Entretien de la machine Lasec 1807

MECAPRO / MECASIGN installation and maintenance instructions

REVISION A dated 25/01/2006

Table of Contents:

21.Introduction

22.Description of the machines

23.Unloading and installation

23.1.Safety instructions

33.2.Installation site

33.3.Unloading

33.4.Unpacking

43.5.Connections

43.5.1. Electrical connection

43.5.2. Pneumatic connection

53.5.3. Drainage connections

53.6.Levelling

63.7.Startup

64.Equipment maintenance

64.1.Safety instructions

74.2.Daily maintenance

74.2.1.Cleaning the machine

74.2.2.Cleaning the filters and maintaining the vacuum table pumps

84.3.Pneumatic component maintenance

84.4.Electrical cabinet maintenance

84.5.Guide and drive system maintenance

94.5.1.Greasing

104.6.Spindle maintenance

104.6.1.General

114.6.2.Spindle cooling systems

114.7.Lubrication system maintenance

114.8.Summary of maintenance operations

125.Control panel screen

136.Appendix 1

167.Appendix 2

1. IntroductionThis manual is intended for owners of machines from the MECAPRO or MECASIGN ranges, 1015, 3015, 3020 or 4020 series.

It provides all the information required for unpacking and setting up the machine's main systems as well as for their maintenance.2. Description of the machinesThe machines from the MECAPRO or MECASIGN ranges consist of a mechanically welded, large cross-section chassis and gantry and of a cast iron carriage supporting the Z-axis vertical sliding part.The translation guidance of the moving parts is ensured by pre-stressed ball pads and the parts are driven by Brushless type motors via ballscrew or rack-and-pinion systems.

The machines can optionally be fitted with an automatic tool changer, suction pumps for holding the parts in place, and with other cutting or viewing systems (roller box tool, positioning camera, etc.).

The assembly drawings in appendix 1 give, for each series of machine, the overall dimensions, the position of the hoisting rings and the slots for the forklift truck's forks.

Fig. 13. Unloading and installation

3.1. Safety instructionsThe unloading, handling and installation operations must be carried out by qualified personnel.

Make sure that the personnel carrying out these operations are all wearing the necessary individual safety equipment (helmet, gloves, safety shoes, etc.).

Make sure that all the handling equipment (slings, forklift trucks, straps, etc.) are in good condition and are capable of supporting the load.

Clear and protect the route the machine will take from its delivery point to the installation site.Electrical connection to the mains shall be carried out by a qualified electrician who must take every precaution relative to live working.

3.2. Installation siteInstall the machine:

on a site that is sufficiently large and clear of obstacles to allow easy loading and unloading of the materials to be cut, on a site where the operator can work in complete safety (move away any objects that could cause a fall or a false manoeuvre), on a floor that is stable and sufficiently strong to withstand the weight of the machine, on a site with sufficient lighting, approximately 300 lux one metre from the floor.Do not install the machine:

in a place directly exposed to sunlight, close to a strong heat source, close to equipment that generates vibrations, in a dusty place, in an excessively damp place, in a place with a high concentration of organic or corrosive gas.Machine environment:

Permissible temperature range in use: +5 to +40C

Temperature variation lower than 1C every 30 minutes

Permissible relative humidity: lower than 90% for an ambient temperature of 20C and lower than 50% for an ambient temperature of 40C

Dust and other foreign matter: less than 0.3 mg/m33.3. UnloadingThe machine can be unloaded either using a crane or an overhead crane using slings, or using a forklift truck with its forks passing on the side or to the rear of the machine.

There is a diagram on the machine's packaging indicating the position of the hoisting rings, the slots for the forklift truck's forks, the required capacities of the handling equipment and the machine's weight.

3.4. UnpackingIf you use cutting tools to unpack the machine, take care not to damage the power supply cable and pipes or any other part of the machine.

Once the machine has been unpacked, check its general condition and in particular: power supply cables and pipes protection bellows cable runs safety pads chip suction pipe (depending on option)

presence and condition of all of the machine's support legsWhen the machine has been placed on its installation site and unpacked, remove the 4 hoisting rings and remove all the wedges used to immobilise the axes during transport (depending on the type of transport and options).

3.5. Connections3.5.1. Electrical connection Power supply requirements:A class D (formerly class 3*) ground connection or better is required to connect the power supply cable to the machine.

Class D ground:

The grounding resistance is lower than or equal to 3.

A 15-meter cable suited to the machine is supplied. If this cable is too short, use a cable whose conductors have a cross-section at least equal to those supplied.Cable supplied: three-phase + ground, reference HO7 RN-F, 4 G 2.5 to 4 G xx (xx depending on the machine's power consumption)Install a circuit-breaker with current leak to ground (differential circuit-breaker) defined for the machine as far upstream as possible in the workshop's electrical cabinet.

Differential circuit-breaker characteristics: nominal opening current: 300 mA

calibre greater than the maximum current consumed by the machine.

The machine includes equipment commanded by voltage and frequency converters. These devices have filters with a high current leakage to ground, which is why you are strongly recommended not to use a differential circuit-breaker with a nominal opening current of 30 mA because that could result in faulty operation.Power supply voltage:Three-phase 400 VAC + ground

Permissible fluctuation: 10 %

Mains frequency:50 Hz

Permissible fluctuation: 1 %

Maximum current absorbed:xx A per phase

Maximum power consumption:xxxx W

Important: these values are also indicated on the identification plate. If there is a difference between the values given in this manual and those on the plate, it is always the values given on the identification plate that apply. Verifications:

Check the presence of the correct voltage, the ground connection and of the neutral if applicable.

Check the presence and calibre of the differential protection.Check that the cross-section of the machine's power supply cable is sufficient.

Connection operations:

Make sure that the circuit-breaker associated with the machine's line is open.

Make sure that the machine's general cutout switch is in the OFF position.Connect the machine's power supply cable to the circuit-breaker.Connect the chip suction connector to the connector located at the rear of the machine (depending on the option)

3.5.2. Pneumatic connection Power supply requirements:The compressed air supply must conform to the pressure and flow rate recommended by Mcanumric.

The air must be dry and de-oiled so as not to damage the control systems and the actuators.Pneumatic power supply:Dry, de-oiled air

Pressure at machine input:7 bar

Maximum flow rate:xx m3/hour

Important: these values are also indicated on the identification plate. If there is a difference between the values given in this manual and those on the plate, it is always the values given on the identification plate that apply.

In any event the pressure at machine input must never exceed 12 bars.

The 5-metre hose delivered with the machine is fitted with a union designed for connection to a quick-disconnect union. If this union is not suitable, it may be replaced with a different type of union provided it is suited to the pressure, flow rate and internal diameter of the hose. The clamping system used to fasten the new union must not damage the hose. Verifications:

For machines fitted with a shutoff valve (fig. 2), check that it is closed.

Check the condition of the connection hose.

Connection operations:

Connect the power supply hose to the compressed air network.Open the valve.

Check the pressure indicated on the pressure gauge (fig. 2), adjust it if necessary by means of the adjustment knob. fig.23.5.3. Drainage connectionsThe machines have troughs at the front and rear of the table designed to recover the lubrication liquid.A metal pipe on each of the troughs allows a pipe, with an internal diameter if 21mm, to be connected. Place a recipient at the end of the pipes to recover the liquid.3.6. LevellingYou must level the equipment before putting into service to ensure optimum cutting quality.

Procedure:

Use a mechanic's spirit level and make sure that it has been calibrated recently (precision at least equal to 0.5 mm/m), Loosen the locknut on each leg and check that each leg is effectively in contact with the floor, Slide the spirit level over the whole length of the chassis' two rails and over the whole length of the gantry's lower rail to check that the machine is horizontal, If the machine is not level, turn the nut on the leg to correct the defect, Once the machine is level, tighten the locknut on each of its legs.

fig.3Position of the spirit level on the chassis' left-hand railPosition of the spirit level on the gantry's lower rail

Fig. 4It is essential to repeat this procedure whenever the machine is moved.

3.7. StartupRefer to the utilisation manual.4. Equipment maintenance4.1. Safety instructionsThe maintenance operations must be carried out by qualified personnel equipped with the necessary individual protection equipment (gloves, goggles, helmet, etc.).The person in charge of the maintenance operations must make sure that every measure has been taken to guarantee the safety of people, in particular isolate the machine from the electrical network by switching the cutout switch OFF, and from the pneumatic network by closing the main pneumatic valve. Furthermore these two devices must be padlocked to prevent any untimely starting up of the machine.

Fig. 54.2. Daily maintenanceThe machine and the vacuum table's pump filters (for machines equipped with the VAC option) must be cleaned daily.4.2.1. Cleaning the machine

In order to avoid any accumulation of dust or chips on the cutting table or in the bellows the machine must be cleaned every day (or at each change of shift for machines operating 2 x 8 or 3 x 8) using a vacuum cleaner.For machines equipped with a chip suction system you must make sure that no cutting residue accumulates inside the suction nozzle, the bellows around the electric spindle or in the suction pipe. Regularly check and empty the suction container.

Fig. 6Clean the suction nozzle:

remove the tool from the clamp holder taper to avoid any injuries, lower the suction nozzle to the down position, use a vacuum cleaner to remove any chips that may have accumulated inside.It is prohibited to use a compressed air blower to perform this operation because that could seriously damage the electric spindle.

It is recommended to move each axis over its complete travel distance once a day in order to clean the guides.

4.2.2. Cleaning the filters and maintaining the vacuum table pumpsDepending on the option chosen, the machine is equipped with one or more pumps:

turbine pumps for the VAC xx - x option (xx - x: number of zones number of pumps) vane pump for the VAC GR xx option (xx depending on the type and number of pumps)

Fig. 7Before using the machine, consult the pump manual provided with the machine to familiarise yourself with its operation and all the maintenance operations to be performed.

Clean with a vacuum cleaner and check the filter located upstream of each pump every day.These cleaning operations can be carried out less frequently if the filters do not have any excessive accumulation of cutting residues.If the operator notes any deterioration of a filter (tearing, etc.) it must imperatively be replaced.

4.3. Pneumatic component maintenanceThe machine is equipped with a filter installed on the main air treatment system situated on the rear of the chassis on the right-hand side as well as other filters installed on the pneumatic circuit according to the electric spindles and the machine's options.All of the filter cartridges must be replaced at least once a year or every 2,000 hours.The table below gives the reference of the filter cartridges for most of the filters.SITUATIONFILTERCARTRIDGECODE

Main air treatmentLFR-1/4-D-7-MINI-ALFP-D-MINI-40M100755670

Main air treatmentLFR-3/8-D-MIDI-ALFP-D-MIDI-40M100752760

SpindleLF-1/8-D-MINI-5MLFP-D-MINI-5M

SpindleLFM-1/8-SLFMP-1/8-S-C100752640

The references of the filters are given on the machine's pneumatic diagram and on the components themselves.

4.4. Electrical cabinet maintenanceThere are ventilation louvres on the right- and left-hand sides of the electrical cabinet allowing the circulation of air to cool the components.

At least once a month check the condition of the filters placed on the ventilation louvres, and clean them if necessary.

It is recommended that you should replace these filters once a year.

Check the condition of the door's seals.4.5. Guide and drive system maintenanceThe machine's moving parts (gantry, Y carriage and Z carriage) are guided in translation by ball pads which slide on hardened and ground steel rails.

The gantry is driven, depending on the type of machine or option, by:

one or two fixed ballscrews situated to the right and left of the chassis. The screw's nut is integral with the gantry and is driven in rotation by a pulley-belt system, two rack-and-pinion assemblies.

The gantry is driven by a rotating ballscrew driven in rotation by a pulley-belt system. The screw's nut is fixed to the Y carriage.

The Z carriage is driven by a rotating ballscrew driven directly by the motor via a coupling.

The location of some of the components whose maintenance is described in the following paragraphs is shown in the diagram in appendix 2. This diagram will also facilitate the dialogue with our technicians if you call our customer support service.4.5.1. Greasing Greases to be usedThe machine is factory greased with ORAPI CT4-608 grease (lithium-based molybdenum disulphide grease)

In accordance with the recommendations of our guidance system suppliers, we recommend the use of a grease of consistency NLGI2 and classified K2K or KP2K per standard DIN 51825 or DIN 51502. This designation means: K: grease for smooth bearing blocks with ball bearings P: lubricant with active agents (EP additives) for friction and wear reduction

2: class NLGI2 consistency index K: utilisation temperature higher than 120C

Greasing frequencyWe recommend regreasing every 3 months or 500 hours in the case of one 8-hour shift being worked each day.

This interval should be reduced to 2 months if the machine is used for 2 shifts a day. Components to be greasedFor the X axis, regrease the 4 pads situated to the right and left of the gantry and the nut on both of the ballscrews (according to the option).The pads can be accessed from the front and from the rear of the gantry.You can remove the right- and left-hand side covers from the gantry to make it easier to access the ballscrew nut's lubricator.

The ballscrew nut's ball bearings are greased for life and do not require any maintenance.

fig. 8For the Y axis, regrease the 4 pads situated to the rear of the Y carriage and the Y ballscrew's nut.

You must unclip the protection bellows to the right and left of the carriage to access these components.

Fig. 9For the Z axis, regrease the 4 pads situated to the rear of the Z carriage and the nut of the Z ballscrew.

You must unclip the protection bellows above and below the carriage to access these components.

You can also remove the 2 upright bellow guides to facilitate access to the lubricator of the 2 lower pads.

fig. 104.6. Spindle maintenance4.6.1. General

Before using the machine consult the spindle manual to familiarise yourself with the way it functions and with the maintenance operations to be performed.

For the automatic tool changer spindles you are advised to clean the clamp holder tapers with an oiled soft cloth to prevent oxidation and reduce the risk of seizing in the spindle nose.

For spindles with an air overpressure system make sure that the pneumatic circuit's filter is in good condition and maintain it per the recommendations of the Pneumatic component maintenance paragraph.

Never use a compressed air blower to clean the spindle or spindle nose.

4.6.2. Spindle cooling systems Air coolingSome spindles are cooled:

either by forced air circulation by means of a fan located above the spindle. In this case no particular maintenance is required. or by compressed air circulation in the body of the spindle. In this case apply the recommendations given in the Pneumatic component maintenance paragraph.

In all cases you must take care not to block or modify the ventilation louvers situated around the spindle. Liquid coolingIn this case the spindles are cooled by water circulating through the body of the spindle.

The water is cooled in a 100-litre tank or refrigerated by a cooling unit.

In both cases you must:

Check and, if necessary, top up the water level once a week Every 500 hours, empty the tank or cooling unit and circulate clean water through the circuit for 24 hours. Then fill the tank with water with an anti-algae additive.

For machines with a cooling unit, refer to that unit's manual. If the operating and maintenance conditions given by the manufacturer are more restrictive than this, apply the manufacturer's instructions.4.7. Lubrication system maintenanceDrain the lubrication tank once a week and operate the lubrication system with clean water for at least 5 minutes to flush out all compounds and prevent deposits from forming.

Never re-use the lubrication liquid.

Consult the recommendations of the lubricant manufacturer to determine what special steps must be taken to eliminate the product.4.8. Summary of maintenance operations

FREQUENCY

DailyClean the machine:

table bellows suction nozzle filters and vacuum systems tool holder tapers and spindle nose

Once / weekCheck the water level in the spindle cooling tank

Once / monthCheck the seals on the electrical cabinet's doorsClean the filters on the electrical cabinet's ventilation louvres

Once / 3 monthsor 500 hoursGrease the guide and drive systems

Once / yearReplace the electrical cabinet filter

Once / year or 2000 hoursReplace the pneumatic circuit's filter cartridges

Once / yearCheck the belts and replace them if necessary

5. Control panel screenSwitch off the screen before cleaning itClean the screen with a dry, soft, lint-free cloth.Do not use ammoniac, alcohol or solvent based products.Do not touch the screen with a hard or abrasive object.

6. Appendix 1Mecapro / Mecasign 1015..

Mecapro / Mecasign 3015

Mecapro / Mecasign 3020

Mecapro / Mecasign 4020

7. Appendix 2General view of the machine's main mechanical systems. These views are shown with part of the protection covers and bellows hidden or drawn with fine lines.

DETAIL B

SCALE 0.140

SEE DETAIL A

LH X motor

SEE DETAIL B

Z axis motor

X axis LH PON sensor

LH X ballswcrew

Y axis motor

LEG NUT

LOCKNUT

Lower pad

Upper pad

Y axis pad

Z axis pad

Bellows guide

Y axis ballscrew

Ballscrew nut lubricator

Pad lubricator

Upper bellows

Pressure adjustment knob

Pressure gauge

Shutoff valve in open position

Turn through 1/4 turn to close

Pad lubricator

Z axis PON sensor

Pad lubricator

Ballscrew nut lubricator

Y axis lower rail

LH X ballscrew nut

Ballscrew nut lubricator

Pad lubricator

Pad lubricator

Y ballscrew nut

Y carriagehorizontal shift(right/left)

Y axis PON sensor

LH side cover

Z axis rail

Emergency shutdown pushbutton

Suction nozzle

Y axis bellows

Chip suction tube

Safety pad

Safety pad

Gantry

Y axis cable run

Z axis cable run

X axis cable run

Electrical cabinet

Chassis

Padlockable electrical cutout switch

Padlockable pneumatic valve

Upstream filter

Upstream filter

Vane pump

Turbinepump

Y axis upper rail

Z carriage

Vertical shift

DETAIL ASCALE 0.140

slot for forklift truck forks

2. hoisting ring

1.slot for forklift truck forks

2. hoisting ring

16