Theta LC3015q2
Laser Machine
User Pre-installation Guide
October, 2003
Amada America, Inc.
7025 Firestone Blvd.
Buena Park, CA 90621
Tel. (714) 739-2111
Fax. (714) 228-0536
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CONTENTS
Pre-Installation Checklist ..............................................................................................................i
Items to be Obtained:
i
i
Preparation
ii
ii
Description of the Major Components .........................................................................................1
Major Components ......................................................................................................................2
Size and Weight of Major Components .......................................................................................3
Basic Specifications.....................................................................................................................4
Laser and Production Cutting Specifications...............................................................................5
Supply Requirements ..................................................................................................................6
Other Requirements ....................................................................................................................7
Air specifications - ISO 8573.1 standard
Connections
8
8
Laser Pre-mix Gas.......................................................................................................................9
Laser Pre-mix Gas Specification ...............................................................................................10
Assist Gas Recommendations...................................................................................................11
Oxygen Purity
11
Machine Dimensions - LC3015 Theta Front View .....................................................................12
Machine Dimensions - LC3015 Theta Side View ......................................................................13
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Machine Dimensions - LC3015 Theta Plan View ......................................................................14
Planning The Location of the Machine ......................................................................................15
The Chiller .................................................................................................................................16
Chiller Dimensions.....................................................................................................................17
Orion Chiller
17
Dust Collectors ..........................................................................................................................18
Farr GS-12
18
20
Machine Foundations ................................................................................................................21
Machine Foundations Cross Section
Foundation End View
J- Bolt Detail
22
23
24
Lifting.........................................................................................................................................25
Installing The Air Supply............................................................................................................26
Installing The Electrical Power Supply ......................................................................................27
Protective Coatings ...................................................................................................................32
Revision history
33
33
Contact Information
iv
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Table of Figures
Machine.......................................................................................................................................2
Gas connection kit.......................................................................................................................2
Dust Collector..............................................................................................................................2
Chiller ..........................................................................................................................................2
Transformer (optional) .................................................................................................................2
Accessory crate...........................................................................................................................2
Figure 1: Machine from shuttle end...........................................................................................12
Figure 2: Machine from operator side........................................................................................13
Figure 3: Machine from top........................................................................................................14
Figure 4: Orion RKL-15000 ......................................................................................................17
Figure 5: Torit DFT3-18, front side.............................................................................................18
Figure 6: Torit DFT3-18, side view.............................................................................................19
Figure 7: Farr GS-12 .................................................................................................................20
Figure 8: Foundation plan and side views.................................................................................22
Figure 9: Foundation right end view ..........................................................................................23
Figure 10: Foundation left end view ..........................................................................................23
Figure 11: J- bolt detail ..............................................................................................................24
Firgure 12: Lifting the Machine..................................................................................................25
Figure 13: Electrical connect 460 VAC ......................................................................................28
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Figure 14: Electrical connect 230 VAC ......................................................................................29
Figure 15: Entry point for cables................................................................................................31
Figure 16: NC & machine power connect.................................................................................31
Figure 17: Laser power connect...............................................................................................31
vi
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LC3015 Theta Pre-Install Check List
(checklist page i)
Pre-Installation Checklist
This form must be completed, signed, and faxed back to Amada’s service department.
This is required before installation of your Amada laser can begin.
Each of the following items must be completed prior to scheduling a service engineer for installation.
Please contact the Laser Service Department if you have any questions in completing these steps.
East Coast office: Covington, GA
West Coast office: La Mirada, CA
1-800-345-2374 Voice
1-800-334-2374 Voice
1-770-787-0934 Fax
1-714-690-3248 Fax
q Uncrate the machine.
q Before placing the machine on the foundation, put all the jack bolts in place in the machine feet,
and screw them down so that about 1” of the bolts extend below the bottom of the feet.
q Do not install the anchor bolts (required) until after A.E.S.I. completes the initial installation.
It is the purchaser’s responsibility to install necessary safety devices.
Items to be Obtained:
q Distilled Water (Koolant Kooler: 75 gallons, CKD: 100 gallons, Orion: 50 gallons)
q Laser gas mix: two bottles. See page 9 for details.
q Assist gas: Oxygen, Nitrogen. See page 10 for details.
Placement of the Machine and Components:
q Plan the location of the machine, gas bottles, chiller, dust collector and any other accessory equip-
ment. Take into account all the maintenance areas indicated on the floor plan.
q Prepare the machine foundation as required.
q The floor must be cleared of obstructions, clean and free of debris
q Each system component has been placed according to the Pre-install Guide
q Laser Gas bottle placed and secured from falling (25’ of gas hose is supplied)
q Assist gases placed (50’ of gas hose is supplied for nitrogen and oxygen) (see page 10)
i
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LC3015 Theta Pre-Install Check List
(checklist page ii)
Electrical Requirements
Electrical power has been connected to the top of the disconnects for each of the following:
q NC cabinet
q Laser power supply
q Dust collector
q Chiller
Preparation
q Chiller tank has been filled with distilled water only.
(on the CKD chiller, water hoses must be connected before filling tank)
q All plastic and paper coverings removed.
q Clean protective coating (cosmoline) from ball screws and LM guides.
q Each system component has been placed per the layout
q Shop air plumbed and connected to the machine. See page 7 for details.
q Shop air plumbed to dust collector with regulator. See page 7 for details.
I certify that each of the actions checked off above have been performed.
I understand that all of the above are needed for a successful installation and if any of the require-
ments are not met the installation will be delayed and I will be billed for one day’s service at normal
service charges, including expenses.
If the delay is to be more than one day the Engineer will be rescheduled to begin the installation on
the first available Monday after the problem has been corrected and I will be billed for the additional
travel expenses also.
Signature
Title
Date
ii
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Description of the Major Components
Your laser systems will arrive in several crates. The machine and accessories are packaged in
one crate. The chiller, dust collection system, gas regulators, and any optional equipment
(such as transformers or safety mats) will be crated individually.
The major components are:
q The machine - includes laser oscillator. Note that several parts including the laser cutting head,
lenses and nozzles may be inside the accessory crate rather than mounted in place.
q The chiller - this controls the running temperature of the laser oscillator. Flexible hoses and fit-
tings are provided to connect it to the oscillator. The chiller can be positioned anywhere within a
reasonable distance from the machine. For exact distance limitations, see the chiller section (be-
ginning page 15) or contact Amada.
q The accessory crates - these crates contain many small pieces of equipment required to install
and operate the machine.
q The gas connection kit - this kit contains regulators, hoses, and fittings to connect the laser and
q The optional transformer 1 - all components except the dust collector operate on 200~220 VAC
3 phase. If your supply is 230V, 460V or other voltage, a step down transformer will be required.
q The optional transformer 2 - the dust collector requires 460V, 3 phase. If you do not have 460V
at sufficient current for the unit selected, a transformer will be required.
q The Shuttle System - (option) provides rapid transfer of pallet table in/out of the machine.
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Size and Weight of Major Components
Ensure that you discuss the following dimensions and weights with your selected rigger, be-
fore the delivery of the machine.
Item
Approximate Dimensions
(Length x Width x Height)
Approximate Weights
3015 Machine
340 inches x 150 inches x 105
inches
12,056 lb. (5480 KG)
(with laser)
Shuttle
included
included in machine
63” x 36” x 78”
included
included in machine
1540 lb.
Laser (all)
Chiller Orion RKL-15000 (for 4KW laser)
Dust collector - Torit DFT3-1B
Dust collector - Farr GS-12
93” x 72” x 141”
3000 lb.
141” x 42 x 135”
call
Optional transformer
(for 4KW laser)
call Amada's Laser Group
call Amada's Laser Group
* approximate or estimated value
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Basic Specifications
FEATURE
NC unit
Laser
SPECIFICATION
Fanuc 160iL (32 bit)
Fanuc AF4000 4kW CO Fast Axial Flow
2
X
Y
120 inches (3050mm)
60 inches (1530mm)
Axis Travel
X
19.6 inches (500mm)
U
135° (Head Tilt)
V
370° (Head Rotation)
W
0.29 inches (7.5mm)
Maximum axis speed
X, Y
Z
3150 inches per minute (80m/min)
2165 inches per minute (55m/min)
250º per second
U, V
Maximum cutting thickness
Maximum worksheet weight
see table on page 5
1
1540lbs. 700(kg)
1
Depends on pallet/material handling system.
4
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Laser and Production Cutting Specifications
FEATURE
SPECIFICATION
Fanuc C4000AF
4,000 Watts
CW Power
Peak pulse power
5,000 Watts
Maximum material thicknesses:
(maximum sheet size according to weight limitation)
2
Carbon steel (O )
2
0.5 inches (12 mm)
0.375 inches (10 mm)
0.25 inches (6mm)
Stainless steel (N )
2
Aluminum (N )
2
2
Note that, especially in greater thicknesses, good results depend on good material quality
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Supply Requirements
Electrical power supply
UNIT
Machine (CNC)
Laser
RATING
SUPPLY
200V~220 VAC 3 phase 60 Hz (15 Amp, 12 KVA)
200~220 VAC 3 phase**
200~220 VAC 3 phase**
Fanuc AF4000 4kW CO Fast Axial Flow:
2
200V~220 VAC 3 phase 60 Hz (160 Amp, 55 KVA)
Chiller
Orion RKL-15000:
200~220 VAC 3 phase**
200 VAC 3 phase ±10% 60 Hz (97 Amp, 36 KVA)
Total @ 200-220
Beam purge unit
125 KVA
200~220 VAC 3 phase**
Orion QSP180-11CA : 115V 1ph ±10% 50/60 Hz (23W)
Farr GS-12: 460 VAC* 3 phase ±10% 60 Hz (20 KVA)
3
Dust collector
* Units at other than 208 V not included in transformer sizing.
** This is a min-max specification: no additional ± applies.
3
Contact Amada to determine which dust collector is provided.
6
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Other Requirements
Air supply
ITEM
Pressure/Volume
ISO8573.1 standard
Class 3-4-3
3
4
Machine
80 psi at 9 ft /min
3
5
As cutting gas
140 psi at 35 ft /min
Class 3-4-3
Dust collector - Torit DFT3-18
Dust collector - Farr GS-12
Laser Oscillator Gas
9 scfm at 90-100 psi
12 scfm at 90 psi
Class 4-5-5
see laser pre-mix gas specification (p. 9 )
see assist gas recommendations (p. 10 )
n/a
n/a
Assist gases
Coolant
Chiller coolant includes the following:
Distilled water
(Koolant Kooler: 75 gallons, CKD: 100 gallons, Orion: 50 gallons)
1 gallon provided (mix 1:100 additive:water)
6
Additive (provided with machine)
Connections
Hoses to connect air supplies to machine and dust collector
Laser pre-mixed gas (see page 9)
Assist gas (oxygen minimum) (see page 10)
4
5
6
2 micron maximum particulate size
Pressure and flow based on process requirements (material type and thickness) - contact Amada to discuss.
ISOGUARD Corrosion inhibitor, part# 71679859. Additional quantities available from AESI, at (714) 670-2111
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Air specifications - ISO 8573.1 standard
The standard provides a uniform way to specify air quality in terms of particle size, pressure
dewpoint, and oil content.
Class 2-4-3 means class 2 particulate, class 4 dewpoint, and class 3 oil content.
(1 micron particulate, 37 °F dewpoint, 1 mg/m3 oil content) (maximums)
The following table lists the maximum contaminations in each category.
Quality Class
Particle size in microns
Pressure dewpoint
–70 °c (–57°F)
–40 °c (–40°F)
–20 °c (–4°F)
+3 °c (37°F)
Oil content
3
1
2
3
4
5
0.1
1
0.01 mg/m
3
0.1 mg/m
3
5
1 mg/m
3
15
40
5 mg/m
3
25 mg/m
+7 °c (45°F)
Connections
The customer must provide:
Hose, regulator, and fittings for the dust collector.
Hose and fittings for the machine.
Laser pre-mixed gas (see page 9)
Assist gas (oxygen minimum) (see page 10)
8
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Laser Pre-mix Gas
Laser gas quality is critical to the performance and reliability of the laser. Based on our experi-
ence, we recommend BOC’s LASERSHIELD F or AGA’s LaserMix 21.
Call either of these national 800 numbers to locate the supplier closest to you.
AGA Gas Inc.
BOC GASES
1-800-837-7226
A two stage regulator and twenty-five feet of hose with 3/8" fittings is provided to connect the
gas bottle to the laser. If the installation requires a longer length, use Teflon/polyethylene hose
only.
IMPORTANT - The installation of your machine can not be completed without the correct laser
gas. Be sure to obtain at least two bottles prior to scheduling installation. The typical gas bot-
tle will hold 220 ft3 of usable gas. For the 2000W laser, a single bottle of gas should last one
to two months on a single shift basis. However, during installation, more gas is used than in
normal operation.
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Laser Pre-mix Gas Specification
Laser gas quality is critical to the performance and reliability of the laser. Based on our experi-
ence, we recommend AGA’s LaserMix 21 or BOC’s LASERSHIELD F. If you choose a supplier
other than AGA or BOC, use the following laser gas specification.
NOTE: If the gas is not mixed to the required specifications, the laser will not run correctly.
The laser uses a mix of carbon dioxide (CO2), Nitrogen (N2) and Helium (He) at 28 psi. Give
this specification to your gas supplier.
Laser Oscillator Gas Mixture
Gas
CO2
N2
He
Pre-mix ratios
5% ±0.25%
4.75% - 5.25%
55% ±2.75%
40% ±2.0%
52.25% - 57.75% 38% - 42%
99.99%
Purity
Moisture
5 ppm total maximum
1 ppm total maximum
Hydrocarbon CnHm
We recommend that you purchase gas that is certified to meet the specifications provided.7
7
This means that any impurities from the bottle are included in the certified purity.
10
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Assist Gas Recommendations
The machine has provision for three kinds of assist gases. The assist gas inputs are at the
rear of the machine. The inputs are labeled OXYGEN, CLEAN CUT, and AIR.
Oxygen is normally used to cut steel and stainless steel.
Nitrogen is used to Clean Cut™ stainless steel and aluminum with an oxide free edge.
Shop air can be used to cut aluminum at reduced cost (see page 26).
Two-stage regulators and hoses are provided in the gas connection kit for the oxygen and the
nitrogen. For high-volume/frequent use, cutting gases should be purchased in liquid form.
Note that the liquid gases will “boil-off” at some minimum rate, even if not used. Gases which
are used in low volume or infrequently should be bought in high-pressure bottles rather than in
liquid form.
An evaporator will be needed when using liquid high-pressure Nitrogen.
For usage and pressure requirements, contact Amada America’s Laser Group.
Gas Assignment
Oxygen
Inlet Port
OXYGEN
CLEAN CUT
AIR
Nitrogen
Shop air
Oxygen Purity
When cutting carbon steel with oxygen, higher purity means higher speed.
“Increasing the oxygen purity from 99.7% to 99.9% resulted in a cutting speed increase in ex-
cess of 10%.” according to the BOC article referenced below.
For a great discussion on assist gas purity, see BOC article - gases and lasers J T Gabzdyl &
D Sullivan - Presented to Lumonics User Group, Minneapolis USA, May 1996
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Planning The Location of the Machine
The diagrams following provide the details for positioning your new machine.
q No obstacles are allowed in the table travel area, and the machine must be at least 3 feet from any
wall or obstruction, and the ceiling must be at least 40" above the top of the machine.
q The machine must be placed on a single continuous foundation (see Machine Foundations section).
q In addition to the maintenance areas recommended, ensure that
(1) the doors of the NC and Laser cabinets are unobstructed,
(2) the chiller airflow is unobstructed, and
(3) the NC unit is protected from direct sunlight.
q The positioning of the chiller and dust collector are flexible. Please see those sections for details.
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The Chiller
q The chiller must be placed so that an adequate flow of air is maintained.
q The positioning of the chiller is flexible. Two lengths of flexible hose and appropriate fittings are
provided for connection to the system.
q If you plan to hard plumb the system, use only Brass, Stainless Steel, and/or Plastic.
Black steel or Galvanized pipe and fittings are not permitted.
If the system is hard-plumbed, the total restriction of piping and fittings must not add up to more
restriction than the standard flexible hose and fittings would have.
q The chiller is a closed loop system, but requires periodic addition of water and/or additives to re-
place evaporative losses.
q The chiller must be filled with proper coolant mixture. See page 7 for details.
DO NOT FILL THE CHILLER WITH CITY WATER, OTHERWISE SERIOUS AND
EXPENSIVE DAMAGE MAY BE INFLICTED ON THE LASER OSCILLATOR
16
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Dust Collectors
The dust collector is very important to the
safe operation of your laser cutting machine.
It will collect dust and particulate generated
by the laser cutting process.
More than one dust collector type is available
for the machine. Either unit, in standard con-
figuration, is suitable for cutting most metallic
materials. Neither one is suitable for cutting
non-metallics for an extended period. Addi-
tional filters or alternate venting is generally
required when cutting non-metallics.
q The positioning of the dust collector is
flexible. The dust collector is connected
with twenty feet of flexible hose and ap-
propriate fittings.
Torit DFT3-18
Drawings of this unit are on this and the
following page(s).
See page 7 for compressed air require-
ments.
Figure 5: Torit DFT3-18, front side
18
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Machine Foundations
The machine must be properly secured to a suitable foundation. If an existing floor is used, it
must be capable of supporting the weight of the machine. The load bearing and vibrational
secifications are listed below.
2
Bearing capacity required
Maximum external vibration /
disturbance allowable
1124 lb/ft
0.05G
Max acceleration
Max amplitude
5 microns
It is the purchaser’s responsibility to determine the necessary thickness of the foundation con-
crete to meet these requirements.
OTE: The machine does not require any special foundation to produce accurate parts, but the laser
N
and machine may not stay properly aligned if not properly supported and anchored. Improper support
(floor cracking/motion) will result in more frequent service needs and reduced machine life.
A preferred foundation is given on the following pages.
Please note the following:
q The machine must be placed on a single continuous foundation. (This means no cracks or voids
in the supporting slab)
q The base plates, anchor bolts, nuts and washers for the machine are provided in the accessory
crate.
q Make sure that the machine will not be exposed to excessive external vibration. If the machine is
located near a punch press, stamping press, large shear or other vibration source, it may be nec-
essary to cut the foundation around the laser or provide additional isolation.
q Do not install the machine where it is exposed to direct sunlight or any other heat source.
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Machine Foundations Cross Section
These drawings include pockets for the j-bolts (preferred method). If anchors are to be used
instead, then the j-bolt pockets may be omitted when preparing the foundation.
184.25
21.65
J-Bolt locations
13.75"
13.75"
178.38"
10.825"
228.25"
Figure 8: Foundation plan and side views
22
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Foundation End View
6.0”
6.0”
Anti-vibration
material
42.1”
8.3”
134”
1"
Figure 9: Foundation right end view
Anti-vibration
material
10.6
134”
42.9
1"
Figure 10: Foundation left end view
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J- Bolt Detail
4 - ANCHOR BOLT J-TYPE
4 - HEX NUT M16
4 - JACK BOLT
4 - HEXAGON NUT M30 x 3.5
4 - BASE PLATE
4 - HEX NUT M16
6 - WASHER M16
ø16
350
ANCHOR BOLT DETAIL
Figure 11: J- bolt detail
24
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Installing The Air Supply
The machine must be connected to a compressed air system by hose or pipe. The com-
pressed air must be clean and dry. It may be necessary for you to purchase an air drier/filter.
Please note the following:
q The air flow and pressure requirements are listed on page 7.
1
2
q The minimum inner pipe diameter for the machine is ".
3
4
from the pulsing of the dust collector.
q Clean dry shop air can be used as an assist gas for cutting some materials. To cut aluminum with
air you must supply (at least) an additional 22.0 ft3/min. at 200 p.s.i.
q The air inlet is at floor level at the rear of the machine.
q The air must be dry at ambient temperature.
The air must meet the specifications on page 7.
26
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Installing The Electrical Power Supply
The system requires four separate 3 phase power supplies. Power must be supplied to the CNC unit, the laser, the
chiller and the dust collector. Power should be supplied from a line separate from those for welding machines and
other processes that produce electrical noise. Ground rods must be installed next to the laser and CNC cabinets.
Laser and CNC grounding
cable gauge
at least same as power leads
less than 10 ohms
grounding resistance
A sample wiring layout is shown on the following pages.
Wiring entry and connect points are shown on pages 29.
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460 VAC
DISCONNECT
(ASSUMES DELTA PRIMARY )
H2
460 VAC
H1
H2
H3
76 4 21
5 3
76 4 21
5 3
76 4 21
5 3
H3
H1
SHIELD
X0
X1
X2
X3
TRANSFORMER
X2
X3
X0
X1
200-220 VAC
DISCONNECT
DISCONNECT
DISCONNECT
NC & MACHINE
200-220 VAC
LASER
200-220 VAC
CHILLER
200-220 VAC
DUST COLLECTOR
460 VAC
Figure 13: Electrical connect 460 VAC
28
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200-220 VAC
DISCONNECT
(ASSUMES DELTA PRIMARY )
H2
200-220 VAC
H3
H2
H1
H3
H1
76 4 21
5 3
76 4 21
5 3
76 4 21
5 3
SHIELD
X2
X0
X1
X2
X3
X0
X1
TRANSFORMER
X3
460 VAC
DISCONNECT
DISCONNECT
DISCONNECT
NC & MACHINE
200-220 VAC
LASER
200-220 VAC
CHILLER
200-220 VAC
DUST COLLECTOR
460 VAC
Figure 14: Electrical connect 230 VAC
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29
Notes
30
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Laser power in
Figure 16: NC & machine power connect
Figure 15: Entry point for cables
CNC power connect, Figure 16
A: Power cable
B: Breaker
Laser
power connect
Figure 17: Laser power connect
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Protective Coatings
The machine may have protective coatings, possibly including wrapping paper and/or
cosmoline or other grease.
When present, the wrapping paper must be removed before moving the machine axes. Protec-
tive grease or cosmoline must be thoroughly cleaned off before running the machine.
q Check the X-axis, Y-axis, and Z-axis LM guides for wrapping paper and protective coating.
Make sure that you remove any paper from both sides of the carriage.
q Check Z-axis guides and ballscrew and clean up as needed.
q A suitable solvent such as kerosene may be used to remove the protective coating.
32
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Revision history
Version
Details
Initial (May 2001)
Initial version
Revised dwg p. 22 . Asstd formatting, editing revisions.
Revised foundation drawings
Oct 01
Jan 03
Electrical supply p. 6. Formatting, editing revisions
Electrical supply- correct kVa and amperage for CNC
October, 2003
Contact Information
Company/group
purpose
Phone
Amada America Inc., Laser
group
Questions regarding machine configura- 714 739-2111
tion, equipment, operation
800 626-6612 - US
800 634-7952 - Calif. only
Amada America Inc., School
/Publications
Questions / comments regarding this doc- As above
ument.
Amada Service
Requests for service and service-related 800 334-2374 Pacific region
issues.
800 345-2374 Atlantic region
LC3015 Theta User Installation Guide - October, 2003
33
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