fanuc C1000, C2000, C4000 Operators Manual

GE Fanuc Automation

Computer Numerical Control Products

Laser C1000 / C2000 / C4000―Model E for CE Mark

Operator's Manual

GFZ-70314EN/01

May 2001

GFL-001

Warnings, Cautions, and Notes as Used in this Publication

Warning

Warning notices are used in this publication to emphasize that hazardous voltages, currents, temperatures, or other conditions that could cause personal injury exist in this equipment or may be associated with its use.

In situations where inattention could cause either personal injury or damage to equipment, a Warning notice is used.

Caution

Caution notices are used where equipment might be damaged if care is not taken.

Note

Notes merely call attention to information that is especially significant to understanding and operating the equipment.

This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance. Features may be described herein which are not present in all hardware and software systems. GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made.

GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purpose shall apply.

©Copyright 2001 GE Fanuc Automation North America, Inc.

All Rights Reserved.

B-70314EN/01

PREFACE

PREFACE

This manual covers the following models:

Model	Abbreviation
FANUC LASER C1000-MODEL E	C1000-E
FANUC LASER C2000-MODEL E	C2000-E
FANUC LASER C4000-MODEL E	C4000-E

And, these models conform with EMC Directive 89/336/EEC, and

Low Voltage Directive 73/23/EEC.

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B-70314EN/01 TABLE OF CONTENTS

TABLE OF CONTENTS

PREFACE................................................................................................................................................				p-1
1	OVERVIEW.........................................................................................................................................			1
	1.1	MANUAL CONTENTS .....................................................................................................................		2
	1.2	APPLICABLE MODELS...................................................................................................................		3
	1.3	RELATED MANUALS......................................................................................................................		4
	1.4	FOR SAFE OPERATION..................................................................................................................		5
	1.5	NOTES ON READING THIS MANUAL .........................................................................................		6
2	SAFETY		..............................................................................................................................................	7
	2.1	LASER BEAM ...................................................................................................................................		8
	2.2	HIGH VOLTAGE.............................................................................................................................		13
	2.3	SAFETY ENCLOSURE (AT YOUR WORK STATION) ...............................................................		17
	2.4	FIRE .................................................................................................................................................		18
	2.5	TOXIC FUME..................................................................................................................................		19
	2.6	HIGH TEMPERATURE..................................................................................................................		20
	2.7	WARNING LABELS .......................................................................................................................		24
	2.8	HIGH-PRESSURE GAS..................................................................................................................		35
	2.9	KEY CONTROL...............................................................................................................................		36
	2.10	SHUTTER LOCK ............................................................................................................................		37
	2.11	EMERGENCY STOP BUTTON .....................................................................................................		38
	2.12	WARNING LIGHT (OPTIONAL)...................................................................................................		39
	2.13	INAPPOSITE USE OF LASER OSCILLATOR.............................................................................		40
3	INSTALLATION...............................................................................................................................			41
	3.1	CONDITION....................................................................................................................................		42
	3.1.1		Environmental Conditions ......................................................................................................	42
	3.1.2		Power Source............................................................................................................................	42
	3.1.3		Laser Gas..................................................................................................................................	42
	3.1.4		Cooling Water ..........................................................................................................................	43
	3.2	TRANSPORTATION.......................................................................................................................		45
	3.2.1		Lifting Laser Oscillator ...........................................................................................................	45
	3.2.2		Packing .....................................................................................................................................	46
	3.2.3		Environmental Condition........................................................................................................	50
	3.3	STORAGE........................................................................................................................................		51
	3.3.1		Environmental Condition........................................................................................................	51

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	3.4	BASE OF OSCILLATOR ........................................................................................................................		52
	3.5	MAINTENANCE AREA .................................................................................................................		54
	3.6	WATER CONNECTION .................................................................................................................		57
	3.6.1		Chiller.......................................................................................................................................	57
	3.6.2		Cooling Water Temperature ...................................................................................................	58
	3.6.3 Cooling Water Flow Rate ........................................................................................................			58
	3.6.4		Plumbing ..................................................................................................................................	58
	3.7	LASER GAS.....................................................................................................................................		59
	3.7.1		Gas Bottle.................................................................................................................................	59
	3.7.2		Laser Gas Tubing.....................................................................................................................	59
	3.7.3		Gas Pipe....................................................................................................................................	59
	3.8	LASER BEAM .................................................................................................................................		61
	3.8.1 Position and Tolerance of Laser Beam Exit...........................................................................			61
	3.8.2		Beam Divergence .....................................................................................................................	62
	3.8.3 Tolerance of Beam Direction...................................................................................................			62
	3.8.4		Beam Guide..............................................................................................................................	62
	3.9	ELECTRIC CONNECTION............................................................................................................		63
	3.9.1 Power Cable (L1, L2, L3).........................................................................................................			65
	3.9.2		Ground Cable ...........................................................................................................................	65
	3.9.3		I/O Signal Cable.......................................................................................................................	65
	3.9.4 Other Signal Cables to the IF PCB.........................................................................................			66
	3.9.5		Safety Interlock........................................................................................................................	67
	3.9.6		EMC Countermeasure.............................................................................................................	71
4	FUNCTIONS.....................................................................................................................................			72
	4.1	INTERNAL STRUCTURE..............................................................................................................		73
	4.1.1		Outline......................................................................................................................................	76
	4.2	COMPONENT DETAILS................................................................................................................		78
	4.3	OPERATION SEQUENCE.............................................................................................................		85
	4.4	LASER PROCESSING MACHINE SYSTEM................................................................................		88
5	MAINTENANCE ..............................................................................................................................			90
	5.1	DAILY INSPECTION .....................................................................................................................		91
	5.2	PERIODIC MAINTENANCE .........................................................................................................		92
	5.3	DETAILS OF MAINTENANCE .....................................................................................................		93
	5.3.1 Maintenance Panels and Oil Gauge Position.........................................................................			93
	5.3.2		Turbo Blower Oil......................................................................................................................	97
	5.3.3		Exhaust Pump Oil ...................................................................................................................	99

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	5.3.4		Exhaust Pump Filter .............................................................................................................	100
	5.4	AGING ...........................................................................................................................................		101
	5.4.1		Leak Check Method ...............................................................................................................	101
	5.4.2		Aging Method.........................................................................................................................	102
	5.5	MAINTENANCE PARTS..............................................................................................................		104
	5.5.1		Spare Parts.............................................................................................................................	104
	5.5.2		Maintenance Tools.................................................................................................................	105
6	TROUBLESHOOTING...................................................................................................................			106
	6.1	CHECKING ON FAULTS ............................................................................................................		107
	6.2	RESPONDING TO ALARM MESSAGES ON THE SCREEN ...................................................		108
APPENDIX
A	EXTERNAL VIEW OF LASER OSCILLATOR..............................................................................			123
B	SPECIFICATIONS .........................................................................................................................			126
C	ERROR CODE LIST .......................................................................................................................			127
D	FANUC SERVICE NETWORK ......................................................................................................			128
E	GLOSSARY .....................................................................................................................................			129

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1.OVERVIEW

1 OVERVIEW

In this manual, we have tried as for as possible to address all issues. However, space restrictions prevent us from describing everything that must not be done, or which cannot be done, because there are so many possibilities.

Therefore, all matters which are not specifically described as being possible should be regarded as being "impossible".

	Contents of this chapter
1.1	MANUAL CONTENTS ..............................................................	2
1.2	APPLICABLE MODELS ............................................................	3
1.3	RELATED MANUALS...............................................................	4
1.4	FOR SAFE OPERATION ...........................................................	5
1.5	NOTES ON READING THIS MANUAL...................................	6

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1.OVERVIEW

B-70314EN/01

1.1 MANUAL CONTENTS

This manual consists of the following chapters and appendixes:

1.OVERVIEW

Chapter 1 covers the configuration of the manual, applicable models, related manuals, and provides notes on reading the manual.

2.SAFETY

Chapter 2 covers the warnings and precautions related to laser beams, high voltages, high temperatures, and a toxic substances. To ensure safe operation, read this chapter first.

3.INSTALLATION

Chapter 3 describes the condition for installation and connection of electrical cables, water tubes, gas tubes.

4.FUNCTIONS

Chapter 4 describes the structure and operation of the laser oscillator.

5.MAINTENANCE

Chapter 5 describes the periodic maintenance of the laser oscillator.

6.TROUBLESHOOTING

Chapter 6 describes the actions to be taken if the oscillator malfunctions.

APPENDIX

A.EXTERNAL VIEW

B.FANUC LASER C SERIES SPECIFICATIONS

C.ERROR CODE LIST

D.FANUC SERVICE NETWORK

E.GLOSSARY

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B-70314EN/01 1.OVERVIEW

1.2	APPLICABLE MODELS
		This manual covers the following models:
		Model	Abbreviation
		FANUC LASER C1000-MODEL E	C1000-E
		FANUC LASER C2000-MODEL E	C2000-E
		FANUC LASER C4000-MODEL E	C4000-E

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1.OVERVIEW

B-70314EN/01

1.3 RELATED MANUALS

The following manuals are available for the FANUC LASER C1000/

C2000/C4000-MODEL E :

		DESCRIPTIONS	B-63192EN
	FANUC Series 16i-LA	CONNECTION MANUAL	B-63193EN
		OPERATOR’S MANUAL	B-63194EN
		MAINTENANCE MANUAL	B-63195EN
		PARAMETER MANUAL	B-63200EN
	FANUC LASER	OPERATOR’S MANUAL	B-70314EN
		(This manual)
	C1000/C2000/C4000-MODEL E
		MAINTENANCE MANUAL	B-70315EN

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1.OVERVIEW

1.4 FOR SAFE OPERATION

This manual contains precautions which must be observed during operation of the laser oscillator, to ensure the operator's safety and prevent damage to the oscillator. Each precaution is indicated by "Warning" or "Caution" according to its severity.

Supplementary information is indicated by "Note".

Read the contents of each "Warning", "Caution", and "Note" before attempting to use the oscillator.

WARNING

Precautions to be applied in those situations where there is a danger of the operator being killed or seriously injured.

CAUTION

Precautions to be applied in those situations where there is a danger of the operator being slightly injured or the oscillator being damaged.

NOTE

Supplementary information other than precautions.

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1.OVERVIEW

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1.5 NOTES ON READING THIS MANUAL

The functions of a laser machining system depend not only on the laser oscillator, but also on the machine, power magnetics cabinet, servo system, CNC, and operator's panel. This manual describes only the laser oscillator. For a description of the other components, refer to the corresponding manuals, supplied by the machine tool builder.

Read this manual thoroughly and store it in a safe place.

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2.SAFETY

2 SAFETY

C1000-E, C2000-E, and C4000-E produce the rated output laser power of 1000W, 2000W, and 4000W. The CO2 laser beam is the wavelength of 10.6 m, far infrared, and is invisible to human eyes.

The adequate care must be taken when CO2 laser is operated, therefore. When removing the panel, always turn the power source off and confirm no power is applied to the laser machine.

This oscillator fulfills the requirements of the relevant product safety standard of EN60825-1:1994.

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2.SAFETY

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2.1 LASER BEAM

1)Potential hazards

Laser oscillator emits CO2 laser beam(10.6 m), which is high power and invisible.

•Being directly exposed to the CO2 beam could severely burn you.

•The CO2 beam could bource off your workpiece and burn your eyes or skin.

LASER oscillator have a guide laser. The guide laser beam is visible (red color) and low power. It is used to ensure that the CO2 beam is correctly positioned on your workpiece.

•The diode laser beam is not considered harmful to your skin. But if you stared head on into the guide laser beam, it could harm your eyes.

2)Safety recommendations

Never expose the eyes and skin to the laser beam. Be careful of the laser beam when performing the inspection and maintenance. Do not turn on the power supply to the oscillator when the panel open and do not drive. It is bleached to radiation of the laser beam and high voltage.

Do the countermeasure (For instance, installs safety glasses and the protection gloves) to danger in case of stopped no finish and nor opening the panel while it energizes the oscillator.

Install beam safety cover after mirror cleaning or replacement. And if not beam safety cover installation, do not operation and alignment.

Confirm when it does alignment, the protection pipe (Safety cover) is installed. If it dose not install the protection pipe, it will put the finger in the laser beam and there is possibility to do the burn.

When entering the area exposed to the scattered beam, wear the safety glasses. Mount the stand made of acrylic resin or any

material which can absorb the CO2 laser beam to protect the personnel from the scattered beam.

Avoid exposure of any part of your body to the CO2 laser beam. When testing the beam output, any personnel other than the maintenance personnel should be out of the working environment.

In designing a material processing machine utilizing laser

oscillator, be sure that the CO2 laser beam goes from laser to the workpiece only through the enclosed beam delivery system. This prevents the exposure to laser beam by the operator switch could otherwise take place. It is absolutely necessary to include the instructions given here in the manuals of the laser materialprocessing machine as a whole, which are to be read.

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2.SAFETY

3)Position of laser beam emission

Fig.2.1(a) is the position of panel that laser beam exposure is occurred without panel in C1000-E, when your maintenance. Fig.2.1(b) is the position of panel that laser beam exposure is occurred without panel in C2000-E, when your maintenance. Fig.2.1(c) is the position of panel that laser beam exposure is occurred without panel in C4000-E, when your maintenance. Fig.2.1(d) is the position of laser beam delivery in C1000-E. Fig.2.1(e) is the position of laser beam delivery in C2000-E. Fig.2.1(f) is the position of laser beam delivery in C4000-E.

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2.SAFETY

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Fig.2.1(a) Laser beam exposure position without panel as operating (C1000-E)

Fig.2.1(b) Laser beam exposure position without panel as operating (C2000-E)

Fig.2.1(c) Laser beam exposure position without panel as operating (C4000-E)

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2.SAFETY

Fig.2.1(d) The position of laser beam delivery (C1000-E)

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2.SAFETY

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Fig.2.1(e) The position of laser beam delivery (C2000-E)

Fig.2.1(f) The position of laser beam delivery (C4000-E)

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2.SAFETY

2.2 HIGH VOLTAGE

1)Potential hazards

There is RF voltage of 3 to 4kVo-p in the cabinet of the laser oscillator.

There is 200 VAC power in the relay panel, be careful not to touch the high voltage.

2)Safety recommendations

When it checks the oscillator and exchange the unit, intercept a main breaker of the oscillator and the power supply. Lock the breaker to prevent misconnection and display the sign while working.

Install safety cover after unit replacement or cable connection. Unless safety cover is installed, never perform operation. Follow standard industrial safety practices for working with high voltage.

EXAMPLES

•Do not work on the laser oscillator if you are tired or have taken medicine.

•Do not wear anything metal, like a ring, bracelet, watch, belt buckle, earrings, or keys.

•They might contact high voltage.

•Never stand on a wet surface.

•Do not touch electrical components in the cabinets with both hands at once. Keep one hand in a pocket.

3)Position of high voltage

Fig.2.2(a) is the position of high voltage in C1000-E (Front, maintenance side).

Fig.2.2(b)is the position of high voltage in C1000-E (Back side). Fig.2.2(c) is the position of high voltage in C2000-E (Front, maintenance side).

Fig.2.2(d)is the position of high voltage in C2000-E (Back side). Fig.2.2(e) is the position of high voltage in C4000-E (Front, maintenance side).

Fig.2.2(f) is the position of high voltage in C4000-E (Back side).

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2.SAFETY

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Fig.2.2(a) Position of high voltage in C1000-E (Front, maintenance side)

Fig.2.2(b) Position of high voltage in C1000-E (Back side)

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2.SAFETY

Fig.2.2(c) Position of high voltage in C2000-E (Front, maintenance side)

Fig.2.2(d) Position of high voltage in C2000-E (Back side)

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2.SAFETY

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Fig.2.2(e) Position of high voltage in C4000-E (Front, maintenance side)

Fig.2.2(f) Position of high voltage in C4000-E (Back side)

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2.SAFETY

2.3 SAFETY ENCLOSURE (AT YOUR WORK STATION)

1)Potential hazards

CO2 beam is delivery from oscillator. Direct or scattered beam is exposed.

2)Safety recommendations

Mount the safety enclosure made of acrylic resin which can absorb the laser beam around the working environment.

Mount the interlock switch on the safety enclosure door which extinguishes the laser beam output when the door is open. Never perform operation without safety cover of laser machine.

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2.SAFETY

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2.4 FIRE

1)Potential hazards

When you work with the laser oscillator or machine, hot

fragments or slag can scatter from your workpiece. The CO2 beam or a reflection of it could ignite flammable material.

2)Safety recommendations

The direct or scattered laser beam can ignite flammable materials such as paper, cloth, and wood. Provide a beam absorber behind the workpiece and around it during maintenance. The absorber can be anodized aluminum, graphite or brick.Put a shield

between yourself and the workpiece when the CO2 beam is on. Even diffuse reflections can harm eyes and skin and may ignite flammable material.

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2.SAFETY

2.5 TOXIC FUME

1)Potential hazards

Some materials such as certain plastics can emit toxic fume when they burn under the laser beam.

2)Safety recommendations

Install the exhaust system to remove toxic fume from the work environment.

Consult the manufacturer of the material you are processing to learn if it creates any fumes when heated or burned.

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2.SAFETY

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2.6 HIGH TEMPERATURE

1)Potential hazards

When you touch a part of high temperature, your skin burn.

2)Safety recommendations

The pipes of the gas circular system are very a high temperature. Do not touch pipes, heat exchanger and turbo blower because it does not do the burn. It is hot immediately after having stopped driving. After getting cold enough in case of removing, dismount it.

3)Position of high temperature

Fig.2.6(a) is the position of high temperature in C1000-E (Front, maintenance side).

Fig.2.6(b) is the position of high temperature in C1000-E (Back side).

Fig.2.6(c) is the position of high temperature in C2000-E (Front, maintenance side).

Fig.2.6(d) is the position of high temperature in C2000-E (Back side).

Fig.2.6(e) is the position of high temperature in C4000-E (Front, maintenance side).

Fig.2.6(f) is the position of high temperature in C4000-E (Back side).

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2.SAFETY

Fig.2.6(a) Position of high temperature in C1000-E (Front, maintenance side).

Fig.2.6(b) Position of high temperature in C1000-E (Back side).

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2.SAFETY

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Fig.2.6(c) Position of high temperature in C2000-E (Front, maintenance side).

Fig.2.6(d) Position of high temperature in C2000-E (Back side).

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2.SAFETY

Fig.2.6(e) Position of high temperature in C4000-E (Front, maintenance side).

Fig.2.6(f) Position of high temperature in C4000-E (Back side).

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2.SAFETY

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2.7 WARNING LABELS

Fig.2.7(a)-(f) show the location of the warning labels indicating the high voltage and laser beam path.

Fig.2.7(a) is the location of the warning sticker (C1000-E:Front side). Fig.2.7(b) is the location of the warning sticker (C1000-E:Back side). Fig.2.7(c) is the location of the warning sticker (C2000-E:Front side). Fig.2.7(d) is the location of the warning sticker (C2000-E:Back side). Fig.2.7(e) is the location of the warning sticker (C4000-E:Front side). Fig.2.7(f) is the location of the warning sticker (C4000-E:Back side).

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