Serial No.

311487

MAINTENANCE MANUAL

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OPTIPLEX CHAMPION 3015 FIBER

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(2.0 kW/3.0 kW Laser Specification)

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Manual No.: H699MA0014E

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NC: MAZATROL PREVIEW 3

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Serial No.:
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Before using this machine and equipment, fully understand the contents of this
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manual to ensure proper operation. Should any questions arise, please ask the
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nearest Technical Center or Technology Center.

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IMPORTANT NOTICE
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1. Be sure to observe the safety precautions described in this manual and the contents of the
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safety plates on the machine and equipment. Failure may cause serious personal injury or
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material damage. Please replace any missing safety plates as soon as possible.
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2. No modifications are to be performed that will affect operation safety.

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3. For the purpose of explaining the operation of the machine and equipment, some illustrations
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may not include safety features such as covers, doors, etc. Before operation, make sure all
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such items are in place.

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4. This manual was considered complete and accurate at the time of publication, however, due to
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our desire to constantly improve the quality and specification of all our products, it is subject
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to change or modification. If you have any questions, please contact the nearest Technical
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Center or Technology Center.

5. Always keep this manual near the machinery for immediate use.
6. If a new manual is required, please order from the nearest Technical Center or Technology
Center with the manual No. or the machine name, serial No. and manual name.
7. The export of machining programs may be restricted to prevent them from being used for
military purposes. The machining programs you prepared are your property, so you should
manage them yourself in accordance with the law.
Issued by Manual Publication Section, YAMAZAKI MAZAK CORPORATION, Japan

04.2020

Copyright (C) 2017 YAMAZAKI MAZAK CORPORATION. All Rights Reserved.

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Serial No. 311487

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 Serial No. 311487

CAUTION
 To maintain the high performance (in processing speed) of the laser machine, level the
machine properly.
Accordingly, a foundation must be built to the foundation plan supplied by Mazak, or the
machine must be installed on a floor which is approved as meeting our design requirements.
If the machine is installed on a floor or foundation which does not meet our design
requirements and a problem arises due to improper installation, free services may be denied
even within the guaranteed period.
 The laser processing performance values specified in the catalogs and manuals (operating
manual and maintenance manual) are for reference purposes only and they are not the

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values which Mazak guarantees. These values are obtained only under the conditions

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(material, gas, processing conditions, etc.) in which the machine is installed in a Mazak plant

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and when the machine is properly maintained according to the instructions specified in the

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maintenance manual.

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Serial No. 311487

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 Serial No. 311487

CONTENTS

1 INTRODUCTION ................................................................................. 1-1

1-1 Machine Outline ................................................................................................. 1-1

1-1-1 Characteristic and intended use of the machine .................................................... 1-1

1-1-2 Operating positions ............................................................................................... 1-1

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1-2 List of Manuals to Be Used ................................................................................. 1-2

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1-3 Numbering System for Pages ............................................................................. 1-2

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1-4 Numbering System for Figures and Tables ........................................................ 1-2

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2 SAFETY PRECAUTIONS .................................................................... 2-1

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2-1 Rules .................................................................................................................. 2-1
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2-2 Residual Risks .................................................................................................... 2-2

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2-3 Laser Safety Precautions ................................................................................... 2-5

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2-3-1 Safety of the laser machine ................................................................................... 2-5

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2-3-2 Contact of the laser beam ..................................................................................... 2-5

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2-3-3 Danger of fire from spatter or laser beam .............................................................. 2-6

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2-3-4 Danger of a fire from assist gas ............................................................................. 2-6

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2-3-5 Potential fire and explosion hazards of the dust collector ...................................... 2-7
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2-3-6 Cleaning the head and periphery .......................................................................... 2-7

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2-3-7 Oxygen leakage check .......................................................................................... 2-7

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2-3-8 Danger of fire due to fast piercing ......................................................................... 2-7

2-3-9 Toxic fumes........................................................................................................... 2-8

2-3-10 Lethal high voltage shock ...................................................................................... 2-8

2-3-11 Laser and laser irradiation ON keys ...................................................................... 2-8

2-3-12 Machining a material covered with a protect sheet ................................................ 2-9

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2-3-13 Handling precautions on optical parts .................................................................... 2-9

2-3-14 Safety devices (Laser beam) ................................................................................. 2-9

2-3-15 Safety plates (Laser) ........................................................................................... 2-10

2-3-16 Other gravities ..................................................................................................... 2-15

2-3-17 Service ................................................................................................................ 2-15

2-3-18 Compliance ......................................................................................................... 2-15

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2-4 Machine Safety Precautions ............................................................................. 2-16

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2-4-1 Basic safety precautions ..................................................................................... 2-16

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2-4-2 Clothing and personal safety ............................................................................... 2-16

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2-4-3 Precautions related to operation .......................................................................... 2-16

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2-4-4 Precautions on continuous operation .................................................................. 2-17
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2-4-5 Precautions related to maintenance .................................................................... 2-18

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2-4-6 Precautions related to workplace ........................................................................ 2-18

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2-4-7 Safety devices ..................................................................................................... 2-19

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2-4-8 Safety plates on the machine .............................................................................. 2-20

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2-4-9 Work and working area that cause laser radiation exposure ............................... 2-28
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2-4-10 Others ................................................................................................................. 2-28

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2-5 Installation Precautions .................................................................................... 2-29

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2-5-1 Wiring .................................................................................................................. 2-29

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2-5-2 Grounding ........................................................................................................... 2-29

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2-5-3 Gas and air pipings ............................................................................................. 2-30

2-5-4 Environmental conditions .................................................................................... 2-32

3 SAFETY IN MAINTENANCE ............................................................... 3-1

3-1 Safety Equipment Inspection .............................................................................. 3-1

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4 DAILY INSPECTION OF LASER MACHINE........................................ 4-1

4-1 Maintenance and Inspection ............................................................................... 4-1

4-2 Pallet Assembly Drawing and Component Parts ................................................ 4-2

4-3 Heat-Resistant Plate Assembly Drawing and Component Parts ...................... 4-20

5 PERIODIC MAINTENANCE AND INSPECTION ................................. 5-1

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5-1 Daily Maintenance and Inspection ...................................................................... 5-1

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5-2 Periodic Maintenance and Inspection of the Oscillator ....................................... 5-1

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5-3 Maintenance and Inspection of the Chiller Unit .................................................. 5-2

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5-4 Periodic Maintenance and Inspection of the Dust Collector ............................... 5-2

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Periodic Maintenance and Inspection of the Laser Machine .............................. 5-3
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5-6 Inspection of Devices using Freon...................................................................... 5-4

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5-7 Removing Chips ................................................................................................. 5-5

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5-7-1 Scrap bucket ......................................................................................................... 5-5

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5-8 Inspection of Bellows .......................................................................................... 5-6

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6 LUBRICATION .................................................................................... 6-1

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6-1 Replenishing Grease for Slideway Lubrication (as Needed) .............................. 6-2
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6-2 Removing Grease from the Lower Surface of the Z-Axis ................................... 6-8
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7 CHANGE AND MAINTENANCE OF THE AIR FILTERS ..................... 7-1

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7-1 Maintenance of the Air Circuit Filters .................................................................. 7-1

7-1-1 Daily inspection ..................................................................................................... 7-1

7-1-2 Periodic inspection ................................................................................................ 7-5

7-2 Replacing the Batteries in the Battery Box ......................................................... 7-8

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7-2-1 Battery box for the absolute position detection system .......................................... 7-8

7-2-2 Battery box for the machine relocation detector (RD) (Only for machines
with a machine relocation detector) ..................................................................... 7-12

8 CHILLER UNIT .................................................................................... 8-1

8-1 Freezing Prevention ........................................................................................... 8-1

8-2 Quality of Cooling Water..................................................................................... 8-1

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8-3 Disposal of Refrigerant ....................................................................................... 8-1

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8-4 3.0 kW Laser Machine ........................................................................................ 8-2

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8-4-1 Preparation for operation (how to feed water) ....................................................... 8-2

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8-4-2 Operation procedure of the chiller unit ................................................................... 8-3

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8-4-3 External view of chiller unit and location of water feed and drain ports .................. 8-4
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8-4-4 Maintenance ......................................................................................................... 8-5

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9 MACHINING TORCH .......................................................................... 9-1

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9-1 Manual Torch 2 .................................................................................................. 9-1

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9-1-1 Outline .................................................................................................................. 9-1

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9-1-2 Specifications ........................................................................................................ 9-1

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9-1-3 Construction .......................................................................................................... 9-3

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9-1-4 Functions .............................................................................................................. 9-5

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9-1-5 Preparation before machining ............................................................................... 9-5

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9-2 Torch Made by Laser Mech (Optional for Use in USA Only) ............................ 9-26
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9-2-1 Outline ................................................................................................................ 9-26

9-2-2 Specifications ...................................................................................................... 9-26

9-2-3 Construction ........................................................................................................ 9-27

9-2-4 Functions ............................................................................................................ 9-27

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9-2-5 Preparation before Machining ............................................................................. 9-27

10 MAINTENANCE OF MACHINING TORCH ........................................ 10-1

10-1 Maintenance of Machining Torch...................................................................... 10-1

10-2 Maintenance of the Manual Torch 2 ................................................................. 10-2

10-2-1 Clothing and cautions on handling the optical parts ............................................. 10-3

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10-2-2 Handling new optical parts .................................................................................. 10-4

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10-2-3 Storing the optical parts....................................................................................... 10-5

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10-2-4 Construction of the manual torch 2 ...................................................................... 10-6

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10-2-5 Maintenance of the protective window cartridge .................................................. 10-8

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10-2-6 Replacement of the condensing lens................................................................. 10-27

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10-2-7 Cleaning of the nozzle adapter and the coupler................................................. 10-27
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10-2-8 Replacing the non-contact profiling cable and the non-contact profiling
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preamplifier ....................................................................................................... 10-28

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11 MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION........... 11-1

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11-1 Focus Detection (Option).................................................................................. 11-2

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11-1-1 Replacing the plate ............................................................................................. 11-2

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11-2 Automatic Nozzle Change Function (Option) ................................................... 11-4

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11-2-1 Cleaning the nozzle holder .................................................................................. 11-4

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11-3 Nozzle Cleaning Brush ..................................................................................... 11-6

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11-3-1 Replacing the nozzle cleaning brush ................................................................... 11-6

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12 REMOTE CONTROL CONNECTOR (CLASS IV SYSTEM) .............. 12-1

12-1 Description ....................................................................................................... 12-1

12-2 Function............................................................................................................ 12-1

12-3 How to Reset Interlock ..................................................................................... 12-1

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12-4 Connection ....................................................................................................... 12-2

13 CHART OF CONDITIONS WHEN TURNING ON THE POWER

AND RESETTING ............................................................................. 13-1

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 Serial No. 311487

INTRODUCTION 1
1 INTRODUCTION
This manual describes the machine(s) specified in the title of this manual.

1-1 Machine Outline

1-1-1 Characteristic and intended use of the machine

The present machine is a 2D laser cutting machine designed in pursuit of operability and high
productivity. With high mechanical rigidity, high cutting performance, high accuracy and high
accuracy retaining ability, the machine is a highly reliable machine.
The machine can take corrective and preventive measures, reduce the setup time, and so on,

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using intelligent functions, so it can be used for various types of machining. In addition, this

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machine with an ergonomic and beautiful design has also automatic functions to improve the

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operability and reduce the setup time.

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In addition, this machine has features such as the use of a fiber laser oscillator requiring no laser

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gas, low power consumption, ease of maintenance, etc., so that it can be expected to contribute

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to a significant reduction in running and maintenance costs while performing machining with a

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high degree of efficiency.

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1-1-2 Operating positions

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The machine is designed to be operated in the diagonally shaded areas in the figure (top view)
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Operating area
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NC operating panel
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Fig. 1-1 Operating area

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1-1
 Serial No. 311487

1 INTRODUCTION

1-2 List of Manuals to Be Used

For this machine, the following manuals are provided.

Manual name Coverage

Operating manual General information on operation and handling
Maintenance manual General maintenance information including inspection and
adjustment procedures
Laser Machining Description General information on laser machining and machining conditions
Alarm List Information on NC alarms
Programming manual Information on CNC programming
Parts list Details of the parts
Electrical wiring diagrams Electrical connections

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1-3 Numbering System for Pages

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1. Normal case

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Page number in chapter

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Chapter number

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2. For addtional pages to be inserted R

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3 - 16 - 1
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Additional page
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1-4 Numbering System for Figures and Tables

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1. Figure number
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Fig. 3-1 Main machine components(1/2)

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Number of figures with this title, as indicated by

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the denominator, and the serial number of the

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figure within the figures with this title, as indicated

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by the numerator.
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Title
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Number of figure in chapter

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Chapter number
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2. Table number
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Table 2-1 Safety nameplate details

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Title
Number of table in chapter
Chapter number

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 Serial No. 311487

SAFETY PRECAUTIONS 2
2 SAFETY PRECAUTIONS
The precautions to be observed to ensure safe operation of the machine are described here.
The machine must not be operated until these precautions have been thoroughly understood.
For safe operation of the machine, also read carefully the safety precautions given in the
Programming Manual and always keep safety in mind when operating the machine.

2-1 Rules
1. This chapter contains the precautions to be observed as to the working methods and states
usually expected. Of course, however, unexpected operations and/or unexpected working
states may take place at the user site.

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During daily operation of the machine, therefore, the user must pay extra careful attention to

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its own working safety as well as to observe the precautions described below.

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2. The meanings of our safety precautions to DANGER, WARNING, and CAUTION are as

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follows:

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: Failure to observe these instructions could result in loss of life.

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DANGER

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: Failure to observe these instructions could result in serious harm to a human
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life or body
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WARNING
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: Failure to observe these instructions could result in minor injuries or serious

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machine damages.
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CAUTION
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 Serial No. 311487

2 SAFETY PRECAUTIONS

2-2 Residual Risks

1. Residual risk map

Residual Risk Map Showing the Residual Risks

Requiring Customer’s Protective Measures
Products: OPTIPLEX CHAMPION 3015 FIBER
Prepared at: April 12, 2018
Yamazaki Mazak Corporation

* Operate the machine only after reading the instruction manual carefully and understanding the contents thoroughly.
This material is a reference for the instruction manual and do not operate the machine after understanding the contents only in this
material.
“Seriousness of harm” is classified and described according to the definition indicated below.

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 DANGER: Failure to follow these instructions could result in loss of life.

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 WARNING: Failure to observe these instructions could result in serious harm to a human life or body.

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 CAUTION: Failure to observe these instructions could result in minor injuries or serious machine damage.

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The numbers shown in the figure below correspond to the Nos. in the “Residual risk table” of the machine. Refer to the “Residual

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risk table” for details of residual risks.

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DANGER No.2 DANGER
Location Location
WARNING No.1, No.3 WARNING No.18
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CAUTION CAUTION

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DANGER
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Location No.1, No.5,

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WARNING
No.13, No.18 A DANGER
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CAUTION No.6 Location

WARNING No.11, No.12
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CAUTION
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DANGER
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Location
WARNING No.7, No.8, No.10, No.14, No.17, No.18
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CAUTION
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DANGER No.2
DANGER Location
Location WARNING No.1, No.3
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WARNING No.4
G CAUTION
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CAUTION
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Location
WARNING No.16
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Location
WARNING
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DANGER CAUTION No.4

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Location
WARNING No.15
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CAUTION
DANGER DANGER
Location Location
WARNING No.18 WARNING No.9, No.17
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CAUTION CAUTION No.6

DANGER No.2
Location P
No.1, No.3, No.7, No.9, No.10, No.13,
(inside the WARNING Received on Year/Month/Day:
No.14, No.17, No.18
machine)
CAUTION No.6
Customer name
Residual risks for which DANGER No.2 Department/Section
corresponding machine WARNING No.1
location cannot be specified CAUTION Person in charge Signature

2-2
 Serial No. 311487

SAFETY PRECAUTIONS 2
2. Residual risk table
Reference in
Location in
operating
Qualifications machine manual
Operation Protective measures to be taken
No. Work or training Details of harm
step by the customer Reference in
needed Seriousness
maintenance
of harm
manual
Serious personal injury by getting Do not turn on the power with the 2-4-1, 2-4-7
BELP
caught in moving machine parts protective cover removed.
1 Use Power ON
2-4-1, 2-4-7
WARNING

Serious personal injury due to Do not remove the protective cover 2-3-1, 2-4-1,
BEP
Machine exposure to diffused light and the light shielding window. 2-4-7
2 Use
operation 2-3-1, 2-4-1,
DANGER
2-4-7
Serious personal injury by getting  Do not perform operation with the 2-4-1
BEP caught in moving machine parts protective cover or the door

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Machine

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operation 2-4-1
WARNING  Do not get in any moving machine

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part.
 Do not operate any switch with

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Serious machine damage due to 2-3-1, 2-4-2,
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Machine erroneous operation of the gloves on. 2-4-3
4 Use
operation machine  Do not operate the machine unless 2-3-1, 2-4-2,

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CAUTION 2-4-3
you are in good shape.

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Serious personal injury by getting  Use proper equipment and tools to
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Carrying in of caught between the machine and carry in materials.
5 Use
materials a material that fell  Do not enter a material falling area.

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WARNING —

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Collection of  Laceration by a sharp edge of a When working, always wear gloves 2-4-2, 2-4-6

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machined KLP worksheet and burn by touching or similar to avoid bare hand-contact.

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worksheets a hot worksheet
6 Use
and disposal  Laceration by a sharp knife edge

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2-4-2, 2-4-6
of waste CAUTION
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materials A
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Replacement Serious personal injury by getting Do not get in any moving machine 2-4-5
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of nozzle/ caught in a moving machine part part.

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7 Use
protective due to erroneous operation 2-4-5, 5-6,
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window WARNING
Chap 10
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Replacement Fire caused by the spatters that Do not operate the machine with the 2-3-3, 2-3-5,
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of nozzle/ flew onto an oxygen hose during Z-axis protective cover removed. 2-3-8, 2-4-6
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protective machining 2-3-3, 2-3-5,

WARNING
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window 2-3-8, 2-4-6

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Replacement FKP Fire due to the radiation of a laser Clean the machine on a regular basis 2-3-5, 3-6
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of nozzle/ beam to the aluminum dust to prevent the accumulation of

9 Use
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protective accumulating under the table aluminum dust. 2-3-5

window WARNING
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Replacement Serious personal injury or fire due Add necessary equipment, such as 2-3-1, 2-3-3,
FP
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of nozzle/ to the noxious or flammable gas an exhaust system, if cutting plastic 2-3-9, 2-4-8
10 Use
protective produced during the cutting of a materials. 2-3-1, 2-3-3,
WARNING
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window plastic material 2-3-9, 2-4-8

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Fire in the dust collector duct due Clean the duct on a regular basis to 2-3-5, 3-6
Cleaning of J
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to incomplete removal of dust remove dust.

11 Use dust collector
duct 2-3-5, 5-4
WARNING
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Serious personal injury due to the  Wear protective goggles.

Cleaning of J —
Mainte- dust that got in the eye of the  Do not use compressed air to
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12 dust collector
nance worker cleaning the duct remove dust. 4-1
duct WARNING
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 Serious personal injury by getting  Turn off the power and put a sign 2-4-5
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LP caught in moving machine parts saying “Working in the machine. Do

Mainte- Replacement
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13  Hand laceration during not turn on the power” on the

nance of knife edge 2-4-5, 4-2
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replacement work operation panel.

WARNING
 Wear gloves.
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Maintenance Serious personal injury by getting Turn off the power and put a sign 2-4-5
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FP
Mainte- and repair caught in moving machine parts saying “Working in the machine. Do
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nance inside the not turn on the power” on the 2-4-5, 5-5
machine WARNING operation panel.
Maintenance Electric shock, or serious personal Be sure to turn the main power 2-4-5, 6-1
and repair M injury by getting caught in a breaker to the OFF position and lock
inside the moving machine part it with a padlock.
Mainte-
15 electrical
nance 2-4-5
control cabinet
and the WARNING
machine
Serious personal injury (electric Leave the adjustment and repair of 2-3-10, 2-4-8,
Adjustment N
Mainte- shock) by touching a 400 V power the laser oscillator to a Mazak 2-3-7.4
16 and repair of
nance supply line service engineer. 2-3-10, 2-4-8,
laser oscillator WARNING
2-3-7.4

2-3
 Serial No. 311487

2 SAFETY PRECAUTIONS

Reference in
Location in
operating
Qualifications machine manual
Operation Protective measures to be taken
No. Work or training Details of harm
step by the customer Reference in
needed Seriousness
maintenance
of harm
manual
Removal of Serious personal injury by getting Turn off the power and put a sign 2-4-5
chips from and FKP caught in moving machine parts saying “Working in the machine. Do
Mainte-
17 cleaning of the not turn on the power” on the
nance 2-4-5, 5-7
inside of the WARNING operation panel.
machine
Maintenance ACFLP Serious personal injury or machine Stop the supply of air and gas before 2-3-4, 2-4-5
Mainte- of air and damage due to the supply of gas starting maintenance work.
18
nance assist gas 2-3-4, 2-4-5,
lines WARNING
5-5, 7-1

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2-4
 Serial No. 311487

SAFETY PRECAUTIONS 2
2-3 Laser Safety Precautions

2-3-1 Safety of the laser machine

Here is explained the safe operation of the machine. The MAZAK laser machine is a safe
industrial laser machine tool. There are, however, some basic precautions that you must follow
to ensure the safety of your operator.
There are four basic hazards associated with fiber laser cutting machines as follows.
1. Contact of laser beam
The contact of the laser beam to eye or skin.
2. Fire

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Fire danger by either splattering from the worksheet or from direct contact of the laser beam

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with flammable materials, or due to use of assist gas.

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3. Toxic fumes

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Toxic fumes emitted from exotic materials.

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4. Lethal high voltage shock

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Lethal high voltage shocks from electrical cabinets caused by untrained personnel.

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2-3-2 Contact of the laser beam

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 Do not use the machine with the window and the cover removed.

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 Do not use the machine when the window is broken or cracked.

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 Do not use any window other than the dedicated one.

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DANGER
31

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1. Possible hazards
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The laser machine emits a very high powered fiber laser beam that is not visible to the human
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eye. Contact with the laser beam can cause serious burns. So it is very important to handle this
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machine with an extreme care.

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 Do not place any part of your body or clothing underneath or in front of the direct path of
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the laser beam. Contact of your skin or clothing with the laser may result in immediate
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ignition of either skin or clothing or both.

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WARNING
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 The laser machine system has safety devices to ensure operator’s and machine safety.
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No modifications are to be performed that will affect operation safety. We take no

responsibility for any personal accidents or machine trouble due to inobservance of this
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warning.
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2. Recommended safety precautions

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Gloves are recommended to ensure safety when operating the system. Parts that come from the
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laser machine (especially steel parts) are sometimes very hot after they have been laser
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processed. Wearing gloves helps to prevent any minor burns that can occur after processing.
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NEVER STARE DIRECTLY AT THE LASER BEAM WHILE IT IS CUTTING.

 NEVER make contact with the fiber laser beam!

WARNING

2-5
 Serial No. 311487

2 SAFETY PRECAUTIONS

2-3-3 Danger of fire from spatter or laser beam

1. Possible fire hazards

When laser processing with the laser machine there is a possibility of scattering hot fragments to
flammable materials near the workpiece area. It is strongly recommended that you are aware of
the following hazards.
Hot fragments of the material can scatter and hit objects in the surrounding area.
The fiber laser beam or a reflection of it could come into contact with flammable materials.

2. Recommended safety precautions

Keep flammable materials at least 10 feet away from the work area. Flammable materials are

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considered to be any solid material (paper, wood, cardboard or plastic) or volatile liquid (such as

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gasoline, acetone, kerosene, aerosol cans etc.) that can ignite on contact.

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When laser processing materials such as plastics and wood, use an inert gas such as nitrogen or

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helium to prevent uncontrollable ignition of the material.

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 NEVER use oxygen as an assist gas when processing wood, plastic, cardboard, paper or

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cloth products.

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 Fire could arise when wooden, plastic or other flammable materials are machined. In this

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WARNING
case it is the responsibility of management to ensure a fire extinguisher is readily available

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as a safety measure to ensure safety.

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2-3-4 Danger of a fire from assist gas

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1. Possible hazards
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There are times when oxygen gas is used at the assist gas for laser processing. When oxygen
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gas is used, provide a special gas circuit. If the oxygen gas is connected to any but a special
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oxygen gas circuit and laser processing is conducted a fire could occur. There should be no oil
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inside the piping used to connect the oxygen gas cylinder.

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2. Recommended safety precautions

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When oxygen gas is used as the assist gas during laser processing then connect the oxygen to a
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special oxygen supply port.

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Air
3rd assist gas
4th assist gas
Oxygen

D698SA0015

2-6
 Serial No. 311487

SAFETY PRECAUTIONS 2
 Never feed oxygen to either the 3rd assist gas piping or the 4th assist gas piping. If
oxygen is fed to any piping other than the oxygen piping during laser cutting, a fire will
result.
WARNING

2-3-5 Potential fire and explosion hazards of the dust collector

1. Potential hazards
 The laser machine gives off sparks, soot, coal dust, and/or other dust particles. Emission of
these substances can result in dust explosions.
 The chips occurring during no-oxidation cutting (such as aluminum machining with a nitrogen

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gas) may get burned or ignited by chemical reactions with the moisture that is contained in

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air.

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2. Recommended safety precautions

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Institute the following measures so as to avoid the hazards mentioned above:

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 Keep combustibles away from the dust collector.

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 During and after no-oxidation cutting, perform the periodic inspection and clear dust

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particles away from the dust collector and the hose connection box as far as possible.
WARNING

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 If the user is to install a special dust collector, design and fabricate it so that sparks or fire

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does not break out. Also, install a pre-duster and provide metallic piping.
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2-3-6 Cleaning the head and periphery

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Clean all sections dirty with dust particles and/or oils each day so as to prevent fire from
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occurring. Use a cloth to clean.

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2-3-7 Oxygen leakage check

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If oxygen leakage is discovered, immediately stop the machine. Continued operation of the
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machine with oxygen leaking can result in fire.

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2-3-8 Danger of fire due to fast piercing

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1. Possible hazards
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Machining that uses fast piercing causes very hot spattering in great quantities. Spattering can
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result in fire.
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2. Recommended safety precautions

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For piercing, use step piercing method, but do not use fast piercing method.
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2-7
 Serial No. 311487

2 SAFETY PRECAUTIONS

2-3-9 Toxic fumes

1. Possible hazards
When cutting some materials, there is a potential danger from the fumes emitted as the material
is laser processed. It is necessary to evaluate the material before processing and to be very
careful in the selection of materials that are to be cut with the laser. Some materials (such as
lead, PVC, fiberglass, galvanized steed and some calcium based composites) are very
dangerous to cut because of the toxicity of the fumes they emit.

2. Recommended safety precautions

 Before machining, check with the guidebook of dangerous materials for welding that a

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worksheet material does not generate toxic gases.

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WARNING

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For details of danger from toxic fumes, refer to the guidebook of dangerous materials for welding,

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etc.

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2-3-10 Lethal high voltage shock

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1. Possible hazards

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The laser oscillator of the laser machine operates at 400 V.
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 The only person allowed to touch the laser oscillator should be a certified electrical
PO
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engineer or Mazak service engineer. AT NO TIME SHOULD AN EMPLOYEE OF THE

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COMPANY THIS MACHINE IS SOLD TO BE RESPONSIBLE FOR ANY ENTRY INTO

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N

DANGER THE POWER SUPPLY OF THE LASER. Mazak waives any legal responsibility of injury or
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death due to unauthorized entry into the power supply unit, beam enclosure or oscillator
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cabinet.
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2. Recommended safety precautions

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The user is prohibited from doing any repairs or adjustments to the electrical parts of the laser
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oscillator. Please contact a Mazak service engineer for adjustment and repair.
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2-3-11 Laser and laser irradiation ON keys

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There are two keys on the machine that demand attention in regards to safety: the laser control
01

key and the laser irradiation ON key. These keys should be removed by an authorized person
)2

when the machine is not in operation. These keys should be put in a safety place and should not
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be accessible to any personnel other than the person responsible for them.
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Remark : The laser irradiation ON switch key is not necessary for operation of the laser
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machine system. Its main purpose is for maintenance. The user should properly control
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this key so that it is not handled by persons not officially trained by Mazak.
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 If a person not trained handles the laser irradiation ON switch key, he or she may or will
suffer injury such as burns.

WARNING

2-8
 Serial No. 311487

SAFETY PRECAUTIONS 2
2-3-12 Machining a material covered with a protect sheet

 If the material to be machined has an attached protect sheet of vinyl chloride, detach the
protect sheet before machining the material. If the vinyl chloride itself is machined, this will
not only cause machining defects, but also send off a chlorine gas, thus resulting in
WARNING machine corrosion and/or personal injury.
Confirm the kind of material used as the protect sheet.

2-3-13 Handling precautions on optical parts

Observe the following instructions when handling a condensing lens, a condensing lens
protective window, a collimating lens, etc. for machining torches.

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1. Optical parts, such as condensing lenses, condensing lens protective windows and

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collimating lenses, are made of synthetic quartz, and the same disposal rules as for general

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glass products apply to them. Adhere to the municipal ordinances when disposing of them.

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2. There are no special rules for the disposal of machining torch parts, such as cartridges, that

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have become unnecessary because of the breakage of an optical part or for any other

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reason. However, adhere to the municipal ordinances when disposing of them.

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2-3-14 Safety devices (Laser beam)

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Working personnel intentionally must not remove or bypass the limit switches, interlocks, or other

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safety devices provided in or on various units.
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1. Protective housing
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The laser oscillator and external beam delivery system is enclosed by metallic covers with the
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exception of the work station.

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A focus adjusting operator must be qualified by Yamazaki Mazak Corporation.

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2. Safety interlocks
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An interlock is provided for every door through which to enter the machining area, so opening a
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protective door during operation will stop the irradiation of a laser beam and also stop the
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machine.
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3. Laser key switch

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A key switch on the control board is the master control switch. The key is removable in the “O”
3

position and the laser will not be operational when the key is removed. One person should be
01

responsible for the key.

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4. Remote control connector

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The remote control connector is provided so that the user can connect to a remote barrier
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interlock, emergency stop switch or similar device. Generally, the connector is short-circuited.
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When the connector is opened, the irradiation of a laser beam will stop, the machine will stop and
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an alarm will occur (please see the maintenance manual for details).

2-9
 Serial No. 311487

2 SAFETY PRECAUTIONS

5. Emission indicator
The yellow light is an emission indicator. This light will blink when the high voltage switch is
tripped. Then laser discharge inside the oscillator will begin.
The red indicator lights during Laser beam emission.

Protective housing

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Emission indicator

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Laser key switch

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Safety interlock

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D698SA0016

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Fig. 2-1 Safety devices (Laser beam)

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2-3-15 Safety plates (Laser)

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1. Safety plates for the machine

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To prevent accidents, safety plates are attached on the laser machine body, peripheral
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equipment, and other places which are suspected to be dangerous or mis-operated because of
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the characteristics of the laser machine. Always follow the precautions instructed in the safety
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plates.
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Safety plates are attached on the machine to ensure safe machine operation as shown below:
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1. Certification and identification label (FDA Compliance)

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2-10
 Serial No. 311487

SAFETY PRECAUTIONS 2
2. Warning labels and descriptive labels

Warning label (Class 1)

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0X106415190 0X106415170
Descriptive labels for 2.0 kW laser system (Class 1) Descriptive labels for 3.0 kW laser system (Class 1)

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X106417001
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Optional specification only for USA

Descriptive labels for 3.0 kW laser system (Class 1)
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Fig. 2-2 Warning labels and descriptive labels (for 2.0 kW/3.0 kW Fiber laser system)
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3. Aperture label located on the Z-axis head

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INVISIBLE LASER RADIATION

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IS EMITTED AVOID EXPOSURE

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FROM THIS APERTURE

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Fig. 2-3 Aperture label

2-11
 Serial No. 311487

2 SAFETY PRECAUTIONS

4. Labels for windows and covers

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Fig. 2-4 Label for non-interlocked protective housing

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5. Labels for non-interlocked protective housing

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Located at fixed mirror plates, mirror mount blocks and maintenance cover

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DANGER

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INVISIBLE LASER RADIATION

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WHEN OPEN A
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AVOID EYE OR SKIN EXPOSURE TO

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DIRECT OR SCATTERED
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RADIATION
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Fig. 2-5 Label for non-interlocked protective housing

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6. Labels for interlocked panels

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Fig. 2-6 Label for interlocked panels

2-12
 Serial No. 311487

SAFETY PRECAUTIONS 2

INVISIBLE LASER RADIATION

IS EMITTED
AVOID EXPOSURE
FROM THIS APERTURE

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Inside

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D699SA0020E
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Fig. 2-7 Label locations for Class 1

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2-13
 Serial No. 311487

2 SAFETY PRECAUTIONS

2. Warning labels
Where there is a danger of high voltage or of being struck by the laser beam in the oscillator,
there are labels affixed to positions as indicated in the following illustration.

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D699SA0001
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Fig. 2-8 Safety plates on the laser oscillator (2.0 kW laser system)
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D699SA0002

Fig. 2-9 Safety plates on the laser oscillator (3.0 kW laser system)

2-14
 Serial No. 311487

SAFETY PRECAUTIONS 2

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D699SA0031

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Fig. 2-10 Safety plates on the laser oscillator (3.0 kW laser system) (Optional specification only for USA)

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2-3-16 Other gravities

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1. Compressor fire hazards

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 Do not place oxygen containers or oxygen release valves near the air intake port of the
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compressor. Failure to observe this precaution leads to fire.

N

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WARNING
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2-3-17 Service
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If you have a problem with your laser machine system, please contact Mazak Technical Center
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or Technology Center. DO NOT ATTEMPT TO SERVICE THE MACHINE YOURSELF.

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2-3-18 Compliance
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1. Using a high-pressure gas

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Before using a high-pressure gas, make provisions in accordance with the local laws and
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regulations.
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Note : For more information, contact your local gas supplier.

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2-15
 Serial No. 311487

2 SAFETY PRECAUTIONS

2-4 Machine Safety Precautions

2-4-1 Basic safety precautions

 The laser oscillator uses high 400 volts. Users are not allowed to adjust or repair it.
Negligence may be endangered to death or electric shock.
 There are high voltage terminals on the electrical control panel, transformer, motors,
DANGER
junction boxes and other equipment (with a battery warning mark attached).
Do not touch any of them under any circumstance.

 Never touch or try to touch a moving part like the torch, the pallet, etc. of the machinery
during operation. Or never place a part or whole of your body in the place catching it.

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 Fully understand the operation of the emergency stop pushbutton so that you can operate
WARNING

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it at any time.

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 Don’t turn on the power under the condition of the door or the protective cover removed.

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 Do not cancel any interlocks associated with the door, even when performing

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maintenance work.

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 Don’t open the door, the cover, etc. of the laser machine during automatic operation.

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 Don’t operate the switches or the like with wet hands.

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 Take full care not to have your hands or fingers caught by the worksheet clamp, or the

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worksheet support. A
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 Do not touch knife edges with bare hands.

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CAUTION
31

 Shut down the main breaker when the power failed.

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2-4-2 Clothing and personal safety

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 Tie up your long hair back and loose sleeves and avoid wearing a necktie, necklace, etc.
A
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to prevent them from being caught by a machine drive.

 Always wear safety protectors like safety shoes.
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WARNING
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 Wear a dust mask if a material which produces dust is machined.

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 Wear gloves to handle a hot or sharp edge worksheet.

YA

CAUTION  Always operate the machine in good health conditions. Should any abnormality be felt,
3
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avoid operating the machine.

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2-4-3 Precautions related to operation

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1. Fully understand the contents of the OPERATING MANUAL before starting operation of the
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machine.
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 Check that all safety covers, etc. are in position and perfect. If imperfect, change or repair
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it.
 Make sure that a worksheet has securely been clamped by the worksheet clampers
WARNING
before operation so that it does not move while in operation.

2-16
 Serial No. 311487

SAFETY PRECAUTIONS 2
 Don’t operate the switches on the operating panel with gloves on. Failures will cause
machine misoperation or other troubles.
 When opening or closing the operator door, do not put your hand or fingers between the
CAUTION
door and the panel. Doing so may cause your hand or fingers to get caught between them.
 A power failure or a momentary voltage drop, if occurs when the NC machine is
energized, could cause a failure of the hard disk drive. If a thunderstorm is approaching,
power off the NC machine immediately, because thunderstorms can cause a power failure
and a momentary voltage drop. If the hard disk drive has broken because of such a
phenomenon, it will need to be repaired at your cost, even if it is still under warranty.
 A hard disk failure makes it impossible to use the machine. It can also result in the lost of
machining programs.

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 When you leave the machine after operation, turn off the power switch on the NC

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operating panel but don’t shut down the main breaker of the machine.

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2. Precautions when starting an automatic operation

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When starting a programmed automatic operation for the first time, a human or mechanical

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harm or damage is most likely to occur by the spatters flying from improper cutting

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conditions or by a mechanical interference due to an improper motion path. So carry out an

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.A
automatic operation, giving the following attentions:

N
 Before starting the machining operation, take all necessary steps to prevent the

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generation of spatter due to improper machining conditions and to avoid injury due to the
87

reflection of a laser beam. A

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WARNING
PO
31

 Don’t start an automatic operation abruptly but check the machining paths correct on the
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NC screen beforehand.
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 After checking the paths on the screen, move the machine in a single block mode to check
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CAUTION
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the paths proper on the machine. In such an operation, validate the override function in
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the feedrate and select a safe speed under the power off condition.
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2-4-4 Precautions on continuous operation

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Continuous operation must always be placed under the supervision of a person. Avoid un-
A
M

attended continuous operation.

YA

 The lens and nozzle on the laser machine may be used within their standard service lives
3

(specified separately). As for protective window, it may suddenly be damaged due to an

01

unexpected burst and the spatters thereby, resulting in machining defects. Machining
)2

WARNING defects, in turn, can result in a burst, and laser beam reflections can cause fire.
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 The conditions of the laser beam cutting have to accord with the thickness, internal stress,
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etc. of the material to be cut. Machining defects may arise from inappropriate cutting
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conditions and result in a burst, and laser beam reflections can cause fire.
CAUTION
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Operation must always be placed under the supervision of a person in order to immediately take
measures against burst and fire caused by machining defects and laser beam reflections,
respectively, and to perform necessary adjustments.

2-17
 Serial No. 311487

2 SAFETY PRECAUTIONS

2-4-5 Precautions related to maintenance

Fully understand the contents of the MAINTENANCE MANUAL before starting maintenance.

 Users are not permitted to adjust or repair electrical components of the laser oscillator.
Ask Mazak service engineer for such work.

DANGER

 Shut down and lock the main breaker to prevent someone from misoperating the main
breaker or NC operating panel switches by mistake.

WARNING  Stand a big signboard near a location of maintenance which requires power on so that any
unconcerned person may not touch the machine. Be sure that such a maintenance be

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carried out by two persons or more as each can give a sign and confirm every operation

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step each other to go to the next step. In addition, if the maintenance needs no pneumatic

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pressure, stop it before maintenance.

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 Residual voltage stays for a while after the power is shut down. So don’t start

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maintenance until the maintaining circuit is checked by a gauge that no voltage is left.

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 Substances that have adverse effects on the environment if not disposed of appropriately

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are used in some of the equipment used in Mazak laser machine. In order to protect the

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environment, dispose of laser machine and accessory equipment in accordance with the

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laws of the country concerned. Entrust the processing to a contractor who deals with

O
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industrial waste. Note that any expenses associated with this processing are to be borne
87

by the customer. A
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PO

 For replacement of knife edges or protecting plate, wear gloves and do not touch them
31

with bare hands.

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N

CAUTION
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2-4-6 Precautions related to workplace

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 Don’t put your hand or finger between a belt and a pulley, a chain and a sprocket, etc.
K
ZA

 Provide a countermeasure to protect floor feeding cables, etc. from a short circuit caused
A

by cut chips or the like.

WARNING
M
YA

 A floor slippery with a substance such as an oil or water is very dangerous since persons
3

could overturn. Always keep the floor surface dry and clean.
01

 Start a machine operation after you have mounted back a cover, etc. in place.
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CAUTION
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 After a maintenance, keep everything (environmental and maintenance parts) in order and
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wipe off water and oil so as to get a safe and normal operation back.
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 To replace maintenance parts or consumables, always use ones of the same

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specifications or standards.
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 When removing chips, do not touch with bare hands and be sure to put on safety gloves.

2-18
 Serial No. 311487

SAFETY PRECAUTIONS 2
2-4-7 Safety devices
The laser machine system has safety devices like doors, covers, interlocks, emergency stop
switch, etc. to ensure operator’s and machine safety.

 The machine is provided with various devices for the operator’s safety.
Do not cancel any of the devices.
Failure to observe this instruction could result in serious harm to a human life or body.
WARNING

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1 2
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D698SA0018
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Fig. 2-11 Safety devices of the machine

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No. Part Description

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1 Emergency stop button Pressing the button on the operating panel stops the machine, stops the laser
IM

irradiation, and shuts off the laser high-voltage.

2 Safety interlock switches Installed in the electric cabinet door
K

When the electric cabinet door is opened, the power breaker trips to prevent an
ZA

unexpected electric shock.

A

Operator’s door
M

When the operator’s door is opened in the automatic operation, the machine will
YA

be placed in the feed hold state. In the manual operation, the axis feed rate is
limited to F2000.
3
01

3 Light barrier The Light barrier shields the 2-pallet changer periphery of the laser beam
)2

machine by activating photoelectric sensors to prevent the machine operator

from inadvertently touching or getting caught in the machine during operation.
(c

Contact with the sensors brings the machine to a feed-hold stop.

ht
ig

1. Light barrier interlock specifications on the 2-pallet changer

yr
op

When the light barrier on the 2-pallet changer side detects an obstruction (that is, the interception
C

of the sensor light), the following status will result:

A. Message display on the monitor

When the light barrier detects the obstruction, the message 275 PALLET LIGHT BARRIER will
be displayed.

2-19
 Serial No. 311487

2 SAFETY PRECAUTIONS

B. Ladder hold of the sensor-detected status

Once the light barrier has detected the obstruction, ladder software holds the sensor-detected
status. The sensor-detected status will remain held, even when the light barrier is reset (the
intercepted status of the sensor light is cleared).
Press the reset key or the clear key to clear the sensor-detected status.

C. Deactivation of automatic operation

Pallet change operation cannot be executed under the sensor-detected status. During automatic
operation, when the light barrier operates, an alarm message will be displayed and the machine
will come to a feed-hold stop.
Clear the alarm status by pressing the clear key, and then press the cycle start button. Automatic

d.
operation can then be continued.

ve
er
Automatic operation cannot be continued if the alarm status is cleared by pressing the reset key.

s
re
D. Conditional permission of manual operations

ts
gh
When the SETUP switch is set to “I”, the pallet changer can be moved at a speed of 2 m/min or

ri
less.

ll
.A
The pallet changer will stop when the light barrier operates.

N
O
E. Deactivation of the light barrier with the safety fence remaining closed (Only in the case

TI
of system specifications)
87

A
R
14

For a cell system or a flexible manufacturing system, if the safety fence remains closed, the light
PO
31

barrier of the laser machine will be deactivated. Even if the light barrier detects an obstruction,
R

the detection itself will be ignored.

o.

O
N

The light barrier is valid only when the safety fence is open.
al

K
ri

ZA

F. Self-diagnosis of the light barrier sensors

Se

A
IM

If the light-receiving ratio decreases below 50%, the light barrier sensors will detect their own
abnormality and generate an error output signal.
K

This state is caused by trouble with the sensors themselves, misalignment of their optical axes,
ZA

or the presence of dirt on the light-receiving or light-projecting surface.

A
M

When the light barrier sensors generate the error output signal, the message 252 LIGHT
YA

BARRIER SENSOR ALARM will be displayed and the laser machine will come to an alarm stop.
As a result, automatic operation will be impossible.
3
01

To clear the alarm status, press the reset key or the clear key after removing the cause of the
)2

alarm by replacing, adjusting, or cleaning the sensors.

(c
ht

G. Deactivation of on-alarm power cutoff

ig

On-alarm power cutoff will not be conducted, even when the light barrier operates.
yr
op

On-alarm power cutoff will be conducted if 252 LIGHT BARRIER SENSOR ALARM occurs.
C

2-4-8 Safety plates on the machine

To prevent accidents, safety plates are attached on the laser machine body, peripheral
equipment, and other places which are suspected to be dangerous or mis-operated because of
the characteristics of the laser machine. Always follow the precautions instructed in the safety
plates.

2-20
 Serial No. 311487

SAFETY PRECAUTIONS 2

.
d
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ser
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.A
N
O
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87

A
R
14

PO
31

R
o.

O
N

C
al

K
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Se

A
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K
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A
M
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3
01
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D698SA0019E
Fig. 2-12 Safety plates on the machine

2-21
 Serial No. 311487

2 SAFETY PRECAUTIONS

1. Safety plates

A. Danger

Safety plates Description

98 (white), 100 (black) Be sure to turn off the power before starting
the operation.
Do not operate any switch with a wet hand.
Do not start the operation in several minutes
after turning off the power.

d.
ve
s er
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ts
White: 0X106401011

gh
Black: 0X106401980

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163 Do not turn off the safety interlock. Doing so

ll
could cause a serious physical accident.

.A
N
O
TI
87

A
R
14

0X106404100
PO
31

B. Warning
o.

O
N

C
al

Safety plates Description

K
ri

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86 This plate shows basic and general safety

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instructions.
A
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K
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A
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0X106404071

2-22
 Serial No. 311487

SAFETY PRECAUTIONS 2
Safety plates Description
105 Do not remove the maintenance cover for
any purpose other than maintenance.
Before removing the maintenance cover, turn
off and lock the main power breaker.
Do not turn on the power when the
maintenance cover is removed.

0X106401430

386 Do not step on.

.
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s er
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.A
N
0X106405930

O
TI
139 When cutting a combustible material (such
87

A as wood and plastic), do not use oxygen as

an assist gas.
R
14

PO

Prepare a fire extinguishing system yourself,

31

just in case.
R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA

0X106404110
A

127 When abnormal spatter is generated, stop

M

the processing immediately.

YA
3
01
)2

0X106404090
(c
ht

151 Operate the dust collector in auto processing.

ig
yr
op
C

0X106404120
175 Never feed oxygen to either the third assist
gas piping or the fourth assist gas piping.

0X106404130

2-23
 Serial No. 311487

2 SAFETY PRECAUTIONS

2. Auxiliary plates for operation and maintenance

Safety plates Description

187 This plate shows cautions in performing
maintenance of the main air system.

d.
ve
s er
0X106404490

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374 This plate shows the cautions in performing

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maintenance of the fiber cables.

gh
ri
ll
.A
N
0X106405910

O
TI
44 This plate shows the direction in which each
87

A axis of the machine moves.

R
14

PO
31

R
o.

O
N

C
al

06971800140
K
ri

ZA

39 This plate shows the travel of each axis of

Se

machine and the maximum workpiece

IM

loading capacity.
(2-pallet changer)
K
ZA
A
M
YA
3
01
)2
(c

mm: 06971800220
ht

in: 06971800230
ig
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2-24
 Serial No. 311487

SAFETY PRECAUTIONS 2
Safety plates Description
58 This plate shows the items to be checked on
a daily basis.

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.A
N
O
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87

A
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14

PO
31

R
o.

06991800030
N

71
al

This plate shows the items to be checked

K

periodically.
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K
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06991800040

2-25
 Serial No. 311487

2 SAFETY PRECAUTIONS

Safety plates Description

253 This plate shows the pressure of the gas to
be supplied to the third and fourth assist gas
circuits.

0X106404140

261 This plate shows the pressure of the oxygen

to be supplied to the oxygen circuit.

0X106406690

256 This plate shows the pressure of the air to be

supplied to the air circuit.

d .
ve
0X106404150

er
263 This plate shows the type of the lubricant to

s
re
be fed.

ts
gh
06971800100

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42 Foot switch for operating the work lifter

ll
.A
N
O
TI
87

A0X106404320
R
14

31
PO

Switch for operating the automatic work

31

clamp
R

(2-pallet changer)
o.

O
N

C
al

K
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ZA

0X106404330
Se

A
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K
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A
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3
01
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2-26
 Serial No. 311487

SAFETY PRECAUTIONS 2
3. Other plates

Safety plates Description

23 This plate shows cautions about
the relocation and export of the
machine.

0X106400334

3 This plate shows the place of

d .
destination, model name, serial

ve
number, date of manufacture

er
and weight of the machine.

s
re
(Plate A or B is attached to the
machine.)

ts
gh
ri
ll
.A
A: 0X106400501 B: 06971800640

N
O
9 This plate shows the main

TI
specifications of the control
87

A panel.
R
14

(Plate A or B is attached to the

PO

machine.)
31

R
o.

O
N

C
al

K
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A: 0X106400251 B: 0X106400371
IM

15 This plate shows the main

specifications of the main power
K

breaker.
ZA

(Plate A or B is attached to the

A

machine.)
M
YA

A: 0X106400261 B: 0X106400382
3
01

363 This plate shows the model

name, serial number and date of
)2

manufacture of the machine.

(c

(This plate is additionally

ht

attached to the machine with

ig

plates A of Nos. 3, 9 and 15.)

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op
C

0X106406740

2-27
 Serial No. 311487

2 SAFETY PRECAUTIONS

2-4-9 Work and working area that cause laser radiation exposure

1. For ordinary laser processing during automatic operation

Applicable workers Operators and other workers, Mazak service engineer

Safety device Machine cover
Laser power Maximum 2000 W for a 2.0 kW laser/Maximum 3000 W for a 3.0 kW laser
Exposure to laser radiation Less than the 2 W·m–2
Safety area The area indicated by hatching is the safety area where exposure is lower than the
Class 1 accessible emission limit (hereinafter it is referred to as AEL) of 50 W·m–2.

 When the machine cover is closed, both reflections and scattering reflections of the beam
are shielded by the steel cover and the resin cover which is designed to take the laser

d .
ve
transmissivity into account; this means your eyes and skin will not be harmed.
WARNING

ser
re
ts
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ll
.A
N
O
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87

A
R
14

PO
31

R
o.

O
N

C
al

Operator
K
ri

ZA
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D698SA0022
A
IM

Fig. 2-13 Safety working area

K

2-4-10 Others
ZA
A

When the knife edge supporter is required to change, be sure to mount it so that the knife edge
M

top level does not come above the level of the gripper (clamping jaws) of the worksheet clamp.
YA

Otherwise the worksheet is shifted and a machining defect will occur.

3
01
)2

Worksheet clamp
(c

Worksheet
ht
ig
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Gripper

Knife edges D627SA0006

Fig. 2-14 Precautions on replacing the knife edge supporter

2-28
 Serial No. 311487

SAFETY PRECAUTIONS 2
2-5 Installation Precautions
To ensure safe operation of the laser machine, note the following during installation.

2-5-1 Wiring
1. Be sure to use electrical conductors with performance ratings equivalent or superior to
those described in the maintenance manual.
2. Do not connect to the power distribution panel any power cables for devices which can
cause line noise, such as are welders and induction hardening machines.
3. Arrange for a qualified engineer to connect the power lines.
4. When connecting the power cable to the main breaker, carry out wiring in such a way that

.
d
the breaker box can be of the protection grade IP54.

ve
er
2-5-2 Grounding

s
re
The grounding resistance must be 10 ohms or less, and the grounding cable must be of the

ts
2

gh
same size as that of the power cable (except for a cross-sectional area of at least 38 mm ; for
2

ri
more than 38 mm , at least 50% of the power cable size).

ll
Generally, the laser machine should be grounded to a separate grounding rod. If an independent

.A
ground cannot be provided for the machine, prepare the ground connection as follows.

N
1. Connect a single conductor to its own grounding terminal. This will avoid possible serious

O
TI
accidents resulting from ground currents which might otherwise flow in the laser machine if
87

a peripheral device should malfunction. A

R
14

PO

2. A separate grounding wire should be used, one whose length is as short as possible.
31

3. Check the resistance to ground by actual measurement. This should measure less than10
o.

O
N

ohms if a single device is connected to its own grounding rod.

C
al

 Do not use a building steel frame as a grounding electrode.

ri

ZA
Se

A
IM

CAUTION
K
ZA

Desirable independent grounding:

A
M
YA
3
01

Earth resistance: Less than 10 ohms

)2

Common grounds:
(c
ht
ig
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op

Resistance to ground = 10/the number of devices connected (ohms) to the grounding.

C

Never ground equipment as shown in the following figure:

Fig. 2-15 Grounding

2-29
 Serial No. 311487

2 SAFETY PRECAUTIONS

2-5-3 Gas and air pipings

The laser machine uses assist gas (oxygen, nitrogen, or high-pressure air, etc.) for machining,
and air for the laser machine drive and dust prevention. Qualities of these gases and air piping
for them largely effect machining performance and machine life.

1. Assist gas

A. Oxygen or nitrogen
1. Use oxygen or nitrogen containing less than 5 ppm water and of more than 99.9% purity.
Otherwise machining fails.
2. Use a bomb regulator which qualifies the following specifications:

d .
ve
Primary pressure: 14.71 MPa

er
Secondary pressure: 0 - 1.96 MPa

s
3

re
Flow amount: More than 320 L/min (11.30 ft /min) [0.99 MPa]

ts
Insufficient flow amount causes machining failure due to pressure loss.

gh
3. When you use a liquefied gas, use an evaporator whose capability is more than double of

ri
the flow amount. Otherwise it invites pressure drop as well as equipment failures due to

ll
.A
invasion of cold gas into the gas control circuit.

N
4. To prevent gas leakage or impurity invasion from gas piping use metallic pipes.

O
TI
5. Flush rust and foreign materials off the pipe interior. Otherwise the gas control system fails.
87

6.
A
Oxygen gas is flammable, so the pipe interior must be free from petroleum, oil, grease, and
R
14

PO

other flammable materials.

31

7. If the diameter or length of the assist gas pipe is not adequate, the assist gas pressure may
o.

O
N

not reach the specified value.

C
al

K
ri

B. High-pressure air
ZA
Se

1. Dirty air invites lens damage and machining failure. Use a filter and a drier to remove oil and
IM

water out of air.

K

2. Check the drain, oil, and filter of the compressor as specified so that dirty air does not come
ZA

out.
A
M

3. Provide a receiver tank in the assist gas piping to prevent pulsation from occurring.
YA

2. Air for the laser machine drive and dust prevention

3
01

1. Air for laser machining is used for cooling and protecting the laser oscillator and the optical
)2

system from dust.

(c

2. Air containing dirty air or moisture will damage the optical components.
ht
ig

3. Never let the laser machining air be mixed with organic compounds or solvents. Otherwise
yr

the beam diffuses to cause cutting failures.

op

4. Provide a drain hole at a concave portion and at a pipe rising portion to drain water from the
C

pipe between the compressor and the laser machine import.

5. Air must be supplied at a pressure from 0.91 to 0.83 MPa and a flow rate of 210 L/min
3
(ANR) (7.42 ft /min (ANR)).

2-30
 Serial No. 311487

SAFETY PRECAUTIONS 2
6. Air quality
ISO 8573-1 Class 2  6  4 or higher
[1] [2] [3]

[1] Solid Particles [2] Moisture Content [3] Oil Content

Maximum number of particles in 1 m3 Dew-point temperature

Class under pressure Oil concentration
(Particle diameter d m) (at air pressure of 0.7 MPa)
0.1 < d  0.5 0.5 < d  1.0 1.0 < d  5.0 °C mg/m3
1  20000  400  10  –70  0.01
2  400000  6000  100  –40  0.1
3 No stipulation  90000  1000  –20 1

d .
4 No stipulation No stipulation  10000  +3 5

ve
 100000  +7

er
5 No stipulation No stipulation

s
6  +10

re
ts
Note 1: The dew-point temperature under pressure of +10C (+50F) is equivalent to a

gh
dew point of –17C (+1.4F) under atmospheric pressure.

ri
ll
Note 2: Avoid taking air directly from the air compressor into the machine through a short

.A
pipe. Doing so will cause the hot air to cool in the machine and the moisture and

N
oil in it will condense, block the valve and pipe and cause rust, and thus may

O
cause the contamination of the optical parts.

TI
87

A
Note 3: Do not use an absorption air dryer (such as an activated alumina air dryer),
R
14

because it may reduce the CO 2 concentration in the air and adversely affect the
PO
31

laser beam.
R
o.

O
N

3. Cooling water specifications

al

K
ri

Use the water which conforms to the following water quality standard:
ZA
Se

Fresh water quality

A
IM

pH Conductivity Chloride ion Sulfate ion

Standard items
[25°C (77F°)] S/cm mgCl-/l mgSO42-/l
K

[25°C (77F°)]
ZA

Circulating water 6.8 to 8.0 400 or less 50 or less 50 or less

A

Acid consumption [pH4.8] Total hardness Calcium hardness Ionic silica

M

Standard items
mgCaCO3/l mgCaCO3/l mgCaCO3/l mgSiO2/l
YA

Circulating water 50 or less 70 or less 50 or less 30 or less

3

Iron Copper Sulfide ion

01

Standard items
mgFe/l mgCu/l mgS2-/l
)2

Circulating water 1.0 or less 1.0 or less It must not be detected.

(c

Ammonium ion Residual chloride Free carbon

ht

Standard items
mgNH4+/l mgCl/l mgCO2/l
ig

Circulating water 1.0 or less 0.3 or less 4.0 or less

yr
op

The use of water other than the specified ones could cause damage to the product and
C

liquid to leak, thus resulting in an electric leakage and an electric shock. Moreover, the
service life of the filter may be significantly shortened.

4. Air for an optional FMS

The FMS air is used to suck a worksheet and to move the loader/unloader vertically. Dirty or wet
air will clog filters to shorten filter lives.

2-31
 Serial No. 311487

2 SAFETY PRECAUTIONS

5. Air for a dust collector

Dirty air and wet air cause filter clogs and shorten filter life. So air is needed to blow dust off the
filters of the dust collector.

6. Others
With the compressor
Purchase the required compressor from YAMAZAKI MAZAK or use the compressor specified by
us.

2-5-4 Environmental conditions

Generally, the machine will have the following specifications. However, these may change over a

d .
ve
period of time or in response to seasonal changes.

er
Supply voltage: +10 to –10% rated supply voltage

s
re
Source frequency: Rated frequency ±1 Hz

ts
Ambient temperature: 5 to 40°C (41 to 104°F) (Note)

gh
Humidity: Max. 85%

ri
(Temperature changes should not cause condensation.)

ll
.A
Atmosphere: Free from excessive dust, acid fumes, corrosive gases and salt.
Exposure to direct sunlight or heat rays which can change the environmental temperature should be avoided.

N
O
Avoid exposing the NC machine to abnormal vibration.

TI
Maximum acceleration: 0.686 m/s2 (0.23 ft/s2)
87

7 m
A
R
Maximum amplitude:
14

PO
31

Note: If you intend to install the machine where the ambient temperature will rise above 40°C
o.

O
N

(104°F), contact Mazak Technical Center or Technology Center.

C
al

If it is difficult to meet these conditions, contact Mazak Technical Center or Technology Center
ri

ZA

immediately.
Se

A
IM
K
ZA
A
M
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3
01
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(c
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2-32 E
 Serial No. 311487

SAFETY IN MAINTENANCE 3
3 SAFETY IN MAINTENANCE

3-1 Safety Equipment Inspection

If any trouble occurs in the laser machine, contact Mazak Technical Center or Technology
Center.

1. Operation switches

No. Inspection items Contents Remarks

1 Emergency stop button When the emergency stop button is pressed: Daily
 The laser oscillator will be unready for laser

. d
irradiation.

ve
2 Feed hold button When the feed hold button is pressed during automatic Daily

er
operation:

s
 The laser irradiation is stopped,

re
 The assist gas supply is stopped, and

ts
gh
 Movement along the axes is stopped.

ri
ll
2. Alarm system

.A
N
No. Inspection items Contents Remarks

O
TI
1 Laser irradiation ready When the HIGH VOLTAGE l (laser irradiation ready Daily
87

indicator ON) key is pressed, the yellow signal light goes on and
A
R
14

then the laser oscillator will be ready for laser

PO

irradiation in about 4 seconds.

31

R
o.

3. Interlock system
N

C
al

K
ri

No. Inspection items Contents Remarks

ZA
Se

1 M CODE LOCK The M-codes are properly skipped in the flow of the Daily
A

function program when the [M CODE LOCK] menu key is

IM

pressed.
K

2 Laser irradiation ON The red signal light goes on when the laser irradiation Daily
ZA

indicator ON switch is set to the ON (open) position.

A

3 Operator door interlock Opening the operator door causes the following for Daily
M

each mode of operation:

YA

 For automatic operation: Feed hold state,

 For manual operation: Axis motion speed is limited to
3
01

F2000.
)2
(c
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ig
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3-1
 3

C
op
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ht
(c
)2
SAFETY IN MAINTENANCE

01
3
YA
M
A Se
ZA
K ri
al
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N
A o.
ZA 31
K

3-2 E
14
C
O 87
Serial No. 311487

R
PO
R
A
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N
.A
ll
ri
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ser
ve
d.
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

4 DAILY INSPECTION OF LASER MACHINE
Inspect the following items daily before operating the laser machine.

4-1 Maintenance and Inspection

Table 4-1 Daily inspection items

No. Inspection items Contents Remark Reference section

1 Air supply pressure 0.83 MPa during machine operation —
2 Cooling water level Between E and F on the level gauge Chiller unit Maintenance Manual
indicator 8-4, 8-5
3 Cooling water pressure Check the pressure. Chiller unit Operating manual of the
(When the laser operation switch is ON) chiller unit

d .
ve
4 Set-point of cooling water Cooling water system 1 (oscillator): Chiller unit Operating manual of the

er
temperature 21.0°C (69.8°F) chiller unit

s
Cooling water system 2 (optical system):

re
30.0°C (86.0°F)

ts
5 Filter of the chiller unit Contamination on condenser air filter Operating manual of the

gh
Y-strainer for the cooling water circuit chiller unit

ri
6 Laser oscillation conditions Power indication as specified Contact Mazak Technical

ll
.A
Center or Technology
Center.

N
7 Scrap bucket Removing chips Maintenance Manual

O
5-7

TI
87

8 Centralized lubrication Automatic lubrication A X- and Y-axis Maintenance Manual 6-1

R
14

grease pump Lube MP0 (NGLI#0) linear guide

PO

Replace a 400-mL (24.41-in3) grease

31

X- and Y-axis
cartridge. rack and pinion
R
o.

9 Nozzle To be free of dross. Torch

N

—
C

Nozzle hole to be free of deformation.

al

10 Protective window Check for spatters, dust and clouds on Torch Maintenance Manual
ri

ZA
Se

the window. 10-2-5

A

Operating manual of the

IM

torch made by Laser Mech

(optional for USA only)
K
ZA

11 Knife edges with their Wear of knife edges must be less than Pallet
—
supporting brackets 3 mm (0.12 in). (Note)
A
M

12 Air circuit filter Checking the filter elements for dirtiness Maintenance Manual
Checking the operation of the automatic 7-1-1
YA

drain
Checking for air leakage
3
01

Checking for draining water from the filter

)2

13 Machine cover and windows To be free of breakage and deformation

—
To be in place
(c
ht

14 Bellows To be free of damage such as breaks, Y-axis bellows Maintenance Manual 5-8
tears, frays or holes
ig

To be in place
yr
op

Note : Knife edges with their brackets (of the type and dimensions as required for the
C

particular machine) may be manufactured by the user referring to the following

drawings. The table preceding the drawings enumerates the relevant parts with their
required quantity for the particular type and specification of machine.

4-1
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

4-2 Pallet Assembly Drawing and Component Parts

Check the status of each component part and if necessary, replace the part with a new one that
is to be manufactured by the user. Using the pallet improperly could cause damage to the
machine.

.
d
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
D699MA0001
87

Fig. 4-1 General view

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

4-2
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

164 254 217

193

265
172 222
264 217

.
181

d
ve
er
s
211 210

re
ts
gh
ri
ll
.A
A

N
C

O
B3 C
TI
A
87

B2 A
R
B1
14

PO
31

R
o.

O
N

270
al

K
ri

257
ZA
Se

266
A
IM
K

254 B1: 202

164
ZA

189
B2, B3: 217
A
M
YA
3
01
)2
(c
ht

260
ig
yr

B1, B3: 171 218

177
op

B2: 172 259

C

210
211

B
D639MA0002

Fig. 4-2 Pallet assembly drawing (standard)

4-3
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

164 254
193 217

265
172
264 222
181 217

d.
250

ve
er
164

s
211 210

re
ts
gh
242

ri
ll
.A
A

N
O
B3 C
TI
87

B2 A A
R
B1
14

PO
31

R
o.

O
N

274
al

K
ri

ZA

273
Se

C
A
IM

254 B1: 202

K

164 189
ZA

B2, B3: 217

A
M
YA
3
01
)2
(c

260
ht

B1, B3: 171

ig

B2: 172 218

177
yr

259
op
C

246 164 210

211

238

B
D639MA0003

Fig. 4-3 Pallet assembly drawing (loader specification)

4-4
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Table 4-2 Table of parts

Reference Laser
No. Parts No. Name Standard Remarks
No. FMS
1 164 06265205650 Knife edge 62 98 Knife edge
2 171 06265206931 Plate 8 Outer frame
3 172 06265206941 Plate 8 Outer frame
4 177 06265206890 Bracket 6 Outer frame
5 181 06265206900 Bracket 2 Outer frame
6 189 06265206910 Bracket 6 Outer frame
7 193 06265206921 Bracket 2 Outer frame
8 202 06265207050 Cover 4 Diagonal cover
9 210 06265207070 Bracket 16 Spatter protective cover for mounting screw

d .
ve
10 211 06265207080 Bracket 16 Spatter protective cover for mounting screw

er
11 217 06265207060 Cover 16 Diagonal cover

s
re
12 218 06265207030 Cover 12 Diagonal cover
13 222 06265207040 Cover 4 Diagonal cover

ts
gh
14 254 06265205150 Plate 40 Adhesion prevention plate

ri
15 257 06265205740 Plate 2 Center joint

ll
16 259 06265206950 Plate 6 Center

.A
17 260 06265206970 Plate 6 Center

N
18 264 06265206960 Plate 2 Center

O
TI
19 265 06265206980 Plate 2 Center
87

20 266 06275201050 Bracket 2 A 0 Center end face

R
14

PO

21 270 06275201060 Bracket 2 0 Center end face

31

22 166 06265206200 Knife edge 0 24 Knife edge

R
o.

23 238 06265206990 Plate 0 6 Fixing plate

N

24 242 06265207000 Plate 0 2 Fixing plate

al

K
ri

ZA

25 246 06265207010 Plate 0 6 Fixing plate

Se

26 250 06265207020 Plate 0 2 Fixing plate

A
IM

27 273 06265207090 Bracket 0 2 Center end face

28 274 06265207100 Bracket 0 2 Center end face
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

4-5
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

Part No.: 06265205650

PO
31

Fig. 4-4 Knife edge (No. 1)

R
o.

O
N

Unit: mm [in]
C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265206931

Fig. 4-5 Plate (No. 2)

4-6
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

Part No.: 06265206941

PO
31

Fig. 4-6 Plate (No. 3)

R
o.

O
N

Unit: mm [in]
C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265206890

Fig. 4-7 Bracket (No. 4)

4-7
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

Part No.: 06265206900

PO
31

Fig. 4-8 Bracket (No. 5)

R
o.

O
N

Unit: mm [in]
C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265206910

Fig. 4-9 Bracket (No. 6)

4-8
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

Part No.: 06265206921

PO
31

Fig. 4-10 Bracket (No. 7)

R
o.

O
N

Unit: mm [in]
C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265207050

Fig. 4-11 Cover (No. 8)

4-9
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
Part No.: 06265207070
14

PO
31

Fig. 4-12 Bracket (No. 9)

R
o.

O
N

Unit: mm [in]
C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265207080

Fig. 4-13 Bracket (No. 10)

4-10
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06265207060
87

Fig. 4-14 Cover (No. 11)

A
R
14

PO
31

Unit: mm [in]
R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265207030

Fig. 4-15 Cover (No. 12)

4-11
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06265207040
87

Fig. 4-16 Cover (No. 13)

A
R
14

PO
31

Unit: mm [in]
R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265205150

Fig. 4-17 Plate (No. 14)

4-12
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
Part No.: 06265205740

O
TI
Fig. 4-18 Plate (No. 15)
87

A
R
14

PO

Unit: mm [in]
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265206950

Fig. 4-19 Plate (No. 16)

4-13
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
87

A Part No.: 06265206970

R
14

PO
31

Fig. 4-20 Plate (No. 17)

R
o.

O
N

Unit: mm [in]
C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265206960

Fig. 4-21 Plate (No. 18)

4-14
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
87

A Part No.: 06265206980

R
14

PO
31

Fig. 4-22 Plate (No. 19)

R
o.

O
N

Unit: mm [in]
C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06275201050

Fig. 4-23 Bracket (No. 20)

4-15
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
Part No.: 06275201060

O
TI
Fig. 4-24 Bracket (No. 21)
87

A
R
14

Unit: mm [in]
PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265206200

Fig. 4-25 Knife edge (No. 22)

4-16
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
Part No.: 06265206990

O
TI
Fig. 4-26 Plate (No. 23)
87

A
R
14

PO

Unit: mm [in]
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op

Part No.: 06265207000

C

Fig. 4-27 Plate (No. 24)

4-17
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
Part No.: 6265207010

O
TI
Fig. 4-28 Plate (No. 25)
87

A
R
14

PO

Unit: mm [in]
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op

Part No.: 06265207020

C

Fig. 4-29 Plate (No. 26)

4-18
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06265207090
87

Fig. 4-30 Bracket (No. 27)

A
R
14

PO
31

Unit: mm [in]
R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06265207100

Fig. 4-31 Bracket (No. 28)

4-19
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

4-3 Heat-Resistant Plate Assembly Drawing and Component Parts

1. How to open the operator door when replacing the heat-resistant plate or cleaning the
inside of the machine

A. Items to be checked
Before replacing the heat-resistant plate or cleaning the inside of the machine, always make sure
of the following.
Be sure to follow the safety instructions when performing operations.

 Do not close the operator door when you are in the machine.

d.
 When entering the machine, hang a “Caution: Now working in the machine” plate on the

ve
emergency stop button on the NC operating panel to make it known to other workers that

er
WARNING
you are working in the machine.

s
re
Check to make sure that both pallets 1 and 2 are placed on the pallet changer side.

ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM

D699MA0011
K

Fig. 4-32 Machine with a 2-pallet changer

ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

4-20
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

B. Opening the operator door

(1) Set the machine setup switch to “l” (ON).

Machine setup switch

.
d
ve
er
s
re
D697MA0035

ts
Fig. 4-33 Turning on the machine setup switch

gh
ri
(2) Press the door unlock key to open the operator door.

ll
.A
N
Door unlock key

O
TI
87

A
R
14

PO
31

R
o.

1. Press the door unlock key.

N

C
al

K
ri

ZA
Se

2. Open the
A

operator door.
IM

D698MA0003
K
ZA

Fig. 4-34 Opening the operator door

A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

4-21
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

2. Heat-resistant plate assembly drawing and component parts (2.0 kW/3.0 kW)
Check the status of each component part and if necessary, replace the part with a new one that
is to be manufactured by the user. Using the heat-resistant plate improperly could cause damage
to the machine.

2.0 kW machine

7 2 6 2 6 2 5

d .
ve
s er
re
1
1

ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

PO
31

8 3 4 9 4 3 9 4 3 8
R
o.

O
N

3.0 kW machine
al

K
ri

ZA
Se

12 13 10 15 14 10 15 14 20 21 10 13 12
IM
K
ZA
A
M
YA

1
1
3
01
)2
(c
ht
ig
yr
op
C

17 16 11 19 18 11 19 18 11 16 17

D698MA0004

Fig. 4-35 Heat-resistant plate assembly drawing

4-22
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Table 4-3 Table of parts

No. Name Parts No. Q’ty No. Name Parts No. Q’ty
1 Cover 06983700290 4 12 Cover 06983700130 2
2 Cover 06983700050 3 13 Cover 06983700180 2
3 Cover 06983700090 3 14 Cover 06983700141 2
4 Cover 06983700040 3 15 Cover 06983700190 2
5 Cover 06983700060 1 16 Cover 06983700110 2
6 Cover 06983700070 2 17 Cover 06983700210 2
7 Cover 06983700080 1 18 Cover 06983700120 2
8 Cover 06983700020 2 19 Cover 06983700220 2
9 Cover 06983700030 2 20 Plate 06983700260 12

.
10 Cover 06983700160 3 21 Plate 06983700240 48

d
ve
11 Cover 06983700171 3

s er
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

4-23
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700290
87

A
R
Fig. 4-36 Cover (No. 1)
14

PO
31

Unit: mm [in]
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06983700050

Fig. 4-37 Cover (No. 2)

4-24
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700090
87

A
R
Fig. 4-38 Cover (No. 3)
14

PO
31

Unit: mm [in]
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06983700040

Fig. 4-39 Cover (No. 4)

4-25
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700060
87

A
R
Fig. 4-40 Cover (No. 5)
14

PO
31

Unit: mm [in]
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06983700070

Fig. 4-41 Cover (No. 6)

4-26
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700080
87

A
R
Fig. 4-42 Cover (No. 7)
14

PO
31

Unit: mm [in]
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06983700020

Fig. 4-43 Cover (No. 8)

4-27
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700030
87

A
R
Fig. 4-44 Cover (No. 9)
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

4-28
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700160
87

A
R
Fig. 4-45 Cover (No. 10)
14

PO
31

Unit: mm [in]
R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06983700171

Fig. 4-46 Cover (No. 11)

4-29
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700130
87

A
R
Fig. 4-47 Cover (No. 12)
14

PO
31

Unit: mm [in]
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06983700180

Fig. 4-48 Cover (No. 13)

4-30
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700141
87

A
R
Fig. 4-49 Cover (No. 14)
14

PO
31

Unit: mm [in]
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06983700190

Fig. 4-50 Cover (No. 15)

4-31
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700110
87

A
R
Fig. 4-51 Cover (No. 16)
14

PO
31

R
o.

Unit: mm [in]
O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06983700210

Fig. 4-52 Cover (No. 17)

4-32
 Serial No. 311487

DAILY INSPECTION OF LASER MACHINE 4

Unit: mm [in]

d .
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Part No.: 06983700120
87

A
R
Fig. 4-53 Cover (No. 18)
14

PO
31

Unit: mm [in]
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

Part No.: 06983700220

Fig. 4-54 Cover (No. 19)

4-33
 Serial No. 311487

4 DAILY INSPECTION OF LASER MACHINE

Unit: mm [in]

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Part No.: 06983700260
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Fig. 4-55 Plate (No. 20)
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Unit: mm [in]
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Part No.: 06983700240

Fig. 4-56 Plate (No. 21)

4-34 E
 Serial No. 311487

PERIODIC MAINTENANCE AND INSPECTION 5

5 PERIODIC MAINTENANCE AND INSPECTION
To operate the laser machine, carry out the periodic maintenance and inspection as listed below:
 Daily maintenance and inspection
 Periodic maintenance and inspection of the oscillator
 Periodic maintenance and inspection of the chiller unit
 Periodic maintenance and inspection of the dust collector
 Periodic maintenance and inspection of the laser machine

5-1 Daily Maintenance and Inspection

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 Refer to Section 4-1 “Maintenance and Inspection.”

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5-2 Periodic Maintenance and Inspection of the Oscillator

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Table 5-1 Periodic maintenance and inspection items of the oscillator

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By By Mazak
No. Inspection item Contents Work Remarks Reference section

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customer (Note)

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1 Measurement of Inspection Once a year

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 —
87

output
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14

The intervals indicated in the “Remarks” column are only for reference purpose and do not show
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the values for guarantee.

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Note : Please consign to Mazak Technical Center or Technology Center the items falling
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within the scope of Mazak. Consumables costs and part replacement expenses,
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however, are to be borne by the customer.

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5-1
 Serial No. 311487

5 PERIODIC MAINTENANCE AND INSPECTION

5-3 Maintenance and Inspection of the Chiller Unit

Table 5-2 Maintenance and inspection items of the chiller unit

By By Mazak
No. Inspection item Contents Work Remarks Reference section
customer (Note)
1 Condenser air filter 1 filter Cleaning If very dirty, or every Maintenance
 6 months Manual 8-7-1
Change If the net is broken or torn
2 Y-strainer 1 seal Cleaning Every 6 months (At the Operating manual
time of replacement of the of the chiller unit
 filter)
Change If the mesh is broken or
torn

.
3 Cooling water 2.0 kW machine Change Every 6 months Maintenance

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Fresh water: 20 L Manual 8-2, 8-4,
(0.71 ft3) 8-6

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(laser system) 

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Fresh water: 10 L
(0.35 ft3)

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(optical system)

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3.0 kW machine Change Every 6 months Maintenance

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Fresh water: 60 L Manual 8-2, 8-4,

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(2.12 ft3) 8-6

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(laser system) 

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Fresh water: 10 L

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(0.35 ft3)

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(optical system)
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4 Water filter element Oscillator system: 1 Change

A If the pressure loss Operating manual
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Optical system: 1 increases more than of the chiller unit

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
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0.07 MPa with respect to

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the initial value

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5 Simplified inspec- Exterior checking Visual Every 3 months Maintenance

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tion of the chiller inspection Manual 5-6

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
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unit Operating manual

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of the chiller unit

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The intervals indicated in the “Remarks” column are only for reference purpose and do not show
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the values for guarantee.

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Note : Please consign to Mazak Technical Center or Technology Center the items falling
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within the scope of Mazak. Consumables costs and part replacement expenses,
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however, are to be borne by the customer.

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3

5-4 Periodic Maintenance and Inspection of the Dust Collector

01
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Table 5-3 Periodic maintenance and inspection items of the dust collector
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By By Mazak
No. Inspection item Contents Work Remarks Reference section
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customer (Note 1)
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1 Dust collector (Note 2) (Note 2) (Note 2) Maintenance

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 manual of the dust

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collector
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The intervals indicated in the “Remarks” column are only for reference purpose and do not show
the values for guarantee.
Note 1: Please consign to Mazak Technical Center or Technology Center the items falling
within the scope of Mazak. Consumables costs and part replacement expenses,
however, are to be borne by the customer.
Note 2: Refer to the maintenance manual accompanying the dust collector.

5-2
 Serial No. 311487

PERIODIC MAINTENANCE AND INSPECTION 5

5-5 Periodic Maintenance and Inspection of the Laser Machine
Table 5-4 Periodic maintenance and inspection items of the laser machine

By By Mazak
No. Inspection item Contents Work Remarks Reference section
customer (Note)
1 Assist gas circuit Cleaning As required
 —
filter
2 Air circuit filter  Cleaning the auto Cleaning As required Maintenance
drain Change Manual 7-1-2
 Replacing the
filter elements 
 Cleaning the
rotary receive
type air filter

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3 X- and Y-axis rack Replacing the Change Every 4500 hours

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 —
and pinion lubrication pinion

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4 X- and Y-axis LM Replacing the Change Every 2000 hours Maintenance

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guide grease cartridge of Manual 6

the grease pump

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X- and Y-axis rack

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and pinion

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5 Z-axis LM guide Grease lubrication Lubrication Every 6 months Maintenance

Manual 6

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6 Intelligent setup  Replacing the Cleaning As required Maintenance
function nozzle cleaning Change Manual 11

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brush Operation

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check

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 Cleaning and
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operation check of A
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the automatic
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nozzle changer
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(as required)
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 Replacing the
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focus detection
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plate
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7 Replacing the torch Replacing the ring Change As required Maintenance

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tip insulating rings Manual 9-5-1

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8 Cleaning the torch Cleaning Every 6 months Maintenance


tip Manual 9-5-3
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9 Protective window Replacing the Change Every 6 months or when Maintenance


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O-ring O-ring damaged Manual 10-5-3

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10 Cartridge upper and Replacing the Change Every 6 months or when Maintenance
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lower surface O-ring  damaged Manual 10-5-3

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O-rings
11 Cartridge lower Replacing the resin Change Once a year or when Maintenance

3

surface resin seal seal damaged Manual 10-5-3

01

12 Protective window Replacing the Change Once a year or when Maintenance

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cartridge cover O-ring  damaged Manual 10-5-5

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O-ring
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13 Battery box Replacing the Change Once a year Maintenance


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batteries Manual 7-2

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14 X-axis belt Replacing the belt Change  Every 6000 hours —

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The intervals indicated in the “Remarks” column are only for reference purpose and do not show
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the values for guarantee.

Note : Please consign to Mazak Technical Center or Technology Center the items falling
within the scope of Mazak. Consumables costs and part replacement expenses,
however, are to be borne by the customer.

5-3
 Serial No. 311487

5 PERIODIC MAINTENANCE AND INSPECTION

5-6 Inspection of Devices using Freon

The machine is equipped with devices using Freon or a similar cooling medium that causes
global warming.
Check the following items and the exterior of the device every 3 months and keep a record of the
checking results (simplified inspection).
 Fouling and clogging of filters
 Cooling medium leakage from pipe connections
 Abnormal or excessive operation noise
Note : Devices requiring periodic inspections (see the table below) have to undergo an expert
inspection at least once a year. Periodic inspections should be carried out by or in the

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presence of a person having adequate knowledge of how to examine the machine.

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These periodic inspections should be performed systematically, e.g. by an external

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expert.

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Chiller unit
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D698MA0021
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Fig. 5-1 Location of the device using Freon

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Simplified Periodic
Laser output/
3

No. Name Model No. inspection inspection

01

Frequency
(every 3 months) (every year)
)2

1 Chiller unit 2.0 kW/50 Hz, 60 Hz RKE2200B1-V-2CH-MF  —

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3.0 kW/50 Hz, 60 Hz RKE3750B-V-2CH-MF  —

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Remark : The chiller unit installed differs according to the laser output of the machine and the
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supply frequency.
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5-4
 Serial No. 311487

PERIODIC MAINTENANCE AND INSPECTION 5

5-7 Removing Chips

5-7-1 Scrap bucket

1. Removing chips from the scrap bucket

A bucket needs to be pulled out from the machine to remove the chips.

 Be sure to power off the machine when cleaning up the chips.

 If a bucket is pulled out during machining, the machine will be brought to a feed hold stop.
WARNING  When removing chips from a bucket, use a scoop or similar, but do not directly touch them
with hands. Failure to follow this instruction may result in injury.

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<Procedure>

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(1) Stop and turn off the machine.

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(2) Pull out the bucket, using the handle on it.

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(3) Remove chips from the bucket, using a scoop or similar.

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(4) Push the bucket along the guide to return it to the same position where it was.

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At that time, push in the bucket as far as it will go and return the handle to the handle holder.

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Handle Handle holder

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Bucket
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D699MA0012
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Fig. 5-2 Scrap bucket

5-5
 Serial No. 311487

5 PERIODIC MAINTENANCE AND INSPECTION

2. Steps to follow to restore the machine in case a bucket is pulled out by mistake during
operation
If a bucket is pulled out during machining, the machine will be brought to a feed hold stop.
(1) Push in the bucket as far as it will go and return the handle to the handle holder.

(2) Press the clear key to turn off the alarm 1797 CHIP BUCKET SENSOR ALARM.
The program being executed at that time is not reset by this operation.

(3) To restart the suspended program, press the cycle start button .

5-8 Inspection of Bellows

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 Check to make sure that the bellows is free of damage such as breaks, tears, frays or

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holes. If any damage is found, immediately stop the use of the machine and replace the
bellows. Using the machine with the damaged bellows might cause serious damage to the

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CAUTION

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machine or cause a fire.

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Y-axis bellows
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D698MA0043’
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5-6 E
 Serial No. 311487

LUBRICATION 6
6 LUBRICATION

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Grease pump

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D698MA0006

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Fig. 6-1 Lubricating points

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Table 6-1 Lubrication table

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Lubricating Recommended Reference

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points Application Quantity Parts No. Remarks section
oil
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Grease X- and Y-axis 400 mL Lube MP0 P52LA000100 Every year or 6-1
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pump linear guide (24.41 in3) (NLGI #0) every 2000 h

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X- and Y-axis (Replacing the

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rack and pinion grease cartridge)

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The intervals indicated in “Remarks” column above are only for reference purpose and do not
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show the values for guarantee. If there is not enough grease or oil left, add it.
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6-1
 Serial No. 311487

6 LUBRICATION

6-1 Replenishing Grease for Slideway Lubrication (as Needed)

Replace the grease cartridge for the slideway lubricating grease well in advance.

 The “Low” level line to indicate the replacement timing of the cartridge is only a guideline.
An alarm may occur even when the level is approximately 20 mm (0.79 in) above the Low
level, and this is not abnormal.
CAUTION

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Approx. 20 mm

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(0.79 in)

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Level line (guideline)

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Fig. 6-2 Low level line on the grease cartridge cover

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Once the alarm 258 GEAR GREASE ALARM has occurred, the lubrication system stops
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sucking grease. After the occurrence of the alarm, replace the grease cartridge quickly by
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following the procedure described in “3. Replenishing grease at the occurrence of an alarm” to
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supply grease.
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6-2
 Serial No. 311487

LUBRICATION 6
1. Prohibitions about the use of grease

 Failure to observe these prohibitions might result in a machine trouble, coagulation or

performance degradation. (The term “coagulation” refers to a phenomenon in which
grease becomes hard.)
CAUTION

 Do not use any brand of grease other than those recommended by the manufacturer.

 For the recommended brands of grease, see Table 6-1, “Lubrication table”.

 It is recommended to use NLGI #0 grease. If used, NLGI #1 or higher grease with a high

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consistency may coagulate in the piping, prevent the lubrication of the rack and the linear

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guide, and thus shorten their lives.

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 Do not use grease that has been stored for a prolonged period and whose oil has been

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separated from the base material, though there is no harm in using grease whose oil has

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slightly oozed to the surface.

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 Do not allow entry of foreign matter into the grease pump when replacing the grease

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cartridge.

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 Always bleed the air by opening the air bleed valve after replacing the grease cartridge.

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 Do not use grease containing substances that corrode brass or rubber.

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2. Notes on the storage of grease

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 Close the lid securely.

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 Store the grease indoors, in a cool place where it will not be exposed to sunlight, rain water
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and dust.
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 Neither the product name nor the product type is marked on the grease cartridge, so be
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careful not to mistake it for another cartridge.

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 Be sure to replace the whole cartridge when adding grease.

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 Always keep a spare cartridge handy.

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 Do not replenish the cartridge with grease to reuse it. Doing so will cause air and dust to get
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into the cartridge and may cause a breakdown.

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3. Replenishing grease at the occurrence of an alarm

3
01

If the alarm message 258 GEAR GREASE ALARM is displayed, perform the steps below.
)2

When grease has been used up, replace the grease cartridge following the procedure explained
(c

in item “4. Replacing the grease cartridge” and then perform the steps below.
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If grease remains in the grease pump although the alarm occurred, air could have been
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entrained in the greasing circuit. In this case, bleed the air following the procedure explained in
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item “5. Bleeding air” and then perform the steps below.
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6-3
 Serial No. 311487

6 LUBRICATION

<Procedure>

(1) Press the clear key to turn off the alarm.

(2) Press the [MAINTENANCE] screen selection key to display the screen selection
keys in the same group.
Press the [SWITCH] screen selection key to display the SWITCH screen shown below.

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(3) Select the [BUTTON1] tab in the middle to display the BUTTON1 window.
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6-4
 Serial No. 311487

LUBRICATION 6
(4) Press the [Gear Grease Pump ON] key.
The LED indicator at the side of the button lights up and the supply of grease starts. After
about 5 minutes in which the supply of grease is completed, the LED indicator is turned off.
To prevent overheating, the gear lubrication pump cannot be operated within 15 minutes
after the completion of the supply of grease.
(5) If the alarm 258 GEAR GREASE ALARM is raised again, air may be present in the circuit.
So purge the air following the instructions in the “5. Bleeding air” section, and then perform
the above steps again.

4. Replacing the grease cartridge

3

.
Grease cartridge capacity: 400 mL (24.41 in )

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 Do not use any brand of grease other than those recommended by the manufacturer.

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 Never refill the grease cartridge that has been used up. Failure to observe this instruction

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can cause machine trouble.

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CAUTION

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 Store a grease cartridge in a cool dark place not exposed to rain and dust.

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<Procedure>

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(1) Turn off the NC unit.

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Note : Starting the pump with no cartridge on it will cause the pump to suck air and lead to a

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serious problem.
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(2) Turn the cover by hand in the counterclockwise direction to remove it from the pump.
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(3) Remove the empty cartridge by turning it in the counterclockwise direction.

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Note : Do not wipe around the suction port of the pump with a waste cloth or the like.
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Fig. 6-3 Replacing the grease cartridge (1/4)

3
01

(4) While holding a new cartridge by hands, push it by hands to extract grease about 10 mm
)2

(0.39 in).
(c

 This can minimize the entry of air into the pump suction port.
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Fig. 6-4 Replacing the grease cartridge (2/4)

6-5
 Serial No. 311487

6 LUBRICATION

(5) Mount the cartridge by turning the cartridge in the clockwise direction while putting the
extracted grease into the cartridge mounting hole.
 Pay attention so that foreign matter may not enter the cartridge mounting hole.

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Fig. 6-5 Replacing the grease cartridge (3/4)

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(6) Fit the cover by turning it in the clockwise direction by hand until it stops.

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Fig. 6-6 Replacing the grease cartridge (4/4)

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(7) Turn on the NC unit and operate the pump to confirm that it operates correctly.
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6-6
 Serial No. 311487

LUBRICATION 6
5. Bleeding air
<Procedure>
(1) Loosen the air bleed valve by turning it about one turn in the counterclockwise direction with
a wrench (hex. 8 mm).
(2) Operate the pump.
 Grease will ooze through the air bleed hole with air.
 Air bleeding is complete if grease not containing air oozes continuously.
(3) Tighten the air bleed valve by turning it in the clockwise direction with a wrench.
(4) Operate the pump again to confirm that there is no grease leakage through the air bleed
plug. After that confirm that the pump is operating correctly.

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Air bleed valve

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D626MA0004
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Fig. 6-7 Air bleed valve

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Air bleed hole

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D626MA0005
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Fig. 6-8 Air bleed hole

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6-7
 Serial No. 311487

6 LUBRICATION

6-2 Removing Grease from the Lower Surface of the Z-Axis

As the Z-axis ball screw is lubricated with grease, used grease accumulates in the grease
receptacle on the lower surface of the Z-axis. To prevent grease from dropping on the material
and causing a machining failure, wipe off the grease on a regular basis.

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A D699MA0014
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Fig. 6-9 Cleaning point of grease on the lower surface of the Z-axis linear guide
31

 Before stating cleaning, be sure to press the emergency stop button.

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 Be sure to take out the used waste cloth etc. from the machine before starting operation.
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Failure to do so could result in a fire.

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WARNING
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 Be very careful not to hit against the tip of the torch or the like when doing the cleaning.
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 To avoid a machining failure, do not allow grease to contact the tip of the nozzle.
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CAUTION
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6-8 E
 Serial No. 311487

CHANGE AND MAINTENANCE OF THE AIR FILTERS 7

7 CHANGE AND MAINTENANCE OF THE AIR FILTERS

7-1 Maintenance of the Air Circuit Filters

The maintenance operations required differ according to the type of filter.

7-1-1 Daily inspection

Perform the following items during daily inspection of the air circuit filters:

Note:
AME150C AMF150C AME150C The filter element of this filter does not require replacement.
Never disassemble.

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AMH250C AMH150C

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IDG60SA
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AFF2C
AFF2B
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AMG350C
D698MA0008’
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Fig. 7-1 Daily inspection

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Table 7-1 Daily inspection

Reference
3

Filter Parts No. Maker Inspection item

01

section
)2

Micro mist separator (Note) AMH150C SMC Dirtiness of the filter elements 7-1-1, 1
(c

Super mist separator (Note) AME150C SMC Dirtiness of the filter elements 7-1-1, 1
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Odor-removable filter (Note) AMF150C SMC — —

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Micro mist separator AMH250C SMC Draining water from the filter 7-1-1, 2
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Checking the operation of the 7-1-1, 3

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automatic drain
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Main line filter AFF2C SMC Draining water from the filter 7-1-1, 2
Water separator AMG350C SMC Draining water from the filter 7-1-1, 3
Air dryer IDG60SA SMC Checking the dew-point checker 7-1-1, 4

Note : The detection of any dirty filters results in machine alarm 283 DIRT OF AIR FILTER.

 If this alarm occurs, replace the filter elements seeing Item 1 in Subsection
7-1-2.

7-1
 Serial No. 311487

7 CHANGE AND MAINTENANCE OF THE AIR FILTERS

1. Dirtiness of the filter elements

A. AMH150C
Check whether machine alarm 283 DIRT OF AIR FILTER is occurring. If this alarm is occurring,
replace all filter elements.

 For details refer to Item 1 in Subsection 7-1-2.

B. AME150C
Check for red spots visible from the sight glass. If any red spots are visible, replace all filter

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elements.

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 For details refer to Item 1 in Subsection 7-1-2.

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2. Draining water from the filter

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.A
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A. AMH250C, AFF2C (with drain cock)

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Check whether the liquid level is visible from the sight glass. If the liquid level is visible, perform
87

the following items: A

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(1) Fully rotate the knob counterclockwise (through about one and a half turns) to drain the
31

water.
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Knob
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D614M0052
3
01
)2

(2) Return the knob to its original position.

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7-2
 Serial No. 311487

CHANGE AND MAINTENANCE OF THE AIR FILTERS 7

3. Checking the operation of the automatic drain

A. AMH250C (with automatic drain), AMG350C (with automatic drain)

Check whether the liquid level is visible from the sight glass. If the liquid level is visible, perform
the following items:

Sight glass

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D614M0053

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The automatic drain is not functioning when the casing contains water.

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(1) Fully rotate the knob counterclockwise to drain the water.

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Knob
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D614M0052
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If the water is not drained even so, the casing assembly may be in trouble. Replace the assembly.
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Model: AMH-CA250C, AM-CA350C

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3
01
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7-3
 Serial No. 311487

7 CHANGE AND MAINTENANCE OF THE AIR FILTERS

4. Checking the dew-point checker

Dew-point checker

IDG60SA

D614M0101

d .
ve
er
A. IDG60SA

s
re
During operation, closely observe the color of the grains within the dew-point checker. If the color

ts
of the grains is either yellow, pink, or white, this indicates a decrease in performance; replace the

gh
membrane module set in that case.

ri
ll
Table 7-2 Status of the membrane air dryer

.A
Color of the grains

N
Dryer status
in the dew-point checker

O
TI
Green or blue Normal
87

Yellow, pink, or white A

Decrease in performance
R
14

PO
31

Note 1: It takes about one hour for the grains within the dew-point checker to react in color after
R

air has been supplied.

o.

O
N

Note 2: Return the air pressure to zero before attempting any maintenance steps.
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
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C

7-4
 Serial No. 311487

CHANGE AND MAINTENANCE OF THE AIR FILTERS 7

7-1-2 Periodic inspection

1. Replacing the filter element

A. Replacing timing
Replace all filter elements if either of the following applies:
 2000 hours have passed
 Red spots are visible
 Machine alarm 283 DIRT OF AIR FILTER has occurred

B. Types of filters to be replaced

. d
ve
 AMH150C, AME150C, AMF150C, AMH250C, AMG350C, AFF2C (SMC)

s er
C. SMC filter replacement procedure

re
ts
<Tools and materials required>

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Allen wrench

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Filter element

ll
.A
Filter model Filter element model Part No.

N
O
AMH150C AMH-EL150 G48SV002630

TI
AME150C AME-EL150 G48SV002640
87

AMF150C AMF-EL150
A
G48SV002650
R
14

PO

AMH250C AMH-EL250 G48SV002690

31

AMG350C AMG-EL350 G48SV001940

R
o.

AFF2C AFF-EL2B G48SV003670

N

C
al

<Procedure>
ri

ZA
Se

(1) Depressurize the body. (Reduce the pressure to 0 MPa.)

A
IM

(2) Remove the screws while holding the housing with a hand.
K

(3) Remove the element, O-ring and gasket.

ZA

(4) Clean the housing.

A
M

(5) Set an element, an O-ring and a gasket.

YA

(6) Attach and tighten the screws.

3
01
)2

Hexagonal socket
head screw
(c

O-ring (new)
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ig

O-ring (used) O-ring

Gasket (new)
yr
op

Gasket (used)
Gasket
C

Filter element
(new)
Filter element (used) Filter
element

Housing
D628MA0035

7-5
 Serial No. 311487

7 CHANGE AND MAINTENANCE OF THE AIR FILTERS

D. Replacing the membrane module set and the dew-point checker

Dew-point checker

IDG60SA

D614M0101

.
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ve
Name of the replacement part Model Part number

ers
Membrane module set IDG-EL60LA G48SV005020

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Dew-point checker IDG-DP01 G48SV003600

ts
gh
Replacement timing

ri
Replace the membrane module set as soon as possible after a color change to yellow, pink, or

ll
.A
white, in the dew-point checker.

N
Part to be replaced

O
TI
IDG60SA (manufactured by SMC)
87

A
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14

PO
31

R
o.

O
N

C
al

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A
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A
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3
01
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7-6
 Serial No. 311487

CHANGE AND MAINTENANCE OF THE AIR FILTERS 7

Procedure for replacing the membrane module set
(1) Return the internal air pressure of the membrane air dryer to zero.
(2) Loosen the holder.
(3) Lower the casing vertically and remove it from the body.
(4) Remove the old membrane module set from the casing.
(5) Make sure that the new membrane module set to be used has a packing and a spacer.
(6) Hold the new membrane module set vertically and fully insert the module set into the casing.
(7) Fit the packing to the edge of the casing and set the packing.
(8) Insert the casing into the body vertically.
(9) Rotate the holder to screw it up into the body (the purging hole in the casing can face in any

d .
ve
direction).

ser
(1) Return the air pressure to zero. (2) Loosen the holder. (3) Remove the casing.

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Body

ts
Threaded
section

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Membrane air

ri
dryer Holder

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Casing

.A
N
O
TI
(4) Remove the membrane module (5) Confirm the presence of a (6) Mount the new membrane
87

set. packing and a spacer. module set.

A
R
14

Module New membrane

PO

Old membrane
31

module set
module set New
R

Packing
o.

membrane Mount the module

O
N

module set set so that the

C

round hole in the

al

module is invisible
ri

Casing
ZA

from the slot in the

Se

Spacer
casing.
A
IM

(7) Fit the packing. (8) Insert the casing. (9) Tighten the holder.
K

Fit the packing to the edge of

Body
ZA

the casing and set the packing.

Be careful so as not to slide the
A

Holder
packing too deeply.
M
YA

Edge of the casing

Casing
3
01
)2

Casing
(c
ht
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C

7-7
 Serial No. 311487

7 CHANGE AND MAINTENANCE OF THE AIR FILTERS

7-2 Replacing the Batteries in the Battery Box

There are two types of battery boxes: battery box for the absolute position detection system and
battery box for the machine relocation detector (RD). See the figure below for their locations.
When replacing the batteries, follow the battery replacement procedure for each battery box.

.
d
ve
ser
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ts
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ri
Battery box for the absolute

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Battery box for the machine relocation

.A
position detection system detector (RD) D699MA0013

N
Fig. 7-2 Installation position of the battery box

O
TI
87

7-2-1 Battery box for the absolute position detection system A

R
14

PO

Replace the batteries annually even if the alarm is not raised.

31

If the voltage of the batteries in the box drops, one of the following alarms will be raised:
R
o.

O
N

No. Alarm message No. Alarm message

al

5002 X1 Battery warning 5302 Z Battery warning

ri

ZA
Se

5102 X2 Battery warning 5602 2PC Battery warning

A

5202 Y Battery warning

IM
K

If this is the case, replace the batteries in the battery box shown in the figure above following the
ZA

steps described below. Three D size alkaline batteries are used for each battery box.
A

Note : The alkaline batteries that came installed in your device could run down in a year or
M

less. When the batteries have run down, replace them with new alkaline batteries to be
YA

supplied by the customer.

3
01

Danger with the battery box:

)2

2
 Do not store or use the equipment under conditions subjected to vibrations (9.8 m/s
(c

2
(32 ft/s ) or heavier) or an impact shock, foreign matters such as dust, metal particles, oil
ht

DANGER
mist, liquids such as water, oil and coolant near flammable objects, in an atmosphere of
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corrosive gas (such as H2S, SO2, NO2, Cl2), or in an atmosphere of flammable gas.
op

 Do not place any flammable objects near the battery box.

C

 Do not install the equipment near the heating object such as heater or large wire-wound
resistor. (Install a thermal shield, etc. to avoid the influences of heating object.)
 Do not supply power to the battery box from the exterior.
 Do not use the equipment under conditions subject to strong vibrations or an impact
shock.
 Install and mount the equipment securely to prevent personal injury caused by poor
installation or mounting during an earthquake.

7-8
 Serial No. 311487

CHANGE AND MAINTENANCE OF THE AIR FILTERS 7

 When replacing a battery, avoid entry of conductive dust such as wire chippings inside the
battery box.
 Please tighten the screw of battery box body and lid firmly below max. torque [M4:
DANGER
1.0 N·m (0.74 ft·lbf), M5: 2.5 N·m (1.84 ft·lbf)].

Carefully read and understand the “Handling Precautions” before using the battery.
As a reference, we provide warnings of the recommended battery (Panasonic made alkaline
battery).
WARNING
 Do not short circuit batteries. Do not carry or store batteries with necklaces, hairpins,
coins, keys, or other metal objects. Also do not remove and damage the exterior of a
battery. Metal objects can cause short circuit in the positive and negative terminals of

d.
batteries, resulting in the flow of large electrical currents that can cause heat generation,

ve
er
explosion or fire, or generate heat in the metal objects.

s
 Do not insert a battery with the positive and negative poles reversed. There is a risk that

re
the battery may generate heat, leak the liquid, rupture because of abnormal reaction to the

ts
gh
charge or be short circuited.

ri
 Do not put the battery in fire, apply heat or modify. Damaging safety valve or insulator may

ll
cause heat generation, leak or rupture.

.A
 Do not recharge alkali primary battery. Alkali primary battery cannot be recharged.

N
O
Charging battery will generate gas inside a battery. As a result, there is a risk of heat

TI
generation, leaking liquid or rupture because the internal pressure will damage the
87

insulator.
A
R
14

PO
31

 Do not use a new battery with a used battery, and also do not use batteries of different
R

types or sizes together. Using batteries of different voltages or sizes together may cause
o.

O
N

not only the device to malfunction, but also the battery that is exhausted earlier to be
C
al

overused (overdischarge) because of a difference in performance between the batteries.

K
ri

ZA

So, it is not only uneconomical, but may cause the batteries to generate heat, the
Se

electrolyte to leak, the batteries to explode, and the device to be damaged.

IM

 Do not give a shock or strong vibration to battery, do not drop, do not throw, do not
K

deform. There is a possibility that the battery generates heat or leaks the liquid or rupture.
ZA

Disassembling a battery is dangerous and may result in explosion or fire, and the content
A

may cause chemical burns or injure eyes.

M

 Do not apply solder directly to batteries. There is a possibility that the battery generates
YA

heat or leaks the liquid or ruptures because the heat will melt the insulator or damage a
3

safety valve.
01
)2

 Do not use, do not leave, and do not store the battery in the place where direct sunshine is
(c

strong and the place of the high temperature such as in cars under hot weather. There is a
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possibility that the battery generates heat or leaks the liquid or ruptures. Also battery
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performance and service life might be decreased.

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 Do not use a battery at the high temperature over 45°C (113°F).

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C

 Do not use a battery in the humid environment exceeding 85% relative humidity, in the
environment where it may get wet or a liquid may adhere.
 Do not wet the battery with water etc., and do not put it in water. There is a possibility that
the battery generates heat.
 Do not use a battery in atmosphere except standard atmospheric pressure. There is a
possibility that the battery leaks the liquid or ruptures.

7-9
 Serial No. 311487

7 CHANGE AND MAINTENANCE OF THE AIR FILTERS

 Be careful not to touch the electrolyte of the battery directly. Should fluid from the battery
accidentally get into your eyes, there is a threat of loss of eyesight, do not rub them.
Immediately rinse your eyes with clean tap water and then consult a physician
WARNING immediately.
 After using up the batteries, immediately remove them from the device. If the dead
batteries are left connected to the device for a long time or if an electric circuit is left closed
(for example, as a result of forgetting to turn off the switch), the batteries will continue to
weaken and be excessively discharged (over-discharged), with the result that gas might
be formed in the batteries, causing them to generate heat and explode, the electrolyte to
leak, and the device to be damaged. Be careful not to forget to turn off the switch on the
device. If you will not use the device for an extended period of time, be sure to remove the

.
d
batteries from the device. Also, do not discharge the batteries forcibly using an external

ve
er
power supply.

s
 Keep the battery out of the reach of children. Should a child swallow a battery or lick the

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leaked liquid, gargle immediately and consult a physician. Do not let the infant exchange

ts
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the batteries.

ri
ll
Caution about the battery box:

.A
 Avoid a strong shock to the battery box.

N
O
CAUTION  Do not drop or turnover the battery box during transportation or installation work.

TI
87

 Do not place a heavy item on the battery box. A

R
14

 Do not put a foreign substance into the battery box.

PO
31

 Do not use the battery box under direct sunlight. When storing the battery box, avoid
R
o.

direct sunlight and store under conditions of operating temperature and humidity. Be sure
N

not to disassemble or modify the battery box. If the battery box is broken, contact Mazak
al

K
ri

Technical Center or Technology Center.

ZA
Se

 Insert without mistaking the polarity of a battery.

A
IM

 Install the battery box by specified procedures and in specified orientation.

K

 Please remove the battery when it is not used or backup operation is not done for a long
ZA

time. (For instance, the power supply of the machine is not scheduled to be turned on for
A

one year or more.)

M
YA

* It is necessary to contact Mazak Technical Center or Technology Center for the

restoration of the machine.
3
01
)2

1. Procedure for replacing the batteries in the battery box

(c

Note 1: Before replacing the batteries, set the main power breaker to the ON position and turn
ht
ig

on the power of the operating panel. Replacing the batteries with the main power
yr

breaker and the power of the operating panel turned off will make it impossible for the
op

machine to operate.
C

Note 2: After replacing the batteries do not set the main power breaker to the OFF position
before making sure no alarm is displayed on the ALARM screen.
Note 3: Do not use any batteries other than new size D alkaline batteries.
Here is the recommend battery.

Name Manufacturer’s type Parts No.

D size alkaline battery (LR20) Panasonic D50MB002020

Note 4: Insert the batteries in the correct orientation.

Note 5: Do not mix new and old batteries or batteries of different brands.

7-10
 Serial No. 311487

CHANGE AND MAINTENANCE OF THE AIR FILTERS 7

Note 6: Replace the batteries once a year.
Required tool: Phillips screwdriver
(1) Check to see that the main power breaker is in the ON position and the power of the
operating panel is turned on.
(2) Remove the lid of the battery box. It is fastened with 4 screws.

.
d
ve
ers
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ts
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D627MA0014

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Fig. 7-3 Lid of the battery box

ll
.A
(3) Replace the three alkaline batteries with new ones.

N
O
TI
Main body of the battery box
87

A
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14

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31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM

The polarities are viewed from this side.

K
ZA

Lid of the battery box D627MA0015

A
M

Fig. 7-4 Placement of the batteries in the battery box

YA

(4) After making sure which is the upside or downside of the lid, fasten the lid with 4 screws
3

while pushing it down.

01
)2
(c
ht
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yr
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C

Enlarged view of the battery box lid Enlarged view of the inside of
the battery box
D627MA0016

Fig. 7-5 Checking which is the upside or downside of the battery box

7-11
 Serial No. 311487

7 CHANGE AND MAINTENANCE OF THE AIR FILTERS

2. Check after replacing the batteries

Check if the batteries are replaced properly, following the steps below.
Note : If the main power breaker is set to OFF while the batteries are not replaced properly, it
will become impossible for the machine to operate. To restore the machine to normal
operation, servicing by Mazak is required.
(1) Open the ALARM screen.
(2) Press the reset key on the operating panel.
(3) After pressing the reset key, check to make sure that the alarms 5002, 5102, 5202, 5302,
and 5602 are not displayed.
If the alarm does not disappear even though the above steps are completed, check the battery

d.
replacement procedure again without turning off the main power breaker.

ve
If the alarm remains displayed in spite of this action, contact Mazak Technical Center or

ser
Technology Center.

re
ts
7-2-2 Battery box for the machine relocation detector (RD) (Only for machines with a

gh
machine relocation detector)

ri
ll
 For battery replacement procedure of the machine relocation detector, refer

.A
to the Maintenance Manual “Machine Relocation Detector Battery

N
O
Replacement Procedure Manual.”

TI
87

A
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14

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31

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o.

O
N

C
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A
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A
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3
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7-12 E
 Serial No. 311487

CHILLER UNIT 8
8 CHILLER UNIT

8-1 Freezing Prevention

Do not turn off the main power of the machine.
The pump runs in automatic mode to prevent the water temperature from falling and the water in
the tank and piping from freezing in cold seasons. Therefore do not turn off the main power of the
machine.

 When carrying out maintenance on the chiller unit, be sure to turn off all of the power
sources. Failure to do this may sometimes result in the pump, fan or other electrical
device operating, which may cause personal injury.

d .
WARNING

ve
 The refrigerant circuit may be very hot, so perform maintenance of the chiller after the

er
temperature has come down enough. Also, when performing maintenance, always wear

s
re
protective gloves and be careful not to burn yourself.

ts
Portions that tend to get very hot:

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Be careful of the following portions because they tend to get very hot.

ri
Pump and the surrounding pipes, compressor and the surrounding pipes, heater and the

ll
surrounding portions, etc.

.A
N
O
8-2 Quality of Cooling Water
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87

A
Use the water which conforms to the following water quality standard:
R
14

PO
31

Fresh water quality

R
o.

pH Conductivity Chloride ion Sulfate ion

O

Standard items
N

[25°C (77F°)] S/cm mgCl-/l mgSO42-/l

C

[25°C (77F°)]
al

Circulating water 6.8 to 8.0 400 or less 50 or less 50 or less

ri

ZA
Se

Acid consumption [pH4.8] Total hardness Calcium hardness Ionic silica

Standard items
A

mgCaCO3/l mgCaCO3/l mgCaCO3/l mgSiO2/l

IM

Circulating water 50 or less 70 or less 50 or less 30 or less

K

Iron Copper Sulfide ion

Standard items
ZA

mgFe/l mgCu/l mgS2-/l

A

Circulating water 1.0 or less 1.0 or less It must not be detected.

M

Ammonium ion Residual chloride Free carbon

YA

Standard items
mgNH4+/l mgCl/l mgCO2/l
3

Circulating water 1.0 or less 0.3 or less 4.0 or less

01
)2

The use of water other than the specified ones could cause damage to the product
(c

(oscillator, chiller or optical system) and liquid to leak, thus resulting in an electric leakage
ht

and an electric shock. Moreover, the service life of the filter may be significantly shortened.
ig
yr

8-3 Disposal of Refrigerant

op
C

The chiller unit uses HFC (alternative Freon) as the refrigerant. The law of each country makes it
mandatory that HFC (alternative Freon) must be reclaimed and disposed of in accordance with
applicable laws and regulations. Therefore, when disposing of the chiller unit, contact a toxic
industrial waste collector to reclaim and dispose of alternative Freon properly.
Note : If you cannot find an appropriate toxic industrial waste collector, contact Mazak
Technical Center or Technology Center. Upon request, we will make necessary
arrangements for the disposal at your cost.

8-1
 Serial No. 311487

8 CHILLER UNIT

8-4 3.0 kW Laser Machine

8-4-1 Preparation for operation (how to feed water)

Before performing maintenance of the chiller, be sure to set the main power breaker of the laser
machine to the OFF position.

1. Oscillator system
(1) Remove the cover for the water filler port on the cabinet. (See Fig. 8-1.)
(2) Remove the water filler cap on the oscillator system. (See Fig. 8-1.)
(3) Feed water directly to the tank, using a hose or a container with a nozzle.

. d
(4) Check if the water level is above the midpoint of E and F on the level gauge. If not, add

ve
water. (See Fig. 8-1.)

s er
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2. Optical system

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(1) Remove the cover for the water filler port on the cabinet. (See Fig. 8-1.)

gh
ri
(2) Remove the water filler cap on the optical system. (See Fig. 8-1.)

ll
(3) Feed water directly through the filler port, using a hose or a container with a nozzle.

.A
N
(4) Check if the water level is above the midpoint of E and F on the level gauge. If not, add

O
water. (See Fig. 8-1.)

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87

A
R
14

PO

Fixing screws (2 locations)

31

R
o.

Handle
N

F
C

Filler port
al

Water level (optical system)

ri

ZA

should be (with a plug)

Se

Filler port on
in this
A

cabinet
range.
IM
K

E
ZA
A
M

Level gauge
YA
3

Feed pump (oscillator system)

01
)2
(c
ht
ig
yr
op

Filler port (oscillator system)

C

Feed pump (optical system)

Cooler (optical system)

D699MA0003

Fig. 8-1 Water filler port and water gauge

8-2
 Serial No. 311487

CHILLER UNIT 8
3. How to purge air from the cooling water piping
When the chiller unit is used for the first time, when it is used after a long period of storage, or
after the water in the tank was replaced, there may be air in the piping, even if the water tank is
filled up.
If this is the case, perform a test run of the feed pump, following the steps below.
(1) On the Home screen of the chiller unit touch panel, hold down [PUMP ONLY] for 3 seconds.
 The message Pump-only op. is displayed in the operation status display area to
indicate that the feed pump has come into operation.
 The water in the tank starts circulating, and when air has been purged from the piping,
the water level in the tank lowers.

.
 The alarm Water shortage alarm is raised and the chiller stops automatically.

d
ve
(2) Add water to the tank in which the amount of water has decreased, and then perform Step

s er
(1) again.

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When the alarm Water shortage alarm is no longer raised, stop the operation of the chiller.

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gh
(3) On the Home screen, hold down [STOP] for 0.5 seconds.

ri
 The message Stopped is displayed in the operation status display area and the chiller

ll
.A
stops.

N
O
TI
87

A
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14

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31

R
o.

O
N

C
al

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Se

A
IM
K
ZA

Operation status display Operating buttons

A

D639MA0026E
M
YA

Fig. 8-2 Home screen of the touch panel

3
01

8-4-2 Operation procedure of the chiller unit

)2

 For the specifications and operation procedure of the chiller unit provided on
(c
ht

the machine, refer to the separate chiller unit operating manual.

ig
yr
op
C

8-3
 Serial No. 311487

8 CHILLER UNIT

8-4-3 External view of chiller unit and location of water feed and drain ports

Left side Front

Eye bolt Air discharge
Operating part
(touch panel)

HFC display plate

Condenser

Filter Specification plate

Charge symbol

Breaker
Air suction

d .
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s er
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Bypass valve operating port

.A
(with a inspection cap)
(built-in bypass valve)

N
(oscillator system)

O
Right side

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87

Cabinet filler port A

R
14

PO
31

1 9 11
2 12
R

10
o.

3
O
N

13
C

4
al

14
ri

ZA
Se

5
A
IM

6 15
K

7
16
ZA

17
A
M
YA

8 18
A
Detail of A
3
01
)2

Names of parts at part A

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No. Part name No. Part name

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Cool water outlet (oscillator system)

1 10 Water pressure gauge (optical system)
25-mm (0.98-in) hexagon hose nipple
ig

Cool water outlet (optical system)

2 Water filter (oscillator system) 11
yr

19-mm (0.75-in) hexagon hose nipple

op

3 Overflow (optical system) Rp1/2 12 Water filter (optical system)

4 Level gauge (oscillator system) 13 Overflow (oscillator system) Rp1
C

5 Level gauge (optical system) 14 Bypass valve (optical system)

Power line port (30 mm (1.18 in)) Cool water inlet (optical system)
6 15
(with cable connector) 19-mm (0.75-in) hexagon hose nipple
Cool water inlet (oscillator system)
7 Drain pan drain Rc1/2 16
25-mm (0.98-in) hexagon hose nipple
Water tank drain (optical system) Rc1/2 Cooling water drain port (oscillator system) Rc1/4
8 17
(with 1/2B valve) (with a plug)
Water filler port (optical system) Water tank drain (oscillator system) Rc1/2
9 18
(with a plug) (with 1/2B valve)

D699MA0004

Fig. 8-3 External view of chiller unit and location of water feed and drain ports

8-4
 Serial No. 311487

CHILLER UNIT 8
8-4-4 Maintenance

1. Replacing the condenser filter

Part name Part No.

Condenser filter U34QQ018250

(1) Before performing maintenance of the chiller, be sure to set the main power breaker of the
laser machine to the OFF position.
(2) Loosen the filter retainer fixing screws and slide the filter retainer upward to remove it.
(3) Slide the filter upward to release it from the locking tabs, and then pull it toward you to
detach.

.d
ve
(4) Install a new filter.

s er
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ts
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(3)

ri
Fixing screw

ll
.A
N
O
(2)

TI
87

Filter retainer A
R
14

PO
31

R
o.

D639MA0053
N

C
al

Fig. 8-4 Replacing the condenser filter

K
ri

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Se

A
IM
K
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A
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3
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(c
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8-5
 Serial No. 311487

8 CHILLER UNIT

2. Replacing the mesh for Y-strainer

Part name Part No.

Mesh for Y-strainer (oscillator system) U34QQ015830
Mesh for Y-strainer (optical system) U34QQ015840

(1) Before performing maintenance of the chiller, be sure to set the main power breaker of the
laser machine to the OFF position.
(2) Close the valves at the cool water inlet and outlet.
(3) Remove the plug from each Y-strainer and take out the mesh.
(4) Mount a new mesh.

.
d
ve
er
Valve

s
re
Y-strainer

ts
gh
Valve

ri
ll
.A
N
O
TI
87

A
R
14

PO

Mesh
31

Y-strainer (oscillator system) Y-strainer (optical system)

R
o.

D699MA0005
O
N

Fig. 8-5 Replacing the mesh for Y-strainer

al

K
ri

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Se

A
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K
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A
M
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3
01
)2
(c
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8-6
 Serial No. 311487

CHILLER UNIT 8
3. Replacing the water filter element

Part name Part No.

Water filter element (oscillator system) U34QQ015910
Water filter element (optical system) U34QQ015920

(1) Before performing maintenance of the chiller, be sure to set the main power breaker of the
laser machine to the OFF position.
(2) Fully close the valves at the water filter inlet and outlet.
(3) Press the air purge valve to relieve the internal pressure gradually. (Air and water come
out.) (Only for the oscillator system)

.
(4) After making sure that the pressure is completely relieved, remove the lower part of the

d
ve
housing with a wrench. (The lower part of the housing is heavy because there is water in it,

er
so be careful not to drop it when removing. In addition, have a water pan or the like handy

s
because water may spill out.)

re
ts
(5) Take out the filter element from the lower part of the housing. If the housing is dirty inside,

gh
clean it with water. Also, clean the O-ring if it is dirty or replace it with a new one if it is

ri
damaged.

ll
.A
(6) Insert a new filter element into the guide in the lower part of the housing to mount it in the
upper part of the housing.

N
O
(7) Open the valves at the water filter inlet and outlet.

TI
87

A
(8) Circulate water before the start of operation to make sure that there are no water leaks from
R
14

the housing, joints and pipes.

PO
31

R
o.

Oscillator system Optical system

O
N

Air purge valve

al

Valve
K

Valve
ri

ZA
Se

Guide
A

Guide
IM

Housing
Housing Guide
K

Valve
ZA

Valve Guide Loosen Tighten

Wrench
A
M
YA

Loosen Tighten
3
01

D639MA0056
)2
(c

Fig. 8-6 Replacing the water filter element

ht
ig
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op
C

8-7
 8

C
op
CHILLER UNIT

yr
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(c
)2
01
3
YA
M
A Se
ZA
K ri
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N
A o.
ZA 31
K

8-8 E
14
C
O 87
Serial No. 311487

R
PO
R
A
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O
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ll
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ser
ve
d.
 Serial No. 311487

MACHINING TORCH 9
9 MACHINING TORCH

9-1 Manual Torch 2

9-1-1 Outline
This torch is a two-dimensional laser cutting head with a simple structure developed in pursuit of
ease-of-use and a high cost performance.
Its function of adjusting the focus makes it possible to optimize the beam according to the
material to be cut, and so provides high speed and reliable cutting conditions.

9-1-2 Specifications

d .
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er
1. Nozzles specifications

s
re
Item Specification Remarks

ts
Laser output 2.0 kW 3.0 kW

gh
N.F range of the single –3.0  N.F  4.0 –3.5  N.F  4.0 The limits of the N.F depend on
1.0 (0.039)

ri
nozzles (–0.12  N.F  0.16) (–0.14  N.F  0.16) the type of nozzle and lens to be

ll
(Unit: mm (in)) used.
–4.0  N.F  5.0 –4.5  N.F  5.0

.A
1.2 (0.047)
(–0.16  N.F  0.20) (–0.18  N.F  0.20)

N
N.F range of dual nozzles
–5.5  N.F  5.0 –6.0  N.F  5.0
1.5 (0.059)

O
4.5-1.2 (0.177-0.047) and
(–0.22  N.F  0.20) (–0.24  N.F  0.20)

TI
5.0-1.2 (0.197-0.047) is
87

–6.5  N.F  5.0 A –7.0  N.F  5.0 smaller than that of other dual
2.0 (0.079)
(–0.26  N.F  0.20) (–0.28  N.F  0.20)
R
nozzles because of their inner
14

PO

–8.0  N.F  5.0 –9.0  N.F  5.0 packing small diameter.

31

2.5 (0.098)
(–0.31  N.F  0.20) (–0.35  N.F  0.20)
R
o.

–8.0  N.F  5.0 –10.5  N.F  5.0

O

3.0 (0.118)
N

(–0.31  N.F  0.20) (–0.41  N.F  0.20)

C
al

–8.0  N.F  5.0 –12.0  N.F  5.0

3.5 (0.138)
ri

ZA

(–0.31  N.F  0.20) (–0.47  N.F  0.20)

Se

–8.0  N.F  5.0 –13.5  N.F  5.0

A

4.0 (0.157)
(–0.31  N.F  0.20) (–0.53  N.F  0.20)
IM

–8.0  N.F  5.0 –14.5  N.F  5.0

4.5 (0.177)
K

(–0.31  N.F  0.20) (–0.57  N.F  0.20)

ZA

–8.0  N.F  5.0 –16.0  N.F  5.0

5.0 (0.197)
(–0.31  N.F  0.20) (–0.63  N.F  0.20)
A
M

–8.0  N.F  5.0 –16.0  N.F  5.0

5.5 (0.217)
YA

(–0.31  N.F  0.20) (–0.63  N.F  0.20)

N.F range of the dual 1.5-1.5 –0.5  N.F  5.0 –1.0  N.F  5.0
3

nozzles (0.059-0.059) (–0.02  N.F  0.20) (–0.04  N.F  0.20)

01

(Unit: mm (in))
2.0-1.5 –0.5  N.F  5.0 –1.0  N.F  5.0
)2

(0.079-0.059) (–0.02  N.F  0.20) (–0.04  N.F  0.20)

(c

2.5-1.8 –2.0  N.F  5.0 –2.5  N.F  5.0

ht

(0.098-0.071) (–0.08  N.F  0.20) (–0.10  N.F  0.20)

ig

3.0-1.8 –2.0  N.F  5.0 –2.5  N.F  5.0

yr

(0.118-0.071) (–0.08  N.F  0.20) (–0.10  N.F  0.20)

op

3.5-1.8 –2.0  N.F  5.0 –2.5  N.F  5.0

C

(0.138-0.071) (–0.08  N.F  0.20) (–0.10  N.F  0.20)

4.0-1.8 –2.0  N.F  5.0 –2.5  N.F  5.0
(0.157-0.071) (–0.08  N.F  0.20) (–0.10  N.F  0.20)
4.5-1.2 +1.0  N.F  5.0 +1.0  N.F  5.0
(0.177-0.047) (+0.04  N.F  0.20) (+0.04  N.F  0.20)
5.0-1.2 +1.0  N.F  5.0 +1.0  N.F  5.0
(0.197-0.047) (+0.04  N.F  0.20) (+0.04  N.F  0.20)
5.5-2.0 –2.5  N.F  5.0 –3.0  N.F  5.0
(0.217-0.079) (–0.10  N.F  0.20) (–0.12  N.F  0.20)
7.0-1.8 –1.5  N.F  5.0 –2.0  N.F  5.0
(0.276-0.071) (–0.06  N.F  0.20) (–0.08  N.F  0.20)

9-1
 Serial No. 311487

9 MACHINING TORCH

Item Specification Remarks

For an explanation of the assist
gas switching device, see
Withstand pressure limits (Assist gas) 2.5 MPa (setting pressure)
Subsection 3-4-3 in the
Operating Manual.
Lens cooling system Air-cooling
This unit cannot be used for
Type of profiling unit MAZAK non-contact profiling unit
nonmetallic materials.

Note 1: N.F (nozzle focus) denotes the distance from the leading end of the nozzle to the
focus.
Note 2: The range of N.F varies depending on the nozzle diameter, as shown in the table
above.

d .
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s er
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ll
.A
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TI
87

A
R
14

PO
31

R
o.

O
N

C
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K
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ZA
Se

A
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K
ZA
A
M
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3
01
)2
(c
ht
ig
yr
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C

9-2
 Serial No. 311487

MACHINING TORCH 9
9-1-3 Construction
The torch consists of following parts:
1. Torch main body 1 set
2. Jig
Protective window nut mounting/removing jig 1 pc.
Protective window mounting/removing jig 1 pc.
Condensing lens mounting/removing jig 1 pc.
Condensing lens holder mounting/removing jig 1 pc.
Piston jig (upper/lower) 1 pc. each
Torch tip mounting/removing jig 1 1 pc.
Torch tip mounting/removing jig 2 1 pc.

d .
Nozzle mounting/removing jig 1 pc.

ve
Nozzle center adjustment handle 2 pcs.

er
Maintenance plate 1 pc.

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1. Torch body

gh
ri
ll
.A
N
O
TI
Focus adjustment dial
87

A
R
14

PO
31

Focus adjustment
R
o.

dial locking screw

O
N

C
al

K
ri

ZA
Se

Body
A

Protective cover of the

IM

profiling preamplifier
K
ZA
A
M
YA

Protective window
3
01
)2
(c
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ig

Machining nozzle
yr

Protective window
op

cartridge Protective window Knurled screw

cartridge cover
C

D699MA0015

Fig. 9-1 Components of manual torch 2

9-3
 Serial No. 311487

9 MACHINING TORCH

2. Jig

A. Jigs for optical parts

Condensing lens
Protective window nut Protective window Condensing lens
Name holder
mounting/removing jig mounting/removing jig mounting/removing jig
mounting/removing jig

Form

d .
ve
er
Name Piston jig (upper) Piston jig (lower)

s
re
ts
gh
ri
Form

ll
.A
N
O
TI
Note : The condensing lens mounting/removing jig, the condensing lens holder mounting/
87

A
removing jig and the piston jigs (upper/lower) are intended to be used by a Mazak
R
14

PO

service person.
31

R
o.

B. Jigs for torch tip

N

C
al

Torch tip Torch tip Nozzle Nozzle center

ri

Maintenance
ZA

Name mounting/removing mounting/removing mounting/removing adjustment

Se

plate
jig 1 jig 2 jig handle
A
IM
K
ZA

Form
A
M
YA
3
01
)2
(c
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ig
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9-4
 Serial No. 311487

MACHINING TORCH 9
9-1-4 Functions

1. Non-contact profiling
The distance from the front end of the machining nozzle to the worksheet is referred to as the
nozzle worksheet, which is expressed as N.W.
The clearance (distance) between the worksheet and the machining nozzle during machining
can be maintained at any value by specifying that N.W value in the program.

2. Manual focus positioning function

The distance between the nozzle tip and the focal point can be adjusted by turning the focus
adjustment dial.

d .
ve
The distance from the front end of the machining nozzle to the focal point is referred to as the

er
nozzle focus, which is expressed as N.F.

s
re
<N.F adjustment procedure>

ts
(1) Turn the focus adjustment dial locking screw 1/2 to 3/4 turns counterclockwise to release

gh
the lock.

ri
Note : Be careful not to loosen the locking screw more than necessary. Doing so will

ll
.A
cause the locking screw from coming off the dial and adversely affect the

N
dust-proofness of the torch.

O
(2) Turn the focus adjustment dial to align the red line with the target N.F scale mark on the

TI
87

scale plate. A
R
14

(3) Tighten and lock the focus adjustment dial locking screw securely by turning it clockwise.
PO
31

R
o.

Turn the focus adjustment dial to align the

O
N

red line with the target N.F scale mark.

C

* In this example, N.F is set to –16 mm.

al

Focus adjustment dial Scale plate

ri

ZA
Se

Focus adjustment
IM

dial locking screw

K
ZA

Tighten
A
M
YA

Loosen
3
01

D699MA0010
)2
(c

9-1-5 Preparation before machining

ht

This section shows how to dismount/mount the torch tip and to perform center adjustment.
ig
yr

1. Replacing the torch tip insulating rings (resin and ceramic)

op
C

A. Part names
The torch tip insulating rings (resin and ceramic) are listed in Table 9-1. The composition and
components of the torch tip are as shown in Fig. 9-2.

 For details of the components of the torch tip, refer to Paragraph 7. “Exploded
view and parts list of the torch tip”.

9-5
 Serial No. 311487

9 MACHINING TORCH

Table 9-1 Torch tip insulating rings (resin and ceramic)

Name Parts No. Q’ty Remarks

Ring 1 46143312101 1 Resin 38 mm (1.50 in) × 4.5 mm (0.18 in)
Ring 2 46143312130 1 Resin 40 mm (1.57 in) × 4 mm (0.16 in)
Spacer 3 46143312170 1 Resin 40 mm (1.57 in) × 6 mm (0.24 in)
Ring 4 46143312180 1 Ceramic 23 mm (0.91 in) × 4 mm (0.16 in)
Ring 5 46143312120 1 Resin 40 mm (1.57 in) × 5 mm (0.20 in)

[6] O-ring
J25NV003070

[7] Bracket
46143300282

d .
ve
[8] Ring assembly

er
For details of components see

s
refer to Paragraph 7.

re
ts
Ring 1 (resin) [9] Special screw
46143312101

gh
A51NX000210

ri
[10] Nut (M5)
A40JJ00M050

ll
.A
[21] Maintenance plate [11] Adjustment handle

N
06143355661 06143355421

O
TI
[12] Screw
87

A A06CB040100
R
14

[13] Bracket
PO
31

46143307421
R
o.

O
N

Ring 2 (resin)
al

46143312130
ri

ZA
Se

[1] Bracket
A

46143300290 [14] Screw

IM

46683301180
Ring 4 (ceramic)
K

46143312180 [19] Coupler

ZA

36143310531
Spacer 3 (resin)
A

[15] Screw
M

46143312170
A05GS002560
YA

[4] Steel ball

46143300230 [16] Connector
3
01

46143308190
)2

Ring 5 (resin) [17] Spacer

46143312120
(c

46143308170
ht

[3] Spring [18] Housing

ig

46143300220 36143310550
yr

[2] Socket
op

36143310542
C

[20] Nozzle adapter

36143310523

[5] Nozzle (1.2)

36143312220
D628MA0115

Fig. 9-2 Part names of the torch tip

9-6
 Serial No. 311487

MACHINING TORCH 9
B. Necessary tools
The following tools are required to replace the torch tip insulating rings (resin and ceramic).

 Use the Mazak-recommended jigs and tools included with the machine to avoid damage
to parts.
 The torch and nozzle are very hot and may cause a burn or any other harm immediately
CAUTION
after machining. So, start the work after their temperature has lowered sufficiently.

[21] Maintenance plate

06143355661
[23] Torch tip mounting/removing jig 1
46143300510

. d
[24] Torch tip mounting/removing jig 2

ve
46143307600

er
[26] Allen wrench (1.3)

s
Z99ZZII1770

re
[25] Nozzle mounting/
removing jig

ts
46143310690

gh
ri
ll
.A
[22] Wrench
36143308963 D639MA0038’

N
O
Fig. 9-3 Necessary tools

TI
87

A
R
14

C. How to replace
PO
31

This section describes how to replace the torch tip insulating rings 1 to 5.
R
o.

Note 1: The presence of a cracked, broken or burned torch tip insulating ring may cause
N

profiling operation to be unstable and interfere with proper machining.

al

K
ri

ZA

Note 2: Follow the specified steps to replace the torch tip insulating rings. After replacing the
Se

insulating rings, mount them following the removal steps in reverse. At that time, make
IM

sure every part is securely mounted and fastened. Be very careful about the screws [14]
(2 pieces) in particular.
K
ZA

Note 3: To assemble the housing [18] and the ring assembly [8] removed, follow the steps (a) to
A

(e) in (5).
M
YA

Note 4: When replacing the insulating ring, be sure to mount the maintenance plate to prevent
the spring from jumping out.
3
01

Note 5: Do not remove two M3 screws shown below from the ring assembly [8]. Otherwise, the
)2

spring may jump out.

(c
ht

[8] Ring assembly

ig
yr

[27] Screw
op

A26B03X0060
C

[29] Base
06143355800
[28] Ring
06143355642

9-7
 Serial No. 311487

9 MACHINING TORCH

(1) Remove the nozzle [5] and the nozzle adapter [20], using the nozzle mounting/removing jig
[25].

Torch tip

.
d
[20] Nozzle adapter

ve
36143310523

er
[5] Nozzle (1.2)
36143312220

s
[25] Nozzle mounting/removing jig

re
46143310690

ts
D639MA0039’

gh
Fig. 9-4 Removal of nozzle and its adapter

ri
ll
(2) Replace the rings 1 and 2 with new ones.

.A
 Remove the bracket [7] from the torch tip by rotating it with the torch tip

N
O
mounting/removing jig 1 [23] fitted in the groove on the bracket [7] while fixing the bracket

TI
[1] with the wrench [22]. This makes it possible to remove the rings 1 and 2.
87

 Replace these rings as appropriate.

A
R
14

PO
31

[23] Torch tip mounting/removing jig 1

o.

[7] Bracket
O

46143300510
N

46143300282
C
al

Ring 1 (resin)
ri

ZA

46143312101
Se

A
IM

[8] Ring assembly

[22] Wrench
K

36143308963
ZA

Torch tip
A
M

Ring 2 (resin)
YA

46143312130
3
01

[1] Bracket
46143300290
)2
(c

D639MA0040’’
ht
ig

Fig. 9-5 Replacing the rings 1 and 2

yr
op

 For details of components see Subsection refer to Paragraph 7. “Exploded

C

view and parts list of the torch tip.”

9-8
 Serial No. 311487

MACHINING TORCH 9
(3) Replace the spacer 3 and the ring 4 with new ones.
 Remove the bracket [1] from the torch tip, using the wrench [22]. This makes it possible to
remove the spacer 3 and the ring 4.
 Replace these parts as appropriate.

[1] Bracket
[22] Wrench 46143300290
36143308963
Ring 4 (ceramic)
46143312180

Spacer 3 (resin)

.d
46143312170

ve
er
s
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ts
Torch tip

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ri
D639MA0034’

ll
.A
Fig. 9-6 Replacing the spacer 3 and the ring 4

N
(4) Replace the ring 5 with a new one.

O
TI
 Remove the screw [14] on the upper surface of the bracket [13], using the Allen wrench [26].
87

A
Next, remove the profiling connector [16] from the housing [18]. After that, using the Allen
R
14

PO

wrench [26], remove the screw [14] on the side surface of the bracket [13] through the hole
31

from which the profiling connector was removed.

R
o.

O
N

[13] Bracket
C
al

46143307421 Remove.
K

[14] Screw
ri

ZA

46683301180
Se

A
IM
K

[18] Housing
ZA

36143310550 Remove.
[16] Connector
A

46143308190
M

[17] Spacer
YA

46143308170 Remove.
[26] Allen wrench (1.3) [15] Screw [14] Screw
3

Z99ZZII1770 A05GS002560 46683301180

01

D626MA0046’
)2
(c

Fig. 9-7 Replacing the ring 5 (1/2)

ht

Note : Before disassembling the torch tip, be sure to remove the screws [14] from the
ig

bracket [13]. Otherwise, the screws will be bitten by the threaded portion of the
yr
op

coupler [19] during disassembly and they will not be able to be removed anymore.
C

 Disassemble the torch tip, using the torch tip-fastening jig 2 [24] for the bracket [13] and
Disassemble the torch tip, using the torch tip mounting/removing jig 2 [24] for the bracket
[13] and the torch tip mounting/removing jig 1 [23] for the coupler [19]. This makes it
possible to remove the ring 5.

9-9
 Serial No. 311487

9 MACHINING TORCH

 Replace this ring as appropriate.

[24] Torch tip mounting/removing jig 2

46143307600

[4] Steel ball [13] Bracket

46143300230 46143307421

Touch tip [19] Coupler

36143310531
[23] Torch tip mounting/removing jig 1
46143300510
Ring 5 (resin)
46143312120

.
d
[18] Housing

ve
36143310550

er
s
[3] Spring

re
46143300220

ts
gh
[2] Socket
36143310542

ri
ll
.A
D628MA0116’

N
Fig. 9-8 Replacing the ring 5 (2/2)

O
TI
(5) After replacing the torch tip insulating rings, put the parts removed in (1), (3) and (4)
87

A
together by following the removal steps in reverse order.
R
14

PO

To assemble the housing [18] and the ring assembly [8] removed in (2), follow the steps (a)
31

to (e) below.
R
o.

O
N

(a) Adjust the clearance on each side between the component parts (base and ring) of the
al

ring assembly [8] to 2 mm (0.08 in).

ri

ZA
Se

A
IM

Adjust the clearance on each side to 2 mm (0.08 in) to place the base in the center of the ring.
K
ZA

2 mm (0.08 in)
A
M

2 mm
YA

(0.08 in)
3
01
)2
(c
ht

2 mm
2 mm (0.08 in)
ig

Ring (0.08 in)

yr

06143355642 Base
op

06143355800 D619SA0024’
C

Fig. 9-9 Adjustment of the positions of the component parts (base and ring) of the ring assembly [8]

 For details of components, see Paragraph 7. “Exploded view and parts list of
the torch tip.”

9-10
 Serial No. 311487

MACHINING TORCH 9
(b) To adjust the clearance, put a ruler at the edge of a hollow of the housing [18] and rotate
the housing [18] until the edges of the hollow align with the arrows marked on the ring
assembly [8].

Markings on the ring assembly [8] Align the edge of the hollow
with the arrow. (2 places)

.
Ruler

d
ve
er
s
re
ts
gh
Edges of the hollow of the housing [18] 36143310550
D619SA0025

ri
Fig. 9-10 Adjustment of the positions of housing and ring

ll
.A
(c) Using the torch tip mounting/removing jig 1 [23] and the wrench [22], fasten the torch tip

N
to prevent misalignment between the arrows and the edges of the hollow.

O
TI
87

A
Fasten the torch tip to prevent misalignment between the arrows and the edges of the hollow.
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K

[22] Wrench
ZA

[23] Torch tip mounting/

removing jig 1 36143308963
A

46143300510
M
YA
3

D619SA0026’
01
)2

Fig. 9-11 Putting the housing and the ring together

(c
ht
ig
yr
op
C

9-11
 Serial No. 311487

9 MACHINING TORCH

(d) Put a ruler at the edge of a hollow of the housing again to see if there is no
misalignment between the arrows and the edges of the hollow. (If there is a
misalignment, make an adjustment again.)

Check if the edge of each hollow is aligned with the arrow.

. d
ve
s er
re
ts
gh
Ruler

ri
D619SA0027

ll
Fig. 9-12 Checking the mounted positions of the housing and ring

.A
N
(e) Mount the torch tip on the torch and connect the profiling cable. If the profiling cable

O
cannot be connected or it is too tight, readjust the position of the bracket securing the

TI
non-contact profiling pre-amplifier unit.
87

A
R
14

PO

Mount the torch tip on the lower part of the torch.

31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM

Bracket securing
K

the non-contact profiling Non-contact profiling

ZA

preamplifier unit preamplifier unit

A
M
YA

Profiling cable
3

Torch tip
01

D619MA0029
)2
(c

Fig. 9-13 Mounting the torch tip on the lower part of the torch
ht

 For a detailed explanation of the mounting of the bracket securing the

ig
yr

non-contact profiling pre-amplifier unit, see Paragraph 1. C. “Replacing the

op

non-contact profiling preamplifier [3]” of Subsection 10-2-8.

C

 At the mounting of the torch tip on the torch, align it at the position indicated with the
marking arrow. If there is a significant misalignment between them, the profiling cable may
collide with the nozzle at the time of automatic nozzle change.
CAUTION

9-12
 Serial No. 311487

MACHINING TORCH 9
2. Replacing the nozzle

A. Necessary tools
The following tools are required to replace the nozzle.

.
d
ve
Wrench (19 × 22) Jig (17 × 34)

er
P03ML000410 36143308963

s
D698MA0025

re
ts
B. How to replace

gh
ri
The following is the procedure for installing and removing the nozzle.

ll
.A
 Use Mazak’s recommended jig which is provided with this machine.

N
 Fully tighten the nozzle. If the nozzle is insufficiently tightened, it is liable to work loose,

O
TI
leading to a malfunction when machining is taking place or the intelligent functions are
87

CAUTION A
being executed.
R
14

PO

 The torch and nozzle are very hot and may cause a burn or any other harm immediately
31

after machining. So, start the work after their temperature has lowered sufficiently.
R
o.

O
N

How to install the nozzle

al

K
ri

(1) Fit the nozzle into the nozzle adapter by hand.

ZA
Se

(2) Fit the jig into the groove in the nozzle adapter so as to fix the nozzle adapter.
A
IM

(3) Using a wrench (22 mm), turn the nozzle so as to fix it.
K

To remove the nozzle, carry out the reverse procedure to the above installation procedure.
ZA
A

Nozzle
M

Removal direction Installation direction

YA
3
01
)2
(c
ht
ig

Wrench
yr

Jig
op
C

Nozzle adapter
D698MA0026

9-13
 Serial No. 311487

9 MACHINING TORCH

3. Cleaning the torch tip

If the nozzle does not move smoothly at the time of centering, clean the torch tip by following the
steps below.

A. Necessary tools
The following tools are required to clean the torch tip.

 Use the Mazak-recommended jigs and tools included with the machine to avoid damage
to parts.
 The torch and nozzle are very hot and may cause a burn or any other harm immediately
CAUTION
after machining. So, start the work after their temperature has lowered sufficiently.

. d
ve
s er
[23] Torch tip mounting/removing jig 1

re
46143300510

ts
gh
ri
[25] Nozzle mounting/

ll
[21] Maintenance plate

.A
removing jig
06143355661
46143310690

N
O
TI
87

A
R
14

[22] Wrench
PO
31

36143308963
D628MA0117’
R
o.

Fig. 9-14 Necessary tools

N

C
al

B. How to clean
ri

ZA
Se

This section describes how to clean the torch tip.

A
IM

(1) Remove the ring assembly [8] by following the steps in Paragraph 1. “Replacing the torch tip
K

insulating rings (resin and ceramic).”

ZA

(2) Remove the maintenance plate [21].

A
M

(3) Loosen the nut (M5) [10] and the special screw [9] and slide the base to the end. (Fig. 9-15)
YA
3

[8] Ring assembly Base

01
)2
(c
ht
ig
yr

[21] Maintenance plate

op

06143355661
C

[10] Nut (M5) [9] Special screw Slide the base to the end.
A40JJ00M050 A51NX000210

D628MA0118

Fig. 9-15 Procedure of cleaning the torch tip (1/4)

9-14
 Serial No. 311487

MACHINING TORCH 9
(4) Remove the screws (M3) [27] and the plates [30], and then remove the springs [31].
(Fig. 9-16)

 To prevent the springs from jumping out, hold them with a hand when removing.

CAUTION

[27] Screw (M3) Be careful not to allow

A26B03X0060 the springs to jump out.
[31] Spring
06143355680

. d
ve
s er
re
ts
gh
[30] Plate
06143355530

ri
ll
.A
Base

N
O
TI
Ring
87

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA

D628MA0119
Se

Fig. 9-16 Procedure of cleaning the torch tip (2/4)

IM

(5) Wipe the dirt off the base with a cloth moistened with anhydrous ethanol. (Fig. 9-17)
K
ZA

[1] Dirt Clean every part of the base.

A

If the surfaces [1] and [2] are dirty,

M

the sliding performance will be

YA

deteriorated, resulting in malfunction.

3
01
)2
(c

[2] Dirt
ht
ig
yr

Waste cloth
op
C

D628MA0120

Fig. 9-17 Procedure of cleaning the torch tip (3/4)

9-15
 Serial No. 311487

9 MACHINING TORCH

(6) Clean the dirt off the ring with a cloth moistened with anhydrous ethanol. (Fig. 9-18)

Clean every part of the ring.

Dirt If the surface [1] is dirty, the sliding performance
will be deteriorated, resulting in malfunction.
[1] Dirt

. d
ve
Dirt

s er
re
ts
gh
Waste cloth

ri
ll
.A
D628MA0121

N
Fig. 9-18 Procedure of cleaning the torch tip (4/4)

O
TI
The cleaning of the torch tip is now complete. So, reassemble the torch tip by following the steps
87

A
in Paragraph 1. “Replacing the torch tip insulating rings (resin and ceramic)”.
R
14

PO
31

4. Confirming tool data

R
o.

After manual replacement of the nozzle, there is a need to confirm the TOOL screen.
N

C
al

 For the confirmation procedure, refer to Chapter 3 of the Intelligent Function

ri

ZA
Se

Operating Manual.
A
IM
K

5. Center adjustment
ZA

When the torch tip is changed, the center of the laser beam must be adjusted.
A
M

If the laser beam does not pass through the center of the nozzle, the machining accuracy may be
YA

lowered, or the parts of the non-contact nozzle may be damaged on account of the laser beam
scattering.
3
01

When the nozzle is changed by replacing the nozzle adapter, center adjustment is not required
)2

because the nozzle center does not become misaligned.

(c

Note : The following procedure is explained on the premise that the laser operation switch is
ht

turned on and the machine is ready for operation.

ig
yr

Procedure for the center adjustment

op

(1) Make TRACER on the SWITCH screen invalid (OFF).

C

(On the COMMAND screen, press [MAINTENANCE] . Then press [SWITCH]

and TRACER in this order to turn OFF the function.)
(2) Set the nozzle-focus distance (N.F) to 0 mm.
(3) Check the position of the center so as to prevent the part from being damaged by the laser
beam.

9-16
 Serial No. 311487

MACHINING TORCH 9
(a) Put mending tape at the lower end of the nozzle. Care should be taken since the nozzle
accumulates heat.

Center
adjusting
push screw

Mending tape

.
d
(b) Press the laser SET key to switch the display to MANUAL LASER SCREEN.

ve
er
(c) In the MANUAL LASER SCREEN, press each item to perform the following settings.

s
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA

D698MA0013E
A
M
YA

Input 800 to Power. .................................................................

Input 100 to Frequency. ........................................................
3
01

Input 10 to Duty. ......................................................................

)2
(c

Set Normal for Pulse Type. (Always select Normal hereinafter.)

ht

Set Air for Assist Gas.

ig
yr

Input 0 to Gas Pressure. .......................................................

op

Press SET. .............................................................................

C

Press the DISCHARGE I (ON) key. .........................................

(d) Press the handle key of mode selection (×100).

(e) Turn the laser shutter switch momentarily to the open side (for about 0.5 second).

9-17
 Serial No. 311487

9 MACHINING TORCH

 Since the laser beam is projected when the laser shutter switch is turned to the open side,
never put a hand or something under the torch.

WARNING

d.
Note : Here the laser irradiation ON switch is turned so as only to make a hole in the

ve
mending tape. The switch must be returned to the close side immediately.

ser
re
(f) Press the reset key to stop the projection of the laser.

ts
(g) Confirm that the position of the laser beam, which is indicated with a black point, is at

gh
about the center of the torch, looking at it in a mirror.

ri
ll
 Before checking the position of the black point using the mirror, make sure to turn off the

.A
laser pointer in order to prevent the laser pointer light from getting into the eyes of the

N
operator.

O
WARNING

TI
87

A
R
14

PO
31

R
o.

O
N

C
al

Mending tape
ri

ZA

(Color is milky)
Se

Mirror
IM
K
ZA

Note : If the black point is not at the center, follow the procedure stated below;
A

[1] Mount the center adjustment handles.

M
YA
3
01
)2
(c
ht
ig

Adjustment handle
yr
op
C

[2] Loosen the nuts (in 2 places), while leaving the handles mounted.

Nut (2 places)

Wrench (8 mm)

9-18
 Serial No. 311487

MACHINING TORCH 9
[3] Adjust the center position using the two handles.
Turn the handle clockwise to move the nozzle backward, or turn it counterclockwise to
move the nozzle forward.
* The nozzle moves about 0.4 mm (0.016 in) each time the handle is turned a half turn
(180 degrees).
Example 1: If the laser beam (black point) is located on the rear side (X direction) of the
nozzle, turn the X-direction handle counterclockwise.

Laser beam
(black point)

d.
ve
er
s
re
X

ts
gh
Mirror Y

ri
ll
Example 2: If the laser beam (black point) is located on the front side (Y direction) of the

.A
nozzle, turn the Y-direction handle clockwise.

N
O
Laser beam

TI
(black point)
87

A
R
14

PO
31

R
o.

O
N

X
al

K
ri

ZA
Se

Mirror Y
A
IM

[4] Remove the mending tape and put a new one.

K
ZA

[5] Remove the mirror.

A

[6] Starting from Step (b), repeat these steps until the laser beam (black point) comes to
M

the center of the torch.

YA

[7] Tighten the nuts (in 2 places), while holding the handles.
3
01
)2
(c
ht
ig
yr

Nut (2 places)
op
C

Wrench (8 mm)

9-19
 Serial No. 311487

9 MACHINING TORCH

[8] Remove the handles.

 After completing the adjustment, be sure to remove the handles. Operating the machine
with them left mounted could cause damage to the machine.

d.
ve
CAUTION

ser
re
(4) Make TRACER on the SWITCH screen valid (ON).

ts
gh
ri
(On the COMMAND screen, press [MAINTENANCE] . Then press [SWITCH]

ll
.A
and TRACER in this order to turn ON the function.)

N
Note : Be sure to press the HIGH VOLTAGE l (ON) key before the projection of the laser

O
beam, and to press the HIGH VOLTAGE O (OFF) key after the projection.

TI
87

A
The adjustment of the laser beam center is completed by the procedure above. Now the
R
14

adjustment of the focus will be treated as the next step.

PO
31

R
o.

6. Focus adjustment
O
N

Besides the Focus Detection (option) described in the Intelligent Function Operating Manual
al

K
ri

(Section 3-5), the following procedure allows to find the focal point height.
ZA
Se

The laser beam emitted by the laser oscillator is concentrated at one point by the condensing
IM

lens. This point is referred to as the focal point or focus, where the laser beam is most intense.
This means that the position where the best machining performance is delivered can be
K
ZA

determined by a focus adjustment.

A

This adjustment is made to set the focal point to the height of the nozzle tip. The height adjusted
M

here is used as the reference height W of 0.

YA

Note : The following procedure is explained on the premise that the laser operation switch is
3

turned on and the machine is ready for operation.

01
)2

A. How to make an adjustment

(c
ht

Cut slits in a worksheet, while moving the focus in stages in the Z-axis direction using sample
ig

machining programs 1 and 2. Using a thickness gauge or similar, determine the focal point at the
yr

time when the narrowest slit is cut, and adjust the handle position according to the difference
op

from the specified N.F in order to compensate for the focus error.
C

Sample program 1 is used to roughly adjust the focus, and sample program 2 is used to precisely
adjust it.

9-20
 Serial No. 311487

MACHINING TORCH 9

Z + 0.5 mm (0.020 in)

d .
B. Procedure [1]: Rough focus adjustment of the laser beam

ve
er
This section describes the steps to follow when adjusting the focus using sample program 1.

s
re
(1) Turn the focus adjustment dial to adjusted N.F to –2.5 mm (–0.098 in).

ts
(2) Press TRACER on the SWITCH screen to make the function valid (ON).

gh
ri
ll
(3) Make test cuts using a focus adjustment program (see the “Sample program 1” below).

.A
N
Set the distance between the nozzle tip and the worksheet within the range of 1 to 4.0 mm

O
(0.039 to 0.16 in), and cut 7 slits 30 mm (1.18 in) in length in the X-axis direction, while

TI
87

raising the focal point in steps of 0.5 mm (0.02 in) in the Z-axis direction. The focal point of
A
R
14

the laser beam is roughly where the narrowest slit is cut.

PO
31

(4) Determine the focal point at the time when the narrowest slit is cut, using a thickness gauge
R
o.

or similar, and add the error to the current set value.

O
N

Example 1: If the slit at Z of 1.0 mm (0.039 in) is the narrowest, the focal point should be
al

located in the vicinity of N.F–2.0 (–1.0 – (1.0) = –2.0 mm) (–0.039 – (0.039) =
ri

ZA
Se

–0.079 in). So, align the red line on the handle with –2.0 by changing the position
A

of the scale plate.

IM

Example 2: If the slit at Z of 0.5 mm (0.02 in) is the narrowest, the focal point should be
K

located in the vicinity of N.F–1.5. So, align the red line on the handle with –1.5 by
ZA

changing the position of the scale plate.

A
M

Example 3: If the slit at Z of 2.0 mm (0.079 in) is the narrowest, the focal point should be
YA

located in the vicinity of N.F–3.0. So, align the red line on the handle with –3.0 by
changing the position of the scale plate.
3
01
)2

Focus adjustment dial Scale plate

(c
ht
ig
yr
op
C

9-21
 Serial No. 311487

9 MACHINING TORCH

40 mm (1.58 in)
Machining start point

X
Machining 30 mm
direction (1.18 in)
Y

* The focal point is raised

0.25 mm (0.01 in) on
completion of the cutting
of each slit.

.
Z = 3.0 mm (0.12 in)

d
Z = 2.5 mm (0.098 in) Total displacement:

ve
Z = 2.0 mm (0.079 in) 2.0 mm (0.08 in)

er
s
Machining order D628SB0002’

re
ts
 A laser beam is emitted when automatic operation is performed by a machining program,

gh
so never put your hand or any object under the machining torch during operation.

ri
ll
.A
WARNING

N
Sample program 1

O
TI
(Shown below is an example of a program for the machining of a 1 mm (0.039 in) thick SPHC
87

A
plate. The machining conditions need to be changed depending on the material.)
R
14

PO
31

% M32 M23
R
o.

O0001 G04X1.0 M09

O
N

G88P50M56 M31 M21

C

G04X3. G91G00Z1.5 G90G53Z0

al

M20 M98P0002 M30

ri

ZA

M32
Se

G04X1.0 M32 O0002

IM

M31 G04X1.0 G88P20M56

G91G00Z3.0 M31 G87P0
K

M98P0002 G91G00Z1.0 G04X1.0

ZA

M98P0002 G82P1000Q100R20
M32 M22
A

G04X1.0 M32 G04X0.8

M

M31 G04X1.0 G88P50M56

YA

G91G00Z2.5 M31 G82P1000Q100R100F3000

M98P0002 G91G00Z0.5 G04X0.3
3
01

M98P0002 G91G01X30.
M32 M23
)2

G04X1.0 M32
(c

M31 G04X1.0 G91G00Z10.

ht

G91G00Z2.0 M31 G91G00X-30.Y-5.

M98P0002 G91G00Z0 M99
ig

M98P0002 %
yr
op
C

9-22
 Serial No. 311487

MACHINING TORCH 9

Narrowest slit
The focal point is located in this area.
[Displacement of Z-axis: 1.0 mm (0.039 in)] D628SB0003

.
d
ve
The exact focal point is located between the two slits sandwiching the narrowest slit.

er
Adjust the focus precisely, using the program described in the next section.

s
re
ts
C. Procedure [2]: Precise focus adjustment

gh
This section describes the steps to follow when adjusting the focus of the laser beam, using

ri
sample program 2.

ll
.A
(1) Complete the “Rough focus adjustment of the laser beam” described in 2 above.

N
(2) Turn the focus adjustment dial to adjusted N.F to –2.0 mm (–0.079 in).

O
TI
(3) Just as in Step (3) of Section 2 above, make test cuts using a machining program (see
87

Sample program 2).

A
R
14

PO
31

Set the distance between the nozzle tip and the worksheet to within the range of 1 to
R

3.0 mm (0.039 to 0.12 in), and cut 9 slits 30 mm (1.18 in) in length in the X-axis direction,
o.

O
N

while raising the focal point in steps of 0.25 mm (0.01 in) in the Z-axis direction. The focal
C
al

point of the laser beam is exactly where the narrowest slit is cut.
K
ri

ZA

(4) Determine the focal point at the time when the narrowest slit is cut, using a thickness gauge
Se

or similar, and add the error to the current set value.

IM

Example : If the slit at Z of 1.25 mm (0.049 in) is the narrowest, the focal point should be
K

exactly in the position of N.F–2.25. As the scale marks are engraved at intervals of
ZA

0.5 mm (0.02 in), move the scale plate about a half scale mark from the N.F–2.0
A

scale mark to align the red line on the handle.

M
YA

Since there are not significant differences in width between the slits, also use as a clue the
resistance that the thickness gauge shows when it is inserted in each slit.
3
01
)2

Narrowest slit
(c
ht
ig
yr
op
C

The gauge can be inserted. The gauge can be inserted.

The gauge cannot be inserted. D628MA0042

9-23
 Serial No. 311487

9 MACHINING TORCH

Machining start point 40 mm (1.57 in)

Machining 30 mm
direction (1.18 in)

X
Z = 1.5 mm (0.059 in)
Z = 1.75 mm (0.069 in)

.
* The focal point is raised 0.25 mm

d
Z = 2.0 mm (0.079 in)

ve
(0.010 in) on completion of the cutting Y
of each slit.

er
Total displacement: 2.0 mm (0.079 in) Machining order
D699MA0033

s
re
ts
Sample program 2

gh
(Shown below is an example of a program for the machining of a 1 mm (0.039 in) thick SPHC

ri
plate. The machining conditions need be changed depending on the material.)

ll
.A
% M32 M23

N
O0001 G04X1.0 M09

O
G88P50M56 M31 M21

TI
G04X3. G91G00Z1.0 G90G53Z0
87

M20 M98P0002 A M30

R
14

M32
PO
31

G04X1.0 M32 O0002

M31 G04X1.0 G88P20M56
R
o.

G91G00Z2.0 M31 G87P0

O
N

M98P0002 G91G00Z0.75 G04X1.0

al

M98P0002 G82P1000Q100R20
K
ri

M32 M22
ZA
Se

G04X1.0 M32 G04X0.8

A

M31 G04X1.0 G88P50M56

IM

G91G00Z1.75 M31 G82P1000Q100R100F3000

M98P0002 G91G00Z0.5 G04X0.3
K

M98P0002 G91G01X30.
ZA

M32 M23
A

G04X1.0 M32
M

M31 G04X1.0 G91G00Z10.

YA

G91G00Z1.5 M31 G91G00X-30.Y-5.

M98P0002 G91G00Z0.25 M99
3

M98P0002 %
01

M32
)2

G04X1.0 M32
M31 G04X1.0
(c

G91G00Z1.25 M31
ht

M98P0002 G91G00Z0
ig

M98P0002
yr
op

The adjustment is now completed.

C

9-24
 Serial No. 311487

MACHINING TORCH 9
7. Exploded view and parts list of the torch tip
An exploded view and the parts list of the torch tip are shown below.
No. Parts No. Name Remarks Q’ty
316 06143355661 Plate Maintenance plate 1
122 J25NV003070 O-ring S-50 (Fluorine) 1
122 80 46143312101 Ring Resin 1
316
96 46143300282 Bracket 1
310 A51NX000210 Special screw M5 (with ball point) 2
96 304 06143355421 Adjustment handle 2
313 A40JJ00M050 Nut M5 2
126 A06CB040100 Screw M4×10 4
80
78 46143312130 Ring Resin 1
74 46143300290 Bracket 1
A

.
310 108 46143312180 Ring Ceramic 1

d
ve
82 46683301180 Screw M2.5×P0.45 1
304

er
313 110 46143312170 Spacer Resin 1

s
84 46143307421 Bracket 1

re
83 46683301180 Screw M2.5×P0.45 1

ts
87 46143312120 Ring Resin 1

gh
126 104 36143310542 Socket 1
98 A05GS002560 Screw M2.5×10 2

ri
74
78 100 46143308190 Connector 1

ll
.A
89 46143300220 Spring 1
82 76 36143310550 Housing 1
108

N
102 46143308170 Spacer 1

O
106 46143300230 Steel ball 6

TI
110 83 91 36143310531 Coupler 1
87

94
A 36143310523 Nozzle adapter 1
R
14

84
87 329 06143355680 Spring 4
PO
31

308 A26B03X0060 Screw 2

R

91 98 311 06143355642 Ring 1

o.

O
N

307 06143355530 Plate 2

C

300 06143355800 Base 1

al

106
K

LG6140010604
ri

ZA

100
1.0
Se

3 06283301190 Nozzle 1
A

4 36143312220 Nozzle 1.2 1

102
IM

5 36143312230 Nozzle 1.5 1

6 36143312240 Nozzle 2.0 1
K

76 89 7 36143312250 Nozzle 2.5 1

ZA

Pencil nozzle
8 36143312260 Nozzle 3.0 1
(single)
3.5
A

9 36143312270 Nozzle 1
104
M

10 36143312280 Nozzle 4.0 1

YA

11 06143355590 Nozzle 4.5 1

94 Nozzle 12 06283301030 Nozzle 5.0 1
3

13 06143355600 Nozzle 5.5 1

01

G614133H005
)2

2 36143312300 Dual nozzle 1.5-1.5 1

(c

3 36143312311 Dual nozzle 2.0-1.5 1

329 2.5-1.8
ht

4 36143312320 Dual nozzle 1

5 36143312330 Dual nozzle 3.0-1.8 1
ig

308
6 36143312340 Dual nozzle 3.5-1.8 1
yr

311 Pencil nozzle

(dual) 7 36143312350 Dual nozzle 4.0-1.8 1
op

307 25 06283301050 Dual nozzle 4.5-1.2 1

C

26 06283301200 Dual nozzle 5.0-1.2 1

300 35 06283301840 Dual nozzle 5.5-2.0 1
45 06283302110 Dual nozzle 7.0-1.8 1
LG6280006300
A Enlarged view 2 06283301790 HP nozzle 1.0 1
Pencil nozzle
3 06283301800 HP nozzle 1.2 1
HP (single)
4 06283301810 HP nozzle 1.5 1
Pencil nozzle
D628MA0122 15 06283301820 HP dual nozzle 1.5-1.5 1
HP (dual)
Fig. 9-19 Exploded view and parts list of the torch tip

9-25
 Serial No. 311487

9 MACHINING TORCH

9-2 Torch Made by Laser Mech (Optional for Use in USA Only)

9-2-1 Outline
This torch is a two-dimensional laser cutting head with a simple structure developed in pursuit of
ease-of-use and a high cost performance.
Its function of automatically adjusting the focus makes it possible to optimize the beam according
to the material to be cut, and so provides high speed and reliable cutting conditions.

9-2-2 Specifications

1. Nozzles specifications

d .
ve
Item Specification Remarks

er
Laser output 3.0 kW

s
re
N.F range of the 1.0 (0.039) –5.5  N.F  5.0 (–0.22  N.F  0.20) The limits of the N.F depend on the
single nozzles type of nozzle and lens to be used.
1.2 (0.047)

ts
–7.0  N.F  5.0 (–0.28  N.F  0.20)
(Unit: mm (in))

gh
1.5 (0.059) –9.5  N.F  5.0 (–0.37  N.F  0.20) N.F range of dual nozzles 4.5-1.2

ri
2.0 (0.079) –11.5  N.F  5.0 (–0.45  N.F  0.20) (0.177-0.047) and 5.0-1.2

ll
(0.197-0.047) is smaller than that of
2.5 (0.098) –15.0  N.F  5.0 (–0.59  N.F  0.20)

.A
other dual nozzles because of their
3.0 (0.118) –16.0  N.F  5.0 (–0.63  N.F  0.20) inner packing small diameter.

N
3.5 (0.138)

O
–16.0  N.F  5.0 (–0.63  N.F  0.20)

TI
4.0 (0.157) –16.0  N.F  5.0 (–0.63  N.F  0.20)
87

4.5 (0.177)
A
–16.0  N.F  5.0 (–0.63  N.F  0.20)
R
14

PO

5.0 (0.197) –16.0  N.F  5.0 (–0.63  N.F  0.20)

31

5.5 (0.217) –16.0  N.F  5.0 (–0.63  N.F  0.20)

R
o.

1.5-1.5
N

N.F range of the

C

–4.5  N.F  5.0 (–0.18  N.F  0.20)

dual nozzles (0.059-0.059)
al

(Unit: mm (in)) 2.0-1.5

ri

ZA

–4.5  N.F  5.0 (–0.18  N.F  0.20)

Se

(0.079-0.059)
A

2.5-1.8
IM

–6.5  N.F  5.0 (–0.26  N.F  0.20)

(0.098-0.071)
3.0-1.8
K

–6.5  N.F  5.0 (–0.26  N.F  0.20)

ZA

(0.118-0.071)
3.5-1.8
A

–6.5  N.F  5.0 (–0.26  N.F  0.20)

M

(0.138-0.071)
YA

4.0-1.8
–6.5  N.F  5.0 (–0.26  N.F  0.20)
(0.157-0.071)
3

4.5-1.2
01

–2.0  N.F  5.0 (–0.08  N.F  0.20)

(0.177-0.047)
)2

5.0-1.2
(c

–2.0  N.F  5.0 (–0.08  N.F  0.20)

(0.197-0.047)
ht

5.5-2.0
–8.0  N.F  5.0 (–0.31  N.F  0.20)
ig

(0.217-0.079)
yr

7.0-1.8
op

–6.5  N.F  5.0 (–0.26  N.F  0.20)

(0.276-0.071)
C

For an explanation of the assist gas

Withstand pressure limits (Assist
2.5 MPa (setting pressure) switching device, see Subsection 3-4-3
gas)
in the Operating Manual.
Lens cooling system Air-cooling
This unit cannot be used for
Type of profiling unit Laser Mech non-contact profiling unit
nonmetallic materials.

Note 1: N.F (nozzle focus) denotes the distance from the leading end of the nozzle to the
focus.

9-26
 Serial No. 311487

MACHINING TORCH 9
Note 2: The range of N.F varies depending on the nozzle diameter, as shown in the table
above.

9-2-3 Construction

 For details of the construction, refer to the operating manual of Laser Mech
torch.

9-2-4 Functions

 For details of the functions, refer to the operating manual of Laser Mech

.
d
torch.

ve
ser
re
9-2-5 Preparation before Machining

ts
gh
This section shows the preparations required before machining.

ri
Contents Reference section

ll
.A
Replacing the torch tip Operating manual of Laser Mech torch

N
Replacing the nozzle Operating manual of Laser Mech torch

O
Cleaning the torch tip Operating manual of Laser Mech torch

TI
87

Confirming tool data Paragraph 1. of Subsection 12-2-5

A
R
14

Center adjustment Operating manual of Laser Mech torch

PO
31

Focus adjustment Paragraph 2. of Subsection 12-1-5

R

Exploded view and parts list of the torch tip Operating manual of Laser Mech torch
o.

O
N

C
al

1. Confirming tool data

ri

ZA
Se

After manual replacement of the nozzle, there is a need to confirm the TOOL screen.
A
IM

 For the confirmation procedure, refer to Chapter 3 of the Intelligent Function

K

Operating Manual.
ZA
A
M

2. Focus adjustment
YA

The laser beam emitted by the laser oscillator is concentrated at one point by the condensing
3
01

lens. This point is referred to as the focal point or focus, where the laser beam is most intense.
)2

This means that the position where the best machining performance is delivered can be
(c

determined by a focus adjustment.

ht

This adjustment is made to set the focal point to the height of the nozzle tip. The height adjusted
ig

here is used as the reference height W of 0.

yr
op

Note : The following procedure is explained on the premise that the laser operation switch is
C

turned on and the machine is ready for operation.

A. How to make an adjustment

Cut slits in a worksheet, while moving the focus in stages in the Z-axis direction using sample
machining programs 1 and 2. Using a thickness gauge or similar, determine the focal point at the
time when the narrowest slit is cut, and adjust the focus by adding the error of the focal point and
commanded N.F distance to the correction parameter.
Sample program 1 is used to roughly adjust the focus, and sample program 2 is used to precisely
adjust it.

9-27
 Serial No. 311487

9 MACHINING TORCH

W + 0.5 mm (0.020 in)

d .
The Focus Act on the TOOL screen is the focal point height correction parameter.

ve
The parameter setting can be changed in the pop-up window that appears when the [FOCUS

er
EDIT] menu key is pressed.

s
re
ts
gh
Focal point height

ri
correction parameter

ll
Reference value:

.A
–16.000

N
Example :

O
Correction value:

TI
0.4 mm (0.016 in)
87

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

B. Procedure [1]: Rough focus adjustment of the laser beam

A
IM

This section describes the steps to follow when adjusting the focus using sample program 1.
K

(1) Set Focus Act to –16.000 on the TOOL screen.

ZA
A

(2) On the COMMAND screen, press [MAINTENANCE] . Then press [SWITCH]

M
YA

.
3

(3) Press TRACER on the SWITCH screen to make the function valid (ON).
01
)2
(c

(4) Make test cuts using a focus adjustment program (see the “Sample program 1” below).
ht
ig

Set the distance between the nozzle tip and the worksheet to 1 mm (0.039 in), and cut 7
yr

slits 30 mm (1.18 in) in length in the X-axis direction, while raising the focal point in steps of
op

0.5 mm (0.020 in) within the range of ±1.5 mm (±0.059 in) in the Z-axis direction. The focal
C

point of the laser beam is roughly where the narrowest slit is cut.
(5) Determine the focal point at the time when the narrowest slit is cut, using a thickness gauge
or similar, and add the error to the current set value.
Example 1: If Focus Act is –16.000 and the slit at W of –1.5 mm (–0.059 in) is the
narrowest, the correction value is –0.5 mm (–1.5 – (–1.0) = –0.5 mm) (–0.059
– (–0.039) = –0.020 in) and so Focus Act needs to be changed to –16.500.
Example 2: If the slit at W of –2.5 mm (–0.098 in) is the narrowest, Focus Act on the
TOOL screen needs to be changed to –17.500.

9-28
 Serial No. 311487

MACHINING TORCH 9
Example 3: If the slit at W of 0.5 mm (0.020 in) is the narrowest, Focus Act on the TOOL
screen needs to be changed to –14.500.

30 mm (1.18 in)
Machining start point

X
Machining 30 mm
direction (1.18 in)
Y

.
* The focal point is raised

d
0.5 mm (0.020 in) on

ve
completion of the cutting

er
W = –1.5 mm (0.059 in) of each slit.

s
W = –2.0 mm (0.079 in) Total displacement:

re
W = –2.5 mm (0.098 in) 3.0 mm (0.12 in)

ts
gh
Machining order D628SB0002

ri
ll
 A laser beam is emitted when automatic operation is performed by a machining program,

.A
so never put your hand or any object under the machining torch during operation.

N
O
WARNING

TI
87

Sample program 1 A
R
14

PO

(Shown below is an example of a program for the machining of a 1 mm (0.039 in) thick SPHC
31

plate. The machining conditions need to be changed depending on the material.)

o.

O
N

% G90G00W0.5 O0002
al

O0001 M98P0002 G88P20M56

ri

ZA

M290 G87P0
Se

G22U-2.5 M23 M32

A

G88P50M56 M09 G04X0.3

IM

G04X3. M21 G82P1000Q100R20

K

M20 G91G28Z0 M22

ZA

G90G00W-2.5 M30 G04X0.8

M98P0002
A

G88P50M56
M

G90G00W-2 G82P1000Q100R100F3000
YA

M98P0002 G04X0.3
G91G01X30.
3

G90G00W-1.5 M23
01

M98P0002 M31
)2

G91G00Z10.
(c

G90G00W-1 G91G00X-30.Y-5.
M98P0002 M99
ht

%
ig

G90G00W-0.5
yr

M98P0002
op
C

G90G00W0
M98P0002

9-29
 Serial No. 311487

9 MACHINING TORCH

Narrowest slit
The focal point is located in this area.
[Displacement of Z-axis: 1.0 mm (0.039 in)] D628SB0003

.
d
ve
The exact focal point is located between the two slits sandwiching the narrowest slit.

er
Adjust the focus precisely, using the program described in the next section.

s
re
ts
C. Procedure [2]: Precise focus adjustment

gh
This section describes the steps to follow when adjusting the focus of the laser beam, using

ri
sample program 2.

ll
.A
(1) After “2. Rough focus adjustment of the laser beam” above, adjust the parameter.

N
(2) Just as in Step (4) of Section 2 above, make test cuts using a machining program (see

O
TI
Sample program 2).
87

A
R
Set the distance between the nozzle tip and the worksheet to 1 mm (0.039 in), and cut 21
14

PO

slits 30 mm (1.18 in) in length in the X-axis direction, while raising the focal point in steps of
31

0.05 mm (0.002 in) within the range of ±0.5 mm (±0.020 in) from the worksheet surface. The
o.

focal point of the laser beam is exactly where the narrowest slit is cut.
N

C
al

(3) Determine the focal point at the time when the narrowest slit is cut, using a thickness gauge
ri

ZA

or similar, and add the error to the current set value.

Se

Example : If Focus Act is –16.500 and the slit at W of –0.65 mm (–0.026 in) is the
IM

narrowest, the correction value is +0.35 mm (–0.65 – (–1.0) = 0.35 mm) (–0.026
K

– (–0.039) = 0.013 in) and so Focus Act needs to be changed to –16.150.

ZA

Since there are not significant differences in width between the slits, also use as a clue the
A
M

resistance that the thickness gauge shows when it is inserted in each slit.
YA
3

Narrowest slit
01
)2
(c
ht
ig
yr
op
C

The gauge can be inserted. The gauge can be inserted.

The gauge cannot be inserted. D628MA0042

9-30
 Serial No. 311487

MACHINING TORCH 9

Machining 100 mm (3.94 in)

start point

Machining 30 mm
direction (1.18 in)

* The focal point is raised X

.
W = –1.4 mm (–0.055 in)

d
0.05 mm (0.002 in) on
W = –1.45 mm (–0.057 in)

ve
completion of the cutting Machining order
of each slit. W = –1.5 mm (–0.059 in) Y

er
Total displacement:

s
re
1.0 mm (0.039 in) D628MA0043’

ts
gh
Sample program 2

ri
(Shown below is an example of a program for the machining of a 1 mm (0.039 in) thick SPHC

ll
plate. The machining conditions need be changed depending on the material.)

.A
N
% G90G00W-0.95 O0002

O
O0001 M98P0002 G88P20M56

TI
M290 G87P0
87

G22U-2.5 G90G00W-0.9 A M32

R
14

G88P50M56 M98P0002 G04X0.3

PO

G04X3. G82P1000Q100R20
31

M20 G90G00W-0.85 M22

R
o.

G90G00W-1.5 M98P0002 G04X0.8

O
N

M98P0002
C

G90G00W-0.8 G88P50M56
al

G90G00W-1.45 M98P0002 G82P1000Q100R100F3000

ri

ZA
Se

M98P0002 G04X0.3
A

G90G00W-0.75 G91G01X30.
IM

G90G00W-1.4 M98P0002 M23

M98P0002 M31
K

G90G00W-0.7 G91G00Z10.
ZA

G90G00W-1.35 M98P0002 G91G00X-30.Y-5.

M98P0002 M99
A

G90G00W-0.65 %
M

G90G00W-1.3 M98P0002
YA

M98P0002
G90G00W-0.6
3
01

G90G00W-1.25 M98P0002
M98P0002
)2

G90G00W-0.55
(c

G90G00W-1.2 M98P0002
ht

M98P0002
ig

G90G00W-0.5
yr

G90G00W-1.15 M98P0002
M98P0002
op

M23
C

G90G00W-1.1 M09
M98P0002 M21
G91G28Z0
G90G00W-1.05 M30
M98P0002

G90G00W-1.0
M98P0002

The adjustment is now completed.

9-31
 9

C
op
yr
ig
MACHINING TORCH

ht
(c
)2
01
3
YA
M
A Se
ZA
K ri
al
IM
N
A o.
ZA 31
K

9-32 E
14
C
O 87
Serial No. 311487

R
PO
R
A
TI
O
N
.A
ll
ri
gh
ts
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ser
ve
d.
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

10 MAINTENANCE OF MACHINING TORCH

10-1 Maintenance of Machining Torch

For maintenance operation of machining torch, refer to the following table.

Machining torch Reference section Remarks

Manual torch 2 10-2 “Maintenance of the Manual Torch 2”
Torch made by Laser Mech Operating manual of the torch made by Laser Mech Optional for use in USA only

 When performing this maintenance operation, be careful not to allow dust and dirt to enter
the torch. Contamination inside the torch could not only cause optical parts to burn out,

d .
but also cause damage to the torch.

ve
WARNING

er
 To avoid contamination, perform the maintenance operation in the shortest time possible

s
without a halt.

re
ts
 Perform the maintenance operation on a clean workbench. Before carrying out

gh
maintenance operation, clean the workbench with clean paper (dust-free paper).

ri
 Mount all the removed parts again to make up the torch correctly.

ll
.A
N
O
TI
87

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

10-1
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

10-2 Maintenance of the Manual Torch 2

Protective windows used for laser machining gradually become dirty and their performance
degrades as they are used. So, they need to be cleaned or replaced periodically to restore the
performance. This chapter explains how to clean or replace these consumable parts.

 Never disengage the optical fiber connector and never remove the condensing lens, the
torch and components other than the maintenance items specified in this section yourself,
but have them done by Mazak service engineers. If necessary, contact the Mazak
DANGER Technical Center or Technology Center. Contamination inside the torch may cause the
torch to break.

 When performing this maintenance operation, be careful not to allow dust and dirt to enter

d.
the torch. It is recommended to clean and replace the protective window in a place where

ve
there is not much dirt or dust, such as an office. Contamination inside the torch could not

er
WARNING only cause optical parts to burn out, but also cause damage to the torch.

s
re
 Do not turn off the NC power during the maintenance operation. If the NC power is turned

ts
off, the protective window cartridge will be clamped, and so it cannot be mounted or

gh
removed. Also, the supply of lens protective air will be stopped, with the result that the

ri
torch will get dirty inside.

ll
.A
 When performing this maintenance operation, hold on the main air supply of the laser

N
machine. A slight amount of lens protective air blows out from the insertion port of the

O
protective window cartridge to prevent dust and dirt from getting in the torch. When the

TI
87

main air supply is off, the supply of lens protective air is stopped.
A
R
14

 Keep the dust collector off during the maintenance work. Failure to do so may cause air to
PO
31

flow around the torch, and thus cause dirt and dust to get in the torch.
R
o.

 If the torch is moved to the maintenance position by selecting TORCH MAINTENANCE

N

C
al

POS. in the DIRECT MDI pop-up window, the dust collector may operate in some cases.
K
ri

ZA

So, use Handle mode when moving the torch to the designated position.
Se

 To avoid contamination, perform the maintenance operation in the shortest time possible
IM

without a halt.
K

 Perform the maintenance operation on a clean workbench. Before carrying out

ZA

maintenance operation, clean the workbench with clean paper (dust-free paper). Also,
A

clean the supplied stainless tray with clean paper (dust-free paper) and keep it handy to
M

place the removed protective window cartridge on it.

YA

 Mount all the removed parts again to make up the torch correctly.
3
01
)2
(c
ht
ig
yr
op
C

10-2
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

10-2-1 Clothing and cautions on handling the optical parts
 Wear clean clothing free of steel particles and oily stains to eliminate the danger of
contaminating the protective window with dust and dirt.
 Tidy the hair and put on a cap to prevent hair or dandruff from falling onto the protective
window.
 Wear a mask to ensure that the protective window is not contaminated by breath, saliva, etc.
 Wash your hands carefully and put on clean gloves (powder-free type) before handling the
protective window.
 Perform the maintenance operations of the protective window in an environment with the
smallest possible amount of dust.

d .
Example : A place with the smallest possible amount of dust, such as an office, but not near

ve
the machine.

ser
re
Wash hands carefully with soap.  Always use clean gloves when handling the

ts
protective window.

gh
 Always use powder-free gloves.

ri
ll
.A
N
O
TI
87

A
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14

PO
31

R
o.

O
N

D619MA0030
al

K
ri

ZA

 Hold the protective window gently at its edges. Never touch the surface of the protective
Se

window.
IM

 Do not press on protective window from the top of the packaging. This could cause the
K

protective window to rub against the wrapping paper and be scratched.

ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

10-3
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

10-2-2 Handling new optical parts

New optical parts have been manufactured under strictly controlled conditions, and have been
carefully packaged. The protective window will be in its cleanest state in this condition. In order
to keep it in this state, the following precautions should be observed when dealing with new
parts.
 When taking the protective window from the case, take great care that it is not caught against
the case and scratched.
 Do not press on the protective window from the top of the packaging. This could cause the
protective window to rub against the wrapping paper and be scratched.
 The protective window should always be picked up gently by the edge.
 Take care when removing wrapping paper from the protective window so that no dusts fall

. d
ve
from the paper onto the surface of the window.

er
 Carefully clean the protective window cartridge in which the window is to be mounted with

s
re
clean paper or anhydrous ethanol. Any dirt on the protective window cartridge can be

ts
transferred to the window.

gh
ri
ll
.A
Clean the cartridge with anhydrous ethanol

N
(clean paper).

O
TI
87

A
R
14

PO

Always use clean gloves when handling

31

the protective window.

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM

Take great care when taking the

K

protective window from the case.

ZA
A
M
YA

The protective window should always be

3

picked up gently (picking up by the edge).

01
)2

Mounting the protective window

(c

on the cartridge D619MA0031

ht

Fig. 10-1 Handling new optical parts

ig
yr
op
C

10-4
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

10-2-3 Storing the optical parts
Optical parts such as protective window cartridge and protective window are not only very
expensive, but also extremely sensitive to dirt. It is therefore very important to take great care in
their storage.

1. Storage location and environment

 A storage location that is easy to manage and not accessible to unrelated personnel should
be selected. If a protective window is touched accidentally, it could easily be damaged.
 Optical parts should be stored in a location where the temperature is constantly between 10
and 30°C (50 and 86°F), and the difference between the temperature of the storage area and
the room temperature should be kept to a minimum. (DO NOT keep optical parts in a

d .
refrigerator or similar environment. Condensation may occur when they are taken out.)

ve
 The relative humidity of the storage area should be kept at 30% or lower.

ser
 Parts should always be kept in their cases when they are in storage. If parts are left

re
unprotected, dust will adhere to the surface. (This is true even when optical parts are in

ts
gh
desiccators. Dust can settle on a lens when the lid is opened and closed.)

ri
 Do not subject protective window cartridge and protective window to shock. This could distort

ll
the protective window or its cartridge.

.A
N
O
TI
87

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

10-5
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

10-2-4 Construction of the manual torch 2

1. Torch body

Automatic focusing and beam diameter

adjustment collimation unit

d .
ve
s er
Protective window cartridge

re
56283315601

ts
* When replacing the Body

gh
protective window nut, have

ri
a protective window
cartridge (56283315601)

ll
.A
handy.
* The protective window is not

N
included.

O
Protective cover of the profiling

TI
preamplifier
87

Protective window
A
R
14

PO
31

R
o.

O
N

Machining nozzle
al

Protective window
ri

ZA

cartridge cover Knurled screw

Se

A
IM

Protective window nut

Cartridge upper surface O-ring
K

J25NV003160
Protective window
ZA

4DG-75 (CO 0210I)

 FIBER 2.0 kW - 8.0 kW
A

56283316801
M

 FIBER 10.0 kW/DDL 6.0 kW

YA

56283316701
 DDL 4.0 kW
56283316901 Protective window O-ring
3

J25NV003810
01

* Each of the above units CO 0531U3 (S-39)

)2

includes cartridge upper and

lower surface O-rings and a
(c

protective window O-ring.

ht

Cartridge lower surface

ig

O-ring
yr

J25NV002130
G45 F422
op
C

Cartridge lower surface

resin seal
J24SH006771
TYH-62.9X55.9X3-T101

D699MA0016’

Fig. 10-2 Construction of the manual torch 2

10-6
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

2. Jig

A. Jigs for optical parts

Condensing lens
Protective window nut Protective window Condensing lens
Name holder
mounting/removing jig mounting/removing jig mounting/removing jig
mounting/removing jig

Form

d .
ve
er
Name Piston jig (upper) Piston jig (lower)

s
re
ts
gh
ri
Form

ll
.A
N
O
TI
Note : The condensing lens mounting/removing jig, the condensing lens holder mounting/
87

A
removing jig and the piston jigs (upper/lower) are intended to be used by a Mazak
R
14

PO

service person.
31

R
o.

B. Jigs for torch tip

N

C
al

Torch tip Torch tip Nozzle Nozzle center

ri

Maintenance
ZA

Name mounting/removing mounting/removing mounting/removing adjustment

Se

plate
jig 1 jig 2 jig handle
A
IM
K
ZA

Form
A
M
YA
3
01

Name Wrench Allen wrench (1.3)

)2
(c
ht
ig
yr

Form
op
C

10-7
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

10-2-5 Maintenance of the protective window cartridge

 When performing this maintenance operation, be careful not to allow dust and dirt to enter
the torch. It is recommended to clean and replace the protective window in a place where
there is not much dirt or dust, such as an office. Contamination inside the torch could not
WARNING only cause optical parts to burn out, but also cause damage to the torch.
 Do not turn off the NC power during the maintenance operation. If the NC power is turned
off, the protective window cartridge will be clamped, and so it cannot be mounted or
removed. Also, the supply of lens protective air will be stopped, with the result that the
torch will get dirty inside.
 When performing this maintenance operation, hold on the main air supply of the laser
machine. A slight amount of lens protective air blows out from the insertion port of the

d.
ve
protective window cartridge to prevent dust and dirt from getting in the torch. When the

er
main air supply is off, the supply of lens protective air is stopped.

s
re
 Keep the dust collector off during the maintenance work. Failure to do so may cause air to

ts
flow around the torch, and thus cause dirt and dust to get in the torch.

gh
 If the torch is moved to the maintenance position by selecting TORCH MAINTENANCE

ri
POS. in the DIRECT MDI pop-up window, the dust collector may operate in some cases.

ll
.A
So, use Handle mode when moving the torch to the designated position.

N
 To avoid contamination, perform the maintenance operation in the shortest time possible

O
without a halt.

TI
87

A
 Perform the maintenance operation on a clean workbench. Before carrying out
R
14

maintenance operation, clean the workbench with clean paper (dust-free paper). Also,
PO
31

clean the supplied stainless tray with clean paper (dust-free paper) and keep it handy to
R
o.

place the removed protective window cartridge on it.

O
N

 Before removing the protective window cartridge, be sure to clean the entire torch to
al

prevent dirt and dust on it from falling.

ri

ZA
Se

 Do not clean the torch using a hand held air nozzle. Failure to observe this precaution is
A
IM

liable to cause dirt or dust to enter the torch, resulting contamination inside of the torch.
 Pull out or insert the protective window cartridge slowly. If it is pulled out or inserted
K
ZA

swiftly, outside air will be sucked, with the result that the inside of the torch will be
A

contaminated.
M

 When handling the protective window cartridge, wear clean gloves (powder-free type) so
YA

as not to touch any parts facing the inside of the torch with your bare hands. Failure to do
3

so will cause dust and dirt to adhere to the protective window cartridge and contaminate
01

the inside of the torch.

)2

 Replace the clean gloves (powder-free type) when they get dirty.
(c
ht

 Never put a hand or something inside of the protective window cartridge insertion port.
ig

This may result in the ingress of dust and dirt, which is liable to cause burnout of the
yr

optical parts.
op
C

 After removing the protective window cartridge, close the protective window cartridge
cover immediately to prevent dust and dirt from entering the torch.

10-8
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

1. Removing the protective window cartridge
(1) Clean all parts around the torch thoroughly with clean paper (dust-free paper) or a brush.
(Ensure that there is no dirt or dust.)

 Never use a hand held air nozzle to clean the vicinity of the torch.
 After cleaning, apply a curing tape to the top of the protective window cartridge cover.
CAUTION

Cleaning the side

face
* Clean the

.
Cleaning the

d
opposite face in

ve
front face
the same way.

s er
re
ts
gh
Insert clean paper into

ri
the gap to clean it.

ll
.A
N
O
TI
87

A D699MA0017
R
14

PO
31

R
o.

O
N

After cleaning, apply a curing tape.

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA

D698MA0045
3
01

(2) Unclamp the protective window cartridge.

)2

(a) Turn the machine setup switch to the ON (I) position.

(c
ht

(b) Press the [Protection window Unclamp] button on the CONTROL

ig

MENU screen while pressing the permission button.

yr
op

 The LED next to the button lights up and the protective window cartridge is unclamped.
C

 Do not turn the setup switch to the OFF (O) position during the operation. Doing so will
cause the protective window cartridge to get clamped.
 Before clamping the protective window cartridge, close its cover.
CAUTION

10-9
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

(3) Loosen the knurled screws [1] and open the protective window cartridge cover [2]. Clean the
protective window cartridge cover and the area around the protective window cartridge slot
with clean paper (dust-free paper) or a cleaning stick.

[2] Protective window

[1] Knurled screw cartridge cover

.d
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
Clean the protective window cartridge cover. Clean the area around the protective
87

window cartridge slot.

A
R
14

D619MA0034
PO
31

(4) Wear clean gloves (powder-free type).

o.

O
N

(5) Remove the protective window cartridge [3] slowly. After removing the protective window
al

cartridge, close its cover immediately and fasten it with the knurled screws.
ri

ZA
Se

 When handling the protective window cartridge, wear clean gloves (powder-free type) so
A
IM

as not to touch any parts facing the inside of the torch with your bare hands.
 Do not turn off the power when the protective window cartridge is removed. Doing so will
K

CAUTION
ZA

stop the supply of lens protection air and cause contamination inside the torch.
A
M

[3] Protective window cartridge

YA
3
01
)2
(c
ht
ig
yr
op

Wear clean gloves

C

(powder-free type).

D619MA0035

10-10
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

(6) Put the removed protective window cartridge in a clean plastic bag and place it on the
supplied stainless tray cleaned with clean paper (dust-free paper). Be sure to replace the
protective window in a clean environment.

 For the protective window replacement procedure, see Paragraph 3.

“Replacement of the protective window.”

2. Mounting the protective window cartridge

(1) Loosen the knurled screws [1] and open the protective window cartridge cover [2].

d .
ve
s er
re
ts
gh
ri
[2] Protective window

ll
[1] Knurled screw cartridge cover

.A
N
O
D698MA0046

TI
87

A
(2) Insert the protective window cartridge [3] slowly as far as it will go.
R
14

PO
31

 When handling the protective window cartridge, wear clean gloves (powder-free type) so
R
o.

as not to touch any parts facing the inside of the torch with your bare hands.
N

 Before inserting the protective window cartridge, check to make sure that the protective
al

CAUTION
ri

ZA

window cartridge and the seal are free of dust and dirt.
Se

A
IM

Body of the torch

End surface of the protective
K

window cartridge
ZA
A
M

Make sure that the protective

YA

window cartridge is fully inserted

and its end surface is inside the
3
01

body of the torch.

)2

(0.3 mm)
(c

Cross-section of the protective window cartridge [0.012 in]

ht

D619MA0037
ig
yr
op
C

10-11
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

(3) Close the protective window cartridge cover [2] and tighten the knurled screws [1] securely.

 If the protective window cartridge cover is not fully closed, the inside of the torch will be
contaminated due to the lack of air tightness.

CAUTION

Make sure these surfaces are flush.

d .
ve
s er
re
Protective window cartridge cover

ts
gh
Make sure there is no gap.

ri
Left side of the torch

ll
D619MA0038

.A
N
(4) Clamp the protective window cartridge.

O
TI
(a) Press the [Protection window Unclamp] button on the CONTROL
87

A
MENU screen while pressing the permission button.
R
14

PO
31

 The LED next to the button is turned off and the protective window cartridge is clamped.
R
o.

 Do not turn the setup switch to the OFF (O) position during the operation.
N

C
al

 Before clamping the protective window cartridge, close its cover. Otherwise, you may get
K
ri

ZA

your fingers caught in it.

Se

CAUTION
A

 Before clamping the protective window cartridge, close its cover. If the protective window
IM

cartridge is not clamped in the correct position, its cover cannot be fully closed and the
K

inside of the torch will be contaminated due to the lack of air tightness.
ZA
A
M
YA
3
01
)2
(c
ht
ig
yr
op
C

10-12
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

3. Replacement of the protective window

 When performing this maintenance operation, be careful not to allow dust and dirt to enter
the torch. It is recommended to clean and replace the protective window in a place where
there is not much dirt or dust, such as an office. Contamination inside the torch could not
WARNING only cause optical parts to burn out, but also cause damage to the torch.
 Do not turn off the NC power during the maintenance operation. If the NC power is turned
off, the protective window cartridge will be clamped, and so it cannot be mounted or
removed. Also, the supply of lens protective air will be stopped, with the result that the
torch will get dirty inside.
 When performing this maintenance operation, hold on the main air supply of the laser
machine. A slight amount of lens protective air blows out from the insertion port of the

d.
protective window cartridge to prevent dust and dirt from getting in the torch. When the

ve
er
main air supply is off, the supply of lens protective air is stopped.

s
 Keep the dust collector off during the maintenance work. Failure to do so may cause air to

re
ts
flow around the torch, and thus cause dirt and dust to get in the torch.

gh
 If the torch is moved to the maintenance position by selecting TORCH MAINTENANCE

ri
POS. in the DIRECT MDI pop-up window, the dust collector may operate in some cases.

ll
.A
So, use Handle mode when moving the torch to the designated position.

N
 To avoid contamination, perform the maintenance operation in the shortest time possible

O
without a halt.

TI
87

 Perform the maintenance operation on a clean workbench. Before carrying out

A
R
14

maintenance operation, clean the workbench with clean paper (dust-free paper). Also,
PO
31

clean the supplied stainless tray with clean paper (dust-free paper) and keep it handy to
R
o.

place the removed protective window cartridge on it.

O
N

 When handling the protective window cartridge, wear clean gloves (powder-free type) so
al

as not to touch any parts facing the inside of the torch with your bare hands. Failure to do
ri

ZA
Se

so will cause dust and dirt to adhere to the protective window cartridge and contaminate
A

the inside of the torch.

IM

 Replace the clean gloves (powder-free type) when they get dirty.
K
ZA

 Never put a hand or something inside of the protective window cartridge insertion port.
A

This may result in the ingress of dust and dirt, which is liable to cause burnout of the
M

optical parts.
YA

(1) Remove the protective window cartridge [3] by following the steps in Paragraph
3
01

1. “Replacement of the protective window.”

)2

(2) Before replacing the protective window, clean the protective window nut mounting/removing
(c

jig [5] and the protective window mounting/removing jig [6], using clean paper (dust-free
ht

paper).
ig
yr

(3) Hold the protective window cartridge [3] with your hand.
op
C

 When handling the protective window cartridge, wear clean gloves (powder-free type).

CAUTION

10-13
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

(4) Turn over the protective window cartridge [3], fit the protective window nut mounting/
removing jig [5] on the protective window nut [4] and turn it counterclockwise to remove the
protective window nut [4].

[3] Protective window cartridge

[4] Protective window nut

06283303240

[5] Protective window nut

d.
mounting/removing jig

ve
06283302890

er
A12002X0080

s
re
D698MA0047

ts
gh
Note : When the protective window nut [4] is removed, the protective window may fall. To

ri
avoid this, remove the nut with care. Also, immediately turn over the protective

ll
window cartridge [3] again.

.A
N
(5) Press the hollow side of the protective window mounting/removing jig [6] against the upper

O
surface of the protective window [7], turn over the protective window cartridge [3] and

TI
87

remove the protective window. When reusing the protective window after cleaning, be sure
A
R
14

to set it in the same orientation (top and reverse sides) as when it was removed.
PO
31

[6] Protective window

o.

mounting/removing jig
N

Press the hollow side of

C

06283303200
the jig against the upper
al

surface of the protective

ri

ZA

window.
Se

[7] Protective window

IM

See Subsection
10-2-4.
K
ZA

Hollow side
A
M
YA

[3] Protective window cartridge D619MA0040

3
01
)2

Note : If the protective window [7] coagulates to the protective window O-ring [8] and it
cannot be removed even if the protective window cartridge [3] is turned over, push
(c

out the protective window [7] with the head of a new cleaning stick.
ht
ig

Failure to do so may cause damage or dirt to the window.

yr
op
C

10-14
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

(6) Clean the surfaces of the protective window cartridge [3], protective window nut [4],
protective window O-ring [8], cartridge upper surface O-ring [9], cartridge lower surface
O-ring [10] and cartridge lower surface resin seal [11], using clean paper (dust-free paper).

[8] Protective window O-ring

J25NV003810
[9] Cartridge upper surface O-ring CO 0531U3(S-39)
J25NV003160
4DG-75 (CO 0210I) Female threaded portion where the
protective window nut is attached

d .
ve
er
[3] Protective window
cartridge

s
[11] Cartridge lower surface resin seal [10] Cartridge lower surface O-ring

re
J24SH006771 J25NV002130
TYH-62.9X55.9X3-T101 G45 F422

ts
D619MA0041

gh
ri
Note 1: If the O-rings [8], [9] and [10] are damaged, be sure to replace them. Even if they

ll
.A
are not damaged, replace them every six months. When removing the O-rings,
apply the curing tape to them. In addition, before replacing the O-rings, be sure to

N
O
clean the new O-rings with clean paper (dust-free paper). Failure to do so may

TI
cause contamination inside the torch.
87

A
R
14

PO
31

R
o.

O
N

When removing
al

the O-rings, apply

K

the curing tape to

ri

ZA
Se

them.
A
IM
K

D698MA0048
ZA
A

Note 2: If the cartridge lower surface resin seal [11] is damaged, be sure to replace it. Even
M

if it is not damaged, replace it once a year. Be sure to remove the cartridge lower
YA

surface resin seal while inserting the tool in the removal groove. At that time, be
3

careful not to damage the cartridge. In addition, before replacing the cartridge
01

lower surface resin seal, be sure to clean the new one with clean paper (dust-free
)2

paper). Failure to do so may cause contamination inside the torch.

(c

Note 3: After removing the O-rings [8], [9] and [10] and the cartridge lower surface resin
ht

seal [11], clean the grooves with clean paper (dust-free paper).
ig
yr
op
C

10-15
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

(7) Using a nylon brush (toothbrush) moistened with two or three drops of anhydrous ethanol
are applied, remove the powder of worn-out seals from the female thread of the protective
window cartridge [3] and the male thread of the protective window nut [4]. After that, remove
the moisture from the thread portions, using clean paper (dust-free paper).

[4] Protective window nut

Male thread

[3] Protective window cartridge

Female thread

d.
ve
s er
re
Nylon brush (toothbrush)

ts
D698MA0044

gh
ri
Note 1: Prepare yourself a nylon brush (toothbrush).

ll
.A
Note 2: If any dirt adheres to the nylon brush, clean it with clean paper (dust-free paper) to

N
remove dirt before use.

O
TI
 Dust and highly-adhesive dirt could cause the optical components to burn out. Do not
87

A
R
14

touch any parts of the optical components other than the side surface.
PO
31

 Wear clean gloves (powder-free type).

CAUTION
R
o.

O
N

(8) Set a new or cleaned protective window [7] on the hollow side of the protective window
al

mounting/removing jig [6].

ri

ZA
Se

Set the protective window [7] with the V mark on the side surface oriented in the same
A

direction as the laser beam. As for protective windows with no V mark on the side surface,
IM

there is no difference between the top and the reverse. Note, however, that when reusing
K

the protective window that has been mounted until now, set it in the same orientation (top
ZA

and reverse sides) as when it was removed.

A
M
YA

[7] Protective window

3

See Subsection 10-2-4.

01
)2
BEAM
(c
ht
ig

[6] Protective window

yr

mounting/removing jig
V mark 06283303200
op
C

D619MA0042

(9) Fit the protective window [7] set on the hollow side of the protective window
mounting/removing jig [6] into the protective window cartridge [3] from under it, and turn
over the protective window cartridge [3].

10-16
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

(10) Remove the protective window mounting/removing jig [6] and tighten the protective window
nut [4] by hand by turning it clockwise until it stops turning.

[3] Protective window cartridge [4] Protective window nut

06283303240

d .
ve
[7] Protective window [6] Protective window
See Subsection 10-2-4. mounting/removing jig

er
06283303200 D619MA0043

s
re
ts
(11) After tightening the protective window nut [4] by hand, turn over the protective window

gh
cartridge [3], and using the protective window nut mounting/removing jig [5], additionally

ri
turn the protective window nut [4] until the match marks are aligned as shown in the figure

ll
below to tighten it securely.

.A
N
O
[4] Protective window nut

TI
06283303240
87

A
R
14

[7] Protective window

PO

See Subsection 10-2-4.

31

R
o.

O
N

C
al

K
ri

ZA
Se

[5] Protective window nut

A

mounting/removing jig
IM

[3] Protective window cartridge

06283302890
A12002X0080
K

D619MA0044
ZA
A

Note : Depending on the variations in the thickness of the protective window, the
M

protective window nut [4] may be heavy to turn.

YA
3
01
)2
(c
ht
ig
yr
op
C

Allowable range: 10 mm [0.39 in]

Even if the protective window nut [4] is heavy to turn, tighten

it until the amount of misalignment falls within the allowable
range (less than 10 mm [0.39 in]).
D619MA0045

(12) Visually check the protective window, using an LED flashlight (preferably 200 lumen or
more) to make sure it is free of dirt.

10-17
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

 If the protective window nut is not tightened securely and the match marks are misaligned
more than 10 mm (0.39 in), dust and dirt may enter through the gap and cause damage
not only to the optical components, but also to the torch.
CAUTION

(13) When inserting the protective window cartridge [3] into the torch, check to make sure that
the protective window O-ring [8], cartridge upper and lower surface O-rings [9] and [10],
cartridge lower surface resin seal [11] are free of dust and dirt. If dust or dirt is found, wipe it
off before inserting the protective window cartridge.

 At that time, be careful not to allow the removed dust to adhere again to the protective
window and not to touch the protective window with a hand.

d.
CAUTION

ve
er
(14) Press the (protective window replace) button on the NC screen.

s
re
Note : If the button is pressed during automatic operation, feed hold stop or single block

ts
stop, the alarm 308570 During auto processing will be displayed and no reset

gh
will be performed.

ri
ll
.A
N
O
TI
87

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

D698MA0045E
IM
K
ZA
A
M
YA
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10-18
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

(15) When the Did you exchange protective window? message box is displayed, select
[CONFIRM].

 The Total Used Time is cleared.

 If the Abnormal LED is lit before replacing the window, the Abnormal LED goes out and
the Normal LED lights up.
 If the Total Used Time is not to be cleared, select [CANCEL]. In this case, the
Abnormal LED will not go out.

d.
ve
ser
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

PO
31

R
o.

O
N

(16) If the alarm PROTECTION WINDOW ALARM is raised before replacing the window, press
C
al

the reset key after replacing the window to clear the alarm.
K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
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10-19
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

4. Cleaning the protective window

 When performing this maintenance operation, be careful not to allow dust and dirt to enter
the torch. It is recommended to clean and replace the protective window in a place where
there is not much dirt or dust, such as an office. Contamination inside the torch could not
WARNING only cause optical parts to burn out, but also cause damage to the torch.
 Do not turn off the NC power during the maintenance operation. If the NC power is turned
off, the protective window cartridge will be clamped, and so it cannot be mounted or
removed. Also, the supply of lens protective air will be stopped, with the result that the
torch will get dirty inside.
 When performing this maintenance operation, hold on the main air supply of the laser
machine. A slight amount of lens protective air blows out from the insertion port of the

d.
protective window cartridge to prevent dust and dirt from getting in the torch. When the

ve
er
main air supply is off, the supply of lens protective air is stopped.

s
 Keep the dust collector off during the maintenance work. Failure to do so may cause air to

re
ts
flow around the torch, and thus cause dirt and dust to get in the torch.

gh
 If the torch is moved to the maintenance position by selecting TORCH MAINTENANCE

ri
POS. in the DIRECT MDI pop-up window, the dust collector may operate in some cases.

ll
.A
So, use Handle mode when moving the torch to the designated position.

N
 To avoid contamination, perform the maintenance operation in the shortest time possible

O
without a halt.

TI
87

 Perform the maintenance operation on a clean workbench. Before carrying out

A
R
14

maintenance operation, clean the workbench with clean paper (dust-free paper). Also,
PO
31

clean the supplied stainless tray with clean paper (dust-free paper) and keep it handy to
R
o.

place the removed protective window cartridge on it.

O
N

 When handling the protective window cartridge, wear clean gloves (powder-free type) so
al

as not to touch any parts facing the inside of the torch with your bare hands. Failure to do
ri

ZA
Se

so will cause dust and dirt to adhere to the protective window cartridge and contaminate
A

the inside of the torch.

IM

 Replace the clean gloves (powder-free type) when they get dirty.
K
ZA

 Never put a hand or something inside of the protective window cartridge insertion port.
A

This may result in the ingress of dust and dirt, which is liable to cause burnout of the
M

optical parts.
YA
3
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10-20
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

 Use anhydrous ethanol with a purity of 99.5 vol%.
 Use a dedicated cleaning stick. Failure to do this may cause fibers and other matter to
adhere to the protective window and soil it.
CAUTION
 When applying anhydrous ethanol to a cleaning stick, be careful not to let the cleaning
stick touch the neck of the anhydrous ethanol bottle. If the stick touches the neck of the
bottle, the inside of the bottle may become dirty.
 If you apply an excessive amount of anhydrous ethanol to cleaning stick or the protective
window, airborne dirt may adhere to it, or evaporation marks may remain on the protective
window.
 Change the cleaning stick after cleaning each side of the protective window.

.
 Be very careful not to drop the protective window during cleaning work.

d
ve
 At that time, be careful not to allow the removed dust to adhere to the protective window

ers
and not to touch the protective window with a hand.

re
 Align the match mark on the protective window cartridge and that on the protective

ts
window nut. Otherwise, dust and dirt may enter through the gap, and may not only cause

gh
the optical components to burn out, but also cause the torch to break.

ri
ll
 When tightening the protective window nut, be extremely careful not to damage the

.A
protective window with the protective window nut mounting/removing jig.

N
O
(1) Prepare a cleaning kit.

TI
87

A
(2) Remove the protective window cartridge using the procedure of Paragraph 1. “Removing
R
14

PO

the protective window cartridge.”

31

(3) Remove the protective window using the procedure of Paragraph 3. “Replacement of the
R
o.

O
N

protective window.”
C
al

 The protective window needs to be set on the protective window cartridge, with the V
K
ri

ZA

mark on the side surface of the protective window oriented in the same direction as the
Se

laser beam. If the protective window has no V mark on the side surface, it should be set
IM

in the same orientation (top and reverse sides) as when it was removed, so remember
K

the orientation.
ZA

 When it is necessary to touch the protective window, be sure to use clean gloves
A

(powder-free type) that are likely to touch the protective window.

M
YA

 Before using the protective window, clean the entire cleaning jig with clean paper
(dust-free paper).
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10-21
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

(4) Place the protective window on the cleaning jig.

 When doing this, ensure that the lower face of the protective window comes to the top.

Protective window

d .
ve
ser
re
ts
gh
ri
Cleaning jig
D698MA0029

ll
.A
N
(5) Set the LED light on the cleaning jig, turn ON the LED light, and check the protective

O
window for dirt.

TI
87

A
 For details of checking the protective window for dirt refer to Fig. 10-3.
R
14

PO
31

R
o.

O
N

 If there are signs of burning or damage on the surface of the protective window, replace
C
al

the protective window.

ri

ZA
Se

A
IM
K

Light
ZA
A
M
YA
3
01
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ig

D698MA0030
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10-22
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

(6) Clean the protective window with anhydrous ethanol and a cleaning stick.
 Place one or two drops of anhydrous ethanol on the cleaning stick.
 Gently place the body of the cleaning stick against the edge of the protective window,
and then slide the cleaning stick slowly in the direction of the arrow.
(Rough guide: One stroke or so per second. Clean the whole surface of the protective
window by sliding the cleaning stick at a rate of 1 stroke or so per second (stroke
represented by the arrow in the figure). Also, perform each adjustment yourself.)
 Do not stop moving the cleaning stick on the protective window while cleaning it.
This may cause anhydrous ethanol evaporation marks or dust and dirt to remain on the
protective window.
After completing each stroke (stroke represented by the arrow in the figure below), take

.
up the cleaning stick to get it off the protective window.

d
ve
s er
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

PO

Cleaning stick
31

D619MA0046
R
o.

O
N

 Use a dedicated cleaning stick. Failure to do this may cause fibers and other matter to
al

adhere to the protective window and soil it.

ri

ZA
Se

 Be very careful not to drop the protective window during cleaning work.
A

CAUTION
IM

 If you apply an excessive amount of anhydrous ethanol, airborne dirt may adhere to it, or
evaporation marks may remain on the protective window.
K
ZA

 If you apply an excessive amount of anhydrous ethanol to the cleaning stick, flick off the
A
M

excess from the cleaning stick.

YA

If you apply an excessive amount of anhydrous ethanol to the cleaning stick, flick the end of the
3
01

cleaning stick with your thumb on a timely basis, so that the excess anhydrous ethanol flies off
the cleaning stick, as shown in the figure below.
)2
(c
ht
ig
yr
op
C

1. Bend the stick with your 2. Release the stick. 3. The excess anhydrous
thumb. ethanol flies off.
D698MA0032

10-23
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

(7) Using a cleaning jig, illuminate the protective window with the LED light, check to see if it
has been cleaned. If dirt, uneven wipe marks, or anhydrous ethanol remain on the surface
of the protective window, carry out cleaning once again.

d.
ve
er
s
OK NG
D698MA0033

re
ts
Fig. 10-3 OK/NG judgment after the protective window has been cleaned

gh
 Check to see if the protective window has dirt or irregular wipe marks on it. Failure to carry

ri
ll
out this check may lead to defective machining or burnout of the component parts of the

.A
torch.

N
CAUTION
 If it is impossible to remove dirt, replace the protective window with a new one.

O
TI
87

(8) Install the cleaned protective window on the cartridge, using steps (8) to (11) of Paragraph
A
R
14

3. “Replacement of the protective window.”

PO
31

 Set the protective window on the protective window cartridge in the same orientation (top
R
o.

O
N

and reverse sides) as when it was removed.

C
al

K
ri

CAUTION
ZA
Se

A
IM
K
ZA
A
M
YA
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10-24
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

5. Replacement of the O-ring of the protective window cartridge cover

 When performing this maintenance operation, be careful not to allow dust and dirt to enter
the torch. It is recommended to clean and replace the protective window in a place where
there is not much dirt or dust, such as an office. Contamination inside the torch could not
WARNING only cause optical parts to burn out, but also cause damage to the torch.
 Do not turn off the NC power during the maintenance operation. If the NC power is turned
off, the protective window cartridge will be clamped, and so it cannot be mounted or
removed. Also, the supply of lens protective air will be stopped, with the result that the
torch will get dirty inside.
 When performing this maintenance operation, hold on the main air supply of the laser
machine. A slight amount of lens protective air blows out from the insertion port of the

d.
protective window cartridge to prevent dust and dirt from getting in the torch. When the

ve
er
main air supply is off, the supply of lens protective air is stopped.

s
 Keep the dust collector off during the maintenance work. Failure to do so may cause air to

re
ts
flow around the torch, and thus cause dirt and dust to get in the torch.

gh
 If the torch is moved to the maintenance position by selecting TORCH MAINTENANCE

ri
POS. in the DIRECT MDI pop-up window, the dust collector may operate in some cases.

ll
.A
So, use Handle mode when moving the torch to the designated position.

N
 To avoid contamination, perform the maintenance operation in the shortest time possible

O
without a halt.

TI
87

A
 Perform the maintenance operation on a clean workbench. Before carrying out
R
14

maintenance operation, clean the workbench with clean paper (dust-free paper). Also,
PO
31

clean the supplied stainless tray with clean paper (dust-free paper) and keep it handy to
R
o.

place the removed protective window cartridge on it.

O
N

 Before removing the protective window cartridge, be sure to clean the entire torch to
al

K
ri

prevent dirt and dust on it from falling.

ZA
Se

 Do not clean the torch using a hand held air nozzle. Failure to observe this precaution is
A
IM

liable to cause dirt or dust to enter the torch, resulting contamination inside of the torch.
K

 Pull out or insert the protective window cartridge slowly. If it is pulled out or inserted
ZA

swiftly, outside air will be sucked, with the result that the inside of the torch will be
A

contaminated.
M

 When handling the protective window cartridge, wear clean gloves (powder-free type) so
YA

as not to touch any parts facing the inside of the torch with your bare hands. Failure to do
3

so will cause dust and dirt to adhere to the protective window cartridge and contaminate
01

the inside of the torch.

)2
(c

 Replace the clean gloves (powder-free type) when they get dirty.
ht

 Never put a hand or something inside of the protective window cartridge insertion port.
ig

This may result in the ingress of dust and dirt, which is liable to cause burnout of the
yr

optical parts.
op
C

 After removing the protective window cartridge, close the protective window cartridge
cover immediately to prevent dust and dirt from entering the torch.

 When replacing the O-ring, do not stop it halfway through the work.
 Be very careful not to drop the protective window during replacement work.
CAUTION

10-25
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

[11] O-ring
J2600S07100
S-71

.
d
ve
[2] Protective window cartridge cover
D699MA0018

er
s
re
 If the O-ring [11] is damaged, replaced it.

ts
 To fit the O-ring [11] into the O-ring groove in the protective window cartridge cover [2],

gh
ri
squeeze it in with your fingers so that it will not protrude from the groove. When fitting the

ll
O-ring, do not deform it by pulling by force.

.A
 Replace the O-ring [11] once a year.

N
O
 Failure to replace the O-ring [11] will cause contamination inside the torch.

TI
87

A
R
14

PO
31

R
o.

O
N

C
al

K
ri

ZA
Se

A
IM
K
ZA
A
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10-26
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

10-2-6 Replacement of the condensing lens
Never replace the condensing lens, because it may cause intrusion of dust and dirt and thus may
result in burnout of optical parts. The replacement of the lens requires expertise, so it should be
performed only by a trained Mazak service person.

 Do not disassemble or replace any component parts for the torch other than the protective
window cartridge. If it is absolutely necessary to do so, contact Mazak Technical Center or
Technology Center.
WARNING
 Intrusion of dust and dirt into the torch could not only cause a cutting error, but also lead to
significant damage involving the replacement of component parts for the torch or optical
fiber cables for the oscillator.

d.
ve
10-2-7 Cleaning of the nozzle adapter and the coupler

s er
To use the machine properly, clean the nozzle adapter and the coupler on a daily basis, following

re
the steps below. If spatters are caught between the nozzle adapter and the coupler, they will

ts
prevent the nozzle adapter from being pulled out easily. As a result, the nozzle will fail to be

gh
replaced automatically and the machine will stop.

ri
ll
<Procedure>

.A
N
(1) Check visually and tactually to see that there are no spatters on either the adapter or the

O
coupler. (See the figure below.)

TI
87

A
R
14

PO
31

Clean here.
R
o.

O
N

Nozzle adapter
al

K
ri

ZA
Se

Tip of the torch

A
IM

Coupler
K

Clean here.
ZA

D626MA0076
A
M
YA

(2) If spatters are adhering to them, remove the spatters using sandpaper or the like.
3
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10-27
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

10-2-8 Replacing the non-contact profiling cable and the non-contact profiling preamplifier
If the non-contact profiling cable is broken or the non-contact profiling preamplifier is broken
down due to an unexpected accident, replace the cable or the preamplifier following the
procedure below.
Before replacement, move the pallet to the 2-pallet changer and lower the Z-axis (–150) to
access the lower part of the column.

 Follow the given procedure exactly to replace the non-contact profiling cable or the
preamplifier. Otherwise it will be broken, causing the non-contact profiling function not to
work normally.
CAUTION

.
The non-contact profiling cables and the non-contact profiling preamplifier are listed in the table

d
ve
below.

ser
Table 10-1 Profiling cables in the torch

re
Name Parts No. Q’ty Remarks

ts
gh
Non-contact profiling cable [1] 06283300552 1 Upper cable for the non-contact

ri
profiling preamplifier

ll
Non-contact profiling cable [2] 06143355320 1 Lower cable for the non-contact

.A
profiling preamplifier

N
Non-contact profiling preamplifier [3] K12YC005890 1 —

O
TI
87

[1] Non-contact profiling cableA

R
06283300552
14

PO
31

[3] Non-contact profiling

R
o.

preamplifier
O
N

K12YC005890
C
al

K
ri

ZA
Se

A
IM
K
ZA
A
M
YA
3
01
)2

Non-contact profiling preamplifier unit

(c

[2] Non-contact profiling cable

ht

06143355320
ig
yr
op
C

[1] Non-contact profiling cable [2] Non-contact profiling cable [3] Non-contact profiling preamplifier
06283300552 06143355320 K12YC005890

D699MA0019

Fig. 10-4 Non-contact profiling cable and the non-contact profiling preamplifier in the torch

10-28
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

1. Non-contact profiling cable/preamplifier replacement procedure
The procedure for replacing each part is shown below.
A. Non-contact profiling cable [1]
B. Non-contact profiling cable [2]
C. Non-contact profiling preamplifier [3]

 When replacing a part, turn off the main power switch of the laser machine. Failure to
follow this instruction may result in machine damage.

CAUTION

.
A. Replacing the non-contact profiling cable [1]

d
ve
er
 Before connecting the non-contact profiling cable [1] to the non-contact profiling pre-

s
re
amplifier [3], check to make sure that the center electrode of the non-contact profiling
preamplifier is not bent.

ts
CAUTION

gh
 When connecting the non-contact profiling cable [1] to the non-contact profiling

ri
preamplifier [3], hold the cable by the root and insert it straight as far as it will go.

ll
Otherwise, the connector will be damaged.

.A
 After replacing the cable, check to see if the new cable is being subjected to an

N
O
unreasonable force, and also if it is interfering with other parts. This is because the

TI
non-contact profiling cable or a non-contact profiling preamplifier may become damaged,
87

A
preventing the non-contact profiling function from operating normally.
R
14

PO
31

 Do not remove the cover of the preamplifier.

R
o.

(1) Remove the cover of the non-contact profiling cable.

N

C
al

K
ri

ZA
Se

A
IM

Cover of the
K

non-contact profiling
ZA

cable
A
M
YA
3
01
)2

[3] Non-contact profiling

preamplifier
(c

D699MA0020
ht

Fig. 10-5 Removing the cover of the non-contact profiling cable

ig
yr
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10-29
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

(2) Disconnect the non-contact profiling cable [1] from the BNC connector and remove the four
screws.
(3) Remove the screws of bracket fixing the non-contact profiling preamplifier, and disconnect
the non-contact profiling cable [1] from the non-contact profiling preamplifier [3].
 Pull out the cable from the BNC connector.

[1] Non-contact profiling

cable
06283300552
Bracket
Screw M3 × 10 2 pcs.

[3] Non-contact profiling

.
preamplifier

d
ve
s er
re
ts
BNC connector

gh
screw
M2.5 × 10 4 pcs. D699MA0021

ri
ll
Fig. 10-6 Disconnecting the BNC connector

.A
(4) Insert a new non-contact profiling cable [1] from the BNC connector and connect the cable

N
to the non-contact profiling preamplifier [3].

O
TI
87

[1] Non-contact profiling cable A [1] Non-contact profiling cable

R
14

06283300552 06283300552
PO

BNC connector BNC connector

31

R
o.

O
N

Disconnect
Connect the
al

the cable
K

cable straight
ri

straight
ZA

holding it by
Se

holding it by
the root.
A

the root.
IM
K
ZA
A
M
YA
3
01

[3] Non-contact profiling preamplifier [3] Non-contact profiling preamplifier

)2

K12YC005890 K12YC005890
D619MA0051
(c
ht

Fig. 10-7 Replacing the non-contact profiling cable [1]

ig
yr
op
C

10-30
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

B. Replacing the non-contact profiling cable [2]

 Before connecting the non-contact profiling cable [2] to the non-contact profiling pre-
amplifier [3], check to make sure that the center electrode of the non-contact profiling
preamplifier is not bent.
CAUTION
 Do not remove the cover of the preamplifier.
 Connect the non-contact profiling cable connector to the port on the torch tip while placing
the torch tip in a position where the edges of hollow of the housing are aligned with the
arrows. For an explanation, see Paragraph 1. “Replacing the torch tip insulating rings
(resin and ceramic)” of Subsection 9-1-5.

(1) Referring to the removal procedures in A, remove the cover of the non-contact profiling

.
d
cable.

ve
er
(2) Remove the nut of the profiling cable connector.

s
re
ts
gh
ri
ll
.A
N
O
TI
87

A
R
14

PO
31

R
o.

O
N

D699MA0022
al

K
ri

ZA

Fig. 10-8 Removing the connector nut

Se

A
IM

(3) Disconnect the non-contact profiling cable [2] from the non-contact profiling preamplifier [3]
and connect a new non-contact profiling cable [2].
K
ZA
A

[3] Non-contact profiling preamplifier [3] Non-contact profiling preamplifier

M

K12YC005890 K12YC005890
YA
3
01
)2
(c
ht
ig
yr

Disconnect the cable Connect the cable

op

straight holding it by straight holding it by

C

the root. the root.

[2] Non-contact profiling cable [2] Non-contact profiling cable

06143355320 06143355320
D628MA0066

Fig. 10-9 Replacing the non-contact profiling cable [2]

10-31
 Serial No. 311487

10 MAINTENANCE OF MACHINING TORCH

C. Replacing the non-contact profiling preamplifier [3]

 Before connecting the non-contact profiling cables [1] and [2] to the non-contact profiling
preamplifier [3], check to make sure that the center electrode of the non-contact profiling
preamplifier is not bent.
CAUTION
 When connecting the non-contact profiling cables [1] and [2] to the non-contact profiling
preamplifier [3], hold the cable by the root and insert it straight as far as it will go.
Otherwise, the connector will be damaged.
 For removing the non-contact profiling preamplifier [3], be sure to remove the M3 locknut
first. If you attempt to remove the M3 screw first, the socket in the head may be crushed,
making it impossible to remove the screw.
 Use an M3 locknut to fasten the non-contact profiling preamplifier. Fastening it with an M3

. d
ve
screw may cause the socket in the head to be crushed.

er
 Do not remove the cover of the preamplifier.

s
re
(1) Referring to the removal procedures in A and B, remove the cover of the non-contact

ts
gh
profiling cable.

ri
(2) Referring to the removal procedures in A and B, disconnect the non-contact profiling cables

ll
[1] and [2] from the non-contact profiling preamplifier [3].

.A
N
(3) Remove the mounting screws of the bracket used to fix the non-contact profiling pre-

O
amplifier.

TI
87

A
R
14

PO
31

R
o.

Screw
O
N

C
al

K
ri

ZA
Se

A
IM

Bracket
K
ZA

Non-contact profiling
preamplifier
A

D699MA0023
M

Fig. 10-10 Removing the bracket mounting screws

YA

(4) Remove the non-contact profiling preamplifier [3] from the bracket.
3
01

Remove the M3 locknut and then M3 screw.

)2
(c

M3 screw
ht

M3 locknut
ig
yr
op

Bracket
C

[3] Non-contact profiling

preamplifier
K12YC005890

D619MA0054

Fig. 10-11 Removing the non-contact profiling preamplifier unit

10-32
 Serial No. 311487

MAINTENANCE OF MACHINING TORCH 10

(5) Attach the bracket to a new non-contact profiling preamplifier [3].
Attach the bracket with the M3 screw and lock it with the M3 locknut.
(6) Referring to the mounting procedures in A and B, connect the non-contact profiling cables
[1] and [2] to a new non-contact profiling preamplifier [3].
(7) After connecting the profiling cable connector to the port on the torch tip, tighten the
mounting screws of the bracket to fix the non-contact profiling preamplifier. At that time,
check to make sure that the cable is not about to disconnect from the preamplifier and that
the cable is not too tight.

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10-33
 10

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M
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MAINTENANCE OF MACHINING TORCH

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10-34 E
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Serial No. 311487

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 Serial No. 311487

MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION 11

11 MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION

Nozzle cleaning brush

Focus detection plate

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Automatic nozzle changer

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D698MA0015

N
Fig. 11-1 Maintenance of the intelligent setup function

O
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Maintenance and check items vary from function to function. Execute the appropriate
87

A
maintenance and check items in accordance with the following list:
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List of inspection items

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o.

Equipment/
N

No. Inspection item Remarks Measure

C

Function
al

1 Focus detection  Check whether an area in which the focus As required Refer to 11-1-1.
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plate detection can be executed is left.

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 Check whether the plate is dirty.

A

Focus detection
IM

sensor  Check whether alarm 1101 CHANGE

(Option) STAINLESS PLATE is occurring.
K
ZA

2 Automatic nozzle Check for sputter or dust and dirt deposits. Monthly Refer to 11-2-1.
changer (option) Check whether the nozzle pin moves upward. As required If no motion occurs, contact
A
M

Confirmation method: Mazak Technical Center or

Technology Center.
YA

1) Press the control menu key .

3
01

2) Press Nozzle Pin Up .

)2

Check for mismatching between the nozzle on As required Refer to the Operating
the TOOL screen and the actually set nozzle. Manual for the Intelligent
(c

Function.
ht

3 Nozzle cleaning  When the bristles on the brush collapse As required Refer to “11-3-1 Replacing
ig

brush  When the bristles on the brush are lost the nozzle cleaning brush.”
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significantly
 When a sputter sticks to the brush
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11-1
 Serial No. 311487

11 MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION

11-1 Focus Detection (Option)

11-1-1 Replacing the plate

If the plate surface runs out of the space available for executing the focus detection, alarm 1101
CHANGE STAINLESS PLATE will appear on the monitor and the machine will enter a feed hold
status. Replace the plate with the required one as directed below.

Automatic calibration plate

(need not to be replaced)
(46263300430)

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Focus detection plate
(46143304232)

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D698MA0016

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Fig. 11-2 Replacing the focus detection plate

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1. Replacement timing

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When alarm 1101 CHANGE STAINLESS PLATE is displayed. A

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2. Tools and materials required

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o.

Focus detection plate: 46143304232

N

C
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3. Procedure
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(1) Open the operator door.

A
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 Set the machine setup switch to “l” and press the door unlock key to turn on the function.
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(2) Replace the focus detection plate with a new one. (Fig. 11-2)
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11-2
 Serial No. 311487

MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION 11

(3) Close the operator door.
 Press the door unlock key to turn off the function. Then set the machine setup switch to
“O.”

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(4) Press once the clear key (see the Note below). This clears the display of alarm 1101

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CHANGE STAINLESS PLATE.

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(5) Press the cycle start button to restart the focus detection program.

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Note : Do not press the reset key . A press of the reset key does not allow counter

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.A
parameter L079 to be changed properly. If the reset key has been pressed, the counter
parameter must be cleared to “0”; change this parameter as directed below.

N
O
<Procedure>

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(a) On the COMMAND screen, press A and in this order.

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(b) Press the tab in the left bottom on the screen.

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O
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(c) Use the page-down key to display the second page.

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(d) Change the setting of L079 to “0.”

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 Press L079.
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 Enter “0” and press Confirm.

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11-3
 Serial No. 311487

11 MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION

11-2 Automatic Nozzle Change Function (Option)

11-2-1 Cleaning the nozzle holder

The deposition of sputters, dust and dirt, or other foreign substances results in improper nozzle
setup and hence in a nozzle-changing failure.
Clean the nozzle holder as directed below.

Clean this side.

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Automatic nozzle

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changer

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D614M0140

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Fig. 11-3 Cleaning the nozzle holder

N
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1. Cleaning interval

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87

A
Clean periodically. The cleaning period differs according to operating environment. Cleaning at
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least once a month is suggested.

31

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2. Tools and materials required

O
N

Vacuum cleaner
al

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3. Procedure
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D699MA0035E

Fig. 11-4 CONTROL MENU screen

11-4
 Serial No. 311487

MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION 11

(1) Open the cover of the automatic nozzle changer.

 Press the control menu key to open the CONTROL MENU screen.

 On the CONTROL MENU screen, press Intelligent Box Cover Open

to enable the function.

(2) On the CONTROL MENU screen, press Nozzle Unclamp to enable the
function.
(3) Open the operator door.
 Set the machine setup switch to “l.” Press the door unlock key to turn on the function.

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(4) Remove one nozzle, clean it with a vacuum cleaner, and remount the nozzle. Clean all

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nozzles.
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(5) Close the cover of the automatic nozzle changer.

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 On the CONTROL MENU screen, press Intelligent Box Cover Open

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O
N

to disable the function.

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(6) Close the operator door.

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 Press the door unlock key to turn off the function. Then set the machine setup switch to
A

“O.”
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11-5
 Serial No. 311487

11 MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION

11-3 Nozzle Cleaning Brush

11-3-1 Replacing the nozzle cleaning brush

Deteriorated nozzle cleaning brush cannot remove sputters.
Replace the nozzle cleaning brush as directed below.

Hexagon socket
head cap screw
Nozzle cleaning brush M6 × 15 - 2 pcs.

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D698MA0018

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Fig. 11-5 Replacing the nozzle cleaning brush
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1. Replacement timing
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 When the bristles on nozzle cleaning brush collapse

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 When the bristles on the nozzle cleaning brush are lost significantly
N

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 When a sputter sticks to the nozzle cleaning brush

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2. Tools and materials required

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 Nozzle cleaning brush: 06263300310

K

 Allen wrench (for M6 hexagon socket head cap screw)

ZA
A

3. Procedure
M
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(1) Open the operator door.

 Set the machine setup switch to “l” and press the door unlock key to turn on the function.
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(2) Remove the nozzle cleaning brush shown in Fig. 11-5.

(3) Mount a new nozzle cleaning brush to the original position of the brush.

11-6
 Serial No. 311487

MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION 11

(4) Close the operator door.
 Press the door unlock key to turn off the function. Then set the machine setup switch to
“O.”

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11-7
 11

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MAINTENANCE OF THE INTELLIGENT SETUP FUNCTION

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11-8 E
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Serial No. 311487

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 Serial No. 311487

REMOTE CONTROL CONNECTOR (CLASS IV SYSTEM) 12

12 REMOTE CONTROL CONNECTOR (CLASS IV SYSTEM)

12-1 Description
A remote control connector is provided so that the user can connect a remote barrier interlock,
emergency stop switch, or similar device.

12-2 Function
When the remote control connector is open, the following items will occur.

1. Auto operation

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1. Feed hold (machine will stop.)

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2. Laser irradiation OFF

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3. Alarm

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2. Manual operation

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1. Laser irradiation OFF

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2. Alarm

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12-3 How to Reset Interlock
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(1) Close the remote control connector.

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(2) Push the reset key.

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N

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12-1
 Serial No. 311487

12 REMOTE CONTROL CONNECTOR (CLASS IV SYSTEM)

12-4 Connection
Switch the main power switch (main power breaker handle) to the OFF position.
Before connecting a limit switch for remote control, first remove the jumper wire between P24N
and 68 of terminal block XT9.
The limit switch to be used here must be the normally ON type. The limit switch must open when
the limit is detected.
If P24N-68 of XT9 is opened, an interlock function is activated.

Connection

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P24

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XT9 XT9

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P24N 68

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JUMPER

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LP111-00155

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Example:
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P24
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XT9 XT9
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P24N 68
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LP111-00156
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12-2 E
 Serial No. 311487

CHART OF CONDITIONS WHEN TURNING ON THE POWER AND RESETTING 13

13 CHART OF CONDITIONS WHEN TURNING ON THE POWER AND
RESETTING
When turning ON Condition upon
Item
the power resetting
JOG feedrate  
Handle multiplication × 
Manual
Axis for handle feed  
operation
Laser condition Becomes initial value 
Origin setting Becomes initial value 
MDI MDI program × 

.
 

d
Program No.

ve
Sequence No. (Search for restart)  

er
Machining time  

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Scale  

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Setting Automatic Nozzle trace display × 

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data operation Single block  

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Block delete  

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Optional stop  

N
M function lock  

O
Beam OFF  

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Common tool Common tool data A  

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Operation parameter  
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Parameter User parameter  

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 
o.

Macro variable
O
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Machining
Machining conditions data  
al

conditions
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Feed override  
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 
A

Rapid override
IM

Power override Becomes initial value 


K

Override Frequency override Becomes initial value

ZA

Duty override Becomes initial value 

A

Assist gas override Becomes initial value 

M

Profiling offset Becomes initial value 

YA

Other data Programs in memory  

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01

: Does not change, or continues the motion. ×: Cleared, or stopped

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13-1
 Serial No. 311487

13 CHART OF CONDITIONS WHEN TURNING ON THE POWER AND RESETTING

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13-2 E