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Flat Sheet Laser Cutting Machine Installation Manual

SAFETY INFORMATION

⚠️ WARNING - READ BEFORE PROCEEDING

Laser Radiation Hazard

• Class 4 laser product - Direct or scattered radiation can cause permanent eye damage and skin burns

• NEVER operate with safety enclosures open or safety interlocks disabled

• ALWAYS verify emergency stop function before operation

Critical Installation Warnings

1. Qualified Personnel Only: Installation must be performed by certified technicians

2. Lifting Requirements: Use overhead cranes rated ≥ 2x machine weight (minimum 8,000kg capacity)

3. Electrical Safety: Lockout/tagout procedures required - 380-480V 3-phase power present

4. Gas Systems: Assist gases under high pressure (1.5-2.0MPa) - leak test required

Required PPE

• ANSI Z87.1 safety glasses

• Cut-resistant gloves

• Steel-toe boots

• Hearing protection

I. PRE-INSTALLATION SITE PREPARATION

A. Facility Requirements

B. Utility Connections

Power Supply (Typical)

• Main: 3-phase 400VAC (±10%) 50/60Hz

• Peak Consumption: 85 kVA

• Dedicated transformer with ±2% voltage regulation

Compressed Air System

• Pressure: 0.7-0.8 MPa (clean, dry)

• Flow: 500 L/min continuous

• Filtration: 0.01μm oil removal + desiccant dryer

Assist Gas Requirements

Exhaust Requirements

• Minimum airflow: 3,500 m³/hour

• Static pressure: 800-1,200 Pa

• Spark-arresting filter required

II. COMPONENT UNPACKING & VERIFICATION

A. Packing List Verification

Main Components (Check upon receipt)

• Main machine frame with gantry system

• 4kW/6kW/8kW Fiber Laser Source

• Industrial Chiller Unit (S&A or similar)

• Control Cabinet with CNC System (Siemens 840D)

• Operator Console with 21" Touchscreen

• Automatic Pallet Changer System

• Fume Extraction Hood & Ducting

Critical Inspection Points

1. Check shipping blocks on linear guides - DO NOT REMOVE until machine is leveled

2. Verify laser source transit brackets are secure

3. Inspect optical components packaging for damage indicators

III. STEP-BY-STEP INSTALLATION PROCEDURE

Phase 1: Foundation & Leveling

Day 1: Foundation Preparation

1. Clean floor surface thoroughly2. Apply anchor bolt templates (supplied)3. Drill foundation holes per drawing DWG-2023-FL4. Install M24 anchor bolts with 300mm embedment

Day 2: Machine Placement

1. Using 4-point lifting rigging, lift main frame

2. Lower onto foundation with 50mm clearance

3. Install leveling pads (8 locations)

4. Torque anchor bolts to 350 N·m in crisscross pattern

Day 3: Precision Leveling

1. Place precision level on X-axis rail (Grade 0.02mm/m)

2. Adjust leveling feet to achieve ≤ 0.05mm/m over full travel

3. Repeat for Y-axis

4. Verify diagonals within 0.1mm over 6m span

5. Grout foundation after final leveling

Phase 2: Mechanical Assembly

Step A: Gantry System Setup

1. Remove shipping brackets from linear guides

2. Apply Way Oil VG68 to all linear rails

3. Manually traverse full travel to verify smooth motion

4. Check motor coupling alignment (≤ 0.05mm runout)

Step B: Cutting Head Installation

1. Mount cutting head assembly to Z-axis

2. Connect pneumatic lines (color-coded)

3. Install capacitive height sensor

4. Torque mounting bolts to 25 N·m

Step C: Pallet System Installation

1. Assemble pallet changer rails

2. Install pallet exchange mechanism

3. Connect hydraulic/pneumatic lines

4. Test pallet transfer cycle without material

Phase 3: Electrical Installation

Critical Sequence - FOLLOW EXACTLY

1. MAIN POWER DISCONNECTED

2. Ground machine frame to facility earth (≤ 0.1Ω)

3. Connect main power cables (95mm² copper minimum)

4. Connect laser source power (provided cable only)

5. Wire emergency stop circuit

6. Connect fieldbus cables (Profinet/Cat6 SFTP)

Cable Management Requirements

• Separate power and signal cables by ≥ 300mm

• Use shielded conduit for all motor cables

• Ground cable shields at one end only

Phase 4: Laser & Optical System

WARNING: OPTICAL COMPONENTS ARE FRAGILE

Laser Source Installation

1. Remove transit brackets

2. Position source within 8m of machine

3. Connect chiller lines (quick-connect fittings)

4. Connect control fiber (DO NOT BEND < 100mm radius)

Beam Path Alignment (Certified Technician Only)

1. Install alignment jig (PN 88-3301)2. Using beam combiner, verify center through aperture #13. Adjust mirror M1 to center on target T14. Repeat for M2, M3 with ≤ 0.5mm tolerance5. Final focus alignment using cutting head camera

IV. COMMISSIONING PROCEDURE

A. First Power-Up Sequence

1. Power ON main disconnect2. Initialize CNC system3. Start chiller (verify ΔT ≤ 2°C)4. Enable servo drives5. Home all axes6. Test emergency stop circuit

B. System Calibration

Day 1: Mechanical Calibration

1. Ballbar test (circularity ≤ 0.03mm)

2. Laser interferometer measurement (positioning accuracy ≤ ±0.01mm)

3. Backlash compensation setup

Day 2: Process Calibration

1. Pierce height calibration

2. Capacitive sensor calibration

3. Cut test (100mm square, 10mm steel)

4. Measure perpendicularity (≤ 0.05mm/300mm)

C. Performance Verification

Cutting Tests Required

Acceptance Criteria

• Positioning repeatability: ≤ 0.015mm

• Cutting accuracy: ≤ ±0.1mm or 0.1% of dimension

• Surface roughness: Ra ≤ 6.3μm (steel)

• Squareness: ≤ 0.05mm/300mm

V. TRAINING & HANDOVER

A. Required Training Sessions

Session 1: Safety & Basic Operation (4 hours)Session 2: Programming & Nesting (8 hours)Session 3: Maintenance & Troubleshooting (8 hours)Session 4: Advanced Applications (4 hours)

B. Documentation Transfer

• Electrical diagrams (PDF)

• Mechanical drawings (DWG)

• PLC program backup

• Laser source maintenance manual

• Spare parts list with cross-reference

VI. TROUBLESHOOTING - INITIAL STARTUP

MAINTENANCE CHECKLIST (First Month)

Daily

• Check air pressure (0.7±0.05 MPa)

• Clean lens (with proper lens tissue only)

• Verify exhaust flow

Weekly

• Clean linear guides & re-lubricate

• Check belt tension (125Hz frequency)

• Clean optical path covers

Monthly

• Replace chiller filters

• Check all bolt torques

• Backup system parameters