command Mirror Alignment dialog box This command opens the Mirror Alignment dialog box and puts the laser in a diagnostic mode used for performing mirror alignment and other mainte- nance functions. In the Mirror Alignment Diagnos- tic Mode, the laser beam is activated directly by the CYCLE START button on the Operator Control Panel or the SHUTTER FLASH button on the...
  • Page 62 “Maintenance / Diagnostics” Command The diagnostic windows are accessible via the Diagnostics submenu, which pops up when the Diagnostics command is selected from the Mainte- nance Menu. Macro Station #1 Inputs Macro Station #1 Outputs Macro Station #2 Inputs Macro Station #2 Outputs 5 I/O Board #3 Inputs 6 I/O Board #3 Outputs 7 I/O Board #4 Inputs...
  • Page 63 tripped, its indicator will display “ON”, using white text on a green background. Otherwise, the indica- tor will display “OFF” in black text on a white back- ground. Once open, this window is automatically updated to reflect any changes in the axis limit switch states.
  • Page 64 Initially, all text boxes will be blank. The Change and click OK. If one of the selected system alarms and Remove buttons are used to configure the occurs, a short diagnostic file will be written to the watch window. To select an I/O point for monitor- hard disk.

  • Page 65: Laser Menu Commands

    Program Run Time: The cumulative part program Total Disk Space: The storage capacity of the Laser execution time. Starts counting each time Cycle host PC’s hard disk drive. Start is pressed. Stops counting when program Free Disk Space: The number of free megabytes on execution is terminated by Cycle Stop, M30, Sys- the Laser host PC’s hard disk drive.
  • Page 66 “Laser / Auto Shutdown” Command ARNING ! ARNING ! CINCINNATI INCORPORATED DOES NOT RECOM- MEND COMPLETELY UNATTENDED OPERATION OF A LASER CUTTING SYSTEM. ALTHOUGH THE OPERATOR NEED NOT BE PRESENT WHILE THE LASER RUNS IN “UNATTENDED” MODE, SOME QUALIFIED PERSONNEL (MAINTENANCE, SECU- RITY, ETC.) MUST BE AVAILABLE TO DEAL WITH...
  • Page 67 Automatic Shutdown Initiation The completion status of the last part pro- gram - "completed successfully" or "termi- Once the automatic laser shutdown function is nated before completion". armed, normal operation resumes until the active part program terminates. Program termination for If the program completion status is "termi- any of the following reasons will trigger automatic nated before completion", a list of all sys-...
  • Page 68 Note: The commands in the Laser Service Sub- internal resonator scaling sources. These scaling menu are to be used only by CINCINNATI sources can be used to manually adjust the max- Service Personnel for set-up and mainte- imum power level and/or the pulse frequency and nance purposes.
  • Page 69 “Laser / Service / Pulse Parameters” Command “Laser / Service / Service Report” Command Use this command to view and edit laser control This command opens the Laser Service Report internal pulse program parameters. The pulse pro- dialog box, which is used to view statistics and gram to be changed is selected in the Program Num- configuration data pertaining to the laser res- ber column.

  • Page 70: Variables Menu Commands

    “Variables / Local/Global” Command Use this command to view and edit the local (#1 to #99) and global (#100 to #999) variables. All vari- ables can be edited. ARNING ! ARNING ! EDITING OF PROGRAM VARIABLES DUR- ING PROGRAM EXECUTION CAN CAUSE IMPROPER PROGRAM EXECUTION AND IS “Laser / Service / Manual Beam Control”...

  • Page 71: Positions Menu Commands

    turn on and stabilize at the desired pressure. This option is very useful for saving time when cutting large quantities of small parts in rapid succession. POSITIONS MENU COMMANDS The Positions Menu offers the following commands: Machine Absolute Work Offsets Axes Home “Positions / Work Offsets”...

  • Page 72: Window Menu Commands

    “Messages / FYI Messages” Command Use this command to display a list of messages to inform operator of certain non-critical machine conditions. Conditions that cause FYI messages do not prevent machine operation, but are useful to the operator as a reminder of some required action or that the machine is in a special mode (i.e.

  • Page 73: Miscellaneous Window Features

    “Help / Index” Command Scroll Bars Use this command to display the opening screen of Displayed at the right and bottom edges of the file Help. From the opening screen, you can jump to window. The scroll boxes inside the scroll bars indi- step-by-step instructions for using the CNC Laser cate your vertical and horizontal location in the file.

  • Page 74: Windows Nt Administration

    These include network set-up, Restore Machine Data: Restores machine specific upgrading CINCINNATI INCORPORATED software, data from a floppy back to the Laser System. disk de-fragmentation, creating emergency repair disks and setting system date and time. All of these CNC Laser: Initiates control application.
  • Page 75 Software Upgrades Insert the floppy or CD from CINCINNATI INCOR- PORATED and double click on the “Setup from Diskette” or “Setup from CD” shortcut. Follow the Setup Network: This is the Network icon from the prompts provided by the Setup software.
  • Page 76 All NT setup files reside on the hard drive. Floppies remain installed on all machines because it is used or CD’s are required for adapter board drivers. by CINCINNATI INCORPORATED to dial up the Setup files are in the following directories: machine using the modem and Remote Access Ser-...
  • Page 77 Do not remove if this mapping is to persist. NetBEUI altogether as this will disable Remote Access, and CINCINNATI INCORPORATED person- Multiple Operator User Accounts nel will not be able to dial the machine up through If the laser control is part of a domain, then any the modem.

  • Page 78: Section 7 Operation

    LOCAL or REMOTE. Failure to follow this procedure can dam- 6. The CNC Laser System application should age the chiller. CINCINNATI INCORPORATED recom- come up automatically on the monitor approx- mends leaving the chiller power disconnect ON at all...

  • Page 79: Chiller Warm Up

    8. When the CNC Laser Application begins run- within 36 inches (915mm) of the machine ning, the System Alarms dialog box will read frame. The barrier includes signs warning per- “Main drives are off” and “Axes have not been sonnel to disable the machine drives before homed”.
  • Page 80 Lens centering: Center the lens using the pro- 3. Load CNC Program cedure in this section. Load the desired CNC program. Refer to the File Menu commands in SECTION 6 for an Focus Setting (manual-focus cutting head): Set explanation of the various methods for loading the focus as specified on the Notes page of the a program.

  • Page 81: Batch Mode Program Execution

    15. The pallets will exchange and the third pro- ever, if the Options page of the Configurations gram will load. window specifies "CINCINNATI Material Handling 16. Press CYCLE START to begin executing the System" for the Automation System, then use the third program.
  • Page 82 BATCH PROGRAM EXECUTION with Automatic Load/Unload System The optional Automatic Load/Unload system consists of a sheet storage tower, pallet lift, load/unload station, pallet carriage and PLC (programmable logic con- Selecting the Browse button in the MHS Shelf col- troller). The Laser System control interfaces with umn opens the MHS Shelf Data window.
  • Page 83 When "Disable Material Handling System" is select- 10. While the first program is running, press the ed, the Laser System control does not interface with PALLETS NOT READY pushbutton. The Mater- the MHS control. The Laser System does not com- ial Handling System will move material for the mand any MHS functions, and does not provide the next program from the specified MHS shelf to...

  • Page 84: Normal Shutdown

    If the chiller is in Local mode, switch it to this procedure can result in internal damage to Standby. the chiller. CINCINNATI INCORPORATED rec- ommends leaving the main power disconnect 7. Shut down the CNC Laser System application ON at all times unless maintenance or repairs by selecting the “Close”...

  • Page 85: Changing Heads

    To re-attach the cutting head and continue the cut- Press the CYCLE START pushbutton/indi- ting process, follow this procedure: cator. The cutting head will return to the position of the beginning of the CNC pro- 1. Except as noted, DO NOT PRESS the on-screen gram block that was being executed when “Rewind”...

  • Page 86: Laser Shot

    attached to the cutting head nozzle. When the laser shot is used for beam alignment as described in SECTION 9, it is called a “card shot” because the beam strikes a target card. When the laser shot is used to determine the characteristics, or mode, of the laser beam, it is called a “mode shot”...

  • Page 87: Lens Centering

    When the SHUTTER FLASH pushbutton is Note: A lens can be easily damaged if mis- depressed, the shutter will open and the laser beam handled. Refer to SECTION 9 for optics will be turned on at the specified power level and handling and lens cleaning procedure.
  • Page 88 5. Apply a small amount of ink to the nozzle tip by pressing an inkpad against the tip or by rub- bing the tip with a felt marker pen. Place a length of masking tape in a known orientation over the orifice in the nozzle tip. Press the tape firmly on the tip.

  • Page 89: Calibrating Nozzle Standoff

    Repeat Steps 5 thru 11 with the cutting tip. NOZZLE STANDOFF ACCURACY CALIBRATING NOZZLE STANDOFF Any CINCINNATI Laser System equipped with a noncontact head includes a capacitive sensor as Note: If the standoff sensor loses accuracy quickly part of the Z-axis positioning system.

  • Page 90: Lens Focal Point Location Procedure

    LENS FOCAL POINT LOCATION FOCUS SCALE CALIBRATION – NONCONTACT HEAD (without Auto Focus) PROCEDURE Note: This procedure applies to the standard (man- MATERIALS REQUIRED ual focus) noncontact head. If the laser sys- tem has the Auto Focus Cutting Head, use ✦...
  • Page 91 b. Rotate the shutter keyswitch on the The kerf width must be measured in 1/2 machine operator panel to the “RUN” posi- thousandth (0.0005 inch) increments to tion. Jog the cutting head to the starting accurately identify the minimum kerf set- point for the kerf cuts and press CYCLE ting.
  • Page 92 ✦ Lens focal length - Verify that the Example: A part program specifies the focal point to be set at -.075” (below the lens focal length is correct. See nozzle tip) and a nozzle tip standoff of SECTION 4 - SPECIFICATIONS. .025”.

  • Page 93: Assist Gas Pressure Adjustment

    For that information, refer to the Process Parameters and Diagnostic Guide for the CL-7A. INTRODUCTION Laser cutting is a thermal cutting process that uses the energy of a focused laser beam in conjunction with a controlled gas jet.
  • Page 94 PIERCE PARAMETERS For thin metals, the pierce process is very simple and requires only a basic set of parameters. For The Pierce Parameters page contains the following thicker metals, more specialized techniques are parameters - Laser power, Frequency, Duty cycle, used for the pierce process.
  • Page 95 One of two assist gas ports can be selected. Port #1 bottom of the nozzle tip to the workpiece surface. is usually connected to the oxygen supply. Port #2 Pierce time determines the duration of the pierce is usually connected to the nitrogen supply. process.
  • Page 96 to 20 steps. Each step defines a power value and If "Dynamic Power Control" is checked on the Cut time. The laser power changes linearly from the parameters page, the window includes Dynamic previous value to the new value in the amount of Power Control parameters on a separate page time specified for each step, creating a user-pro- labeled "DPC".
  • Page 97 The Nozzle Standoff is the distance from the work- meters Page. As the feedrate varies from zero to the piece surface to the bottom of the nozzle tip. When DPC Feedrate, the duty cycle varies proportionately a CNC program commands M45, the nozzle stand- from its minimum value (the Duty Cycle setting off changes to the “Optional (M45)”...

  • Page 98: Rapid Pierce Adjustments

    The material library files sup- DYNAMIC ASSIST GAS PRESSURE plied by CINCINNATI INCORPORATED typically list the recommended lens type (mounting distance), If the Cut parameters page has "Dynamic Assist nozzle orifice diameter, and focal position on the Gas"...
  • Page 99 non-oiled material (but without using automist), a tle mist will be ineffective; too much mist will inter- compressed air supply up to 250 PSI might be nec- fere with the standoff sensor. As a starting point, essary. For non-oiled material, the use of automist set the brass (liquid) valve a quarter turn open and is recommended.

  • Page 100: Auto Focus Cutting Head Operation

    Note: To change the Auto Focus Head Configura- tion Option or the Auto Focus Head Auxiliary Note: The control software only applies the “initial” Configuration settings, contact a CINCINNATI settings the first time it runs on a new Service Representative (the changes require machine.
  • Page 101 In-position band Range: From 0.001 (0.03 mm) to the Auto Focus Max Travel configuration setting. The In-position band field specifies the maximum following error in the Auto Focus drive that the con- Initial Setting: Upper Lens: 0.375 in. (9.52 mm) trol will tolerate when starting a cut sequence.
  • Page 102 Auto Focus Head checked. Initial Setting: -0.060 in., (after opening a new process parameter file). Note: CINCINNATI provides material library files with Focus settings based on zero focus cali- Far field focus (Pierce and Cut) brated in the FAR FIELD of the cutting area.
  • Page 103 Process Status Bar Note: The control detects the type of cutting head using proximity sensors and a signal to veri- fy the Auto Focus cable connection. -0.060 Focus setting: The process status bar indicates the Focus setting with the Auto Focus head indica- -0.050 tion (i.e.
  • Page 104 STANDOFF CONTROL After changing the Auto Focus Home Offset value, press “OK” to close the Z-Axis Setup win- The CNC controls Nozzle Standoff position and dow. Cut another test part to verify the “Min Lens Focus position independently. However, the Kerf”...

  • Page 105: Section 8 Options

    SECTION 8 OPTIONS CONTACT CUTTING HEAD The part coolant option is useful when cutting small, closely spaced features in mild steel with This contact cutting head (see Figure 8-1) can be oxygen assist gas. Use of part coolant in these used in place of the noncontact cutting head.

  • Page 106: Drip Pan For Load Frame

    The FEEDHOLD pushbutton performs the same To help remove the excess heat, CINCINNATI rec- function as the CYCLE STOP pushbutton on the ommends an optional scrap tray cooling system...

  • Page 107: Absorbing Thin Film Reflector (Atfr)

    FIGURE 8-4 Automatic lubrication system reservoir FIGURE 8-3 Ball transfer load station pendant AUTOMATIC LUBRICATION The automatic lubrication system is designed to dis- pense a preset amount of lubricant every three hours of servo drive operation. The components lubricated by this system are the X-Axis ballnut, the X-Axis linear bearings, the Y-Axis ballnut and the Y- Axis linear bearings.

  • Page 108: Rapid Pierce

    RAPID PIERCE NOZZLE COOLING Rapid Pierce is a fast way to pierce mild steel. In 0.5 The standoff accuracy of the noncontact cutting inch (12.7mm) mild steel, for example, the pierce head can change if the nozzle tip assembly absorbs time can be reduced from 12 seconds with a pulsed too much heat.

  • Page 109: Lower Pallet Special Function (Lpsf)

    LOWER PALLET SPECIAL grounded portion of the noncontact cutting head) rides on the material and provides a conductive FUNCTION (LPSF) surface for the capacitive height sensor. The CNC maintains nozzle standoff by controlling the capac- In normal operation, the laser beam can only be on itance between the nozzle and the tactile follower when the cutting nozzle is within 1.5 inches (38 surface.

  • Page 110: Dual Pallets

    DUAL PALLETS The minimum laser system configuration only includes one work pallet. The laser system can be built with a single pallet in the upper or lower location. The Dual Pallet option includes one upper pallet and one lower pallet. The Dual Pal- let option maximizes laser system productivity by allowing the operator to unload parts and load material on one pallet while the laser system is...

  • Page 111: Manual Lubrication Requirements

    ✦ Kinematic Viscosity of 145 CST at 40°C ✦ Waterproof This grease is available from CINCINNATI INCORPORATED - C.I. #920968 (5 gal. pail). Shell Alvania EPRO grease conforms to these specifications. CAUTION Use of grease not comforming to recommended specifications could cause premature bearing failure.

  • Page 112: Fume Fan Lubrication

    Use only C.I. #922433 for this procedure. CAUTION LOCKNUTS (Tighten After Compounds that are not approved by CINCINNATI Completing INCORPORATED may chemically attack the beam Adjustment) delivery components or outgas into the beam deliv- ery cavity, resulting in poor cutting performance and optic life.

  • Page 113: Noncontact Head Cleaning

    UHMW (polyethylene) supports mounted on the ting nozzle. The excess coolant flows down onto the inner wall of the mainframe by 1/4” to 1/2”. scrap trays and drains back into the scrap tote and then into the coolant tank for re-use. 3.

  • Page 114: Optics Handling And Cleaning

    CLEANING PROCEDURE MATERIALS RECOMMENDED ✦ Isopropyl alcohol or acetone (ACS grade or better) 1. Wash your hands using the organic cleaner. ✦ Acetic acid (distilled white vinegar) 2. Disconnect the tip cable and unscrew the noz- ✦ Surgical quality cotton balls zle tip assembly from the noncontact head.
  • Page 115 dures for both sides of the lens. For routine clean- MIRROR MIRROR MOUNT QUICK DISCON- ing, Steps 1 and 2 are often sufficient. MOUNT SHOULDER NECT COOLANT BOLT (3)* FITTINGS Use an air bulb or clean, dry, filtered air to blow away any loose particles on the surface of the MIRROR lens.

  • Page 116: Auto Focus Cutting Head

    MIRROR CLEANING To remove a mirror for beam alignment, cleaning or replacement, follow this procedure: Perform only as many steps of this procedure as are Be sure the shutter is closed and the high volt- required to get the mirror (reflective optic) clean. age is OFF.
  • Page 117 Nozzle Tip Assembly Retainer Nozzle Tip Outer Cone Tip Mounting Flange Tip Cable (SMA) Connector Auto Focus Head and Nozzle Tip Assembly ✦ Electro contact cleaner (C.I. #843512) effective- no conductive path across the insulator between the Tip Retainer and the Outer Cone. ly removes residue produced when cutting some galvanized materials.
  • Page 118 both ballscrew mounting bearings. Do not lubricate the ball bushings Latch Detents and guide rods; they only require periodic cleaning for maintenance. TROUBLESHOOTING FOCUS OUT-OF-RANGE ERROR Hinge Latches The control displays this error mes- sage when it cannot load a program because a G102 macro argument specifies a focus setting outside the Latches Actuate...

  • Page 119: Beam Delivery Alignment

    THIS ALIGNMENT PROCEDURE IS TO BE PER- The heart of this procedure is the “card shot” which FORMED ONLY BY CINCINNATI TRAINED SER- is a special case of the “laser shot” described in VICE PERSONNEL. DO NOT ATTEMPT TO ALIGN SECTION 7.
  • Page 120 FIGURE 9-5A Laser beam delivery system TARGET CARD MIRROR HOUSING Actual Beam Path Desired Path Mirror Steering Screws Beam is not parallel or centered on mirrors. Near Field Far Field Beam is parallel but not centered on mirrors. Near Field Far Field Beam is parallel and centered on mirrors.

  • Page 121: Resonator Warm-Up

    FIRST EXTERNAL MIRROR ALIGNMENT Note: If cutting head assembly has been removed, the HV INTERLOCK keyswitch on the machine If the laser internal optics have been adjusted or operator panel (Figure 6-2) must be rotated to replaced, a complete system alignment must start the “BYPASS”...

  • Page 122: Collimator Beam Alignment

    1. Using a 3/32” hex key, remove the mirror cap and mirror of the first collimator mirror assembly. See Figures 9-3 and 9-8. Note that the mirror mount is not removed from the col- limator housing as is done for the beam ben- der mirrors.
  • Page 123 steering is done by adjusting the second collimator mirror. Centering is done by position adjustments of the moving X-mirror in the Y or Z-direction. Nec- essary adjustments are determined by taking card shots in the moving X-mirror housing at the near- field and the far-field positions of the gantry.

  • Page 124: Y-Axis Beam Alignment

    11. If the impressions are the same, but off-center more than 0.020” (0.5 mm), adjust the position of the moving X-mirror housing in the appro- priate direction. 12. Repeat the two card shots and the adjustments of Steps 10 and 11 until both card shots are centered.

  • Page 125: Z-Axis Alignment

    BE SURE YOU ARE CLEAR OF THE BEAM PATH. Note: If the Y-axis is forced off center more than 1/32” (0.8 mm) by these adjustments, contact CINCINNATI Laser Service. FINAL ALIGNMENT CHECK After completing the Z-axis alignment, do the fol- lowing: 1.

  • Page 126: Air Dryer

    4. When the card shots at all four corners of the cutting area indicate beam alignment within 0.020" (0.5 mm), re-install the cutting head and all mirror covers, box covers and access covers. 5. Label all of the cards that have been kept for reference with the date and machine serial number.
  • Page 127 4. Open “Maintenance/Statistics” window rials that produce flammable residue (alu- (described in SECTION 6 ). Check the “Time minum, plastics, fabrics, etc.). This inspection since laser gas change”. If this time will exceed is also important when the laser system alter- the limit of 72 hours during the next shift, nates between processing aluminum and steel.
  • Page 128 12. Inspect the inside of the beam delivery system 2000 hour service inspection form. Contact the for any evidence of dirt or dust. Clean all CINCINNATI Laser Service for scheduling or areas with a vacuum cleaner if necessary. Re- proper training. Service and inspection of the apply vacuum grease (C.I.

  • Page 129: Alarm And Operator Messages

    18. Note any machine problems that might require 4. Additional resonator maintenance requires additional attention. Contact CINCINNATI proper training. To schedule service or training, Laser Service for assistance in resolving these contact CINCINNATI INCORPORATED.
  • Page 130 DISPLAYED MESSAGE DESCRIPTION POSSIBLE CAUSE(S) Comment syntax error. See Programming Manual. G89 ‘C’ or ‘J’ argument not valid. Coolant call error. Valid arguments are: 8 (use coolant) and 9 (no coolant). Corner radius too large. Current program is active. Cannot load new program.
  • Page 131 No program name in subroutine call. See Programming Manual. No R, I, or J specified for circle. No Rofin program available. Internal error—call CINCINNATI. Optional assist gas data error. G102 ‘I’ argument not valid. Verify arguments are consistent with Must not exceed Assist Gas Valve units used (i.e.
  • Page 132 DISPLAYED MESSAGE DESCRIPTION POSSIBLE CAUSE(S) Power ramp tip cooling time error. G103 ‘F’ argument not valid. Power setting data error. G103 ‘R’ through ‘W’ argument(s) not valid. Precut dwell data error. G102 ‘D’ argument not valid. Valid range: 0-300 sec. Process parameter library not found.

  • Page 133: Operator Fyi Messages

    Configura- tion/Options. Machine will operate without purge gas (for use by CINCINNATI Service personel only). Change laser gas soon. Laser gas change interval will elapse in less than 4 hours. Select LASER- >SERVICE->SERVICE REPORT- >GAS CHANGE to change gas.
  • Page 134 POSSIBLE CAUSE(S) Laser high voltage is off. High voltage disabled by Rofin or If no interlocks tripped: CINCINNATI interlock circuit. • Bad connection from High Voltage relay contact to I/O PC board. • Bad connection / relay in Rofin enclosure.

  • Page 135: System Alarms

    DISPLAYED MESSAGE DESCRIPTION POSSIBLE CAUSE(S) Resonator service due - check Laser The resonator control is indicating • Shutter cycle limit or PM interval Service Report. that service is required. exceeded. • Open the Laser Service Report window. A value highlighted in red indicates that counter limit has been exceeded.
  • Page 136 DISPLAYED MESSAGE DESCRIPTION POSSIBLE CAUSE(S) Auto Focus Head door is open. The Auto Focus Head door is open. • The door was opened intentionally. • The door switch failed. The door must be closed before cutting can begin. Auto Focus Head not homed. The Auto Focus Head has not been •...
  • Page 137 DISPLAYED MESSAGE DESCRIPTION POSSIBLE CAUSE(S) Fume blower fault. Failure: 3-phase motor starter con- • Over current dial set too low on tact did not close within 3 seconds motor starter—see schematics for of being energized. proper setting. • Pump failure / overcurrent. •...
  • Page 138 PC board) to Assist Gas valve. Noncontact head has not been Normal: A Standoff Calibration has calibrated. not been performed since the CNC application was started (CINCINNATI HSS only). Noncontact Head installed proximity Noncontact head proximity switch Proximity mount too far from flange;...
  • Page 139 Normal: An external Emergency • Bad wire connection between but- is disabled. Stop button was pressed on the pal- ton and CL-7A control. let loader control. Pallet motion disabled during auto- Normal: An attempt was made to matic pallet loading.
  • Page 140 DISPLAYED MESSAGE DESCRIPTION POSSIBLE CAUSE(S) PMAC Controller response time-out. Failure: The motion controller is not • Loose ribbon cable connection. responding. • PMAC PC board not fully seated. • PMAC PC board failed. PMAC Driver (WinRT) not function- Failure: Windows NT start-up error. ing.
  • Page 141 DISPLAYED MESSAGE DESCRIPTION POSSIBLE CAUSE(S) Tip standoff calibration not com- Normal: The calibration move was pleted. interrupted before calibration was completed. Unable to read PMAC data from the Failure: Windows NT registry not registry. Exiting application. configured properly. X Motor paramters don’t match. X and Y Encoder Resolution setting •...
  • Page 142 DISPLAYED MESSAGE DESCRIPTION POSSIBLE CAUSE(S) X1 positive soft overtravel/X2 posi- Normal: The position of the motor If occurring during JOG mode: tive soft overtravel. has exceeded the Overtravel Limit • Overtravel limits not correctly set setting on the Configuration screen on Configuration screen.

  • Page 143: Laser Resonator Alarms

    DISPLAYED MESSAGE DESCRIPTION POSSIBLE CAUSE(S) Z-axis fatal following error. Failure: The motor did not go where • Following Error Limit parameter on the Configuration screen is it was commanded to go. (The actu- al position of the motor may not dif- incorrect (default: 0.125 in.).
  • Page 144 • Rofin-Sinar software EPROM not compatible with CNC version - call CINCINNATI Service for correct software version. K1 fault (HV contactor) See Rofin Sinar Manual. K3 fault (Mains contactor) See Rofin Sinar Manual.
  • Page 145 Rofin-Sinar software EPROM not mand less than minimum length. with wrong data length from CNC. compatible with CNC version - call CINCINNATI Service for correct soft- ware version. Remote laser error: received invalid Resonator control received command Rofin-Sinar software EPROM not command I.D.

  • Page 146: Lube Cycle Alarm

    LUBE CYCLE ALARM ✦ In the Maintenance menu, select Configuration. During the auto-lubrication cycle, the Laser System ✦ In the “Machine Configuration” window, press uses a limit switch to detect if the lube cycle is com- the START MANUAL LUBE button to start the pleted.

  • Page 147: Troubleshooting

    The following chart was developed to aid in troubleshooting problems with the machine. The chart contains the questions frequently asked by our customers. If major repairs are required or if the problem has not been identified by using the chart, contact the Service Department at CINCINNATI INCORPORATED for assistance.

  • Page 148: Section 10 Service And Parts

    2. Part number and part name, obtained from the TECHNICAL TRAINING assembly drawings included with this manual. 3. As complete a description of the part as possi- CINCINNATI INCORPORATED offers a variety of ble. Operator and Maintenance Training Programs to 4. Delivery required.
  • Page 149 ã COPYRIGHT 2002 CINCINNATI INCORPORATED...

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