Sauer LASERTECH 40 Operator's manual

LASERTEC 40
Planning documentation LASERTEC 40
Documentation for preparatory measures for installation,
commissioning and operation;
including transport and installation instructions

LASERTEC 40
All rights, also to reprinting, duplication of parts of this manual and to translation are reserved by
the publisher.
It is not allowed to reproduce or copy using electronic data processing systems, any part of this
manual in any form, including for training or educational purposes, without the written approval of
the publisher.
The version in the manufacturer's language (German) is definitive for the technical content.
Issue: 02/10
Ident no.: 2586320*PU*LT40*GB*8124
©2010 SAUER GmbH

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Foreword
Dear customer,
We are pleased you have decided for an Lasertec machine.
Some of the details on your Lasertec machine may vary from the
illustrations in this manual. However, this situation will have no effect
on the operation of the machine.
If you have any questions on this machine manual, or you want to re-
order the booklet, please state the order no.
A few instructions for your safety
It is imperative this machine manual is followed for the safe operation
of the machine. Ensure the manual is available at the machine.
Nobody without the necessary training - whether provided internally, by
a training organisation or directly by SAUER GmbH - is allowed to
operate the machine, even for a short time.
Read the general health and safety regulations published by the
related authorities. If the regulations are not hung on the notice board
in your organisation, ask the responsible safety officer.
Follow the instructions for correct use on the following pages.
A brochure is supplied with every machine manual; this brochure
contains important instructions on health and safety on Lasertec
machines. Read this brochure before you work on an Lasertec
machine for the first time.
Close the splash protection feature before you start machining.
Machines that are used in the automatic mode must always be
equipped with a splash protection feature.
Changes
We reserve the right make changes to the design, features and
accessories in the interest of further development.
It is therefore not possible to derive any claims from the information,
illustrations and descriptions.
Errors excepted.
We wish you every success!
SAUER GmbH

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Planning
What is the purpose of this documentation?
Basics
This documentation is aimed at the people responsible for installing the
machine and their staff. Contained in this documentation is all the
information necessary for the preparation of the machine's installation
location and its surroundings such that the machine can be installed
immediately on delivery. Information on the transport of the machine to the
place it is to be installed is also included.
Please also note the information on the tools and lubricants necessary.
Initial commissioning
The machine is only allowed to be initially commissioned by a person
authorised by the machine manufacturer. Otherwise, SAUER will accept
no liability whatsoever for any damage or malfunctions that may occur.
Effective utilisation of the machine
Training courses
SAUER provides training and further training for specialist personnel as a
service. Whether the machine’s features are actually utilised depends on
the user’s qualifications. For this reason, clarify in good time whether your
staff has the necessary knowledge. Plan your training course dates such
that all training measures are complete before the delivery of the machine.
Notes for your planning
Planning
The floor area mentioned in this documentation applies only to the
machines with the peripheral equipment as shown.
For information on the floor area and space required by the options you
have ordered, please refer to the related installation diagrams.
The machine documentation is applicable independent of the information
in this documentation.

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Symbols used
Note
Specific information on operating sequences, machine reactions and cost-
effective usage of the machine.
•Please pay attention to the related information.
•Also pass on all notes to other operators.
Attention
Specific instructions, requirements and actions that are not allowed to
prevent damage.
•Please pay attention to the related information.
•Also pass on all warnings and safety instructions to other operators.
Danger
Information, actions that must be performed and actions that are not
allowed to prevent injury and extensive damage.
•Please pay attention to the related information.
•Take particular care in these cases to prevent accidents.
•Also pass on all safety instructions to other operators.

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Hazard due electrical power
Warning about hazardous electrical power, mortal danger!
•Please pay attention to the related information.
•Take particular care in these cases to prevent placing people at risk
due to electrical power.
•Also pass on all safety instructions to other operators.
Along with the information in the machine manual, general health and
safety regulations must be taken into account and followed.

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Necessary preparatory measures
Actions to be undertaken by the customer
The customer is responsible for the following preparatory measures:
Installation location
•Preparation of installation location for the machine.
- See “Conditions for installation location”.
•Ensuring the availability of:
- Supply of electricity, light, water, telephone
Transport
•Organise the unloading of the machine.
•Transport within the factory to the installation location and installation
of the machine.
- The machine is to be transported to the installation location.
- The machine is to be placed on levelling elements.
E/P connection
•Connection of machine.
- The machine is to be connected electrically (clockwise rotating
field).
- The machine is not allowed to be connected to mains with a
residual current circuit breaker (fixed connection required).
- On delivery to countries with large voltage fluctuations on the
supply to the machine, a mains stabiliser must be used to protect
the electronic components.
- The machine is to be connected to the compressed air supply.
Placing in operation
•Preparation for commissioning
- Provide the necessary lubricating oils / cooling lubricants.
- Clean machine (de-grease).
- Align machine: ± 0,1 mm/m.
- Provide suitable assistants during commissioning.

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Service / maintenance
"As per and in addition to the general installation conditions, VDW
502 A and LMW 188 A, the operating organisation undertakes the
obligation to provide technical support during installation and repair
work, in particular the provision of suitable ladders, platforms,
scaffolding, heavy tools, lifting gear etc.".
The master switch on the machine is only allowed to be switched on
in the presence of the authorised service engineer!

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Installation location
Customer information
It is imperative this information is checked prior to the delivery of the
machine, safeguarded and implemented.
The responsibility for the correct location of the machine lies with the
customer. The customer is entirely responsible for a suitable installation
location.
If problems should arise later due to failure to follow the information
provided, SAUER cannot be held responsible.
Ambient temperature
The room must be evenly heated and the temperature should fluctuate as
little as possible:
•Adequately shield the machine from direct radiation from radiators,
the sun or neighbouring machines.
Wear reduction
To reduce wear, there must not be any machines in the same room that
may produce dust during machining.
•Also prevent dust from grinding or erosion entering the machine on
workpieces or in the cooling lubricant.

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Corrosion prevention
To prevent corrosion on the workpiece and machine, the installation
location must be dry and free of aggressive vapours:
•No soldering, welding, painting, pickling or electroplating systems in
the same room.
Foundation
A suitable bearing plate approved by a structural engineer is required.
•The bearing plate must not have any expansion joints in the area
covered by the machine.
•Cracks, cable ducts or other interruptions are not allowed in the area
covered by the machine.
•Place the machine on a firm floor that will provide a stable base for
the machine.
•The machine must be level and remain so to ensure the accuracy of
the machine.
•The floor must not give so that the machine remains exactly aligned.

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Load bearing capacity
Ensure the floor has adequate load bearing capacity.
•Have the load bearing capacity checked by a structural engineer.
Have the structural engineer determine in a binding manner
•That the load bearing capacity of the floor, the cellar roof or
intermediate storey, including its substructure, is adequate (also in
older buildings).
•That the building regulations are met.
Note that the centre of gravity moves due to the weight of the workpieces
and travels.
Maximum weight
Take the load bearing capacity of the floor into account
•The maximum installation weight for the machine and also the
maximum weight of tool and accessory cabinets including contents,
- Workpieces and devices,
- People,
- Transport equipment,
- Other features in the immediate vicinity of the machine.

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Cellar roofs, intermediate floors
In case of installation of the machine on cellar roofs, intermediate floors or
other load bearing structures:
Have a structural engineer experienced in structural dynamics determine
in a binding manner, as per DIN 4024 part 1: Flexible structures that
support machines with rotating elements,
•That the load bearing structure is able to absorb the actions of the
machine's inertial forces,
•or, if this validation cannot be provided, that the measures for
vibration damping that are then to be required are adequate.
Floor vibration
Floor vibration or shocks from neighbouring machines or other sources
must not affect the function and accuracy of the machine.

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Access
Adequately large access openings must be available for moving the
machine to its installation location.
Room height
Ensure the room height is adequate so that installation and maintenance
work can be performed unhindered.
Machine area
Ensure there are no pillars or other obstacles in the area of the machine
that could hinder installation and maintenance work.

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Ambient conditions for the machine
•Permissible ambient temperature: +15° to + 35° C
•Maximum installation height: 1000 m above sea level
Max. relative humidity
When the ambient temperature is +15°C, the max. relative humidity must
not exceed 95 %; when the temperature is +35°C, it must not exceed 30
%. Otherwise condensation can form on the end of the laser crystal.
Limit values for the relative humidity referred to the ambient temperature.
If one of these figures is exceeded at the place the machine is installed, or
in case of special operating conditions, e.g.
•action of powerful electric or magnetic fields
•installation in potentially explosive atmospheres or areas containing
potentially explosive substances
consult SAUER GmbH.
Information for machines with series transformer
The cable connection between the overcurrent protection device (main
fuse) and the separate series transformer depends on the operating
voltage at the customer. Appropriate protection against short circuits is to
be provided by the customer.
The cable for the connection between the series transformer and the
machine is not included with the items we supply (to suit the installation
location in the installation diagram).
Empty conduits for external data transfer
If external data transfer is planned, appropriate empty conduits made of
metal must be installed for the data cable.
Data cables must not be laid alongside cables carrying high currents
or cross such cables.

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Installation dimensions
Height
Machine height ……………………………….. mm ………………. 2 370
……………………………….. inch ………………. 93,30
Transport height ……………………………… mm ………………. 2 300
……………………………… inch ………………. 90,55
Width
Machine width …………………………………. mm ………………. 2 476
…………………………………. inch ………………. 97,50
Length
Machine length ………………………………... mm ………………. 2 850
………………………………... inch ……………... 112,20
H
B
L

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Installation area L x W ……………………….. mm …….. 4 250 x 3 876
……………………….. inch …. 167,32 x 152,60
E Mains connection
In addition, escape routes and safety areas are to be maintained in
accordance with local laws, regulations and stipulations.

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Machine Standard

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Weight
Machine weight
Machine ………………………………… Approx. kg …………….. 2 200
Installation weight
Machine with max. weight for workpiece,
oils and liquids ………………………… Max. kg ………………… 2 250
Load of foundation plates …………….. KN ……………………… 2 250
Machine supports
Quantity + type ………………………………. 3 x 20 AV 370, H=26, 20 KN
Arrangement of machine supports:

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Installation data
Electrical supply
During the electrical installation attention is to be paid to ensuring EN 60
204, part 1, point 6.3.3 "Protection by automatic interruption of the power
supply" is met.
On this topic also see IEC 364-4-41 (DIN 57 100, VDE 0100, part 410).
The machine is not allowed to be connected to mains with a residual
current circuit breaker, see EN 50178, point 5.3.2.3 (old VDE 0160, point
5.5.3.4.2).
As our machine has a leakage current higher than 3.5 mA AC due to EMC
measures, it must have a fixed connection.
In addition, one of the measures stated below must be taken, according to
EN 50178, point 5.3.2.1 (old VDE 0160, point 5.5.3.4.1 and 5.5.3.4.2).
•Earth conductor cross section at least 25 mm² Cu.
•Monitoring of the earth conductor by a device that will automatically
shut down the electronic equipment in the event of a fault.
•Laying of a second conductor, electrically in parallel with the earth
conductor, using separate terminals. This conductor alone must comply
with the requirements of section 543 of the harmonisation document
(HD) 384.5.54 S1 (old DIN VDE 0100 part 540) for earth conductors.
The machine can be operated on a 400 V TN supply without a series
isolating transformer.

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Connection ratings
Machine connection:
TN-S supply with 3 conductors (L1, L2, L3) as well as neutral conductor (N)
and earth conductor (PE).
Mains connection ………………… 3N/PE~50/60 Hz …….. 400/230 V
Open cable length above floor …... m ……………………………… 0,8
Connecting cable cross-section …………… accd. to DIN 5710/VDE 0100
* Due to energy return and possible operation for short periods, currents
may occur that make the recommended mains fuse protection necessary.
In max. at
100% ED
A
Power consumption at
100% ED,
KVA
Max. fusing
A
Basic version 40 27 50