01 06 ByVention V03 En

ByAcademy Business Units Laser

& Waterjet

FL9081_30/06/06_de © Bystronic Laser AG, 2006

ByVention Technician Documents

Issued: 06.2007

ByAcademy Business Units Laser & Waterjet

© Bystronic Laser AG, 2006 3

Contents

1 Description of the machine.................................. 5 1.1 ByVention ................................................................... 5 1.2 Bylaser 2200............................................................... 5 1.3 Technical data ............................................................ 6

2 Description of hardware ...................................... 7 2.1 CNC............................................................................. 7 2.2 Frequency converter................................................. 20 2.3 Drives ....................................................................... 22 2.4 IO box ...................................................................... 28 2.5 GASCON6.................................................................. 29 2.6 Gas mix..................................................................... 31

3 Transport and start-up ...................................... 33 3.1 Unloading ................................................................. 33 3.2 Leveling the mineral cast frame ............................... 33 3.3 Resonator ................................................................. 35 3.4 National power supply .............................................. 38 3.5 Beam alignment........................................................ 43 3.6 Setting the CNC network address ............................. 60

4 Software............................................................ 61 4.1 General work rules ................................................... 61 4.2 Setting up the CF card (short instructions)............... 62 4.3 MrAdmin ................................................................... 63 4.4 LaserView................................................................. 70 4.5 Setting up the CNC network drive............................. 73 4.6 BySoft....................................................................... 75 4.7 Loading cutting planson the CNC .............................. 84 4.8 NCP Machine Distributor........................................... 85 4.9 Software installation & update ................................. 87

5 Remote diagnostics ........................................... 95 5.1 System configuration................................................ 95 5.2 Description of operation ........................................... 96 5.3 Security .................................................................. 101 5.4 Establishing and clearing a connection ................... 101 5.5 Requirements ......................................................... 103 5.6 Remote Diagnostics Box (RD box) .......................... 105 5.7 Administration........................................................ 111 5.8 Logging onto the RD server .................................... 118


4 01_06_ByVention_V03_en.doc

5.9 Assigning users to a group ..................................... 119 5.10 Command line reference......................................... 120 5.11 Using a proxy server............................................... 121

6 Maintenance .................................................... 123 6.1 Setting separating cut detection............................. 123 6.2 Servo adjustment and calibration ........................... 125 6.3 Adjusting the table height sensors ......................... 129 6.4 Setting sheet clamps and table position ................. 130 6.5 Setting sheet zero point and docking position ........ 134 6.6 Determining Z-axis reference ................................. 137 6.7 Testing the vacuum system .................................... 138

7 Repair.............................................................. 139 7.1 Setting the reference point on the X- and Y-axes ... 139 7.2 Replacing the X motor ............................................ 141 7.3 Replacing the Y-axis spindle system....................... 147 7.4 Replacing the Z-spindle and guides ........................ 154



1 Description of the machine

1.1 ByVention

Fig. ByVention

The compact laser cutting system is designed for machining sheets up to 8mm thick. Sheets with a format of 3000x1500mm (120x60") or smaller can be used, with the sheet divided into segments for cutting. The cutting area is max. 1562 x 772mm (61.5 x 30.4 inches).

The machine is equipped with a ByLaser 2200 and a combined extraction and cooling unit.

1.2 Bylaser 2200

Max. laser power: 2200 watts

Laser medium CO2

Wavelength 10.6 µm

Polarization circular

Pulse frequency 1-2500 Hz

Beam diameter: 17mm

Optical length 4.830m

Number of folds 3 x

Fig. Bylaser 2200

This ByVention differs from all the other Bystronic machines in that its resonator is supplied with a ready-made gas mix (premix).



1.3 Technical data

1 3000 0/+20 mm 1500 0/+20 mm

120" 0/+1.5" 60" 0/+1.5"

2 2500 0/+20 mm 1250 0/+20 mm

96" 0/+1.5" 48" 0/+1.5"

Dimensions of standard sheet

3 2000 0/+20 mm 1000 0/+20 mm

72" 0/+1.5" 40" 0/+1.5"

X max. 1562 mm

Y max. 772 mm Max. cutting area

Z 100mm

Parts size 1) max. 730 x 1480 mm

Steel 1/1.5/2/2.5/3/4/5/6/8 mm

Stainless steel 1/1.5/2/2.5/3/4/5/6 mm Sheet thicknesses 2)

Aluminum 1/1.5/2/2.5/3/4 mm

Max. traversing speed parallel to the X-axis, Y-axis

100m/min

Max. simultaneous traversing speed 140m/min

Max. acceleration of axes 8m/s2

Machine tolerance in accordance with VDI/DGQ 3441

+/- 0.1 mm

Cutting accuracy 3) +/- 0.03 mm

Maximum weight of cut part 300kg

Machine weight 13500kg

Weight of extraction and cooling system 1380kg

Weight of sheet table 150kg

B 6250mm

L 6000mm Dimensions

H 2150 mm

Foundations normal, reinforced industrial floor

( see installation guide)

Cutting head 5"

Max. power consumption 4) 33 kW

Supply voltage 3x400V/50Hz, 3x400V/60Hz, 3x480V/60Hz

Cutting gas consumption depends on material

Operation easy-to-use hand-held controller with touch

screen

Drives USB 1.1 (KETOP)

Network connection RJ 45 10/100 Mbit/s connection

1) Smaller parts are prevented from falling out by a microjoint 2) The following points must be satisfied to achieve the maximum material thickness that can

be cut:

• optimally maintained and adjusted ByVention

• material meets the requirements specified by Bystronic 3) The precision of the cut parts depends on the quality of the material, material composition,

sheet size, and temperature increase caused by the cutting process 4) complete system including extraction filter and cooling system



2 Description of hardware

2.1 CNC

The following figure shows the layout of the CNC:

The CNC02 Var03 must be treated as a "blackbox" for troubleshooting purposes. I.e. if a component malfunctions then the whole unit must be replaced.

Fig. CNC02 Var03 10007472-A



The CNC rack contains the following components:

CRack slot Card name Data ports Connection to

Ethernet1 Operator console Ethernet2 In-house network 1

cPCI-CPU Kontron

COM1 Laser RS232 X6 Output 0...15

X5 Output 0...15

X4 Input 0...15

2-3 cIOCON

X3 Input 0...15

X6 Output 0...15

X5 Output 0...15

X4 Input 0...15

4-5 cIOCON

X3 Input 0...15

AI1 AI2

6 cLPCON

LCH Clearance sensors AX1 X-axis AX2 Y-axis AX3 Z axis AX4 - A X-servo B Y-servo C Z-servo

7 cMAXCON cmAnalog module

D - AB Laser ( SSI / ASI ) 8 cLTCON

cmSSIASI module

CD GASCON ( SSI )

A cPCI-Power B NCPOWER Operator console Tab. CNC cards

Those components that differ from the CNC02 version for ByVision machines are described in detail below.



2.1.1 cPCI_CPU

cPCI Central Processor Unit

The cPCI-CPU is the central processing unit of the Bystronic CNC controller. The technical data and the look of the card may vary as the design is updated to the latest technology.

1. Compact flash card 2. SD-RAM card 3. Battery

Indicators and controls

Data ports

1. PMC0 2. VGA 3. COM1 RS232 4. USB 2.0 5. Ethernet CH2 (Customers network) 6. Ethernet CH1 (Operator console)

Fig. cIOCON

Fig. Connectors and LEDs on the cIOCON



Button

7. Reset LED

8. HS (blue) Hot Swap Control, LED can be software-controlled

9. Front-I (green) unassigned Front-II (green) unassigned

10.WD (green) Watchdog, lights up during start-up and indicates if a PCI reset is active

11.TH (green) Temperature monitoring, lights up during start-up and indicates a power supply error

Integral Ethernet LED ACT (green) Ethernet Link/Activity SPEED (green/orange) Ethernet Speed SPEED ON (orange) 100 Mbit SPEED ON (green) 10 Mbit

Battery replacement

Assuming 8 hours operation per day and a temperature of 30°C, a 170mAH battery can be expected to last 5 to 6 years. Changing the battery every 4 to 5 years is recommended.

The following types are suitable as replacement batteries:

• VARTA CR2025

• PANASONIC BR2020

CAUTION Switch off the machine before changing the battery.

Check the battery polarity before inserting.



2.1.2 cIOCON

cPCI Digital Input Output Controller

The cIOCON card is an Input / Output card for the Bystronic CNC02 controller.

It is the backbone of CNC I/O communication.

The card has 2 x 16 input channels (X3 and X4) and 2 x 16 output channels (X5 and X6).

Function

The cIOCON card incorporates the following main functions:

• PCI bus interface

• 2 x 16 input channels

• 2 x 16 output channels

• OUTPUT ERROR

• LED

PCI bus interface

The PCI bus interface enables communication to the PCI bus.

Fig. cIOCON



Input channel

The input channels provide DC isolation of the external 24V signals from switches, contacts or processes, and convert them to TTL level.

The input signals are connected to the first 16 terminals of the 18-pin Input connector (X3, X4). Terminal 17 is not connected. The common 0V reference potential for the 16 inputs is connected to terminal 18. The corresponding green signal LED (H3, H4) lies to the left of each input terminal:

it is illuminated when there is a voltage between the input terminal and the reference-potential terminal. Each input is debounced on the TTL side with a 5ms time constant.

Output channel

The output channels provide DC isolation of the internal logic circuitry and convert their TTL signals into the external 24V signal level required for the process.

The common supply for the outputs is applied to terminals 17 (+24V) and 18 (0V) of the 18-pin output connector (X5, X6). The corresponding green signal LED lies to the left of each output terminal:

it is illuminated when the output circuit is driven by the TTL logic, irrespective of whether a load is connected to the output. Each of the 16 outputs is provided with short-circuit protection:

Output ERROR

The output channels are monitored, errors are detected and displayed on LED H1.

LED LED Color Name Function H1 Green STIFLED Indicates card reset, write and read

processes H2 Red ERROR-LED Indicates a fault on the output

channels X5 / X6 channel 0...15 H3 Green Input 0...15 / X3 Signal, input channel 0...15 / X3 H4 Green Input 0...15 / X4 Signal, input channel 0...15 / X4 H5 Yellow Output 0...15 / X5 Signal, output channel 0...15 / X5 H6 Yellow Output 0...15 / X6 Signal, output channel 0...15 / X6 Tab. LED display Refer to the diagram (S2335-0-A) for the functions of the individual signals.



2.1.3 cLPCON

cPCI laser process controller

The cLPCON board is a laser cutting process monitoring board for the Bystronic CNC control. It monitors and controls various laser cutting processes.

A communication module can be connected to the appropriate connector.

Functions

• PCI bus interface

• NC ready

• 16-bit slave interrupt controller

• W axis function

• Interface and signal processing PROMON incl. cutting process monitoring (not available for ByVention)

Fig. cLPCON



LED

LED Name Function Red CRASH Cutting nozzle contact materials Red F-ERR Distance frequency outside valid range Green TK ON Ring sensor (tactile unit) connected Yellow TK END Ring sensor in top or bottom final positionRed NC-

ERROR (bottom right) FPGA not loaded correctly or not

initialized correctly Green STIFLED (bottom left) Indicates card reset, write and read

processes

cmSSIASI

Communication module SSI and ASI for CNC02

The cmSSIASI is a communication interface for CNC cards.

The module has two transfer channels, that can transfer either synchronously and serially (SSI Laser Master) or asynchronously and serially (ASI).

The software sets the transfer mode and transfer rate.

Fig. cmSSIASI



2.1.4 cMAXCON

cPCI Multi Axis Controller

The cMAXCON is a fourfold path-axis card for the CNC ByVision. It is used to control interpolating axes.

Functions

• Path interpolation

• Feed rate generator

• Position encoder interface

• Axis switches

• Interrupt controller

• Overlapping axes

• Target / current value register

• Actual value compensators (software limit switches)

• Position control

• Advance speed control

• Servointerface module connector

• NC ready

Fig. cMAXCON



cmANALOG

The cmAnalog is a communication interface for CNC02 cards. The module has four analog output channels. This outputs the standard feed as a +/-0-10 V voltage via the Ethernet to the AMCOMM02 on the servo. The signal is forwarded unchanged via a two-phase cable, as a target value, to the AMADAP.

In addition, there are two digital inputs and two digital outputs per connection. The module is available with 12Bit or 16Bit resolution.

Fig. cmANALOG



2.1.5 cLTCON

cPCI Laser Trajectory Controller

The cLTCON has four trajectory controllers and two laser module controllers.

Functions

Each trajectory controller is responsible for trajectory control and has the following functions:

• Impulse generation

• Speed interpolation

• Axis master

The process controller is used for real-time control of the laser module and has the following functions:

• Interpolation of laser power

• Pulse generation

• Set current trajectory speed

• Power adjustment using pulse frequency modulation of trajectory speed

• Control of machining cycles

• Drag and laser down-time compensation for precise beam activation and deactivation

Fig. cLTCON



2.1.6 NCPOWER

Monitoring / measuring system supply

NCPOWER is an assembly for the Bystronic CNC02 control

Functions

• generating power for the laser measuring systems

• galvanic separation of signals

LED

LED Color Name Function H1 Green POWER Lights up if 12V measuring system supply.

VCCMS is OK. H2 Green NC READY Lights up if NC ready relay (all boards) is

active. H3 Green ENABLE Lights up if external release is pressed

(safety gate OK). H4 Red FAN ERROR Lights up if fans not turning in CNC02 rack. H5 Red EMERGENCY

STOP Lights up on emergency stop.

Fig. NCPOWER



2.1.7 cPCI-Power

The cPCI power supply provides the required voltages.

LED

LED Name Function

green POWER OK All power supplies OK

yellow FAULT Input or output voltage fault

Supply

Supply is 230VAC and is provided via the backplane.

Output voltages

The cPCI power provides the following output voltages:

+12V

-12V

+5V

+3.3V

Fig. cPCI-Power



2.2 Frequency converter

A frequency converter controls the voltage and frequency of an alternating current. Frequency converters are used to control asynchronous motors. The speed of an asynchronous motor is proportional to the frequency of the supply voltage. The frequency converter controls not only the speed but also acceleration and deceleration processes.

Asynchronous motors are used in ByVention to control the parts-removal equipment and the table-elevating drive.

Technical data

Manufacturer Control Techniques Name Commander SK Model SKB 3400150 Input voltage 380-480 Vac (L1, L2, L3) , 50-60 Hz Input current 5.2 A Output voltage 0-480 Vac (U, V, W), 0-1500 Hz Output current 3.8 A

Fig. Frequency converter



Control unit and display

SmartStick

Fig. Display and controls

The following functions can be read on the display and adjusted using the controls:

• Converter operation status displays

• Error code or error-shutdown code display

• Displaying and modifying parameter values

• Stopping, starting and resetting the converter

Programming

All frequency converter parameters are stored on the SmartStick (see Fig. above). The frequency converter loads the parameters from the SmartStick when switched on. When replacing a frequency converter, you only need to plug the SmartStick into the new frequency converter.

You do not have to edit the parameters. You always program the frequency converter using the SmartStick. The SmartStick must always be connected.

Please refer to the frequency converter operating instructions for details on how to edit parameters.



2.3 Drives

2.3.1 Overview

The travel axes of the ByVention are based largely on familiar components also used in other Bystronic machines. The main drive elements are described briefly below.

Cutting bridge, X-axis

The X-axis drive has a rack-and-pinion design. The drive motor is mounted on the cutting bridge. The rack and pinion is installed on the machine stand. The cutting bridge has a cantilever design and is held by two linear guides.

Cutting carriage, Y-axis

A spindle drive is used to move the cutting carriage. The motor and spindles are fixed in the cutting bridge. The spindle nut can move and is fixed to the cutting carriage.

Tool, Z-axis

The Z axis is a spindle drive. The motor and spindles are fixed in position and the spindle nut moves with the cutting head.

Fig. X-Axis drive including lubricating pinion

Fig. Y-axis drive

Fig. Z-axis drive



Sheet feed

A suction-cup frame is used to move the sheets into the cutting area. Suction cups hold the sheet in place. The suction-cup frame is connected to the cutting carriage by two pneumatic cylinders and taken to the correct position.

Unloader

A rake system driven by an electric motor and synchronous belt is used for removing parts.

Fig. Suction-cup frame

Fig. Parts-removal rake with drive



Table-elevating drive

The table height needs to be adjusted for automatic sheet feed and parts removal. A precision screw jack is used to adjust the table height.

Fig. Elevating drive with cutting table



2.3.2 Position encoder

The position encoder generates electrical pulses as a function of the distance traveled. Inside the position encoder is a disc with markings that are detected by an optical measurement system similar to a light barrier. By counting the number of pulses generated, the CNC can find out the distance traveled.

The internal optical measuring system generates two pulse signals shifted in phase by 90° to each other. This allows high measurement resolution and can be used to determine the direction of rotation. In addition, the position encoder generates a zero pulse every revolution, which is used for the move to reference function. The signals are transmitted via an RS422 interface.

All three directions of travel (X, Y and Z) are measured using a position encoder.

Connector pin-out

Fig. Connector pin-out

Fig. Position encoder



1) Floating with respect to housing N.C. = Not Connected

Fitting / Removing

The diagram on the left shows a schematic view of the position encoder. The parts relevant to fitting are:

1. Collet 2. Hexagonal nut 3. Tensioning screw 4. Lever of special tool or

hexagon-head wrench 5. Lever of special tool or

Allen key 6. Blanking plug 7. Shaft 8. Position encoder clip 9. O-ring

Preparation

Remove blanking plug (6). Insert the collet (1) in the position encoder and screw in the tensioning screw (3) so that the collet is not yet closed. Fit the O-ring (9) to the flange.

PIN HTL signal TTL signal Color Explanation 1 N.C. B black Signal line

2 N.C. Sense + gray Connected with US internally 3 Z Z lilac Signal line 4 N.C. Z yellow Signal line

5 A A white Signal line 6 N.C. A brown Signal line

7 N.C. N.C. orange Not assigned 8 B B pink Signal line 9 Shielding Shielding 10 GND GND blue Ground connection 11 GND Sense - green Connected internally to GND 12 US US red Supply voltage1)

Fig. Position encoder diagram



Assembly

With collet open, push the position encoder onto the locked shaft (7) until the flange rests against the housing. Fix the position encoder to the flange using the three position encoder clips (8). Make sure that the O-ring (9) is seated properly. Attach the special tool to the collet (1). A hex socket wrench SW 8 and an Allen key SW 3 can be used instead of the special tool.

If the zero pulse needs to be adjusted, this can be done by turning the lever (4) or the hex socket wrench.

Fix the lever (4) or hex socket wrench in the required position, and use the lever (5) or Allen key to tighten the collet (tightening torque 2.2 Nm). Remove the adjustment tool and screw on the blanking plug (6).

Collet chuck torque is 2.2 Nm.



2.4 IO box

The IO box is used to transfer sensor and actuator signals via a common cable. We specify which boxes are sensor IO boxes and which are actuator IO boxes: their function cannot be chosen to suit. Most of the signals from proximity switches in ByVention are grouped via IO boxes and transferred to the cIOCON card.

The IO box is not a bus system. each signal cable is looped through separately. Only the +/- supply and ground line are common to all sensors and actuators of an IO box.

Fig. IO box

Fig. IO box circuit diagram and connections



2.5 GASCON6 The GASCON6 unit is located on the cutting bridge under the top cover.

2.5.1 Description

The GACSON6 process-gas unit is a compact device that electronically controls the pressure of various gases.

A digital signal processor (DSP) forms the heart of the GASCON6 electronics. The main mechanical component is a specially adapted slider combination that is driven by a solenoid piston.

1. Supply 2. CNC link, SSI 3. CNC link, HSL 4. Proportional solenoid 5. Fluid intakes 6. Vent, outlet pressure 7. Outputs

Fig. GASCON6



2.5.2 Function

The CNC transmits the required gas pressure to the GASCON6 via the SSI or HSL interface. The DSP processes the signal. The DSP contains the pressure controller and the subordinate current regulator.

An integral pressure sensor detects the actual pressure value. The electronic controller measures the current through the proportional valve solenoid and regulates the current to the required value by pulse width modulation (PWM). The generated magnetic field moves the piston of the proportional valve. The piston transmits the force to the slider, thereby setting the required outlet pressure. A return spring presses the slider against the piston.

Another pressure sensor monitors the intake pressure. If the stipulated gas pressure is greater than the intake pressure, the GASCON6 sends an error message to the CNC.

2.5.3 Automatic calibration

The GASCON6 has an automatic calibration function. The electronics in the GASCON6 calibrate the pressure sensors and measure the sensor offset automatically. This is done when the electronic system is switched on, after the hardware has been initialized and the CNC connection made.

Note: It is essential that the cutting gas supply valves ( electrically controlled valves ) are closed during initialization, otherwise the calibration will not work, resulting in an unsatisfactory cutting quality.

2.5.4 LED display

LED Color Name Function

green Power LED 24V supply (input voltage protected by fuse)green Ready LED DSP program running, FPGA program

running yellow FUNC permanently illuminated: function in

progress Warning flashing: device warning red ERROR permanently illuminated: device error

LED

arr

ay

ERROR flashing: no connection to CNC H2 yellow RCV LED HSL receiving data H3 green TXD LED HSL transmitting data



2.6 Gas mix The ByVention resonator is designed so that it can only operate with a ready-made gas mix. This kind of gas is called premix. A new gas mix unit is used to control the gas supply, which is described briefly below.

2.6.1 Distinctive features

The following components used in the standard gas mix unit (see diagram below) are not included in the new unit:

• CO2 mass flow controller • CO2 gas filter • Pressure switch (-S2) • Pressure switch (-S1) • He mass flow controller • He gas filter • Pressure switch (-S3) • Pressure switch (-S4) • He flooding valve (-Y2) • N2 mass flow controller is replaced with premix mass flow

controller

The Premix gas control unit has integral hardware detection i.e. the electrical connections to the gas mix circuit board (X1, X2) are identical. The missing actual-value signals for He and CO2 are replaced by a reference voltage of 7 to 10V. The LCS detects whether these signals are present to identify whether it is a gas mix or Premix unit. The reference voltage is generated from the LCS +/-15V supply.

Gas mix (part no. 10003539) Premix unit (part no. 10007563)

Fig. Comparison of gas mix and premix unit



2.6.2 Mechanical design and specification

The gas mix block of the Premix unit has a more compact design owing to the smaller number of parts. The block is cooled directly and no longer has an additional cooling plate.

Laser gas consumption, Bylaser2200M Fastmix : 100 Nl/h Fastmix time : 15 minutes Normal mix : 6 Nl/h Premix gas specification 3.1414 % Carbon dioxide CO2 Quality 4.5 ( ≥ 99.995%) 31.414 % Nitrogen N2 Quality 5.0 ( ≥ 99.999%) 65.445 % Helium He Quality 4.6 ( ≥ 99.996%)

Accuracy of mix : ± 2 % relative

2.6.3 Error messages

The following warnings and errors from the LCS are new to Premix mode:

W118 Too large a difference between the actual and setpoint values for the Premix gas controller

W119 The pressure in the Premix gas bottle has dropped to 2 bar

E118 Too large a difference between the actual and setpoint values for the Premix gas controller

E119 The pressure in the Premix gas bottle has dropped to 1 bar

The other errors for He, CO2 and N2 no longer appear.

Fig. Premix unit



3 Transport and start-up Before start-up, check whether the customer / forwarder has correctly performed all items of the installation guide.

3.1 Unloading Transport and unloading are performed by the forwarder. The customer then installs the machine according to the layout plan and levels it roughly. All necessary details are given in the installation guide.

3.2 Leveling the mineral cast frame

ByVention has a mineral cast frame. Raise all four feet to level the machine.

CAUTION The weight of the machine must never rest on the round feet.

These are used only for stabilizing the machine and are not designed to be load-bearing elements. Even raising or supporting the machine on the round feet is not permitted.

Fig. Position of the leveling feet



The machine now stands on three leveling feet and can be aligned using a spirit level. Place the spirit level on the milled surfaces of the bridge. After aligning the machine, lower the round feet until they are under slight pressure.

Then position the material table and check table height with a spirit level (table castors and machine on same level).

CAUTION

When raising the machine, ropes or chains must only be inclined by a maximum of 10° from the perpendicular. Otherwise there is a risk of parts of the mineral cast frame from splitting off.



3.3 Resonator

3.3.1 Cooling circuit

The resonator and machine cooling circuits must be emptied to prevent moisture or frost damage during transport. Connect together the cooling pipelines to the shutter before purging the cooling circuit, otherwise the shutter flowmeter will be damaged by the blast of air.

Before start-up, check that the shutter has been correctly re-connected and that the blow-off valves are closed.

Note:

Before filling cooling water into the combi device, connect the demineralization cartridge!

Fig. Shutter ready / bypassed

Fig. Connections for purging the cooling circuit



3.3.2 Excitation modules

The excitation modules (x2) in the resonator are fitted with an oil overflow tube. The overflow tubes are plugged with blind plugs for transport and must be re-opened for start-up.

3.3.3 Transport securing devices top

The top part of the resonator is protected from jumping out during transport by two threaded rods. This transport securing device must be removed for start-up. The transport securing devices are located between the two flaps on top of the resonator

Fig. Overflow, excitation modules

Fig. Transport securing device



E

W

Foot

Laser support

Gap 3mm

3.3.4 Resonator feet

The Bylaser 2200M is permanently installed on the machine frame and not removed for transport. A transport securing device must be installed to ensure that the laser module is sufficiently protected during transport. To do so, use the nut W to raise the resonator approx. 1.5mm (one rotation) and screw tight to the mineral cast frame (screw E, 170Nm).

"Removing" transport securing device

Note:

Before removing the transport securing device, check that the laser module feet and the two laser supports are secured with lock nuts.

1. After installing at the

customer's premises, unscrew screw E.

2. Unscrew screws W of the transport securing device and turn down until the laser module feet are resting on the laser support. The gap between screw W and U-sheet should be approx. 3mm.

3. Tighten screw E by hand (without any tools).

Removing transport protection



3.4 National power supply In order to prevent damage to the machine due to incorrect connection to the power supply, all machine transformers are disconnected before transport.

Before start-up, connect the six transformers according to national voltage specifications (see diagram).

WARNING

Before working on live parts, switch off the main switch, ground the parts, and check with a voltmeter!

1. Combi device control box

2. Laser relay frame

3. Control cabinet

Fig. Position of transformers



3.4.1 Combination unit

Transformer T47 for 24V power supply to the combi device is located at the top left of the control box. Connect the cables according to the labels on the transformer.

The combi device for countries with 480V/60Hz differ from the standard version (400V/50Hz/60Hz) and have different components and default configurations!

Fig. Combi device transformer



3.4.2 Resonator

Connect the laser module transformers to terminals X1Z, X1E and X1Y on the relay frame (back of resonator) according to the enclosed diagram. The following Fig. shows the position of the terminals.

Transformer T2 for power supply to the dehumidifier must be externally connected to the power supply (see diagram S5018-2 / installation guide).

When delivered, the machine power supply must be switched from internal to external. The jumpers required for this are not indicated in the diagram and can be found in the Fig. to the left.

Connections

From To

Internal X1Z1 X1Z3

X1Z2 X1Z4

External X1Z5 X1Z3

X1Z6 X1Z4

Fig. Relay frame

Fig. Internal / external power supply S5018-0



Then connect transformers T1 and T2 to the terminals according to the national power supply.

The Default order of connections corresponds to the state of the laser cutting machine as delivered.

Dehumidifier transformer with external power supply

Controller transformer with internal power supply

Fig. Terminal selection S5018-2



3.4.3 Machine

Transformer T1 for cabinet cooling system power supply is located in the control cabinet air conditioning unit. Remove the outside cover and transformer cover and connect the terminals according to the transformer labels / enclosed sheet. Caution When opening the outside cover, remove the two cables at the back so as to avoid damaging them!

Transformer T2 for 230V machine power supply can be found at the bottom center of the control cabinet. Connect the second phase depending on the input voltage 400/480V (see diagram S2335-0).

Transformer T1 for 230V drive power supply can be found at the bottom left of the control cabinet. Connect the three phases to 400/480V according to the terminal labels (see diagram S2335-0).



3.5 Beam alignment

3.5.1 General information

The beam guidance system of the ByVention is based on the principle of “flying optics”. In this system, the distance from the laser module to the cutting head changes depending on the position of the cutting head. Initial alignment of the mirrors in this system is carried out when installing and preparing a new machine for use. A distinction is made between “angular” and “linear” alignments. Linear alignment is carried out once by Bystronic service personnel when they first install the machine. Correction of the angular setting of the individual mirrors may, for example, be necessary after replacement or cleaning. When changing the angle of a mirror, note that this also results in a change at all subsequent mirrors.

Scope of these instructions:

These instructions apply to ByVention. They serve as a beam-alignment reference guide for the service engineer.

3.5.2 Purpose and aim

• This section describes how to align the beam guidance system from the last deflecting mirror in the resonator up to the cutting head.

• The optics are aligned so that the beam is reflected from the center of one deflecting mirror to the next. This is done in each position of the "flying optics". The beam can deviate by a tolerance of ±0.1 mm from the crosshairs image, i.e. from the center, of the alignment gage.

• At the cutting head, the beam must exit through the center of the nozzle aperture and in a direction normal to it. This must be achieved at all four corner points of the machining area. The beam can deviate by a tolerance of ±0.5 mm from the cross-wires image, i.e. from the center of the Z-axis alignment gage.

Precise alignment of the laser beam is important for the following reasons:

• Only when the beam is precisely centered on the deflecting mirrors and lenses is it guaranteed for the laser beam to pass through the beam guidance system cleanly without any of its properties impaired.

• Optimum cooling of the deflecting mirrors is only possible if the incident beam is centered.

• Precise alignment increases the service life of the optical system.



3.5.3 Security

Safety must be given top priority when carrying out maintenance work on a machine. Since the risk of an accident increases with the number of people working on the job, the maintenance tasks and specifically the beam alignment job must be carried out by just one person. In addition, it is compulsory to secure the working area to prevent unauthorized people entering, and to wear laser safety goggles.

CAUTION Whenever working with a cover open/removed, always move the

keyswitch on the control cabinet to Laser Beam Alignment position and remove it. This de-energizes the drives.

CAUTION

Owing to the increased risk posed by the laser radiation and moving axes during alignment, this work must be performed in the absence of a third party.

Read the beam-alignment section through carefully before starting beam alignment.

The safety door protects the operator from the laser beam and injury from drives, etc.

Bypassing the safety door is forbidden.

Take utmost care when covers are removed; this may cause dangerous situations for other people too who are not involved in the job.

Fence off the danger zone.

DANGER

Danger! Invisible laser radiation. Laser class 4.

Avoid any irradiation of eyes or skin by direct or stray radiation.

Laser safety goggles must be worn. Risk of crushing by moving parts. Remain outside the range of motion of bridge, carriage, Z-axis and flying optics.

When working in pairs, the person working at the alignment gage must also have the hand-held controller.



3.5.4 Adjustment principle for the deflecting mirrors

Turning the setscrews clockwise moves the mirror towards the deflector vee-block.

Turning the setscrews counterclockwise moves the mirror away from the deflecting prism.

Both coarse and fine adjustment is provided.

Coarse adjustment: Unscrew the three Allen screws and remove the cover, then use an open-ended wrench to adjust the nut roughly. This adjustment method is not necessary after cleaning an optical component.

Fine adjustment: using setscrew B with the cover in place.

Dismantling the mirror: remove mirror holder I, which holds the mirror, by unscrewing the four mirror screws K.

A. “Rough adjustment” nut B. “Fine adjustment” setscrew C. Pressure spring for heat sink D. Deflecting mirror E. O-ring for deflecting mirror F. Cap

G. Cooling-circuit connection H. Cooler I. Mirror holder J. Mirror screws (x 4) K. Mirror mounting L. Deflector vee-block

32.5m

m

1mm

A

B

C

D

E

F

G

H

I

K

L

M

Fig. Cross-section through deflecting mirror



3.5.5 Initial settings

• The initial setting for the setscrew is 32.5mm measured from the deflector vee-block.

• In the pre-assembled deflecting mirror, the gap between deflector vee-block and mirror holder equals 1mm at all three setting points.

3.5.6 Adjustment facility for deflecting mirrors

The deflecting mirror can be adjusted in two planes around the common pivot point B. The pivot point is always located opposite the chamfered edge of the mirror mounting.

A. Setscrew for aligning the beam on the horizontal axis. Screws B and C form the axis of rotation here, and must not be adjusted.

B. Pivot point for alignment using A and C (this screw must not be adjusted).

C. Setscrew for aligning the beam on the vertical axis. Screws A and B form the axis of rotation here, and must not be adjusted.

D. The four screws are used for releasing the clamping ring that holds the mirror in the vee-block.

H. Horizontal axis Screw A is used. The beam moves along the horizontal axis; sideways movement.

V. Vertical axis Screw C is used. The beam moves along the V axis; up and down movement

Fig. Adjustment screws on the mirror

H

V

Fig. Target plate



3.5.7 Beam alignment devices

The beam alignment device consists of a tube containing a pair of cross-wires. A target plate can be inserted through a slot.

The following sections describe how to deliver a laser pulse onto the plate. The laser radiation that hits the cross-wires is absorbed by them. This results in a white cross on the burn image. The position of this cross in the burn image indicates in which direction the beam needs to be adjusted, if at all.

A B

D

C

E Fig. Alignment tool

A. Alignment gage with cross-wires

B. Mirror bracket

C. Z-axis alignment gage

D. Safety goggles

E. Stack of target plates



3.5.8 Preparatory tasks prior to adjustment

Have materials ready

• Mat. -Ensure equipment needed for safe working is provided (safety goggles, marking tape etc.)

• Semi-cardboard target plates

• Glass-ceramic target plates (plaster)

• Beam alignment devices

• 3 mm Allen key (adjustment easier to see with offset Allen key)

• Mirror cleaning materials Mechanical check

• The machine stand must be correctly leveled

• Transport securing devices on resonator removed

• Alignment gage cross-wires cleaned

• Replace the cross-wires with copper or stainless steel wire of the same thickness (1.5 mm) if they are damaged.

• to ensure that the laser module is working properly, the laser beam must not be aligned during the run-in phase. The beam must not be aligned or checked until the machine has warmed up. Warmed-up means: The laser has been running for at least 30 minutes at 50% of maximum laser power.

Recommended values for 2200W resonator

Material Plaster Cardboard

Laser power, single pulse [W] 2200 400-600

Pulse width, single pulse [ms] 200



Note:

Precise and clean working is a basic requirement for trouble-free alignment.

Alignment is always performed from the resonator to the Z-tool.

A burn image must be circular (max. 1.2 times the width = slightly oval). It must have a sharp outline and be centered.

Move the beam and not the cross-wires. It is easier to compare with burn patterns obtained when the machine was first commissioned or during the most recent maintenance.

If the mirror is tilted on insertion or swarf gets into the mirror seating, this will cause deflection of the beam and hence to a poorer cutting result or damage to the beam path (“bellows burn”).

Tighten the mirror holder screws reasonably firmly. They must not be able to work loose. (Machine vibration)



3.5.9 Alignment process

The alignment device is used to check whether the laser beam is in the center of a mirror surface. It is fitted in place of a mirror. A cardboard plate is inserted into the alignment device and a single pulse triggered manually. The laser beam is visible as a burn on the plate. A cross-wire shadow (white) indicating the position of the beam can be seen on the burn. If necessary, the beam is corrected by adjusting the preceding mirror.

Note: Before actually starting alignment work on the machine, it is useful to check that the resonator, i.e. the telescope lens, is delivering an optimally aligned laser beam.

3.5.10 Beam adjustment ByVention

The procedure below describes the alignment of the three beam paths in sequence, starting from the resonator and working towards the tool.

A. Beam path X B. Deflecting mirror 1 C. Beam path Y D. Deflecting mirror 2, beam path Z

1-4 Alignment positions

WARNING Before moving the axes, make sure that no one is present in the

danger zone.

Fig. Overview of alignment procedure



Note:

For reasons of safety (open cover at back of machine), beam alignment of the X and Y axis is performed through the MrAdmin tool and with the key-switch switched in the control cabinet.

Align the Z axis with the safety door and covers closed from the Manual Mode menu.

3.5.11 Aligning beam path X

• Since movement of the cutting bridge occurs in this beam path, the beam must follow a parallel and central path along the whole length.

• Deflecting mirror 1 mounted on the cutting bridge sets a precise path that cannot be changed.

• To center the beam, the resonator must be aligned using the three adjustable feet.

• You should also bear in mind that all further measurements will be made at two positions.

Procedure

1. Secure the danger area against unauthorized access.

2. Move cutting bridge to position 1. The position of the Y-axis is not crucial.

3. Open the safety door so that the drives are de-energized and trip the door switch.

4. Set key-switch on the resonator to Lock and take the key out. This locks the shutter and switches off the high voltage

5. Move the key-switch in the control cabinet to Laser Beam Alignment position.

6. Remove the covers to allow access to the mirror.

7. Undo the four screws on the mirror holder and remove the mirror holder.

8. Place the protective cap on the mirror and fix mirror to the bracket.

9. Fasten the alignment gage on the mirror mounting.

10. Slide a target plate into the alignment device.

11. Move key-switch on the resonator to Unlock.

12. Start the MrAdmin tool and switch to the Laser tab

13. Click the Manual button

14. Set laser power to the desired setting by clicking Set Power



15. The danger area must be checked and a verbal warning given before performing an operation.

16. Click the Shutter open button, input shutter opening time, press the confirm key on the hand-held terminal and fire a laser pulse

17. Check the burn image and slide the target plate across so that a second burn image can be produced beside the existing one.

18. Move the bridge to position 3 by hand. Take care not to damage the mirror during the movement.



21. Move bridge to position 1 again.

22. Check the burn image. If the burn images are exactly centered, as below, clean the mirror before fitting it, then continue with the procedure described under Aligning beam path Y

23. If the burn images are not centered (e.g. as below), adjust resonator position and repeat steps 15-23 until the burn images are centered.

Before adjusting the resonator, set the key-switch to Lock and remove the key.

24. Set key-switch on the resonator to Lock and take the key out.

25. Remove the alignment device and install the mirror.



Adjusting the resonator position

1. The three feet allow adjustment of the resonator in the

horizontal plane, while the four screws provide vertical adjustment. You should normally raise/lower all resonator feet and/or move them horizontally by the same amount (a mark can be helpful). Before you can move the feet you need to undo all the lock nuts and screws on the resonator feet.

2. If both burn images are exactly centered, as shown below, retighten all the screws on the resonator feet and secure with locknuts.

3. Afterwards check the alignment once more. If the beam is still centered, remove the alignment gage, then clean and fit the mirror. Now you must proceed with alignment of beam path Y.

Fig. Fig. left: Correcting the laser beam, right: Adjustment options on the resonator foot



3.5.12 Aligning beam path Y

Note:

To align beam path Y, the cutting bridge should be positioned as close as possible to the resonator (X+). This is important, because then a small alignment error in beam path X has less impact on the subsequent alignment of beam path Y.

Procedure

1. Secure the danger area against unauthorized access.

2. Move the cutting carriage to position 2 so that it is possible to remove the mirror and fit the alignment device.

3. Open the safety door so that the drives are de-energized and trip the door switch.

4. Set key-switch on the resonator to Lock and take the key out. This locks the shutter and switches off the high voltage.

5. Move the key-switch in the control cabinet to Laser Beam Alignment position.

6. Remove the covers to allow access to the mirror.

7. Undo the four screws on the mirror holder and remove the mirror holder. Place the protective cap on the mirror and position the mirror in the appropriate place.

8. Fasten the alignment gage on the mirror mounting.

9. Slide a target plate into the alignment device.

10. Move key-switch on the resonator to Unlock.

11. Move cutting carriage to position 1.




15. Check the burn image. If beam deviation is severe, adjust deflection mirror 1 and repeat steps 9-13.

16. Slide the target plate across so that a second burn image can be produced beside the existing one.






20. Check the burn image. If the burn images are perfectly centered, as below, set key-switch on the resonator to Lock, remove the key, clean and insert the mirror, then proceed according to the Aligning beam path Z section

21. If the burn image is not centered (e.g. as below), the beam must be centered by adjusting the previous deflecting mirror 1.

22. To align the beam, turn the adjusting screws on the deflecting mirror 1 slightly.

23. Now check the beam again.

24. Repeat the procedure from step 9 onwards until the desired result is obtained.

25. Set key-switch on the resonator to Lock and take the key out.

26. Remove the alignment device and install the mirror.



3.5.13 Aligning beam path Z

Settings

• Switch to the main menu on the hand-held controller.

• Press the SE button to enable extended user mode

• Select the Settings menu

• Select the Administration tab

• Start MrAdmin by pressing Start MrAdmin

• Enter code and press OK to confirm

• Switch to the CNC tab and set the scroll list to Setup

• Set pulse width single pulse and laser power single pulse according to the table on p. 45 (note down original settings!)

• Switch to the Main tab and quit MrAdmin by pressing Exit MrAdmin.

• Select No when prompted to restart the CNC

• Once MMC has started, switch to Manual Mode menu

• Select Pulsed laser mode

• Select Toolmode off

Fig. Z-axis alignment gage



Procedure

1. Install all covers. 2. Move the key-switch in the control cabinet to "Operation"

position. 3. Switch to the Manual menu on the control unit. 4. Close safety door 5. Move to position 2. 6. Open the safety door and insert Z-axis alignment gage in place

of the cutting head. Slide a target plate into the lower position of the alignment gage.

7. Close safety door

8. Move cutting head into upper end of travel Z+

9. Fire a pulse at the target plate

10. Open safety door

11. Check the burn image. If the burn image is not centered, adjust the deflecting mirror 2 and repeat the procedure.

12. Close safety door

13. Position alignment gage just above the cutting grid.

14. Fire a pulse at the target plate

15. Open safety door

16. Check that the beam is parallel (Z+ and Z-) and adjust if necessary

17. If the burn image is centered, move to each corner point of the machine 1-4 and fire a pulse at the target plate. All four corner points must now be identical and centered. A deviation of +/- 0.5 mm can be tolerated.

18. Store the target plates with the 4 firing positions, marked with the date, in the resonator. Don’t forget to record this in the log book!

Concluding tasks

• Reset width single pulse and laser power single pulse in setup.

• Clean the cutting head lens and fit the cutting head.

• Check the focus reference setting.

• Perform a test cut at each corner.



3.5.14 Shooting a mode cube

The current software version now offers the possibility of shooting a mode cube.

A later version will have an automatic CNC function for this procedure.

• Switch to Manual Mode menu and load the parameters 0_0_0_N2_MODECUBE (VENTION3015_8120_2200_0_0_0_N2_MODECUBE.PAR), gas type N2, gas pressure 1.5bar

• Press the Manual Mode button and move to service position.

• Fit a targeting tool in place of the cutting head.

• Insert a Plexiglas cube (place on sawn side).

• Launch the MrAdmin program.

• On the Settings tab, press the Manual Mode button. The button now lights up magenta. The Laser sensor key now has the GASJET function (with confirm button pressed)

• Switch to the Laser tab.

• Click the Manual button

• Press STEP ON

• Press the ON button to start the laser.

• Set maximum laser power.

• Select Open Shutter, input time (1.5s), press OK.

• Press and hold confirm key and laser key

• Select Open Shutter.

• Allow Gasjet to run for another 5s, then release laser key and confirm.

• Select Open Shutter, input time (1.5s), press OK.

• Press and hold confirm key and laser key

• Select Open Shutter.

• Allow Gasjet to run for another 5s, then release laser key and confirm.



3.5.15 Determining default focus setting

The default focus setting is determined by cutting a test part (cf. operating instructions, section 7.5.8). Cut the test part with different focal positions. Adjust focal position in steps of 0.5mm up and down from the start setting (in a range of ±3mm) until cutting quality deteriorates. Choose a default focus setting in the middle of the cuttable range. The default focus setting is input in the Maintenance/Machine menu without any conversion.

Example

Focal position

Cut quality Comments

0-40 Sheet no longer cut through

0-45 Coarse cut and burring

0-50 Fine bead formation on the underside of the sheet


6-00 Good Original value

6-05 Good Default focus setting

6-10 Good


6-20 Coarse bead formation on the underside of the sheet

6-25 Cut no longer possible

6-30 -

Settings

Cutting head 5’’

Start value 6-00

Material Structural steel 2mm

Gas type O2

Cutting plan Test_Stahl_2mm_22_O2.ncp

Test_Stahl_2mm_44_O2.ncp



3.6 Setting the CNC network address • Switch to the main menu on the hand-held controller.

• Press the SE button to enable extended user mode.




• Enter code and press OK to confirm.

• Switch to the Connections tab.

• Enter the IP address, subnet mask and gateway specified/reserved by the customer:

• CNC IP Address, Mask and Gateway

• If installed, input the IP address of the Remote Diagnostic Box under Dataservice IP Address.

• Press Install Data to apply the changes.

• Open safety door

• Reset the CNC



4 Software

4.1 General work rules Do not reset the CNC by pressing the hardware button.

When starting up the machine, a communication error may occur if the operating panel is already started up but the CNC is still booting. The error goes away once the CNC has finished starting up. During this time (approx. 2min) do not switch the machine off or perform a CNC hardware reset.

When switching off the machine, only switch the main switch off when the prompt appears on the display.

Only switch the machine off when the CNC has correctly shut down.



4.2 Setting up the CF card (short instructions) Improper operation of the machine may destroy the CNC compact flashcard. The machine will not start up afterwards.

If you perform a hardware reset or switch off while the card is reading/writing data, the software may be damaged.

In this case, you must remove the CF card and write an image file to it.

Procedure

• Copy the zipped CNC image file from the USB stick (included with machine) to a PC.

• Unzip the Zip file ⇒

• Remove the CNC CF card and connect to a CF card reader on the PC.

CAUTION The CNC02 Var03 is very susceptible to ESD (electrostatic

discharge).

Always use a ground cable when changing a board or working on the rack.

• Launch the program

• Select the CF card under Removable drive

• Select the image file under Image file

• Press Write to write to the CF card.

• Install the card in the CNC rack and start the machine.

• Load or re-set all configuration settings in the MrAdmin tool.

Fig. RawWrite



4.3 MrAdmin The MrAdmin tool is provided to help service engineers carry out setup and adjustment tasks.

4.3.1 Start MrAdmin

• Switch to the main menu on the hand-held controller.

• Press the SE button to enable extended user mode




• Enter code and press OK to confirm.

• The MMC operating software is now closed, which means that it is not possible to move the axes or execute any other functions

4.3.2 Quit MrAdmin

• Switch to the Main tab.

• Quit the program by pressing Exit MrAdmin

• Confirm the CNC restart prompt with Yes or No depending on the type of settings you have made.

• The MMC operating software is then started up automatically.

Fig. Starting MrAdmin



4.3.3 Description of MrAdmin functions

Main page

Button Function Log out / log in Switch between Service / Expert level

(Automatic login at program start) Select language Change the language displayed Quit Administrator Ends the MrAdmin tool and automatically

starts the MMC application

Fig. Main page



CNC

Button Function Scroll list Switch between setup and config values Edit Edit the selected value Set target Set system time RamDump Create a CNC RAM dump file Resetting the CNC Restart CNC rack Load config Load config and setup file Save config Save config and setup values to a file

Note: Select the directory / drive IPSM to save config values. This data space is saved even when you switch the machine off.

Before resetting the CNC, always open the safety door to avoid damage caused by uncontrolled movements.

Fig. CNC



Settings

Button Function Save sheet zero point

Saves the current point as sheet zero point. Sheet zero point is the starting point of the cutting plan in remaining sheet production (cf. section 6.5).

Save docking position

The current position of the cutting carriage is set as docking position and the machine coordinate system is adjusted accordingly (reference coordinates recalculated, see section 6.5).

Manual operating mode

Activates manual mode (magenta key). The axes can be moved with the confirm button pressed.

Reference The axes move to reference position.

Fig. Settings



Connection

Button / Value Function CNC IP address IP address of the machine in the network CNC mask Network subnet mask CNC gateway IP address that connects to the next network,

usually the IP address of the router Data service IP address

IP address of the Remote Diagnostic Box (option)

Data service machine No.

Bystronic machine number if multiple machines are present

ByVision IP address For operation of the machine with ByVision. The IP address of the PC on which ByVision is running must be set in order to obtain access to the CNC. If no PC with ByVision is present, you can delete the address.

Delete address Deletes the IP address Install data Sends all settings to the CNC and applies them

(may require a CNC reset) Save data Saves the settings to a file

Fig. Connection



Laser

Button / Value Function Power Current laser power Gas Current gas pressure (laser gas) Water flow Current water flow, shutter Operation mode CNC/manual

Switch between manual and CNC control

Fastmix On/Off Activate/deactivate increased gas exchange Tests Leaktest start/stop

Start/stop vacuum test

Tests Calibr. start/stop

Start/stop performance calibration

Step Mode Step On/Step Off

Stepwise laser start-up/shutdown ON/OFF

Step ++/-- Step forward/backward for step mode Shutter open Open shutter manually for a set time Set Power Change current power Reset Reset laser

Fig. Laser



Software

Button / Value Function Install CNC Install new CNC software Save CNC Save current CNC software Installation of the operating system

Install new CNC operating system

Save operating system

Save current CNC operating system

Install parameters Install new parameter record Save parameters Save current parameter record Backup config Current configurations are saved to a backup

directory. The data are required to repair a defective compact flash. Repair is usually performed automatically.

Repair Data Manually starts repair of the 1st data partition on the CF (configuration)

Repair Data2 Manually starts repair of the 2nd data partition on the CF (CNCpub)

Fig. Software



4.4 LaserView The service technician uses LaserView to control/troubleshoot the laser. The program is installed on the service technician's laptop and the laptop is connected to the laser via a serial interface.

4.4.1 Preparation

An up-to-date version of LaserView (P8805 or later) must be installed on the laptop to operate the laser.

• Start the MrAdmin tool

• Switch to the Laser tab

• Switch laser to manual mode by pressing the Manual button

• Connect laser to the laptop

Connect the laptop to the laser controller with an RS232 cable. To do so, disconnect the RS232 cable from the -X2 connector on the resonator and connect the laptop.

Connecting lead

D-sub cable, 9-pole, 1:1, female/female, 1.8m (max. 25m)

Bystronic order number: 4500842

For laptops without a COM port, use a specified USB / RS232 converter. Please only use the specified converter as other products may cause Windows to crash.

Fig. Schematic representation of connection

Fig. D-Sub cable



USB / RS232 converter

Maxxtro / USB serial converter / 202366 / U-232-9 / type A -> DB09m

Bystronic order number: 10015097

Note: You can only select the new converter COM port in LaserView after installing the appropriate driver and connecting the converter.

4.4.2 Configuration

Fig. Configuring the RS232 connection

• Launch LaserView setup as Administrator (install) • Launch LaserView • Select log in with user name and password

• • Under LaserView Config. on the Com Laser tab you can

configure the serial interface settings. Usually no changes are required except for the number of the COM port.

• Quit LaserView and restart for changes to take effect.

Fig. USB converter



4.4.3 Autostart

After installation, LaserView automatically starts whenever you start Windows – and thus reserves the specified COM port. You can stop this from happening by deleting the appropriate entry (Bystronic LaserView) in the registry. Start\Run…\regedit Path Arbeitsplatz\HKEY_LOCAL_Machine\SOFTWARE\Microsoft\Windows\CurrentVersion\Run

Fig. Registry entry



4.5 Setting up the CNC network drive The following instructions describe how to set up a network drive. A network drive allows you to directly access the shared CNC drive space, e.g. to export cutting plans from BySoft.

The components Client for Microsoft Networks and File and Printer Sharing for Microsoft Networks must be installed in the network settings.

Open Windows Explorer and select Map Network Drive... from the Tools menu.

Select an unassigned drive letter.

In the Folder: field enter the IP address of the CNC as shown for example in the screenshot.

Example: \\192.168.100.101\cncpub

Click on Browse...

Fig. LAN properties menu

Fig. Tools menu

Fig. Map Network Drive...



In the new window select the folder: cncpub

Confirm the selection by clicking on OK

This closes the window.

Confirm with Finish

Now you can access directly from your workstation the machine parameters in the param folder, or cutting plans in the cutprogs folder.

Fig. Selecting the folder



4.6 BySoft This document describes the changes that appear in BYSOFT when individual parts or cutting plans are programmed for a ByVention machine. Programming in BYPART and BYWORK is unchanged.

4.6.1 Definitions

Coordinate system

The machine coordinate system is shown in the diagram below.

EntnahmebereichSchneidbereich

+X

+Y

0,0

Mat

eria

lzufu

hr

Fig. Machine coordinate system

The coordinate system is not changed in BYWORK. The sheet is displayed as usual, i.e. the longitudinal direction is horizontal. First the postprocessor translates and rotates the cutting plan correctly for ByVention.

+X

+Y

+X

+Y

+X

+Y

BYWORK Koordinatensystem Maschinen KoordinatensystemPostprozessor Transformation

Fig. Cutting plan coordinate system



Sheet dimensions and cutting area

The maximum permitted sheet size is 3086mm x 1562mm. In inches this equals 120" x 60" + tolerance of 1.5". The minimum sheet size is 1200mm x 1000mm.

If the sheet is larger than the maximum cutting area, it is split up into separate sheet segments. The maximum permitted cutting area is 772mm x 1562mm. The length of the last sheet segment must be at least 500mm (machining process A) or 650mm (machining process B).

Fig. Dimensions

It should be noted that all dimensions are based on BYWORK coordinates. On the machine, the X (= length) and Y (= width) dimensions are swapped over.

max

. 1562

min. 500

min. 650 max. 772

Machining process A

Machining process B

max. 3086



Machining processes

As already mentioned, a sheet is divided up into separate sheet segments. The way in which this segmentation, or more precisely machining, is performed, is called a machining process. There are two different machining processes.

Machining process A = segment without overlap

Fig. Machining process A

Machining process A divides a sheet into segments each of maximum size 772mm, with no overlapping of segments. The width of each segment can vary, because it cannot always be filled with parts right up to the edge.

Machining process B = segment with overlap

Fig. Machining process A

Machining process B also divides the sheet into segments each of maximum size 772m, but in this case they overlap by 150mm. This means that under certain circumstances more parts can be nested on a sheet. It is not guaranteed, however, that parts in one segment will overlap into an adjacent segment. This depends largely on the parts geometry and the nesting, and the user cannot control this.

Separating cut

Segment 4 Segment 3 Segment 2 Segment 1

Safety distance

Separating cut

Segment 5

Segment 4

Segment 3

Segment 2

Segment 1

Ove

rlap



4.6.2 Programming

A ByVention machine is defined in BYBASE in the machine database by the Machine type field. The field must be set to BYVENTION to enable certain additional options in BYWORK.

Individual parts are programmed as usual in BYPART. Apart from the maximum parts size (772mm x 1562mm), there are no constraints placed on the programming.

Cutting plans are produced in BYWORK. If a ByVention machine has been selected, some of the standard dialog boxes and functions are no longer available. Instead, a new dialog box and a couple of special functions for ByVention plans have been added. The differences are listed below.

Nesting

Nesting is performed segment-by-segment from left to right, and always in an individual sheet segment. The order in which segments are machined is from right to left however. Since nesting is from left to right, the right-hand sheet edge is usually the "fringe". Thus if possible, the whole plan is rotated through 180° (only if without overlap) and shifted to the right-hand edge of the sheet.

Fig. Nesting

Separating cuts

Severance cuts are placed automatically. The severance cut is always made at a variable distance from the parts (default = 10mm). During cutting on the machine, the severance cut is always made before the parts.

If the residual sheet is shorter than 1200mm, additional segments plus the severance cuts are added at the end (i.e. on the far left), so that the residual sheet can be removed automatically.



Manual functions

Most of the existing functions for making final changes manually have been retained. Unlike a standard machine, however, just one segment at a time can be edited for a ByVention machine. This means that a segment must always be enabled for the manual functions (insert, move, rotate and delete part).

A segment is enabled by clicking inside the segment concerned. The active segment has a yellow surround, and the usable area a gray background. All parts assigned to this segment are shown in light blue. All the other parts appear dark gray and cannot be selected for the manual functions.

Special functions

New functions that can only be used on ByVention plans appear under the Special/ByVention menu. These are described below.

Compress segments

This function removes empty segments and reduces the margins of existing segments. In addition, the remaining segments are shifted to the right-hand edge of the sheet. The function automatically checks all limiting conditions during the compression so that a valid plan is always obtained in the end.

Fill with segments

This function can be used to fill up a plan with empty segments (including the necessary severance cuts). The segment width and a possible overlap can be specified for this function. This function also checks the limiting conditions to ensure a valid division of the segments is always obtained.

Rotate plan

This function rotates the whole plan through 180° and shifts the segments to the right-hand edge of the sheet if possible. If the plan cannot be rotated (e.g. because the far-right segment is too short for the left-hand edge), then an error message to this effect is displayed.

Check plan

This function checks whether there are parts on the plan that lie solely in the left-hand overlap zone of a segment. Such parts can cause problems and should therefore be moved out of the overlap zone. The problem parts are shown in red.

Options

The ByVention tab has been added to the Job parameters dialog box. The new options are described below.



Strategy

Without overlap The segments are arranged without an overlap.

With overlap The segments are arranged with an overlap. If during automatic nesting no part fits in such a segment, a segment without overlap is added.

Segment

Variable segment width The segment width is automatically adjusted to suit the parts during automatic nesting.

Fixed segment width The segment is not adjusted during automatic nesting.

Maximum segment width The segment will not be wider than the value set here. If the Fixed segment width option is enabled, all segments are made as wide as the maximum segment width if possible.

Separating cut

Always separate leftover sheet When this option is enabled, the residual sheet is always filled up with empty segments and severance cuts.

Top overcut Indicates the length of the overcut from the separating cut at the top edge of the sheet (machine X+ side). The severance cut including Top overcut has a maximum length of 1562mm + 10mm.

Parts distance Indicates the minimum distance of parts to the separating cut.

Operating mode Indicates the mode with which to perform the separating cut.



4.6.3 Changes

Job Parameters dialog box

Changes have been made to the Job parameters dialog box for ByVention. Some of the tabs are no longer available, and some options have been disabled or have other limits. The changes are detailed below.

General tab:

• Take into account for window nesting option is blocked

Nesting tab:

• Take into account first/end cuts option is permanently enabled

Cutting sequence tab:

• Unchanged

Repositioning tab:

• Removed

Microjoint tab:

• Removed

Common Cut tab:

• Removed

• The Common Cut option in the parts list must not be set for any part (results in an error message during nesting)

Residual Grid/Panel tab:

• Removed

• The Bottom overcut is permanently set to 10mm

• The Top overcut is set in the new ByVention tab

• The Contour distance is permanently set to 0.1mm

• Pulsed piercing is always used for the severance cut

Postprocessor 1 tab:

• Removed

• Cutting parameters in cutting plan option is permanently enabled

Postprocessor 2 tab:

• The Vaporize option is only possible in the area of lead-ins. The film is vaporized with process macro 5 (parameter laser power cutting vaporization)



Raw material work area

Standard sheet:

• Minimum sheet size = 1200mm x 1000mm

• Maximum sheet size = 3086mm x 1562mm

Residual sheet:

• Maximum sheet size = 772mm x 1562mm

• All other format sizes that do not lie within these limits are invalid.

Nest Parts workspace

• Plan menu: the functions Set/Delete/Move remaining grid cuts and Set/Delete/Edit remaining sheet cuts and Auto Technology are no longer available.

• Plan menu: Set/Delete cutting sequence functions are always applied to all the parts. The cutting sequence is always set segment-by-segment from right to left.

• Nesting menu: Set/Invert/Delete window functions not available.

4.6.4 Handling existing parts

Parts not explicitly programmed for ByVention may contain unsuitable technology settings. The machine may not accept the cutting plans. It is recommended to overwrite the existing technologies with the ByVention Technology Wizard. You can find the settings in ByWork under Job Parameters/Postprocessor3.

Fig. Job Parameters/Postprocessor3



4.6.5 Linking job and parameters

A link between job and parameter file is compulsory for ByVention. It is not possible to select or edit the cutting parameters at the machine.

Fig. Postprocessor

In the Postprocessor window under Cutting Param., select the relevant cutting parameter from the local database or select the parameter directly from the CNC (see instructions below).

Select the path for the cutting plan under CNC data path. The cutprogs folder on the CNC can be specified directly for the data path, provided it has been configured as instructed below.

After the file export, the parameter set is entered in the cutting plan.

ByVention reads only the parameter-file name from the cutting plan, and then selects the parameter file from its database. The selected file path in BYWORK has no function.

The parameter files for BYWORK must be named according to the convention shown in the example below.

VENTION3015_8120_2200_1.0161_3_5_N2_GALVANIZED.PAR

Machine type, controller version, laser type, DIN number, material thickness, cutting head, gas type, additional information

The contents of the parameter files is not important, the machine looks for a parameter with the same name in your database.

Note: The CNC ByVention controller only accepts parameter files containing uppercase letters only.



4.7 Loading cutting planson the CNC In ByVention, cutting plans and parameters are saved directly on the CNC.

Cutting plans can be loaded directly into a folder in the CNC and thus into the job list via the network.

Run Explorer and enter the IP address of the CNC in the address line as shown in the screenshot below. Copy the cutting programs to the cutprogs folder.

Fig. CNC folder structure

The param folder contains all machine parameters. It is recommended to copy these to the BySoft computer to create cutting plans.



4.8 NCP Machine Distributor The NcpMachineDistributor program has been developed as an add-on for the ByVention machine. It serves as a cutting plan distributor. The program monitors a freely definable directory at regular intervals for new cutting plans. If it finds a plan in this folder and if the appropriate ByVention machine is switched on, it copies the plan to the machine. This allows the programmer to prepare a plan at night when the machine is not switched on and ensures that the plan is then immediately available on the machine the following morning when the operator switches the machine on.

4.8.1 Installation

The program is installed on any Windows computer connected to the network. The program is installed by simply copying it. The .NET 2.0 framework must be installed on the computer.

4.8.2 Description

The NcpMachineDistributor program contains two basic modes. A State mode and a Setup mode. The State mode is used to copy cutting plans to the machine. The Setup mode is used to edit settings.

Fig. Modes



4.8.3 State mode

Select the Mode menu to put the program into Run mode. This checks the source directories and copies any cutting plans that are present. If the program is terminated in Run mode, it automatically starts up in Run mode then next time the program starts.

Fig. Mode

4.8.4 Setup mode

Select Edit, Add Destination Machine from the menu to add a new machine. This also allows you to select the source and destination directories.

Fig. Edit

4.8.5 Dependencies

The program was developed with C# under .NET 2.0 and therefore requires that the .NET 2.0 framework is already installed.



4.9 Software installation & update This section describes how to install the ByVention operating software on the hand-held controller and the control software on the ByVention 3015 CNC.

4.9.1 Terminal installation

If you install an update, first save the Default Focus Setting under MMC/Maintenance.

1. Copying the installation from CD to USB stick (optional)

Important: You only need to perform this step if the installation data are not already on a USB stick!

The first step is to copy the installation data on the CD to the USB stick on the hand-held controller using a PC or laptop.

If the data, Images and Installation directories already exist on the hand-held controller USB stick, you must delete (or rename) them. You can leave the RamDumps directory if it already exists.

The CD directory structure is as follows:

Fig. CD directory structure



Copy the following directories from the CD to the root directory of the USB stick:

<CD drive>:\data, <CD drive>:\Images, <CD drive>:\Installation

If the "\Hard Disk\RamDumps" does not yet exist on the USB stick, you must also copy the following directory from the CD to the root directory of the USB stick:

<CD drive>:\RamDumps

2. Installing the terminal software on the control unit (ByVention operating software)

a) Plug the USB stick into the hand-held controller.

b) Quit the ByVention user interface (view Settings/Administration -> Quit Program).

c) On the Windows CE desktop, double-click the My Device icon to launch the File Explorer.

Fig. CD directory structure



d) In the File Explorer, switch to the \Hard Disk\Installation\Terminal directory.

Fig. ByVention Terminal directory structure

e) Start the installation by double-clicking on InstallCmd.lnk.

Fig. Installation

f) The installation proceeds and copies all necessary data to the device. Before copying the new data, the old installation is completely removed. Once the copy process is finished, the hand-held controller is automatically reset and the user interface is displayed.



4.9.2 CNC software installation

If you install an update, first save the settings by selecting Save Config under CNC, and make a note of the Connection Data under Connections.

Quit the ByVention operating software and start MrAdmin. Switch to the Software tab.

Fig. Software tab

Operating system

Only install the operating system if there is a new version. If anything goes wrong during the update (power failure, etc.), the CNC will not start up any more and you must load the image to the compact flash in the CNC again.

Press Software/ Operating System / Install and select \Hard Disk\Install\CNC\V2xxx.qnx

After installing the operating system, you must always re-install the connection data as they are overwritten by the default settings. See Connection installation

Quit MrAdmin and reset the CNC.



CNC software

If you install an update, first save the settings by selecting Save Config under CNC, and make a note of the Connection Data under Connections.

Start MrAdmin as described above.

If there is no CNC version yet, the program displays a communication error (HttpClientConnection Error). Click OK to confirm. Answer No to the prompt application ends now. Press OK to confirm next communication error with. The Administrator starts and now has only limited functions.

Press Software/ CNC/ Install and select \Hard Disk\Install\CNC\P812xxx.bin

The software is now loaded onto the CNC.

The new software version is only started after the CNC is reset.

Parameter

Press Software/ Parameters / Install to install the parameters.

The program displays a dialog to select the source directory \Hard Disk \ Data \ Param to copy the new parameters. This overwrites existing parameters with the same file name.



4.9.3 Connection installation

Fig. Connections tab

Switch to the Connections tab.

Enter and check connection data.

Press Install data.

The new connection data only take effect after the CNC is reset.



4.9.4 Loading a CNC configuration

Fig. CNC tab

Switch to the CNC tab.

If a new CNC version has been installed, you must reset the CNC.

Press Load Config and select \Hard Disk\DATA\Setup\ByVention3015.stp.

This downloads the configuration.

Press Set Time and set the time.



4.9.5 Settings

After a new installation or update, you must enter or check the following settings:

• Set docking position as per section 6.4

• Set Z reference as per section 6.4

• Set Z reference distance – cleaning height as per OI section 6.7.4

• Set default focus setting as per OI section 8.5.8

4.9.6 Configuration backup

If the machine has been completely set, you must save the entire machine configuration to a backup directory.

This is required in the event of automatic repair of the data partition. Press Backup Config on the Software tab.



5 Remote diagnostics Remote Diagnostics (= RD) lets Bystronic Customer Services and the customer access data on the various machine modules such as the CNC or the laser. Using Remote Diagnostics, Bystronic Customer Services can identify machine faults and target maintenance work.

5.1 System configuration The Remote Diagnostics system comprises an RD server and a number of RD boxes. The units are connected together via the Internet. TCP/IP and HTTP are used as the communication protocols. The system is operated using a Web browser (Firefox, Internet Explorer, Opera, etc.).

Customer Ethernet

Machine Ethernet

Router

NetboxRouter

Customer

Firewall

Internet

Bystronic Laser AG

SSH Tunnel

Firewall

Machine 1 Machine 2 Machine nRD-Box

RD-Server

Fig. System configuration

5.1.1 RD box

The RD box is normally installed in the FMS network of the laser machine at the customer's site. It requires an Ethernet connection plus operating voltage. The RD box is supplied without monitor or keyboard. Linux Debian is installed as the operating system. One RD box can be used to retrieve information from a number of machines and their associated modules (CNC, MMC, PLC, laser, etc.).



5.1.2 RD server

Bystronic Laser AG looks after the Remote Diagnostics server. The RD server administers the RD boxes installed at the customer sites and performs user authentication.

5.2 Description of operation If the RD box is installed at the customer’s site, and the connection has been activated by the customer, the RD box is automatically logged onto the server via the Internet and SSH tunnel.

The Hotliner can log onto the RD server https://rds.bystronic.com by entering the Internet address in a Web browser, and then entering the user name and password.

Fig. Login

After logging on, those groups assigned to the user (based on the user name) are displayed. Those RD boxes enabled by customers are then displayed in these groups, identified by the customer name.

Fig. Group 1 start-up screen



The System Administrator can see all groups that exist and their logged-on customers = RD boxes. He/she can make changes and updates to groups and users.

Fig. Start-up screen for all groups

Selecting the customer of interest starts retrieval of the diagnostics data.

First of all, the diagnostics command is sent to the Web server in the customer's RD box; then the Web server in the RD box sends a request to each connected module (CNC, MachineService, LaserView, SysInfo, etc.); each of these modules, provided it is configured, sends back its current status, which is indicated in the user's browser by either green (= no problem) or red (= problem exists). The configuration of the customer machinery is also transferred with the same interrogation query.



Fig. Customer screen

If a module in the subordinate branch has a problem, then the higher-level node is also displayed in red.

In addition, the red indicator shows two different fault situations:

1. The module is not responding to the query: the node is shown in red and the word (Offline) is also displayed.

2. The module is responding to the query but is returning an error status: the node is shown in red.

Fig. Service offline

Selecting the relevant module on the left-hand Navigation side displays the more detailed diagnostics data on the right-hand side (see Fig.: Service Laserview). Which data is displayed here and in which order depends on each individual module; it is not within the scope of this document to specify this more precisely. More details can be found in the relevant product information.




5.2.1 SysInfo function

SysInfo can be used to transfer machine screenshots (A) and the logbook entries (B) in ByVision. The data is transferred via the Internet and displayed in the browser.

The Remote Diagnostics facility cannot be used to operate software on the Panel PC.


B



The Logbook function is used to transfer the entries from the logbook and display them on the screen (see Fig.: Logbook)

Fig. Logbook

The Current screen function is used to generate a bitmap of the current screen content and then transfer it (see Fig.: Current Screen)

Fig. CurrentScreen

The page displayed in the browser it not automatically refreshed. This must always be done by the user.



5.3 Security

5.3.1 SSH-V2 – Secure Shell Version 2

SSH enables cryptographically secured communication via unsecured networks and provides a high degree of security --> reliable, mutual authentication of partners plus integrity and confidentiality of the transferred data.

The main functions of the Secure Shell include:

• Login to a remote machine (PC)

• Interactive or non-interactive execution of commands on the remote machine (PC)

• Copying of files between different computers in a network.

5.3.2 SSL - Secure Socket Layer

SSL provides the facility to encrypt transmissions over the Internet and to safeguard them against outside interception. In SSL mode, a certificate guarantees both the authenticity of the contacted server and the connection to it. If an SSL-secured server is accessed, a certificate and the public key is requested and checked for authenticity.

5.4 Establishing and clearing a connection It is the customer who establishes the connection, and who can also terminate it at any time. Keys are transferred between the RD box and the RD server (SSH server) while a connection is being established and during the actual session. A connection is only established when the public key from the SSH server is recognized at the customer end. This ensures that only authorized users can use this connection.

The Hotline end is only able to terminate the connection; if the Hotliner wants to establish a connection again, he must first contact the customer so that the customer can re-activate the link.



Customer Ethernet

Machine Ethernet (Bystronic)

PPC⎝ Sysinfo⎝ MMC⎝ Machine-

Service⎝ Laserview

NetboxRouter

Customer

Internet

Vanco Zürich

Remote DiagnosticsServer

SSL

SSH Tunnel

CNC⎝ Byvision⎝ Midrange

PLC⎝ Transport⎝ Handling⎝ Storage

CPC⎝ Sysinfo⎝ Store -

Manager

Remote Diagnostics

Box

Firewall /Router

Bystronic HotlineFirewall /Router

Firewall /Router

Fig. Concept

5.4.1 Connection between RD box and RD server

The connection between the RD box (customer) and the RD server (Bystronic Laser AG) is secured by SSH. To ensure maximum security, the connection is established from the customer to Bystronic Laser AG. This has the advantage that port 22 in the firewall only needs to be opened for outgoing connections, and this can be terminated at any time by the customer.

5.4.2 Connection between Hotline and RD server

The connection from the Hotline to the RD server is implemented via SSL (Secure Sockets Layer). Bystronic customers cannot use this connection themselves because Bystronic does not wish to perform a provider function for their customers. If the customer wishes to have access to his RD box located in his factory, then he must provide this access via his own VPN.



5.5 Requirements

5.5.1 For the branch office

Broadband access to the Internet ( ADSL or faster )

User name and password for logging onto the RD server

5.5.2 For customers

A broadband connection ( ADSL ) must be present

Port 22 SSH must be open to the outside. The port can be checked using the Putty program (freeware).

Port 53 UDP (DNS) must be open to the outside. The port can be checked using the Putty program (freeware).

5.5.3 Connection test using Putty:

Run the Putty program

Enter rds.bystronic.com as the Host name and 22 as the Port. Then select Open and confirm with Enter (see Fig. Putty).

Fig. Putty



Confirm the following authentication window withYes:

Fig. Safety warning

If ports 22 and 53 are open, login as: from the Remote Diagnostics server is displayed = it was possible to establish the connection.

«Info Titel» Erstellt von : Autor Datum :

Geht an :

Zur Kenntnis :

Fig. Putty Login

If port 53 is closed, then the following error message is displayed:

Fig. Port 53 error

If port 22 is closed, then a timeout message is displayed:

Fig. Port 22 error

If the connection test could not be completed successfully, the customer must contact his IT specialist.



5.6 Remote Diagnostics Box (RD box)

5.6.1 Hardware

The RD box is a self-contained black box (no fan) and has been designed so that it can be placed near the machine. The guarantee expires if the RD box is opened (seal broken).

Default configuration from Bystronic Laser AG

The RD box comes with the following default configuration:

Network: - IP address: 192.168.100.250 - Subnet mask: 255.255.255.0 - Gateway: 192.168.100.200 - Broadcast: 192.168.100.255

Machinery configuration: - Bystar 3015 with Bycell Cross

5.6.2 Software

The system allows an authorized user to update the installed software via the Internet (SW update). In addition, the RD box is fitted with a flash card that contains the Interface configuration (IP addresses) and the configuration for the system services (XML file).

Operating system

Linux

Firebird database

Installation / Configuration

DB backup

DB restore

Apache Webserver

Configuration

Bystronic applications in the RD box

Remote Diagnostics

Data Service

PDR Viewer



5.6.3 Software on the ByVision panel PC

SysInfo Service for retrieving the PC system data and for transferring print-screens and log files.

Logbook Program for electronic recording of logbook entries

PLC web server

Internet Explorer

5.6.4 ByVention software

Every ByVention is prepared for remote diagnostics. The programs required for this run on the CNC controller.

The digital logbook is not available for ByVention.

5.6.5 Location of the RD box

ByVision machines as per UA 06/04

The ByVention does not have a Netbox (router and switch). This means that the machine is connected directly via the CNC rack to the customer network/machine network. The external IP address of the CNC rack therefore may not comply with the Bystronic standards.

Fig. Version 1: Customer has just one ByVention

The IP address of the CNC is set to suit the customer network. The RD box is installed in the customer network and can be located in any position.

The RD box must be configured to comply with the IP-address scheme of the customer.



Fig. Version 2: customer already owns Bystronic machines

The CNC IP address is set to an unassigned number in compliance with the Bystronic standards. The CNC of the ByVention is connected to the Netbox hub. The RD box is installed in accordance with instructions.



5.6.6 Configuring the network interface

Since the RD box is a black box and the service engineer has no means of changing the network settings, these are saved on a flash card.

The default configuration of the RD-box network interface is as follows:

IP address: 192.168.100.250 Subnet mask: 255.255.255.0 Gateway: 192.168.100.200 Broadcast: 192.168.100.255

If the RD box is not operated with the default network configuration, then the settings can be changed using the flash card.

To do this, the flash card must be removed before the RD box is first used, and the file interfaces must be created (with the correct entries) in the new folder on the flash card. The file in the exampleConfig folder can also be copied over.

Fig. Interface configuration

Fig. File interfaces

When the RD box is booted up, the current settings are written to lastConfig and the settings in the new folder are adopted and the file deleted.



5.6.7 Configuring the system services (XML file)

The XML file must follow a defined format. Each service is assigned a type and a port. The IP address and the name (offline) may be different and may differ between the different machine types.

Type and Port definitions for the various services:

ByStar, -Sprint, -Speed and -Jet

Laserview (ByPump): Type Laser, Port 55210 (55910)

CNC: Type CNC, Port 55400

Machineservice: Type MS, Port 55510

SysInfo: Type SysInfo, Port 55710

PLC STL: Type PLC, Port 55801

PLC TRP: Type PLC, Port 55802

ByCell

Storemanager: Type Store, Port 55310


PLC LAG: Type PLC, Port 55803

ByVention

Laser module: Type Laser, Port 55210

CNC: Type CNC, Port 55400


Machineservice: Type MS, Port 55510

The XML file can be depicted in a tree structure to improve clarity and provide a better overview. This structure is defined using nodes.

Fig. Tree structure



Once the XML configuration has been defined and the customer (RD box) named, nodes can be defined.

A node begins with the name <Node Name=“node name“> and ends with </Node>. The various services can be entered in between (<Node Name=“service“ Type=“type“ IP=“IP address“ Port=“number“/>).

The XML file is saved on the flash card, and the XML file configuration can be changed via the flash card.

To do this, the file BystronicMachinePark must be created (with the correct entries) in the new folder on the flash card, or copied from the exampleConfig folder.

Fig. Explorer BystronicMachinePark

This involves removing the flash card from the RD box, and editing the file BystronicMachinePark on another computer. <?xml version="1.0" encoding="ISO-8859-1"?> <BystronicMachinePark Language="de" Customer="Linie 11 (Test)"> <Node Name="Manufacturing Cell 1"> <Node Name="LCC1: Bystar 3015" Type="Bystar"> <Node Name="SPS (STL / TRP)" Type="PLC" IP="192.168.100.101" Port="80"/> <Node Name="Laserview" Type="Laser" IP="192.168.100.101" Port="55210"/> <Node Name="Sysinfo" Type="Sysinfo" IP="192.168.100.101" Port="55700"/> </Node> <Node Name="LCC2: Bystar 3015" Type="Bystar"> <Node Name="SPS (STL / TRP)" Type="PLC" IP="192.168.100.102" Port="80"/> <Node Name="Laserview" Type="Laser" IP="192.168.100.102" Port="55210"/> <Node Name="Sysinfo" Type="Sysinfo" IP="192.168.100.102" Port="55700"/> </Node> <Node Name="Bycell Line" Type="Bystore"> <Node Name="STOREmanager" Type="ByStore" IP="192.168.100.165" Port="19220"/> <Node Name="SPS (Storage)" Type="PLC" IP="192.168.100.165" Port="80"/> <Node Name="Sysinfo" Type="Sysinfo" IP="192.168.100.102" Port="55700"/> </Node> </Node>

</BystronicMachinePark>

Fig. Default configuration

If the RD box is now booted up again, the current settings are written to lastConfig and the settings in the new folder are adopted and the file deleted.



5.7 Administration Various settings, configurations and updates can be made online in the admin (A) area of the RD box.

To access the admin area, open the browser and enter the address of the RD box (http://192.168.100.250).

Fig. RD box start-up page

5.7.1 Connection menu

In this menu the connection from the RD box to the RD server can be enabled (A) and disabled.

Fig. admin Connection

A

A



The status of the connection to the RD server is displayed after every refresh. The various connection statuses are listed in the following table:

State Command Description

Connected disconnect Connected to server. It can be terminated by clicking on disconnect.

Disconnected connect Connection to server lost. It can be established by clicking on connect.

try connecting stop trying Connection terminated because the network connection has been lost. An attempt is made to re-establish the connection. As soon as the server can be reached, the connection is re-established. Click on “stop trying” to terminate the connection procedure.

The user must log onto the system to access all possible menu options. The access permissions are classified into two different levels. The service user has restricted access rights (customer) and the admin user is given full access rights.

The login is set as follows by default:

User name: service; Password: service User name: admin; Password: rdadmin06

Fig. admin login



5.7.2 Update menu

The RD box software can be updated in this menu.

Fig. admin Update



5.7.3 Network menu

The network settings can be configured in this menu.

If it is not possible to work with the default settings, the system administrator must be contacted (connection test using Putty working).

Fig. admin Network

If the RD box cannot be operated using the default network configuration, it can be changed here.

The new values only come into effect after a network restart! If they are incorrect then it may no longer be possible to access the RD box!



5.7.4 User menu

Users can be assigned a new password in this menu.

Fig. admin User

Caution: changing the passwords means that it is no longer possible to access the menu concerned. The passwords can only be reset via the RD Server (administrator)!

5.7.5 Backup menu

The settings edited online can be saved on the flash card in this menu.

A) Backup config: the network and machinery configuration is copied from the HD onto the flash card (backup directory).

B) Restore config: the network and machinery configuration is copied from the flash card (backup directory) onto the HD.

C) Save config to reboot from: the network and machinery configuration is copied from the HD onto the flash card (new directory). These settings are adopted at the next re-boot and the data deleted.



Fig. admin Backup

5.7.6 System menu

The RD box can be shut down or re-started in this menu.

Fig. admin System

A

B

C



5.7.7 Modules menu

The various Remote Diagnostics modules can be configured in this menu.

Currently there is just the Remote Diagnostics module. In the Remote Diagnostics module the machinery configuration can be changed and saved locally. (See Configuring the system services (XML file) for details).

Fig. admin Remote Diagnostics



In addition, the timeout can be set to optimize the supply of data. If too long a time is set, the data display is delayed unnecessarily; if too short a time is set, the data may not be retrieved and the module will be shown incorrectly as offline.

Fig. admin save XML

5.8 Logging onto the RD server

5.8.1 Establishing a connection to the RD server

Start the browser and enter the RD box address: http://192.168.100.250 and switch to the admin section.

The status must be set to connect (A) under State in order to make the connection.

A



5.8.2 Grouping

Start the browser and enter the RD server address: https://rds.bystronic.com and log in with the assigned login data.

New RD boxes connected to the system are assigned by default to the group Not assigned. A user with administrator rights can then assign the box to the relevant group.

Fig. RD server start-up page

5.9 Assigning users to a group The system administrator registers the users and assigns the necessary permissions. At the moment, user administration is performed centrally by Bystronic Laser AG.



5.10 Command line reference Click Windows Start, Run… and input cmd followed by Enter to open the command line.

Fig. Command line input

5.10.1 Ping

Short for Packet InterNet Groper

Ping is a tool for checking whether a data packet can be transmitted to a network address without any errors. The Ping tool is mostly used to check network errors.

If the transmitted data packet does not reach the recipient (network address) because of an incorrect network configuration or because the signal is blocked, the computer displays a timed-out error.

Example

ping 192.168.100.101

Options

ping 192.168.100.101 –t

continuous query (CTRL C to abort)

5.10.2 Ipconfig

Ipconfig is a command to display current network settings. You can use this command to display connection information or network settings.

Options

Ipconfig /all : Displays all network settings



5.11 Using a proxy server

In order to access the RD box, you must set the correct Proxy settings in Internet Explorer. Otherwise, Internet Explorer tries to find all IP addresses on the WWW and cannot find the RD box. The settings are used to define an internal IP address range so that the browser only looks for the RD box in the internal network.

Launch Internet Explorer and click on Internet Options... in the Tools menu.

Fig. Tools menu

Click on the Connections tab.

Click on the Settings button under LAN Settings.

Fig. Internet Options...



Enable the Bypass proxy server for local addresses option.

Click on the Advanced... button.

Fig. Settings...

Input your IP address range in the Exceptions box, as shown in the example.

Fig. Proxy settings

Confirm by clicking on OK

The browser now looks for all IP addresses starting with this prefix locally and no longer sends them to the proxy server.



6 Maintenance

6.1 Setting separating cut detection The laser sensor of the separating cut detection system measures the distance to the material to be cut/table. After the separating cut, the sensor checks whether all parts in the vicinity of the separating cut are further from the encoder head than the set distance. If not, an error message is displayed and unloading is stopped.

This distance is programmed on the back of the sensor using the yellow button and the LED display (see Fig.).

The teach-in process may only be performed after installing the sensor.

Fig. Laser sensor with bracket

LED display

Electrical connection

Connection for inspection window ventilation

Cable tie holes

Yellow button for programming



Procedure

• Move cutting table to unloading position (middle position).

• Place a 40mm (0, +5mm) metal sheet on the cutting table with the sensor's laser beam on it

Note: The sheet defines the minimum distance to the sensor. During subsequent separating cut detection, no part may protrude over this limit.

• Hold down yellow button -> red LED lights up

• After approx. 2 seconds, the LED starts to flash red (approx. 2x per second) -> keep yellow button pressed

• After approx. 4 seconds, flashing speed switches to 5x per second -> release yellow button

• Press the button briefly

• Press the key again briefly -> the LED lights up for approx. 2 seconds to confirm then goes off and flashes again briefly.

• The sensor is now ready for operation again and the switching distance is programmed.



6.2 Servo adjustment and calibration The servos must always be set to the correct values. The settings, shown in the diagram below, can be found in the CNC diagram.

6.2.1 Preparation

• Switch to the main menu on the hand-held controller. • Press the SE button to enable extended user mode • Select the Settings menu • Select the Administration tab • Start MrAdmin by pressing Start MrAdmin • Enter code and press OK to confirm • Switch to the CNC tab and set the scroll list to Setup. • Edit the values (note down original values first)

• feed rate for manual operation, head raised to 12,000 mm/min

• feed rate for manual operation, head lowered to 1000 mm/min

• Switch to the Main tab and quit MrAdmin by pressing Exit MrAdmin.

• Select No when prompted to restart the CNC • Once MMC has started, switch to Manual Mode menu

Note: Carry out the servo calibration for the X- and Y-axis with the cutting head raised (Z+)!

Fig. Example servo settings



6.2.2 AMCONT card switch settings

Before calibrating the servo, check the S2/S3 switch settings against the CNC schematic. The S2/S3 switches are on the Amcont card. To check these remove the Amadap card. Note: The switch settings differ from axis to axis.

Fig. Amcont pcb To achieve an optimal dynamic trajectory behavior of the axes, the speed amplification of all axes must be the same magnitude, i.e. the setpoint value of each axis must be matched. The adjustment has to be performed according to the description for the X, Y and U axes and for the Z axis.



6.2.3 Servo adjustment X and Y axis

1. Connect the tester to connector X43 on terminals 3 and 4 on the AMADAP card.

Fig. Amadap pcb

2. With potentiometer <P1> on the AMADAP card, set the measured value to 0.000 VDC.

3. Switch to the <Manual mode> menu.

4. By means of the manual operation, move the axis to be adjusted in the plus and minus directions.

5. With potentiometer <P2> on the AMADAP card, set the specified adjustment voltage (e.g. 0.8V).

6. Check the voltages for the opposite direction (other sign). The voltage must now be the same in both directions. Using <P1>, set the forwards and backwards symmetry.

7. Check the adjustment voltage and set it to the exact value using <P2>.

8. Repeat step 4 through 7 until the symmetry and level of the adjustment voltage are precisely matched.

9. Once servo adjustment is finished, reset the modified setup values to the original values as per section 6.2.1.



6.2.4 Servo adjustment Z axis

1. Switch to the <Manual mode> menu.

2. Switch the tool to <OFF>

3. By means of the manual control, move the Z axis in the plus and minus directions.

4. With potentiometer <P2> on the AMADAP card, set the specified adjustment voltage (e.g. 0.3V).

5. Check the voltages for the opposite direction (other sign). The voltage must now be the same in both directions. Using <P1>, set the forwards and backwards symmetry.

6. Check the adjustment voltage and set it to the exact value using <P2>.

7. Repeat step 3 through 6 until the symmetry and level of the adjustment voltage are precisely matched.

8. Note the set adjustment voltage in the new controller record card.

9. Once servo adjustment is finished, reset the modified setup values to the original values as per section 6.2.1.

Fig. Amadap pcb

1. Potentiometer P1 Offset setting

2. Potentiometer P2 Control loop amplification

3. Connector X43 CNC setpoint input



6.3 Adjusting the table height sensors

The limit switches S14 and S15 and used to define the upper and lower limit of travel, and must be set so that they trip just after the upper and lower stop position respectively. A slight deflection of the sensor rollers is permitted. Sensors S42, S44 and S46 define the braking point before stop position (cannot be changed). Sensor S43 must be set to that the upper table position is flush with the sheet-feed height. Sensor S45 must be set so that when the parts-removal rake is moved in, it does not push the parts away ( sensor too low ) or collide with the table ( sensor too high ). Adjust closer to the cutting table as the cutting grid wears over time. Sensor S47 defines the bottom end position (cannot be modified).

Note: Set the proximity switches to a distance of approx. 0.5...1mm to achieve correct triggering behavior.

Fig. Table height sensors



6.4 Setting sheet clamps and table position The following instructions describe how to adjust the sheet stops so as to ensure parallel feed of the sheet and alignment of the cutting table to the axes of movement.

Procedure

• Install sheet stops on the cutting table.

• Remove the cover from the longitudinal stop and unscrew fixing screws A+B of the longitudinal stop. Only unscrew first screw A slightly as it serves as a pivot point.

• Use the pedal to lower the Y stop (blue lamp off)

• Insert a standard sheet 3000x1500mm (sheet must be perfectly right-angled)

• Push the standard sheet by hand right up to the front into the Y stop of the cutting table. The X stop is positioned so that the sheet does not touch the sheet in the X direction.

Fig. Longitudinal stop fixing screws



• Press the standard sheet into the longitudinal stops and clamp with the pedal.


• Switch to Settings tab.

• Close safety door

• Activate Manual mode (magenta button)

• Lower Z axis and move center of nozzle to Y+ sheet edge.


• Push the cutting head in Y- direction and check whether the center of the nozzle is always on the sheet edge.

Fig. Table stop

Fig. Sheet edge



• If the center of the nozzle is not always on the edge of the sheet, adjust the sheet and the longitudinal stop with the clamping screw.

• The fixing screws of the longitudinal stop have slots, except for the front-most screw, that acts the pivot point.

• If the edge of the sheet runs parallel to the center of the nozzle, tighten the fixing screws of the longitudinal stop.

• Push the table stop up to the sheet and tighten.

•

Fig. Clamping screw

Fig. Table stop



• Install the right table stop. If the stop is not touching the sheet or if it cannot be installed because the sheet is protruding too far forwards, the whole cutting table (grid support, unscrew four screws) must be moved so that it runs parallel to the X axis.

• Push the cutting head by hand exactly to sheet zero point

• Set zero point and docking position as per the following pages.

Fig. Right table stop



6.5 Setting sheet zero point and docking position The sheet zero point defines the starting point of the cutting plan that is usually moved to in remaining sheet production. The docking position of the sheet feed must be set precisely so that it is possible to connect the cutting carriage to the suction-cup unit by the two pneumatic cylinders. Machine zero point is calculated on the basis of the docking position. It is not necessary to set or determine machine zero point manually. Setting sheet zero point

Fig. Settings tab

• Place sheet on table and position (push up against installed stops), close safety door.


• Switch to the Settings tab.

• Click the Reference button to move axes to reference position.

• Enable Manual mode and move axes to the desired sheet zero point.

• Press Save sheet zero point, machine moves to reference position after setting this value.

• Setting docking position

Note:

After setting sheet zero position, you must always set docking position again!



Setting docking position

• Reduce compressed-air pressure (1st pressure control vale) to 2 bar (the suction-cup frame can be deformed by the pneumatic posts if the docking position is not exactly right!)

• Open the safety door.

• Push the cutting carriage to docking position by hand.

• Extend pneumatic posts by hand (the pneumatic posts can be operated manually from the valve island, which is located on the rear of the machine by the cutting gas supply; see pneumatics circuit diagram).

Fig. Valve island

• When retracting the cylinders, the suction-cup frame must not move! When the suction-cup frame is twisted or even just moved by a cylinder, adjust the carriers (see overleaf).

• Rise the compressed-air pressure to original value (6 bar) and extend the pneumatic posts by hand again

• Once the position has been determined exactly, press the Save Docking Position button on the hand-held controller.


• Reset the CNC



Checking docking position

• Close the safety door.

• Press the Reference button to move the axes to reference position.

• Open the safety door.

• Push the cutting carriage to docking position again. The axis values on the display must be identical to the values Docking Position x/y.

Adjusting the carriers

Adjusting the carriers is important to ensure that sheet feed is parallel. Also, if the carriers are not properly aligned, the side guides may get destroyed.

Fig. Left carrier

• The right carrier cannot be adjusted and should be seen as a reference.

• Unscrew set screws B of the left carrier.

• Unscrew the four fixing screws A.

• Retract docking cylinder.

• Tighten fixing screws A, tighten set screws B and secure with lock nut.



6.6 Determining Z-axis reference Procedure

The Z-axis reference must be determined manually. Bottom sheet edge = 0.00 mm.

• Place sheet on cutting table.

• Switch to manual operation menu (MMC).

• Select the appropriate parameter for the sheet.

• Position the cutting head on the sheet with Tool_Mode enabled.

• The value of Z on the display must equal the sum of sheet thickness and nozzle distance (0.7mm).

• If this value is not correct, correct the value of Z-axis: Reference coordinate by the difference on the CNC tab under Config in MrAdmin.

• Then move to reference on the Settings tab and repeat this procedure.



6.7 Testing the vacuum system

6.7.1 Building up a vacuum according to the Venturi principle

Fig. Venturi tube diagram

A Venturi nozzle (also known as a Venturi tube, after Giovanni Battista Venturi) consists of a smooth-walled tube with two cones pointing towards each other and meeting in the middle, where the diameter is smallest. The Venturi tube builds up a vacuum without any additional motor effect and increases the speed of flow at the narrowest point of the tube.

6.7.2 System test

Fig. Vacuum valve

• Remove the cover on the left of the suction-cup frame.

• Seal off the hose (Fig. right) with a plug.

• Using a screwdriver, manually remove the valve (small screw to side of the right controller)

• If working properly, pressure on the manometer drops approx. 0.5bar and the red pressure sensor LED goes off.

• Check air-tightness of the the vacuum system step by step with blind plugs.

• Manometer pressure at rest is approx. 3.5bar.



7 Repair

7.1 Setting the reference point on the X- and Y-axes The following adjustment work for the X axis is described. The procedure also applies to setting Y reference position, only the direction of movement of rotation may differ.

Fig. Limit switch and reference point (diagram)

Procedure

1. Start the MrAdmin tool and switch to the Settings tab.

2. Close safety door and move to reference position.

3. Note down axis value on the display Example X: 10mm

4. Open safety door

5. Push the axis in minus direction until the proximity switch triggers (red LED on sensor or appropriate LED of IO box).

Sensor position X

Hardlimit X- Softlimit X- Ref. X

20mm



6. Note down axis value on the display Example X: -15mm

7. Calculate difference between the two axis values Example 25mm

8. Calculate the difference to 20mm Example 5mm

9. Open safety door and trip the small lever on the bottom door switch.

10.Open encoder.

Sensor position Y

11.Unscrew the collet chuck with an Allen key and hexagon-head wrench.

12.Check display and adjust display value by the appropriate amount using a hexagon-head wrench Example 5mm

13.Tighten collet chuck to 2.2 Nm.

14.Trip small lever on bottom door switch.

15.Repeat steps 2 through 7 If the difference is not 20mm, repeat step 8 through 15 with different direction of rotation of the hexagon-head wrench.

16.Screw encoder closed.

17.Set docking position as per section 6.4



7.2 Replacing the X motor

7.2.1 Material

• New motor, pinion and tensioning ring

7.2.2 Additional tools and equipment required

Fig. Tool kit

• Set of Allen keys

• Small and large ratchet set

• No. 6 screwdriver

• 8mm hexagon-head wrench

• Torque wrench 12Nm, 3mm hex.



7.2.3 Preparing the machine

1. In Manual operating mode, move machine into a suitable position. Open the safety door and shut down the machine correctly. Switch off cooling unit. Safeguard machine against unauthorized start-up.

2. Remove the orange motor cover on the bridge.



7.2.4 Disassembling the motor

Fig. Motor

1. Feedback connection cable

2. Encoder connection cable

3. Power supply connection cable

4. Set screw for tooth edge play

5. Shaft screw (center of rotation for setting tooth edge play)

6. Fixing screws

Procedure

• Remove all electrical connection cables and encoders.

• Remove set screw 4 including holder.

• Secure motor with crane or place wood underneath.

• Remove fixing screws 6 and shaft screw 5.

• Remove motor.



7.2.5 Assembling the pinion

1. Motor shaft

2. Pinion

3. Tensioning ring

Fig. Pinion

Procedure

1. Clean motor shaft 1, inside of tensioning ring 3, inside and seat of pinion 2 with acetone. Push tensioning ring 3 left-flush (see Fig. right) onto pinion 2.

2. Pish pinion with tensioning ring all the way onto the motor shaft. Tighten tensioning ring straining screws diagonally to 12Nm. Tighten the screws until the torque wrench “cracks” at every screw without any turning (requires 15-20 turns).



7.2.6 Assembling the motor

Fig. Motor

1. Feedback connection cable

2. Encoder connection cable

3. Power supply connection cable

4. Set screw for tooth edge play

5. Shaft screw (center of rotation for setting tooth edge play)

6. Fixing screws

Procedure

1. Install adjustment block 4 on motor (unscrew set screw) Fasten motor with screws 5 and 6. Only engage the screws – do not tighten yet!



2. Setting tooth edge play: Jerk bridge to and fro, adjusting set screw 4 until you cannot hear any more “ringing” pinion and rack and pinion. Secure set screw 4 with lock nut.

3. Tighten motor screws 5 and 6. Install electrical connections and encoders.

7.2.7 Commissioning /Test

• Start up machine

• Function test with 10% switch

• Calibrate servo as per section 6.2

• Set reference point as per section 7.1


• Cut test part



7.3 Replacing the Y-axis spindle system

7.3.1 Material

• new spindle with recirculating ball nut

• possibly new spindle bearings


Fig. Tool kit


• Large ratchet set containing 8mm Allen insert

• Ring wrenches SW 10, 11 and 19

• Hook wrench

• Circlip pliers




1. In Manual operating mode, move machine into a suitable position. Open the safety door and shut down the machine correctly. Switch off cooling unit. Safeguard machine against unauthorized start-up.

2. Remove the covers from the rear of the machine and move the loading table.

7.3.4 Removing the spindle

1. Remove the small cover below the Z axis (2 Allen screws M5). Remove the cover plate under the cutting carriage (5 Allen screws M6).



2. Unscrew the bellows from the cutting carriage (3 hex screws M6). Unscrew and remove the front plate together with the bellows (4 Allen screws M6)

3. Undo the lubrication line to the spindle nut

4. Unscrew the rear bellows on the rear side (4 hex screws M6). Undo the motor coupling (grub screw) Disconnect the three motor connection cables. Unscrew and remove the motor (4 Allen screws M10)

5. Unscrew the two grub screws on the clamping nut. Use a hook wrench and a size 19 ring wrench to unscrew and remove the clamping nut.



6. Remove the circlip from the front end of the spindle. Unscrew the bearing flange plus the bearing and remove (4 Allen screws M10) .

Note: The rear bearing flange acts as a fixed bearing and only needs to be unscrewed and removed to replace the bearing.

7. Unscrew the screws on the recirculating ball nut and remove (8 Allen screws M10)

8. Slide out the spindle towards the safety door, drop it down at the far end and take it out towards the rear of the machine.



7.3.5 Fitting the spindle

1. If necessary, fit the fixed bearing to the rear of the machine and tighten screws (4 Allen screws M10). The adjacent diagram shows the bridge from below.

Note: To insert the spindle, move the cutting carriage to its Y+ limit and if necessary move the recirculating ball nut on the spindle. Caution: the recirculating ball nut must never be pushed beyond the threaded end, because the balls may fall out, making the spindle unusable.

2. Slide the spacer ring onto the fixed-bearing end. Insert the spindle from below through the detachable bearing-flange, then lift up the spindle and guide the end through the cutting carriage into the fixed bearing.



3. Fit the detachable bearing plus flange (4 Allen screws M10) and attach the circlip. Only engage the screws – do not tighten yet! At the opposite end (fixed-bearing end), screw the spacer ring and the clamping nut onto the end of the spindle and screw on slightly. Do not tighten the clamping nut.

4. Screw the recirculating ball nut onto the cutting carriage (8 Allen screws M10) and attach the lubrication line. Only insert the screws – do not tighten yet.

5. Move the cutting carriage as far as possible in the Y+ direction. This centers both the recirculating ball nut and the fixed bearing. Tighten the screws on the recirculating ball nut (8 Allen screws M10).

6. Move the cutting carriage as far as possible in the Y- direction to center the detachable bearing. Tighten screws on the detachable bearing flange.

7. Tighten the clamping nut and secure with the two grub screws.



8. Install the motor (4 Allen screws M10) Tighten the motor coupling (grub screw) Connect the three motor connection cables.

9. Install lubrication connection spindle nut, cover sheets and bellows.




• Calibrate servo as per section 6.2

• Set reference point as per section 7.1

• Position sheet-feed table

• Fit all covers


• Cut test part



7.4 Replacing the Z-spindle and guides

7.4.1 Material

• Spindle

• Guides

• Spindle bearing

• Bearing grease


Fig. Tool kit


• Small ratchet set

• Ring wrenches SW 10,11

• Circlip pliers

• Loctite type 243

• Blanking plugs for water circuit including coupling

• Oilstone HF-33

• Torque screwdriver 50-500 Ncm

• Special hexagonal insert 2.5mm with spherical head and matching insert

• Special wrench for spindle nut

• Special wrench for spindle stud




1. In manual operating mode, move to Service position. If possible, position the Z-axis so that it is just above the cutting table. Open the safety door and shut down the machine correctly. Switch off cooling unit. Safeguard machine against unauthorized start-up.

7.4.4 Removal

1. Unscrew and remove the front mirror housing. Unscrew the front plate plus bellows and remove the whole unit.

2. Unscrew the rear bellows and push out the way.



3. Unscrew the rear bellows flange from the deflecting mirror and remove. Close off the mirror aperture with adhesive tape.

4. Remove the lower cover from the spindle brake. Disconnect the compressed air line from the spindle brake and replace with an M5 screw (used for manual operation of the spindle brake). Brake screw tighten released unscrew tightened Unscrew the bellows on the Z-axis and move the Z-axis downwards. Fix the bellows up at the top.

5. Remove the limit-switch tabs at the lower end of the Z-guides. Caution The roller cages can drop out.



6. Remove the telescopic tube plus all connections and the cable guide from the cutting head support. Unscrew the screws on the carrier plate (connection between cutting head support and spindle). Remove the cutting head support together with roller cages.

7. Unscrew the bellows from the Z-axis and remove. Remove the two covers from the Z guides.

8. Disconnect the motor and position encoder cables. Unscrew the motor coupling and remove the motor together with the coupling and position encoder. Remove the coupling flange.



9. Release the spindle

brake. Push the spindle upwards until the bearings can be seen; fix in this position. Use the special wrenches to unscrew the bearing nut. Remove the bearing nut and the bearings. Move the spindle downwards.

CAUTION

The spindle brake must not be applied without the spindle inserted: the brake cannot be released again afterwards.

10.Unscrew the side screws on the right-hand Z-guide. Unscrew and remove the Z-guides. Also remove the guides from the cutting head support.



7.4.5 Fitting

2. Use an oilstone to hone the guide contact surfaces on the cutting carriage and then clean them. Fit the limit-switch tabs to the upper ends of the guides. Fit the new guides but do not tighten the screws. Press the left-hand guide against the left face and tighten the screws to 110 Ncm. Insert but do not tighten the top and bottom screw in the right-hand guide.

3. Use an oilstone to hone the guide contact surfaces on the cutting head support and then clean them. Press the guides against the inner stop and tighten the screws to 110 Ncm. Fit the limit-switch tabs to the upper ends of the guides (not visible in Fig.), but do not tighten the screws.



4. Pre-assemble the new spindle in the same way that it was dismantled. Only engage the screws in the carrier plate – do not tighten.

Note: Approximately half fill the new bearings with grease. The spindle must not be greased to avoid dirt adhering to the surface. Just spray the spindle lightly with oil.

5. Insert the spindle from below into the hole, and fix. Mount the bearings and spacer rings on the spindle head in the order shown on the right. Tighten the bearing nut until the large intermediate ring is fully seated.

Note:

Fit the angular contact ball bearings with their labeled sides facing each other.



6. Fit the coupling flange, insert 0.3 mm washers and tighten the screws. Fit the bellows to the Z-guides.

7. Slide the cutting head support plus roller cages into the guides on the cutting carriage. The roller cages must rest against the limit-switch tabs at the upper guide end of the cutting head support during this process. Keep sliding the cutting head support along until the roller cages are fully inserted. Fix the cutting head support in this position.

8. Tighten the side screws on the right-hand cutting-carriage guide to a torque of 20 Ncm to press the guide against the guides on the cutting head support, working along half the height of the guide. Slide the cutting head support upwards and then tighten the remaining side screws to a torque of 20 Ncm. Tighten the screws on the right-hand guide to 110 Ncm.



9. Center the limit-switch tabs at the upper ends of the guides with respect to the guide grooves, and tighten the screws. Fit the limit-switch tabs to the lower ends of the guides.

10.Screw the cutting head support onto the carrier plate of the spindle. Only engage the screws slightly – do not tighten yet. Slide the cutting head support upwards. Tighten the fixing screws on the carrier plate and spindle nut through the holes in the cutting head support. Move the cutting head support up and down and tighten the screws on the carrier plate.

11.Fit the motor including coupling.



12.Connect all cables and lines to the cutting head. Fit all the bellows, flanges and covers.




• Perform servo calibration

• Set Z reference and nozzle cleaning height

• Re-align the cutting head

• Cut test part



Documentation

Written by: Reviewed by: Released by: Release date:

M.Hug

Changes to the documentation

Any changes must also appear in the English document.

File Name: Pages: Change: Date: Signed:

01_06_ByVention_V1_XX.doc every page New document 06.03.06 mhu

01_06_ByVention_V2_XX.doc every page New format template, documents joined

22.01.07 mhu

01_06_ByVention_V3_XX.doc 37, 39-41, 58-59, 66, 82, 130-136, 139-146

Updated 07.06.07 mhu

Please remove this page after printing.



Input / output overview

(as per S2335-0-A) A1ST3

Input Output X3 X4 X5 X6

I01 UNLOADER SAFETY COVER CLOSED

I01LIMIT OF TRAVEL CARRIAGE

O01DRIVE RELEASE CNC

O01 RELEASE SAFETY DOOR

I02 CUTTING TABLE READY / ERROR

I02LIMIT OF TRAVEL BRIDGE

O02DRIVE RELEASE CUTTING TABLE

O02 -

I03 UNLOADING TABLE READY / ERROR

I03LIMIT OF TRAVEL CUTTING TABLE UP

O03DRIVE RELEASE UNLOADING TABLE

O03 -

I04 SURGE VOLTAGE PROTECTOR

I04LIMIT OF TRAVEL CUTTING TABLE DOWN

O04LAMP PUSH SHEET INTO SHEET STOP

O04 -

I05 FUSE LASER MODULE

I05LIMIT OF TRAVEL UNLOADING TABLE RETRACTED

O05OPERATING HOURS COUNTER

O05 -

I06

MOTOR CIRCUIT BREAKER DRIVE CUTTING TABLE

I06LIMIT OF TRAVEL UNLOADING TABLE EXTENDED

O06DUST COLLECTION SYSTEM ON

O06 -

I07 MOTOR CIRCUIT BREAKER DRIVE UNLOADING TABLE

I07COMPRESSED AIR MONITORING

O07 - O07 -

I08 MOTOR CIRCUIT BREAKER CNC DRIVE

I08MONITORING ULTRAPAC

O08 - O08 -

I09

MOTOR CIRCUIT BREAKER AIR CONDITIONING UNIT

I09

COOLING UNIT ANDDUST COLLECTION SYSTEM READY

O09CUTTING TABLE RELEASE RESET

O09 -

I10 MOTOR CIRCUIT BREAKER 24VDC

I10

COOLING UNIT AND DUST COLLECTION UNIT WARNING

O10CUTTING TABLE FAST

O10 -

I11 SAFETY DOOR CLOSED

I11

COOLING UNIT ANDDUST COLLECTION SYSTEM ERROR

O11CUTTING TABLE LIFT

O11 -

I12 CNC DRIVES ON

I12MODE SELECTOR SWITCH

O12CUTTING TABLE LOWER

O12 -

I13 NC READY I13NO APPROVAL

O13UNLOADING TABLE RELEASE RESET

O13 -

I14 SEPARATING CUT MONITORING ERROR

I14TEMPERATURE SENSOR CNC MOTORS

O14UNLOADING TABLE FAST

O14 -

I15 FIRE DETECTION BELLOWS

I15CONTINUE KEY

O15UNLOADING TABLE RETRACT

O15 -

I16 CABINET COOLING FAULT

I16CUTTING CARRIAGEUNCOUPLED 2

O16UNLOADING TABLE EXTEND

O16 -



A1ST5

Input Output X3 X4 X5 X6

I01 SUCTION-CUP FRAME UP

I01SHEET STOP LONG. 1 EXTEND

O01CUTTING GAS 1 (O2)

O01 -

I02 CUTTING CARRIAGE UNCOUPLED 1

I02SEPARATING-CUT MONITORING

O02CUTTING GAS 2 (N2)

O02 -

I03 VACUUM MISSING

I03SEPARATING-CUT MONITORING

O03CUTTING GAS 3 (COMPRESSED AIR)

O03 -

I04 SUCTION UNIT CARRIER START POSITION

I04SHEET IN POSITIONLONG.

O04LOWER SUCTION FRAME

O04 -

I05 SUCTION-CUP FRAME COUPLED

I05CUTTING TABLE UPSLOW

O05SUCTION UNIT FIX

O05 -

I06 BRIDGE REFERENCE

I06CUTTING TABLE UPSTOP

O06SHEET CLAMP TENSION

O06 -

I07 CARRIAGE REFERENCE

I07CUTTING TABLE MIDDLE POSITION SLOW

O07SHEET STOP LONG. 1&2 RETRACT

O07 -

I08 Z AXIS REFERENCE

I08CUTTING TABLE MIDDLE POSITION STOP

O08PROTECTIVE FLAP OPEN

O08 -

I09 SHEET IN POSITION CROSS 1

I09CUTTING TABLE DOWN SLOW

O09 SUCTION FLAP 1 O09 -

I10 SHEET IN POSITION CROSS 2

I10CUTTING TABLE DOWN STOP

O10 SUCTION FLAP 2 O10 -

I11 SUCTION UNIT FIXED

I11UNLOADING TABLERETRACT SLOW

O11CUTTING CARRIAGE COUPLE

O11 -

I12 SUCTION UNIT RELEASED

I12UNLOADING TABLERETRACTED

O12SAFETY COVER UNLOADER CLOSED

O12 -

I13 SHEET CLAMP 1 RELEASED

I13UNLOADING TABLEEXTEND SLOW

O13 JET COOLING O13 -

I14 SHEET CLAMP 2 RELEASED

I14CHECK MATERIAL REMOVED

O14 - O14 -

I15 SHEET CLAMP CLAMP & RELEASE

I15PROTECTIVE FLAP OPEN

O15 BLOW-OFF SHEET O15 -

I16 SHEET STOP LONG. 1 RETRACTED

I16UNLOADING TABLEEXTENDED

O16 SUCK ON SHEET O16 -

Date post:	10-Apr-2015
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