fanuc C1000, C2000, C4000 Maintenance Manual

GE Fanuc Automation

Computer Numerical Control Products

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

Maintenance Manual

GFZ-70315EN/01 May 2001

Warnings, Cautions, and Notes as Used in this Publication

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

GFL-001

Warning

Caution

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.

B-70315EN/01 TABLE OF CONTENTS

1 OVERVIEW

This manual describes the maintenance of the FANUC LASER C1000/C2000/C4000-MODEL E, as well as the structure, configuration, and operation of the laser oscillator. This manual is aimed at those personnel responsible for laser oscillator maintenance.

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1.OVERVIEW B-70315EN/01

1.1 ORGANIZATION OF THE MANUAL

This manual is organized as described below.

1. Overview This chapter describes the organization of this manual, applicable models, related manuals, and notes on reading this manual.

2. Safety This chapter describes the handling of lasers, and provides warnings, cautions and notes on high voltages, high temperatures, and toxicity. All users must read this chapter carefully to ensure safety.

3. Internal Structure This chapter describes the structure and operation of the laser oscillator.

4. Installation This chapter describes the installation and checking of the laser oscillator.

5. Maintenance This chapter provides information on when and how the consumable parts of the laser oscillator must be replaced.

6. Troubleshooting This chapter describes the actions to be applied in the event of a fault occurring in the laser oscillator.

7. Oscillator Connections This chapter describes the internal connections of the electrical system, cooling system, and gas system.

8. Unit Configuration This chapter describes the internal units of the laser oscillator.

9. Setting and Adjustment This chapter describes how to set and adjust the controls of the laser oscillator.

10. Replacement Procedures This chapter describes how to replace the individual units and parts of the laser oscillator.

11. Laser Optical System This chapter describes how to clean, replace, and align the optical components of the laser oscillator.

Appendix

1. Appearance of the Laser Oscillator

2. FANUC LASER C series Specifications

3. Error Code List

4. Parameters

5. Control Sequences in Laser Oscillator

6. Refixing and Replacing Gas Tube

7. Refixing and Replacing Water Tube

8. Glossary

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B-70315EN/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-70315EN/01

1.3 RELATED MANUALS

The following manuals are available for the FANUC LASER C1000/ C2000/C4000-MODEL E :

DESCRIPTIONS B-63192EN CONNECTION MANUAL B-63193EN

FANUC Series 16i-LA

OPERATOR’S MANUAL B-63194EN MAINTENANCE MANUAL B-63195EN PARAMETER MANUAL B-63200EN

FANUC LASER C1000/C2000/C4000-MODEL E

OPERATOR’S MANUAL B-70314EN

MAINTENANCE MANUAL (This manual)

B-70315EN

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B-70315EN/01 1.OVERVIEW

1.4 TO USE THE LASER OSCILLATOR SAFETY

In this manual, the words Warning and Caution, corresponding to different levels of safety requirements, are provided to ensure the user's safety and protect against damage to the laser oscillator. Moreover, sections entitled Note are used to provide supplementary information. Before attempting to use the laser oscillator, read Section 2.1 to 2.11, and also the descriptions in the Warnings, Cautions, and Notes that appear in the text.

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.

Before starting any maintenance work, take time to become familiar with the functions of the individual units constituting the laser oscillator, the relationships between the units, and the locations where the units are installed.

WARNING

Never attempt handling, adjustment, or replacement work using a method or procedure other than those described and specified in this manual. Otherwise, dangerous laser light may be emitted.

The function of the laser machining system depends not only on the laser oscillator but also on other system components such as the machine, power magnetics cabinet, servo system, CNC, and operator's panel. This manual covers the laser oscillator only. For information about equipment other than the laser oscillator, refer to the appropriate manuals provided by the machine tool builder.

Take time to become familiar with the contents of this manual. Store this manual in a safe place.

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2.SAFETY B-70315EN/01

2 SAFETY

C1000-E, C2000-E, and C4000-E produce the rated output laser power of 1000W, 2000W, and 4000W. The CO wavelength of 10.6 µm, far infrared, and is invisible to human eyes. The adequate care must be taken when CO 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.

laser beam is the

2

laser is operated,

2

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B-70315EN/01 2.SAFETY

2.1 LASER BEAM

1) Potential hazards Laser oscillator emits CO power and invisible.

• Being directly exposed to the CO

burn you.

• The CO

beam could bource off your workpiece and burn

2

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 CO

beam is correctly positioned on your workpiece.

2

• 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 CO personnel from the scattered beam. Avoid exposure of any part of your body to the CO 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 CO 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.

laser beam(10.6 µm), which is high

2

beam could severely

2

laser beam to protect the

2

laser beam.

2

laser beam goes from laser to the

2

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2.SAFETY B-70315EN/01

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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B-70315EN/01 2.SAFETY

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 B-70315EN/01

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

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B-70315EN/01 2.SAFETY

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 B-70315EN/01

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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B-70315EN/01 2.SAFETY

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 B-70315EN/01

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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B-70315EN/01 2.SAFETY

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 B-70315EN/01

2.3 SAFETY ENCLOSURE (AT YOUR WORK STATION)

1) Potential hazards CO

beam is delivery from oscillator. Direct or scattered beam is

2

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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B-70315EN/01 2.SAFETY

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 CO 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 CO Even diffuse reflections can harm eyes and skin and may ignite flammable material.

beam is on.

2

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2.SAFETY B-70315EN/01

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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B-70315EN/01 2.SAFETY

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 B-70315EN/01

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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B-70315EN/01 2.SAFETY

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 B-70315EN/01

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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