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ByAcademy

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& Waterjet

ByVention Technician
Documents
Issued: 06.2007

FL9081_30/06/06_de

Bystronic Laser AG, 2006

ByAcademy
Business Units Laser & Waterjet
Contents
1

Description of the machine .................................. 5


1.1
1.2
1.3

ByVention ................................................................... 5
Bylaser 2200............................................................... 5
Technical data ............................................................ 6

Description of hardware ...................................... 7


2.1
2.2
2.3
2.4
2.5
2.6

CNC............................................................................. 7
Frequency converter................................................. 20
Drives ....................................................................... 22
IO box ...................................................................... 28
GASCON6 .................................................................. 29
Gas mix..................................................................... 31

Transport and start-up ...................................... 33


3.1
3.2
3.3
3.4
3.5
3.6

Unloading ................................................................. 33
Leveling the mineral cast frame ............................... 33
Resonator ................................................................. 35
National power supply .............................................. 38
Beam alignment........................................................ 43
Setting the CNC network address ............................. 60

Software............................................................ 61
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9

General work rules ................................................... 61


Setting up the CF card (short instructions)............... 62
MrAdmin ................................................................... 63
LaserView ................................................................. 70
Setting up the CNC network drive............................. 73
BySoft....................................................................... 75
Loading cutting planson the CNC .............................. 84
NCP Machine Distributor ........................................... 85
Software installation & update ................................. 87

Remote diagnostics ........................................... 95


5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8

System configuration................................................ 95
Description of operation ........................................... 96
Security .................................................................. 101
Establishing and clearing a connection ................... 101
Requirements ......................................................... 103
Remote Diagnostics Box (RD box) .......................... 105
Administration ........................................................ 111
Logging onto the RD server .................................... 118
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5.9
5.10
5.11

Maintenance .................................................... 123


6.1
6.2
6.3
6.4
6.5
6.6
6.7

Setting separating cut detection............................. 123


Servo adjustment and calibration ........................... 125
Adjusting the table height sensors ......................... 129
Setting sheet clamps and table position ................. 130
Setting sheet zero point and docking position ........ 134
Determining Z-axis reference ................................. 137
Testing the vacuum system .................................... 138

Repair.............................................................. 139
7.1
7.2
7.3
7.4

Assigning users to a group ..................................... 119


Command line reference ......................................... 120
Using a proxy server............................................... 121

Setting the reference point on the X- and Y-axes ... 139


Replacing the X motor ............................................ 141
Replacing the Y-axis spindle system....................... 147
Replacing the Z-spindle and guides ........................ 154

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1

Description of the machine

1.1

ByVention

Fig.

ByVention

The compact laser cutting system is designed for machining sheets


up to 8mm thick. Sheets with a format of 3000x1500mm (120x60")
or smaller can be used, with the sheet divided into segments for
cutting. The cutting area is max. 1562 x 772mm (61.5 x 30.4
inches).
The machine is equipped with a ByLaser 2200 and a combined
extraction and cooling unit.

1.2

Bylaser 2200
Max. laser power:
Laser medium

CO2

Wavelength

10.6 m

Polarization

circular

Pulse frequency

1-2500 Hz

Beam diameter:

17mm

Optical length
Number of folds
Fig.

2200 watts

4.830m
3x

Bylaser 2200

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

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1.3

Technical data
1
Dimensions of standard sheet

2
3

Max. cutting area


Parts size

3000
1500
2500
1250
2000
1000

0/+20
0/+20
0/+20
0/+20
0/+20
0/+20

mm
mm
mm
mm
mm
mm

120" 0/+1.5"
60" 0/+1.5"
96" 0/+1.5"
48" 0/+1.5"
72" 0/+1.5"
40" 0/+1.5"

max. 1562 mm

max. 772 mm

100mm

1)

max. 730 x 1480 mm

Sheet thicknesses

2)

Steel

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

Stainless steel

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

Aluminum

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

Max. traversing speed parallel to the X-axis,


Y-axis

100m/min

Max. simultaneous traversing speed

140m/min
8m/s2

Max. acceleration of axes


Machine tolerance in accordance with
VDI/DGQ 3441
Cutting accuracy

+/- 0.1 mm

3)

+/- 0.03 mm

Maximum weight of cut part

300kg

Machine weight

13500kg

Weight of extraction and cooling system

1380kg

Weight of sheet table

150kg

Dimensions

6250mm

6000mm

2150 mm
normal, reinforced industrial floor
( see installation guide)

Foundations
Cutting head
Max. power consumption
Supply voltage

5"
4)

33 kW
3x400V/50Hz, 3x400V/60Hz, 3x480V/60Hz

Cutting gas consumption


Operation

depends on material
easy-to-use hand-held controller with touch
screen
USB 1.1 (KETOP)

Drives
Network connection

RJ 45 10/100 Mbit/s connection

1)

Smaller parts are prevented from falling out by a microjoint

2)

The following points must be satisfied to achieve the maximum material thickness that can

be cut:
optimally maintained and adjusted ByVention
material meets the requirements specified by Bystronic
3)

The precision of the cut parts depends on the quality of the material, material composition,

sheet size, and temperature increase caused by the cutting process


4)

complete system including extraction filter and cooling system

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2

Description of hardware

2.1

CNC
The following figure shows the layout of the CNC:

Fig.

CNC02 Var03 10007472-A

The CNC02 Var03 must be treated as a "blackbox" for


troubleshooting purposes. I.e. if a component malfunctions then the
whole unit must be replaced.

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The CNC rack contains the following components:
CRack slot

1
2-3

4-5

6
7

8
A
B
Tab.

Card name
Data ports
cPCI-CPU Kontron Ethernet1
Ethernet2
COM1
cIOCON
X6 Output
0...15
X5 Output
0...15
X4 Input
0...15
X3 Input
0...15
cIOCON
X6 Output
0...15
X5 Output
0...15
X4 Input
0...15
X3 Input
0...15
cLPCON
AI1
AI2
LCH
cMAXCON
AX1
cmAnalog module AX2
AX3
AX4
A
B
C
D
cLTCON
AB
cmSSIASI
CD
module
cPCI-Power
NCPOWER

Connection to
Operator console
In-house network
Laser RS232

Clearance sensors
X-axis
Y-axis
Z axis
X-servo
Y-servo
Z-servo
Laser ( SSI / ASI )
GASCON ( SSI )

Operator console

CNC cards

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

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

Fig.

1.
2.
3.

cIOCON

Compact flash card


SD-RAM card
Battery

Indicators and controls

Fig.

Connectors and LEDs on the cIOCON

Data ports
1.
2.
3.
4.
5.
6.

PMC0
VGA
COM1 RS232
USB 2.0
Ethernet CH2 (Customers network)
Ethernet CH1 (Operator console)

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Button
7. Reset
LED
8. HS (blue)
controlled
9. Front-I (green)
Front-II (green)
10.WD (green)

Hot Swap Control, LED can be softwareunassigned


unassigned
Watchdog, lights up during start-up
and indicates if a PCI reset is active
Temperature monitoring, lights up
during start-up and indicates a power
supply error

11.TH (green)

Integral Ethernet LED


ACT (green)
SPEED (green/orange)
SPEED ON (orange)
SPEED ON (green)

Ethernet Link/Activity
Ethernet Speed
100 Mbit
10 Mbit

Battery replacement
Assuming 8 hours operation per day and a temperature of 30C, a
170mAH battery can be expected to last 5 to 6 years. Changing the
battery every 4 to 5 years is recommended.
The following types are suitable as replacement batteries:

VARTA CR2025

PANASONIC BR2020

CAUTION
Switch off the machine before changing the battery.
Check the battery polarity before inserting.

10

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2.1.2 cIOCON
cPCI Digital Input Output Controller
The cIOCON card is an Input / Output card for the Bystronic CNC02
controller.
It is the backbone of CNC I/O communication.
The card has 2 x 16 input channels (X3 and X4) and 2 x 16 output
channels (X5 and X6).

Fig.

cIOCON

Function
The cIOCON card incorporates the following main functions:

PCI bus interface

2 x 16 input channels

2 x 16 output channels

OUTPUT ERROR

LED

PCI bus interface


The PCI bus interface enables communication to the PCI bus.

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Input channel
The input channels provide DC isolation of the external 24V signals
from switches, contacts or processes, and convert them to TTL level.
The input signals are connected to the first 16 terminals of the 18pin Input connector (X3, X4). Terminal 17 is not connected. The
common 0V reference potential for the 16 inputs is connected to
terminal 18. The corresponding green signal LED (H3, H4) lies to the
left of each input terminal:
it is illuminated when there is a voltage between the input terminal
and the reference-potential terminal. Each input is debounced on
the TTL side with a 5ms time constant.
Output channel
The output channels provide DC isolation of the internal logic
circuitry and convert their TTL signals into the external 24V signal
level required for the process.
The common supply for the outputs is applied to terminals 17
(+24V) and 18 (0V) of the 18-pin output connector (X5, X6). The
corresponding green signal LED lies to the left of each output
terminal:
it is illuminated when the output circuit is driven by the TTL logic,
irrespective of whether a load is connected to the output. Each of
the 16 outputs is provided with short-circuit protection:
Output ERROR
The output channels are monitored, errors are detected and
displayed on LED H1.
LED
LED
H1

Color
Green

Name
STIFLED

H2

Red

ERROR-LED

H3
H4
H5
H6

Green
Green
Yellow
Yellow

Input 0...15 /
Input 0...15 /
Output 0...15
Output 0...15

Tab.

Function
Indicates card reset, write and read
processes
Indicates a fault on the output
channels X5 / X6 channel 0...15
X3
Signal, input channel 0...15 / X3
X4
Signal, input channel 0...15 / X4
/ X5 Signal, output channel 0...15 / X5
/ X6 Signal, output channel 0...15 / X6

LED display

Refer to the diagram (S2335-0-A) for the functions of the individual


signals.

12

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2.1.3 cLPCON
cPCI laser process controller
The cLPCON board is a laser cutting process monitoring board for
the Bystronic CNC control.
It monitors and controls various laser cutting processes.
A communication module can be connected to the appropriate
connector.

Fig.

cLPCON

Functions

PCI bus interface

NC ready

16-bit slave interrupt controller

W axis function

Interface and signal processing PROMON incl. cutting process


monitoring (not available for ByVention)

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LED
LED
Red
Red
Green
Yellow
Red

Name
CRASH
F-ERR
TK ON
TK END
NC(bottom right)
ERROR
Green STIFLED (bottom left)

Function
Cutting nozzle contact materials
Distance frequency outside valid range
Ring sensor (tactile unit) connected
Ring sensor in top or bottom final position
FPGA not loaded correctly or not
initialized correctly
Indicates card reset, write and read
processes

cmSSIASI
Communication module SSI and ASI for CNC02
The cmSSIASI is a communication interface for CNC cards.
The module has two transfer channels, that can transfer either
synchronously and serially (SSI Laser Master) or asynchronously
and serially (ASI).
The software sets the transfer mode and transfer rate.

Fig.

14

cmSSIASI

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

Fig.

cMAXCON

Functions

Path interpolation

Feed rate generator

Position encoder interface

Axis switches

Interrupt controller

Overlapping axes

Target / current value register

Actual value compensators (software limit switches)

Position control

Advance speed control

Servointerface module connector

NC ready

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cmANALOG
The cmAnalog is a communication interface for CNC02 cards.
The module has four analog output channels. This outputs the
standard feed as a +/-0-10 V voltage via the Ethernet to the
AMCOMM02 on the servo. The signal is forwarded unchanged via a
two-phase cable, as a target value, to the AMADAP.
In addition, there are two digital inputs and two digital outputs per
connection. The module is available with 12Bit or 16Bit resolution.

Fig.

16

cmANALOG

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2.1.5 cLTCON
cPCI Laser Trajectory Controller
The cLTCON has four trajectory controllers and two laser module
controllers.

Fig.

cLTCON

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

Impulse generation

Speed interpolation

Axis master

The process controller is used for real-time control of the laser


module and has the following functions:

Interpolation of laser power

Pulse generation

Set current trajectory speed

Power adjustment using pulse frequency modulation of


trajectory speed

Control of machining cycles

Drag and laser down-time compensation for precise beam


activation and deactivation

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2.1.6 NCPOWER
Monitoring / measuring system supply
NCPOWER is an assembly for the Bystronic CNC02 control
Functions

generating power for the laser measuring systems

galvanic separation of signals

LED
LED Color Name
H1
Green POWER
H2

Green NC READY

H3

Green ENABLE

H4
H5

Red
Red

Fig.

18

FAN ERROR
EMERGENCY
STOP

Function
Lights up if 12V measuring system supply.
VCCMS is OK.
Lights up if NC ready relay (all boards) is
active.
Lights up if external release is pressed
(safety gate OK).
Lights up if fans not turning in CNC02 rack.
Lights up on emergency stop.

NCPOWER

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2.1.7 cPCI-Power
The cPCI power supply provides the required voltages.
LED

LED

Name

Function

green POWER OK

All power supplies OK

yellow FAULT

Input or output voltage fault

Supply
Supply is 230VAC and is provided via the
backplane.
Output voltages
The cPCI power provides the
following output voltages:

+12V
-12V
+5V
+3.3V

Fig. cPCI-Power

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2.2

Frequency converter
A frequency converter controls the
voltage and frequency of an alternating
current. Frequency converters are used
to control asynchronous motors. The
speed of an asynchronous motor is
proportional to the frequency of the
supply voltage. The frequency converter
controls not only the speed but also
acceleration and deceleration processes.
Asynchronous motors are used in
ByVention to control the parts-removal
equipment and the table-elevating drive.

Fig. Frequency
converter

Technical data
Manufacturer
Name
Model
Input voltage
Input current
Output voltage
Output current

20

Control Techniques
Commander SK
SKB 3400150
380-480 Vac (L1, L2, L3) , 50-60 Hz
5.2 A
0-480 Vac (U, V, W), 0-1500 Hz
3.8 A

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Control unit and display

SmartStick
Fig.

Display and controls

The following functions can be read on the display and adjusted


using the controls:

Converter operation status displays

Error code or error-shutdown code display

Displaying and modifying parameter values

Stopping, starting and resetting the converter

Programming
All frequency converter parameters are stored on the SmartStick
(see Fig. above). The frequency converter loads the parameters
from the SmartStick when switched on. When replacing a frequency
converter, you only need to plug the SmartStick into the new
frequency converter.
You do not have to edit the parameters. You always program
the frequency converter using the SmartStick. The SmartStick
must always be connected.
Please refer to the frequency converter operating instructions
for details on how to edit parameters.

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2.3

Drives

2.3.1 Overview
The travel axes of the ByVention are based largely on familiar
components also used in other Bystronic machines. The main drive
elements are described briefly below.
Cutting bridge, X-axis
The X-axis drive has a rack-and-pinion design. The drive motor is
mounted on the cutting bridge. The rack and pinion is installed on
the machine stand. The cutting bridge has a cantilever design and is
held by two linear guides.

Fig.

X-Axis drive including lubricating pinion

Cutting carriage, Y-axis


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

Fig.

Y-axis drive

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

Fig.

22

Z-axis drive

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

Fig.

Suction-cup frame

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

Fig.

Parts-removal rake with drive

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

Fig.

24

Elevating drive with cutting table

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

Fig.

Position encoder

The internal optical measuring system generates two pulse signals


shifted in phase by 90 to each other. This allows high measurement
resolution and can be used to determine the direction of rotation. In
addition, the position encoder generates a zero pulse every
revolution, which is used for the move to reference function. The
signals are transmitted via an RS422 interface.
All three directions of travel (X, Y and Z) are measured using a
position encoder.
Connector pin-out

Fig.

Connector pin-out

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PIN HTL signal
1
N.C.

TTL signal

2
3
4

N.C.
Z
N.C.

Sense +
Z

5
6

A
N.C.

7
8
9
10
11
12

N.C.
B
Shielding
GND
GND
US

N.C.
B
Shielding
GND
Sense US

Z
A

Color
black

Explanation
Signal line

gray
lilac
yellow

Connected with US internally


Signal line
Signal line

white
brown

Signal line
Signal line

orange
pink

Not assigned
Signal line

blue
green
red

Ground connection
Connected internally to GND
Supply voltage1)

1)

Floating with respect to housing


N.C. = Not Connected

Fitting / Removing
The diagram on the left shows a schematic view of the position
encoder. The parts relevant to fitting are:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Fig.

Collet
Hexagonal nut
Tensioning screw
Lever of special tool or
hexagon-head wrench
Lever of special tool or
Allen key
Blanking plug
Shaft
Position encoder clip
O-ring

Position encoder diagram

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

26

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Assembly
With collet open, push the position encoder onto the locked shaft (7)
until the flange rests against the housing. Fix the position encoder
to the flange using the three position encoder clips (8). Make sure
that the O-ring (9) is seated properly. Attach the special tool to the
collet (1). A hex socket wrench SW 8 and an Allen key SW 3 can be
used instead of the special tool.
If the zero pulse needs to be adjusted, this can be done by turning
the lever (4) or the hex socket wrench.
Fix the lever (4) or hex socket wrench in the required position, and
use the lever (5) or Allen key to tighten the collet (tightening torque
2.2 Nm). Remove the adjustment tool and screw on the blanking
plug (6).
Collet chuck torque is 2.2 Nm.

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2.4

IO box
The IO box is used to transfer sensor and actuator
signals via a common cable. We specify which
boxes are sensor IO boxes and which are actuator
IO boxes: their function cannot be chosen to suit.
Most of the signals from proximity switches in
ByVention are grouped via IO boxes and
transferred to the cIOCON card.
The IO box is not a bus system. each signal cable
is looped through separately. Only the +/- supply
and ground line are common to all sensors and
actuators of an IO box.

28

Fig.

IO box

Fig.

IO box circuit diagram and connections

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2.5

GASCON6
The GASCON6 unit is located on the cutting bridge under the top
cover.
1.
2.
3.
4.
5.
6.
7.

Fig.

Supply
CNC link, SSI
CNC link, HSL
Proportional solenoid
Fluid intakes
Vent, outlet pressure
Outputs

GASCON6

2.5.1 Description
The GACSON6 process-gas unit is a compact device that
electronically controls the pressure of various gases.
A digital signal processor (DSP) forms the heart of the GASCON6
electronics. The main mechanical component is a specially adapted
slider combination that is driven by a solenoid piston.

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2.5.2 Function
The CNC transmits the required gas pressure to the GASCON6 via
the SSI or HSL interface. The DSP processes the signal. The DSP
contains the pressure controller and the subordinate current
regulator.
An integral pressure sensor detects the actual pressure value. The
electronic controller measures the current through the proportional
valve solenoid and regulates the current to the required value by
pulse width modulation (PWM). The generated magnetic field moves
the piston of the proportional valve. The piston transmits the force
to the slider, thereby setting the required outlet pressure. A return
spring presses the slider against the piston.
Another pressure sensor monitors the intake pressure. If the
stipulated gas pressure is greater than the intake pressure, the
GASCON6 sends an error message to the CNC.

2.5.3 Automatic calibration


The GASCON6 has an automatic calibration function. The electronics
in the GASCON6 calibrate the pressure sensors and measure the
sensor offset automatically. This is done when the electronic system
is switched on, after the hardware has been initialized and the CNC
connection made.
Note:
It is essential that the cutting gas supply valves ( electrically
controlled valves ) are closed during initialization, otherwise
the calibration will not work, resulting in an unsatisfactory
cutting quality.

2.5.4 LED display


LED Color Name

LED array

green
green

H2
H3

30

Power LED
Ready LED

yellow FUNC
Warning
ERROR
ERROR
yellow RCV LED
green TXD LED

red

Function
24V supply (input voltage protected by fuse)
DSP program running, FPGA program
running
permanently illuminated: function in
progress
flashing: device warning
permanently illuminated: device error
flashing: no connection to CNC
HSL receiving data
HSL transmitting data

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2.6

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

2.6.1 Distinctive features


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

CO2 mass flow controller


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

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

Gas mix (part no. 10003539)


Fig.

Premix unit (part no. 10007563)

Comparison of gas mix and premix unit

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

Fig.

Premix unit

Laser gas consumption, Bylaser2200M


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

2 % relative

2.6.3 Error messages


The following warnings and errors from the LCS are new to Premix
mode:
W118 Too large a difference between the actual and setpoint values
for the Premix gas controller
W119 The pressure in the Premix gas bottle has dropped to 2 bar
E118 Too large a difference between the actual and setpoint values
for the Premix gas controller
E119 The pressure in the Premix gas bottle has dropped to 1 bar
The other errors for He, CO2 and N2 no longer appear.

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3

Transport and start-up


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

3.1

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

3.2

Leveling the mineral cast frame

Fig.

Position of the leveling feet

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

CAUTION
The weight of the machine must never rest on the round feet.
These are used only for stabilizing the machine and are not
designed to be load-bearing elements. Even raising or
supporting the machine on the round feet is not permitted.

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The machine now stands on three leveling feet and can be aligned
using a spirit level. Place the spirit level on the milled surfaces of the
bridge. After aligning the machine, lower the round feet until they
are under slight pressure.
Then position the material table and check table height with a spirit
level (table castors and machine on same level).

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

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3.3

Resonator

3.3.1 Cooling circuit


The resonator and machine cooling circuits must be emptied to
prevent moisture or frost damage during transport. Connect
together the cooling pipelines to the shutter before purging the
cooling circuit, otherwise the shutter flowmeter will be damaged by
the blast of air.
Before start-up, check that the shutter has been correctly reconnected and that the blow-off valves are closed.

Fig.

Shutter ready / bypassed

Fig.

Connections for purging the cooling circuit


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

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

Fig.

Overflow, excitation modules

3.3.3 Transport securing devices top


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

Fig.

36

Transport securing device

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

"Removing" transport securing device


Note:
Before removing the transport securing device, check that the
laser module feet and the two laser supports are secured with
lock nuts.
1. After installing at the
customer's premises,
unscrew screw E.

2. Unscrew screws W of
the transport securing
device and turn down
until the laser module
feet are resting on
the laser support. The
gap between screw W
and U-sheet should
be approx. 3mm.
3. Tighten screw E by
hand (without any
tools).

Gap 3mm

W
Foot
Laser support

Removing transport protection

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3.4

National power supply


In order to prevent damage to the machine due to incorrect
connection to the power supply, all machine transformers are
disconnected before transport.
Before start-up, connect the six transformers according to national
voltage specifications (see diagram).

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

Fig.

Position of transformers

1. Combi device control box


2. Laser relay frame
3. Control cabinet

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

Fig.

Combi device transformer

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

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

Fig.

Relay frame

Transformer T2 for power supply to the dehumidifier must be


externally connected to the power supply (see diagram S5018-2 /
installation guide).
When delivered, the machine
power supply must be switched
from internal to external. The
jumpers required for this are not
indicated in the diagram and can
be found in the Fig. to the left.
Connections
Internal
External

From

To

X1Z1

X1Z3

X1Z2

X1Z4

X1Z5

X1Z3

X1Z6

X1Z4

Fig. Internal / external power


supply S5018-0

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Then connect transformers T1 and T2 to the terminals according to
the national power supply.
The Default order of connections corresponds to the state of the
laser cutting machine as delivered.
Dehumidifier transformer with external power supply

Controller transformer with internal power supply

Fig.

Terminal selection S5018-2

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

Transformer T2 for 230V machine


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

Transformer T1 for 230V drive


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

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3.5

Beam alignment

3.5.1 General information


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

3.5.2 Purpose and aim

This section describes how to align the beam guidance system


from the last deflecting mirror in the resonator up to the cutting
head.

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

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

Precise alignment of the laser beam is important for the


following reasons:

Only when the beam is precisely centered on the deflecting


mirrors and lenses is it guaranteed for the laser beam to pass
through the beam guidance system cleanly without any of its
properties impaired.

Optimum cooling of the deflecting mirrors is only possible if the


incident beam is centered.

Precise alignment increases the service life of the optical


system.

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

CAUTION
Whenever working with a cover open/removed, always move the
keyswitch on the control cabinet to Laser Beam Alignment
position and remove it. This de-energizes the drives.

CAUTION
Owing to the increased risk posed by the laser radiation and
moving axes during alignment, this work must be performed in
the absence of a third party.
Read the beam-alignment section through carefully before
starting beam alignment.
The safety door protects the operator from the laser beam and
injury from drives, etc.
Bypassing the safety door is forbidden.
Take utmost care when covers are removed; this may cause
dangerous situations for other people too who are not involved
in the job.
Fence off the danger zone.

DANGER
Danger! Invisible laser radiation. Laser class 4.
Avoid any irradiation of eyes or skin by direct or stray radiation.
Laser safety goggles must be worn.
Risk of crushing by moving parts. Remain outside the range of
motion of bridge, carriage, Z-axis and flying optics.
When working in pairs, the person working at the
alignment gage must also have the hand-held controller.

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3.5.4 Adjustment principle for the deflecting mirrors
Turning the setscrews clockwise moves the mirror towards the
deflector vee-block.
Turning the setscrews counterclockwise moves the mirror away from
the deflecting prism.
Both coarse and fine adjustment is provided.
Coarse adjustment: Unscrew the three Allen screws and remove
the cover, then use an open-ended wrench to adjust the nut
roughly. This adjustment method is not necessary after cleaning an
optical component.
Fine adjustment: using setscrew B with the cover in place.

32
.5
m
m

Dismantling the mirror: remove mirror holder I, which holds the


mirror, by unscrewing the four mirror screws K.

1m

D
K
E

L
M

Fig.
A.
B.
C.
D.
E.
F.

Cross-section through deflecting mirror


Rough adjustment nut
Fine adjustment setscrew
Pressure spring for heat sink
Deflecting mirror
O-ring for deflecting mirror
Cap

G.
H.
I.
J.
K.
L.

Cooling-circuit connection
Cooler
Mirror holder
Mirror screws (x 4)
Mirror mounting
Deflector vee-block

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3.5.5 Initial settings

The initial setting for the setscrew is 32.5mm measured from


the deflector vee-block.

In the pre-assembled deflecting mirror, the gap between


deflector vee-block and mirror holder equals 1mm at all three
setting points.

3.5.6 Adjustment facility for deflecting mirrors


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

Fig.

Adjustment screws on the mirror

A.

Setscrew for aligning the beam on the horizontal axis. Screws B


and C form the axis of rotation here, and must not be adjusted.
B. Pivot point for alignment using A and C (this screw must not be
adjusted).
C. Setscrew for aligning the beam on the vertical axis. Screws A
and B form the axis of rotation here, and must not be adjusted.
D. The four screws are used for releasing the clamping ring that
holds the mirror in the vee-block.

V
H

Fig.

46

H. Horizontal axis
Screw A is used. The
beam moves along the
horizontal axis; sideways
movement.
V. Vertical axis
Screw C is used. The beam
moves along the V axis; up
and down movement

Target plate

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3.5.7 Beam alignment devices
The beam alignment device consists of a tube containing a pair of
cross-wires. A target plate can be inserted through a slot.
The following sections describe how to deliver a laser pulse onto the
plate. The laser radiation that hits the cross-wires is absorbed by
them. This results in a white cross on the burn image. The position
of this cross in the burn image indicates in which direction the beam
needs to be adjusted, if at all.

C
Fig.

E
Alignment tool

A. Alignment gage with cross-wires


B. Mirror bracket
C. Z-axis alignment gage
D. Safety goggles
E. Stack of target plates

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3.5.8 Preparatory tasks prior to adjustment
Have materials ready

Mat. -Ensure equipment needed for safe working is provided


(safety goggles, marking tape etc.)

Semi-cardboard target plates

Glass-ceramic target plates (plaster)

Beam alignment devices

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

Mirror cleaning materials

Mechanical check

The machine stand must be correctly leveled

Transport securing devices on resonator removed

Alignment gage cross-wires cleaned

Replace the cross-wires with copper or stainless steel wire of the


same thickness (1.5 mm) if they are damaged.

to ensure that the laser module is working properly, the laser


beam must not be aligned during the run-in phase. The beam
must not be aligned or checked until the machine has warmed
up.
Warmed-up means:
The laser has been running for at least 30 minutes at 50% of
maximum laser power.
Recommended values for 2200W resonator
Material
Laser power, single pulse [W]
Pulse width, single pulse [ms]

48

Plaster

Cardboard

2200

400-600
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Note:
Precise and clean working is a basic requirement for troublefree alignment.
Alignment is always performed from the resonator to the Ztool.
A burn image must be circular (max. 1.2 times the width =
slightly oval). It must have a sharp outline and be centered.
Move the beam and not the cross-wires. It is easier to
compare with burn patterns obtained when the machine was
first commissioned or during the most recent maintenance.
If the mirror is tilted on insertion or swarf gets into the mirror
seating, this will cause deflection of the beam and hence to a
poorer cutting result or damage to the beam path (bellows
burn).
Tighten the mirror holder screws reasonably firmly. They must
not be able to work loose. (Machine vibration)

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3.5.9 Alignment process
The alignment device is used to check whether the laser beam is in
the center of a mirror surface. It is fitted in place of a mirror. A
cardboard plate is inserted into the alignment device and a single
pulse triggered manually. The laser beam is visible as a burn on the
plate. A cross-wire shadow (white) indicating the position of the
beam can be seen on the burn. If necessary, the beam is corrected
by adjusting the preceding mirror.
Note:
Before actually starting alignment work on the machine, it is
useful to check that the resonator, i.e. the telescope lens, is
delivering an optimally aligned laser beam.

3.5.10

Beam adjustment ByVention

The procedure below describes the alignment of the three beam


paths in sequence, starting from the resonator and working towards
the tool.

Fig.

A.
B.
C.
D.
1-4

Overview of alignment procedure

Beam path X
Deflecting mirror 1
Beam path Y
Deflecting mirror 2, beam path Z
Alignment positions

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

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Note:
For reasons of safety (open cover at back of machine), beam
alignment of the X and Y axis is performed through the
MrAdmin tool and with the key-switch switched in the control
cabinet.
Align the Z axis with the safety door and covers closed from
the Manual Mode menu.

3.5.11

Aligning beam path X

Since movement of the cutting bridge occurs in this beam path,


the beam must follow a parallel and central path along the whole
length.

Deflecting mirror 1 mounted on the cutting bridge sets a precise


path that cannot be changed.

To center the beam, the resonator must be aligned using the


three adjustable feet.

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

Procedure
1. Secure the danger area against unauthorized access.
2. Move cutting bridge to position 1. The position of the Y-axis is
not crucial.
3. Open the safety door so that the drives are de-energized and
trip the door switch.
4. Set key-switch on the resonator to Lock and take the key out.
This locks the shutter and switches off the high voltage
5. Move the key-switch in the control cabinet to Laser Beam
Alignment position.
6. Remove the covers to allow access to the mirror.
7. Undo the four screws on the mirror holder and remove the
mirror holder.
8. Place the protective cap on the mirror and fix mirror to the
bracket.
9. Fasten the alignment gage on the mirror mounting.
10. Slide a target plate into the alignment device.
11. Move key-switch on the resonator to Unlock.
12. Start the MrAdmin tool and switch to the Laser tab
13. Click the Manual button
14. Set laser power to the desired setting by clicking Set Power
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15. The danger area must be checked and a verbal warning
given before performing an operation.
16. Click the Shutter open button, input shutter opening time,
press the confirm key on the hand-held terminal and fire a laser
pulse
17. Check the burn image and slide the target plate across so that a
second burn image can be produced beside the existing one.
18. Move the bridge to position 3 by hand.
Take care not to damage the mirror during the movement.
19. The danger area must be checked and a verbal warning
given before performing an operation.
20. Click the Shutter open button, input shutter opening time,
press the confirm key on the hand-held terminal and fire a laser
pulse
21. Move bridge to position 1 again.
22. Check the burn image. If the burn images are exactly centered,
as below, clean the mirror before fitting it, then continue with
the procedure described under Aligning beam path Y

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

Before adjusting the resonator, set the key-switch to Lock


and remove the key.
24. Set key-switch on the resonator to Lock and take the key out.
25. Remove the alignment device and install the mirror.

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Adjusting the resonator position

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

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


horizontal plane, while the four screws provide vertical
adjustment. You should normally raise/lower all resonator feet
and/or move them horizontally by the same amount (a mark can
be helpful). Before you can move the feet you need to undo all
the lock nuts and screws on the resonator feet.
2. If both burn images are exactly centered, as shown below,
retighten all the screws on the resonator feet and secure with
locknuts.

3. Afterwards check the alignment once more. If the beam is still


centered, remove the alignment gage, then clean and fit the
mirror. Now you must proceed with alignment of beam path Y.

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3.5.12

Aligning beam path Y


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

Procedure
1. Secure the danger area against unauthorized access.
2. Move the cutting carriage to position 2 so that it is possible to
remove the mirror and fit the alignment device.
3. Open the safety door so that the drives are de-energized and
trip the door switch.
4. Set key-switch on the resonator to Lock and take the key out.
This locks the shutter and switches off the high voltage.
5. Move the key-switch in the control cabinet to Laser Beam
Alignment position.
6. Remove the covers to allow access to the mirror.
7. Undo the four screws on the mirror holder and remove the
mirror holder. Place the protective cap on the mirror and
position the mirror in the appropriate place.
8. Fasten the alignment gage on the mirror mounting.
9. Slide a target plate into the alignment device.
10. Move key-switch on the resonator to Unlock.
11. Move cutting carriage to position 1.
12. The danger area must be checked and a verbal warning
given before performing an operation.
13. Click the Shutter open button, input shutter opening time,
press the confirm key on the hand-held terminal and fire a laser
pulse
14. Move cutting carriage to position 2.
15. Check the burn image. If beam deviation is severe, adjust
deflection mirror 1 and repeat steps 9-13.
16. Slide the target plate across so that a second burn image can be
produced beside the existing one.
17. The danger area must be checked and a verbal warning
given before performing an operation.

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18. Click the Shutter open button, input shutter opening time,
press the confirm key on the hand-held terminal and fire a laser
pulse
19. Move cutting carriage to position 2.
20. Check the burn image. If the burn images are perfectly
centered, as below, set key-switch on the resonator to Lock,
remove the key, clean and insert the mirror, then proceed
according to the Aligning beam path Z section

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

22. To align the beam, turn the adjusting screws on the deflecting
mirror 1 slightly.
23. Now check the beam again.
24. Repeat the procedure from step 9 onwards until the desired
result is obtained.
25. Set key-switch on the resonator to Lock and take the key out.
26. Remove the alignment device and install the mirror.

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3.5.13

Aligning beam path Z

Settings

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

Press the SE button to enable extended user mode

Select the Settings menu

Select the Administration tab

Start MrAdmin by pressing Start MrAdmin

Enter code and press OK to confirm

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

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

Switch to the Main tab and quit MrAdmin by pressing Exit


MrAdmin.

Select No when prompted to restart the CNC

Once MMC has started, switch to Manual Mode menu

Select Pulsed laser mode

Select Toolmode off

Fig.

56

Z-axis alignment gage

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Procedure
1. Install all covers.
2. Move the key-switch in the control cabinet to "Operation"
position.
3. Switch to the Manual menu on the control unit.
4. Close safety door
5. Move to position 2.
6. Open the safety door and insert Z-axis alignment gage in place
of the cutting head. Slide a target plate into the lower position of
the alignment gage.
7. Close safety door
8. Move cutting head into upper end of travel Z+
9. Fire a pulse at the target plate
10. Open safety door
11. Check the burn image. If the burn image is not centered, adjust
the deflecting mirror 2 and repeat the procedure.
12. Close safety door
13. Position alignment gage just above the cutting grid.
14. Fire a pulse at the target plate
15. Open safety door
16. Check that the beam is parallel (Z+ and Z-) and adjust if
necessary
17. If the burn image is centered, move to each corner point of the
machine 1-4 and fire a pulse at the target plate. All four corner
points must now be identical and centered. A deviation of +/0.5 mm can be tolerated.
18. Store the target plates with the 4 firing positions, marked with
the date, in the resonator. Dont forget to record this in the log
book!
Concluding tasks

Reset width single pulse and laser power single pulse in


setup.

Clean the cutting head lens and fit the cutting head.

Check the focus reference setting.

Perform a test cut at each corner.

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3.5.14

Shooting a mode cube

The current software version now offers the possibility of shooting a


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

58

Switch to Manual Mode menu and load the parameters


0_0_0_N2_MODECUBE
(VENTION3015_8120_2200_0_0_0_N2_MODECUBE.PAR), gas
type N2, gas pressure 1.5bar

Press the Manual Mode button and move to service position.

Fit a targeting tool in place of the cutting head.

Insert a Plexiglas cube (place on sawn side).

Launch the MrAdmin program.

On the Settings tab, press the Manual Mode button. The


button now lights up magenta. The Laser sensor key now has the
GASJET function (with confirm button pressed)

Switch to the Laser tab.

Click the Manual button

Press STEP ON

Press the ON button to start the laser.

Set maximum laser power.

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

Press and hold confirm key and laser key

Select Open Shutter.

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

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

Press and hold confirm key and laser key

Select Open Shutter.

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

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3.5.15

Determining default focus setting

The default focus setting is determined by cutting a test part (cf.


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

Cut quality

Comments

0-40

Sheet no longer cut through

0-45

Coarse cut and burring

0-50

Fine bead formation on the


underside of the sheet

0-55

Fine bead formation on the


underside of the sheet

6-00

Good

Original value

6-05

Good

Default focus setting

6-10

Good

6-15

Fine bead formation on the


underside of the sheet

6-20

Coarse bead formation on the


underside of the sheet

6-25

Cut no longer possible

6-30

Settings
Cutting head

Start value

6-00

Material

Structural steel 2mm

Gas type

O2

Cutting plan

Test_Stahl_2mm_22_O2.ncp
Test_Stahl_2mm_44_O2.ncp

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3.6

60

Setting the CNC network address

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

Press the SE button to enable extended user mode.

Select the Settings menu

Select the Administration tab

Start MrAdmin by pressing Start MrAdmin

Enter code and press OK to confirm.

Switch to the Connections tab.

Enter the IP address, subnet mask and gateway


specified/reserved by the customer:

CNC IP Address, Mask and Gateway

If installed, input the IP address of the Remote Diagnostic Box


under Dataservice IP Address.

Press Install Data to apply the changes.

Open safety door

Reset the CNC

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4

Software

4.1

General work rules


Do not reset the CNC by pressing the hardware button.
When starting up the machine, a communication error may occur if
the operating panel is already started up but the CNC is still booting.
The error goes away once the CNC has finished starting up. During
this time (approx. 2min) do not switch the machine off or perform a
CNC hardware reset.
When switching off the machine, only switch the main switch off
when the prompt appears on the display.
Only switch the machine off when the CNC has correctly shut down.

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4.2

Setting up the CF card (short instructions)


Improper operation of the machine may destroy the CNC compact
flashcard. The machine will not start up afterwards.
If you perform a hardware reset or switch off while the card is
reading/writing data, the software may be damaged.
In this case, you must remove the CF card and write an image file to
it.
Procedure
from the USB stick

Copy the zipped CNC image file


(included with machine) to a PC.

Unzip the Zip file

Remove the CNC CF card and connect to a CF card reader on the


PC.

CAUTION
The CNC02 Var03 is very susceptible to ESD (electrostatic
discharge).
Always use a ground cable when changing a board or working on
the rack.

62

Launch the program

Select the CF card under


Removable drive

Select the image file under


Image file

Press Write to write to the


CF card.

Install the card in the CNC


rack and start the machine.

Load or re-set all


configuration settings in the
MrAdmin tool.

Fig.

RawWrite

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4.3

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

4.3.1 Start MrAdmin

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

Press the SE button to enable extended user mode

Select the Settings menu

Select the Administration tab

Start MrAdmin by pressing Start MrAdmin

Fig.

Starting MrAdmin

Enter code and press OK to confirm.

The MMC operating software is now closed, which means that it


is not possible to move the axes or execute any other functions

4.3.2 Quit MrAdmin

Switch to the Main tab.

Quit the program by pressing Exit MrAdmin

Confirm the CNC restart prompt with Yes or No depending on


the type of settings you have made.

The MMC operating software is then started up automatically.

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4.3.3 Description of MrAdmin functions
Main page

Fig.

Main page

Button
Log out / log in
Select language
Quit Administrator

64

Function
Switch between Service / Expert level
(Automatic login at program start)
Change the language displayed
Ends the MrAdmin tool and automatically
starts the MMC application

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CNC

Fig.

CNC

Button
Scroll list
Edit
Set target
RamDump
Resetting the CNC
Load config
Save config

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

Note:
Select the directory / drive IPSM to save config values. This
data space is saved even when you switch the machine off.
Before resetting the CNC, always open the safety door to
avoid damage caused by uncontrolled movements.

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Settings

Fig.

Settings

Button
Save sheet zero
point
Save docking
position

Manual operating
mode
Reference

66

Function
Saves the current point as sheet zero point.
Sheet zero point is the starting point of the
cutting plan in remaining sheet production (cf.
section 6.5).
The current position of the cutting carriage is
set as docking position and the machine
coordinate system is adjusted accordingly
(reference coordinates recalculated, see
section 6.5).
Activates manual mode (magenta key). The
axes can be moved with the confirm button
pressed.
The axes move to reference position.

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Connection

Fig.

Connection

Button / Value
CNC IP address
CNC mask
CNC gateway
Data service IP
address
Data service
machine No.
ByVision IP address

Delete address
Install data
Save data

Function
IP address of the machine in the network
Network subnet mask
IP address that connects to the next network,
usually the IP address of the router
IP address of the Remote Diagnostic Box
(option)
Bystronic machine number if multiple
machines are present
For operation of the machine with ByVision.
The IP address of the PC on which ByVision is
running must be set in order to obtain access
to the CNC.
If no PC with ByVision is present, you can
delete the address.
Deletes the IP address
Sends all settings to the CNC and applies them
(may require a CNC reset)
Saves the settings to a file

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Laser

Fig.

Laser

Button / Value
Power
Gas
Water flow
Operation mode
CNC/manual
Fastmix On/Off
Tests Leaktest
start/stop
Tests Calibr.
start/stop
Step Mode Step
On/Step Off
Step ++/-Shutter open
Set Power
Reset

68

Function
Current laser power
Current gas pressure (laser gas)
Current water flow, shutter
Switch between manual and CNC control
Activate/deactivate increased gas exchange
Start/stop vacuum test
Start/stop performance calibration
Stepwise laser start-up/shutdown ON/OFF
Step forward/backward for step mode
Open shutter manually for a set time
Change current power
Reset laser

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Software

Fig.

Software

Button / Value
Install CNC
Save CNC
Installation of the
operating system
Save operating
system
Install parameters
Save parameters
Backup config

Repair Data
Repair Data2

Function
Install new CNC software
Save current CNC software
Install new CNC operating system
Save current CNC operating system
Install new parameter record
Save current parameter record
Current configurations are saved to a backup
directory.
The data are required to repair a defective
compact flash.
Repair is usually performed automatically.
Manually starts repair of the 1st data
partition on the CF (configuration)
Manually starts repair of the 2nd data
partition on the CF (CNCpub)

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4.4

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

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

Fig.

Schematic representation of connection

Start the MrAdmin tool

Switch to the Laser tab

Switch laser to manual mode by pressing the Manual button

Connect laser to the laptop


Connect the laptop to the laser controller
with an RS232 cable. To do so, disconnect
the RS232 cable from the -X2 connector on
the resonator and connect the laptop.
Connecting lead
D-sub cable, 9-pole, 1:1, female/female,
1.8m (max. 25m)
Bystronic order number: 4500842

Fig.

D-Sub cable

For laptops without a COM port, use a specified USB / RS232


converter. Please only use the specified converter as other products
may cause Windows to crash.

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USB / RS232 converter
Maxxtro / USB serial converter / 202366 /
U-232-9 / type A -> DB09m
Bystronic order number: 10015097

Fig.

USB converter

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

4.4.2 Configuration

Fig.

Configuring the RS232 connection


Launch LaserView setup as Administrator (install)
Launch LaserView
Select log in with user name and password
Under LaserView Config. on the Com Laser tab you can
configure the serial interface settings. Usually no changes are
required except for the number of the COM port.
Quit LaserView and restart for changes to take effect.

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

Fig.

72

Registry entry

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4.5

Setting up the CNC network drive


The following instructions describe how to set up a network drive. A
network drive allows you to directly access the shared CNC drive
space, e.g. to export cutting plans from BySoft.
The components Client for
Microsoft Networks and File
and Printer Sharing for
Microsoft Networks must be
installed in the network
settings.

Fig.

LAN properties menu

Open Windows Explorer and


select Map Network Drive...
from the Tools menu.

Fig.

Tools menu

Select an unassigned drive


letter.
In the Folder: field enter the
IP address of the CNC as
shown for example in the
screenshot.
Example:
\\192.168.100.101\cncpub
Click on Browse...
Fig.

Map Network Drive...

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In the new window select the
folder: cncpub
Confirm the selection by
clicking on OK
This closes the window.
Confirm with Finish
Now you can access directly
from your workstation the
machine parameters in the
param folder, or cutting plans
in the cutprogs folder.

Fig.

74

Selecting the folder

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4.6

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

4.6.1 Definitions
Coordinate system
The machine coordinate system is shown in the diagram below.
Materialzufuhr

+Y

Schneidbereich

+X

0,0

Fig.

Entnahmebereich

Machine coordinate system

The coordinate system is not changed in BYWORK. The sheet is


displayed as usual, i.e. the longitudinal direction is horizontal. First
the postprocessor translates and rotates the cutting plan correctly
for ByVention.
BYWORK Koordinatensystem

Postprozessor Transformation

Maschinen Koordinatensystem
+Y

+Y

+Y

+X

Fig.

+X

+X

Cutting plan coordinate system

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Sheet dimensions and cutting area
The maximum permitted sheet size is 3086mm x 1562mm. In
inches this equals 120" x 60" + tolerance of 1.5". The minimum
sheet size is 1200mm x 1000mm.
If the sheet is larger than the maximum cutting area, it is split up
into separate sheet segments. The maximum permitted cutting area
is 772mm x 1562mm. The length of the last sheet segment must be
at least 500mm (machining process A) or 650mm (machining
process B).

max. 1562

max. 3086

min. 500
min. 650

Fig.

Machining process A
Machining process B

max. 772

Dimensions

It should be noted that all dimensions are based on BYWORK


coordinates. On the machine, the X (= length) and Y (= width)
dimensions are swapped over.

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Machining processes
As already mentioned, a sheet is divided up into separate sheet
segments. The way in which this segmentation, or more precisely
machining, is performed, is called a machining process. There are
two different machining processes.
Machining process A = segment without overlap
Separating cut

Safety distance

Segment 4

Fig.

Segment 3

Segment 2

Segment 1

Machining process A

Machining process A divides a sheet into segments each of


maximum size 772mm, with no overlapping of segments. The width
of each segment can vary, because it cannot always be filled with
parts right up to the edge.
Machining process B = segment with overlap
Separating cut

Segment 2

Overlap

Segment 4

Segment 5

Fig.

Segment 3

Segment 1

Machining process A

Machining process B also divides the sheet into segments each of


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

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4.6.2 Programming
A ByVention machine is defined in BYBASE in the machine database
by the Machine type field. The field must be set to BYVENTION to
enable certain additional options in BYWORK.
Individual parts are programmed as usual in BYPART. Apart from the
maximum parts size (772mm x 1562mm), there are no constraints
placed on the programming.
Cutting plans are produced in BYWORK. If a ByVention machine has
been selected, some of the standard dialog boxes and functions are
no longer available. Instead, a new dialog box and a couple of
special functions for ByVention plans have been added. The
differences are listed below.

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

Fig.

Nesting

Separating cuts
Severance cuts are placed automatically. The severance cut is
always made at a variable distance from the parts (default =
10mm). During cutting on the machine, the severance cut is always
made before the parts.
If the residual sheet is shorter than 1200mm, additional segments
plus the severance cuts are added at the end (i.e. on the far left), so
that the residual sheet can be removed automatically.

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Manual functions
Most of the existing functions for making final changes manually
have been retained. Unlike a standard machine, however, just one
segment at a time can be edited for a ByVention machine. This
means that a segment must always be enabled for the manual
functions (insert, move, rotate and delete part).
A segment is enabled by clicking inside the segment concerned. The
active segment has a yellow surround, and the usable area a gray
background. All parts assigned to this segment are shown in light
blue. All the other parts appear dark gray and cannot be selected for
the manual functions.

Special functions
New functions that can only be used on ByVention plans appear
under the Special/ByVention menu. These are described below.
Compress segments
This function removes empty segments and reduces the margins of
existing segments. In addition, the remaining segments are shifted
to the right-hand edge of the sheet. The function automatically
checks all limiting conditions during the compression so that a valid
plan is always obtained in the end.
Fill with segments
This function can be used to fill up a plan with empty segments
(including the necessary severance cuts). The segment width and a
possible overlap can be specified for this function. This function also
checks the limiting conditions to ensure a valid division of the
segments is always obtained.
Rotate plan
This function rotates the whole plan through 180 and shifts the
segments to the right-hand edge of the sheet if possible. If the plan
cannot be rotated (e.g. because the far-right segment is too short
for the left-hand edge), then an error message to this effect is
displayed.
Check plan
This function checks whether there are parts on the plan that lie
solely in the left-hand overlap zone of a segment. Such parts can
cause problems and should therefore be moved out of the overlap
zone. The problem parts are shown in red.

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

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Strategy
Without overlap
The segments are arranged without an overlap.
With overlap
The segments are arranged with an overlap. If during automatic
nesting no part fits in such a segment, a segment without overlap is
added.
Segment
Variable segment width
The segment width is automatically adjusted to suit the parts during
automatic nesting.
Fixed segment width
The segment is not adjusted during automatic nesting.
Maximum segment width
The segment will not be wider than the value set here. If the Fixed
segment width option is enabled, all segments are made as wide as
the maximum segment width if possible.
Separating cut
Always separate leftover sheet
When this option is enabled, the residual sheet is always filled up
with empty segments and severance cuts.
Top overcut
Indicates the length of the overcut from the separating cut at the
top edge of the sheet (machine X+ side). The severance cut
including Top overcut has a maximum length of 1562mm + 10mm.
Parts distance
Indicates the minimum distance of parts to the separating cut.
Operating mode
Indicates the mode with which to perform the separating cut.

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

Take into account for window nesting option is blocked

Nesting tab:

Take into account first/end cuts option is permanently


enabled

Cutting sequence tab:

Unchanged

Repositioning tab:

Removed

Microjoint tab:

Removed

Common Cut tab:

Removed

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

Residual Grid/Panel tab:

Removed

The Bottom overcut is permanently set to 10mm

The Top overcut is set in the new ByVention tab

The Contour distance is permanently set to 0.1mm

Pulsed piercing is always used for the severance cut

Postprocessor 1 tab:

Removed

Cutting parameters in cutting plan option is permanently


enabled

Postprocessor 2 tab:

The Vaporize option is only possible in the area of lead-ins.


The film is vaporized with process macro 5 (parameter laser
power cutting vaporization)

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Raw material work area
Standard sheet:

Minimum sheet size = 1200mm x 1000mm

Maximum sheet size = 3086mm x 1562mm

Residual sheet:

Maximum sheet size = 772mm x 1562mm

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

Nest Parts workspace

Plan menu: the functions Set/Delete/Move remaining grid


cuts and Set/Delete/Edit remaining sheet cuts and Auto
Technology are no longer available.

Plan menu: Set/Delete cutting sequence functions are always


applied to all the parts. The cutting sequence is always set
segment-by-segment from right to left.

Nesting menu: Set/Invert/Delete window functions not


available.

4.6.4 Handling existing parts


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

Fig.

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Job Parameters/Postprocessor3

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

Fig.

Postprocessor

In the Postprocessor window under Cutting Param., select the


relevant cutting parameter from the local database or select the
parameter directly from the CNC (see instructions below).
Select the path for the cutting plan under CNC data path. The
cutprogs folder on the CNC can be specified directly for the data
path, provided it has been configured as instructed below.
After the file export, the parameter set is entered in the cutting
plan.
ByVention reads only the parameter-file name from the cutting plan,
and then selects the parameter file from its database. The selected
file path in BYWORK has no function.
The parameter files for BYWORK must be named according to the
convention shown in the example below.
VENTION3015_8120_2200_1.0161_3_5_N2_GALVANIZED.PAR
Machine type, controller version, laser type, DIN number,
material thickness, cutting head, gas type, additional information
The contents of the parameter files is not important, the machine
looks for a parameter with the same name in your database.
Note:
The CNC ByVention controller only accepts parameter files
containing uppercase letters only.

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4.7

Loading cutting planson the CNC


In ByVention, cutting plans and parameters are saved directly on
the CNC.
Cutting plans can be loaded directly into a folder in the CNC and
thus into the job list via the network.
Run Explorer and enter the IP address of the CNC in the address line
as shown in the screenshot below. Copy the cutting programs to the
cutprogs folder.

Fig.

CNC folder structure

The param folder contains all machine parameters. It is


recommended to copy these to the BySoft computer to create
cutting plans.

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4.8

NCP Machine Distributor


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

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

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

Fig.

Modes

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

Fig.

Mode

4.8.4 Setup mode


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

Fig.

Edit

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

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4.9

Software installation & update


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

4.9.1 Terminal installation


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

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


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

The first step is to copy the installation data on the CD to the USB
stick on the hand-held controller using a PC or laptop.
If the data, Images and Installation directories already exist on
the hand-held controller USB stick, you must delete (or rename)
them. You can leave the RamDumps directory if it already exists.
The CD directory structure is as follows:

Fig.

CD directory structure

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Copy the following directories from the CD to the root directory of
the USB stick:
<CD drive>:\data, <CD drive>:\Images,
<CD drive>:\Installation
If the "\Hard Disk\RamDumps" does not yet exist on the USB stick,
you must also copy the following directory from the CD to the root
directory of the USB stick:
<CD drive>:\RamDumps
2. Installing the terminal software on the control unit
(ByVention operating software)
a) Plug the USB stick into the hand-held controller.
b) Quit the ByVention user interface (view
Settings/Administration -> Quit Program).
c) On the Windows CE desktop, double-click the My Device icon to
launch the File Explorer.

Fig.

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CD directory structure

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d) In the File Explorer, switch to the


\Hard Disk\Installation\Terminal directory.

Fig.

ByVention Terminal directory structure

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

Fig.

Installation

f) The installation proceeds and copies all necessary data to the


device. Before copying the new data, the old installation is
completely removed. Once the copy process is finished, the
hand-held controller is automatically reset and the user interface
is displayed.

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4.9.2 CNC software installation
If you install an update, first save the settings by
selecting Save Config under CNC, and make a note of
the Connection Data under Connections.
Quit the ByVention operating software and start MrAdmin. Switch
to the Software tab.

Fig.

Software tab

Operating system
Only install the operating system if there is a new version. If
anything goes wrong during the update (power failure, etc.), the
CNC will not start up any more and you must load the image to the
compact flash in the CNC again.
Press Software/ Operating System / Install and select
\Hard Disk\Install\CNC\V2xxx.qnx
After installing the operating system, you must always
re-install the connection data as they are overwritten by
the default settings. See Connection installation
Quit MrAdmin and reset the CNC.

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CNC software
If you install an update, first save the settings by
selecting Save Config under CNC, and make a note of
the Connection Data under Connections.
Start MrAdmin as described above.
If there is no CNC version yet, the program displays a
communication error (HttpClientConnection Error). Click OK to
confirm. Answer No to the prompt application ends now. Press
OK to confirm next communication error with. The Administrator
starts and now has only limited functions.
Press Software/ CNC/ Install and select
\Hard Disk\Install\CNC\P812xxx.bin
The software is now loaded onto the CNC.
The new software version is only started after the CNC is
reset.

Parameter
Press Software/ Parameters / Install to install the parameters.
The program displays a dialog to select the source directory \Hard
Disk \ Data \ Param to copy the new parameters. This overwrites
existing parameters with the same file name.

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4.9.3 Connection installation

Fig.

Connections tab

Switch to the Connections tab.


Enter and check connection data.
Press Install data.
The new connection data only take effect after the CNC is reset.

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4.9.4 Loading a CNC configuration

Fig.

CNC tab

Switch to the CNC tab.


If a new CNC version has been installed, you must reset the CNC.
Press Load Config and select
\Hard Disk\DATA\Setup\ByVention3015.stp.
This downloads the configuration.
Press Set Time and set the time.

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

Set docking position as per section 6.4

Set Z reference as per section 6.4

Set Z reference distance cleaning height as per OI section


6.7.4

Set default focus setting as per OI section 8.5.8

4.9.6 Configuration backup


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

This is required in the event of automatic repair of the data


partition. Press Backup Config on the Software tab.

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5

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

5.1

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

Internet
SSH Tunnel

Customer

Bystronic Laser AG

Firewall
Firewall
Router
Customer Ethernet
Netbox
Router

Machine Ethernet

RD-Box
Machine 1

Machine 2

Machine n
RD-Server

Fig.

System configuration

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

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

5.2

Description of operation
If the RD box is installed at the customers site, and the connection
has been activated by the customer, the RD box is automatically
logged onto the server via the Internet and SSH tunnel.
The Hotliner can log onto the RD server
https://rds.bystronic.com by entering the Internet address in a
Web browser, and then entering the user name and password.

Fig.

Login

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

Fig.

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Group 1 start-up screen

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

Fig.

Start-up screen for all groups

Selecting the customer of interest starts retrieval of the diagnostics


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

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Fig.

Customer screen

If a module in the subordinate branch has a problem, then the


higher-level node is also displayed in red.
In addition, the red indicator shows two different fault situations:
1. The module is not responding to the query: the node is shown in
red and the word (Offline) is also displayed.
2. The module is responding to the query but is returning an error
status: the node is shown in red.

Fig.

Service offline

Selecting the relevant module on the left-hand Navigation side


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

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Fig.

5.2.1

Connections tab

SysInfo function
SysInfo can be used to transfer machine screenshots (A) and the
logbook entries (B) in ByVision. The data is transferred via the
Internet and displayed in the browser.
The Remote Diagnostics facility cannot be used to operate software
on the Panel PC.

Fig.

Connections tab

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

Fig.

Logbook

The Current screen function is used to generate a bitmap of the


current screen content and then transfer it (see Fig.: Current
Screen)

Fig.

CurrentScreen

The page displayed in the browser it not automatically refreshed.


This must always be done by the user.

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5.3

Security

5.3.1 SSH-V2 Secure Shell Version 2


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

Login to a remote machine (PC)

Interactive or non-interactive execution of commands on the


remote machine (PC)

Copying of files between different computers in a network.

5.3.2 SSL - Secure Socket Layer


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

5.4

Establishing and clearing a connection


It is the customer who establishes the connection, and who can also
terminate it at any time. Keys are transferred between the RD box
and the RD server (SSH server) while a connection is being
established and during the actual session. A connection is only
established when the public key from the SSH server is recognized
at the customer end. This ensures that only authorized users can
use this connection.
The Hotline end is only able to terminate the connection; if the
Hotliner wants to establish a connection again, he must first contact
the customer so that the customer can re-activate the link.

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Internet
SSH Tunnel
Vanco Zrich

Firewall /
Router

SSL

Customer
Remote Diagnostics
Server

Bystronic Hotline

Firewall /
Router
Customer Ethernet

Netbox
Router

Firewall /
Router

Machine Ethernet (Bystronic)

PPC
Sysinfo
MMC
MachineService
Laserview

Fig.

CNC
Byvision
Midrange

PLC
Transport
Handling
Storage

CPC
Sysinfo
Store Manager

Remote
Diagnostics
Box

Concept

5.4.1 Connection between RD box and RD server


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

5.4.2 Connection between Hotline and RD server


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

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5.5

Requirements

5.5.1 For the branch office

Broadband access to the Internet ( ADSL or faster )

User name and password for logging onto the RD server

5.5.2 For customers

A broadband connection ( ADSL ) must be present

Port 22 SSH must be open to the outside. The port can be


checked using the Putty program (freeware).

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

5.5.3 Connection test using Putty:


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

Fig.

Putty

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Confirm the following authentication window withYes:

Fig.

Safety warning

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

Info Titel
Erstellt von : Autor

Datum :

Geht an :
Zur Kenntnis :

Fig.

Putty Login

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

Fig.

Port 53 error

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

Fig.

Port 22 error

If the connection test could not be completed successfully, the


customer must contact his IT specialist.

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5.6

Remote Diagnostics Box (RD box)

5.6.1 Hardware
The RD box is a self-contained black box (no fan) and has been
designed so that it can be placed near the machine. The guarantee
expires if the RD box is opened (seal broken).
Default configuration from Bystronic Laser AG
The RD box comes with the following default configuration:
Network:
- IP address: 192.168.100.250
- Subnet mask: 255.255.255.0
- Gateway: 192.168.100.200
- Broadcast: 192.168.100.255
Machinery configuration:
- Bystar 3015 with Bycell Cross

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

Linux

Firebird database

Installation / Configuration

DB backup

DB restore

Apache Webserver

Configuration

Bystronic applications in the RD box

Remote Diagnostics

Data Service

PDR Viewer

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5.6.3 Software on the ByVision panel PC

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

Logbook
Program for electronic recording of logbook entries

PLC web server

Internet Explorer

5.6.4 ByVention software


Every ByVention is prepared for remote diagnostics. The programs
required for this run on the CNC controller.
The digital logbook is not available for ByVention.

5.6.5 Location of the RD box

ByVision machines as per UA 06/04

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

Fig.

Version 1: Customer has just one ByVention

The IP address of the CNC is set to suit the customer network. The
RD box is installed in the customer network and can be located in
any position.
The RD box must be configured to comply with the IP-address
scheme of the customer.

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Fig.

Version 2: customer already owns Bystronic machines

The CNC IP address is set to an unassigned number in compliance


with the Bystronic standards. The CNC of the ByVention is
connected to the Netbox hub. The RD box is installed in accordance
with instructions.

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5.6.6 Configuring the network interface
Since the RD box is a black box and the service engineer has no
means of changing the network settings, these are saved on a flash
card.
The default configuration of the RD-box network interface is as
follows:
IP address: 192.168.100.250
Subnet mask: 255.255.255.0
Gateway: 192.168.100.200
Broadcast: 192.168.100.255
If the RD box is not operated with the default network configuration,
then the settings can be changed using the flash card.
To do this, the flash card must be removed before the RD box is first
used, and the file interfaces must be created (with the correct
entries) in the new folder on the flash card. The file in the
exampleConfig folder can also be copied over.

Fig.

Interface configuration

Fig.

File interfaces

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

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5.6.7 Configuring the system services (XML file)
The XML file must follow a defined format. Each service is assigned
a type and a port. The IP address and the name (offline) may be
different and may differ between the different machine types.
Type and Port definitions for the various services:
ByStar, -Sprint, -Speed and -Jet

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

CNC: Type CNC, Port 55400

Machineservice: Type MS, Port 55510

SysInfo: Type SysInfo, Port 55710

PLC STL: Type PLC, Port 55801

PLC TRP: Type PLC, Port 55802

ByCell

Storemanager: Type Store, Port 55310

SysInfo: Type SysInfo, Port 55710

PLC LAG: Type PLC, Port 55803

ByVention

Laser module: Type Laser, Port 55210

CNC: Type CNC, Port 55400

SysInfo: Type SysInfo, Port 55410

Machineservice: Type MS, Port 55510

The XML file can be depicted in a tree structure to improve clarity


and provide a better overview. This structure is defined using nodes.

Fig.

Tree structure

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Once the XML configuration has been defined and the customer (RD
box) named, nodes can be defined.
A node begins with the name <Node Name=node name> and
ends with </Node>. The various services can be entered in
between (<Node Name=service Type=type IP=IP
address Port=number/>).
The XML file is saved on the flash card, and the XML file
configuration can be changed via the flash card.
To do this, the file BystronicMachinePark must be created (with
the correct entries) in the new folder on the flash card, or copied
from the exampleConfig folder.

Fig.

Explorer BystronicMachinePark

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

Fig.

Default configuration

If the RD box is now booted up again, the current settings are


written to lastConfig and the settings in the new folder are
adopted and the file deleted.

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5.7

Administration
Various settings, configurations and updates can be made online in
the admin (A) area of the RD box.
To access the admin area, open the browser and enter the address
of the RD box (http://192.168.100.250).
A

Fig.

RD box start-up page

5.7.1 Connection menu


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

Fig.

admin Connection

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

Command

Description

Connected

disconnect

Connected to server. It can be


terminated by clicking on disconnect.

Disconnected

connect

Connection to server lost. It can be


established by clicking on connect.

try connecting

stop trying

Connection terminated because the


network connection has been lost. An
attempt is made to re-establish the
connection. As soon as the server can
be reached, the connection is reestablished.
Click on stop trying to terminate the
connection procedure.

The user must log onto the system to access all possible menu
options. The access permissions are classified into two different
levels. The service user has restricted access rights (customer) and
the admin user is given full access rights.
The login is set as follows by default:
User name: service; Password: service
User name: admin; Password: rdadmin06

Fig.

112

admin login

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5.7.2 Update menu
The RD box software can be updated in this menu.

Fig.

admin Update

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5.7.3 Network menu
The network settings can be configured in this menu.
If it is not possible to work with the default settings, the system
administrator must be contacted (connection test using Putty
working).

Fig.

admin Network

If the RD box cannot be operated using the default network


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

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5.7.4 User menu
Users can be assigned a new password in this menu.

Fig.

admin User

Caution: changing the passwords means that it is no longer possible


to access the menu concerned. The passwords can only be reset via
the RD Server (administrator)!

5.7.5 Backup menu


The settings edited online can be saved on the flash card in this
menu.
A) Backup config: the network and machinery configuration is

copied from the HD onto the flash card (backup directory).

B) Restore config: the network and machinery configuration is

copied from the flash card (backup directory) onto the HD.
C) Save config to reboot from: the network and machinery

configuration is copied from the HD onto the flash card (new


directory). These settings are adopted at the next re-boot and
the data deleted.

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A
B
C

Fig.

admin Backup

5.7.6 System menu


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

Fig.

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admin System

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5.7.7 Modules menu
The various Remote Diagnostics modules can be configured in this
menu.
Currently there is just the Remote Diagnostics module.
In the Remote Diagnostics module the machinery configuration can
be changed and saved locally. (See Configuring the system services
(XML file) for details).

Fig.

admin Remote Diagnostics

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

Fig.

5.8

admin save XML

Logging onto the RD server

5.8.1 Establishing a connection to the RD server


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

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

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5.8.2 Grouping

Start the browser and enter the RD server address:


https://rds.bystronic.com and log in with the assigned login
data.

New RD boxes connected to the system are assigned by default


to the group Not assigned. A user with administrator rights can
then assign the box to the relevant group.

Fig.

5.9

RD server start-up page

Assigning users to a group


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

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

Fig.

5.10.1

Command line input

Ping

Short for Packet InterNet Groper


Ping is a tool for checking whether a data packet can be transmitted
to a network address without any errors. The Ping tool is mostly
used to check network errors.
If the transmitted data packet does not reach the recipient (network
address) because of an incorrect network configuration or because
the signal is blocked, the computer displays a timed-out error.
Example
ping 192.168.100.101
Options
ping 192.168.100.101 t
continuous query (CTRL C to abort)

5.10.2

Ipconfig

Ipconfig is a command to display current network settings. You can


use this command to display connection information or network
settings.
Options
Ipconfig /all :

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Displays all network settings

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

Fig.

and click on Internet Options... in

Tools menu

Click on the Connections tab.


Click on the Settings button under LAN Settings.

Fig.

Internet Options...

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Enable the
Bypass proxy server for local addresses option.
Click on the Advanced... button.

Fig.

Settings...

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


example.

Fig.

Proxy settings

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

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6

Maintenance

6.1

Setting separating cut detection


The laser sensor of the separating cut detection system measures
the distance to the material to be cut/table. After the separating cut,
the sensor checks whether all parts in the vicinity of the separating
cut are further from the encoder head than the set distance. If not,
an error message is displayed and unloading is stopped.
This distance is programmed on the back of the sensor using the
yellow button and the LED display (see Fig.).
The teach-in process may only be performed after installing the
sensor.
Cable tie holes

LED display

Yellow button for

Electrical
connection

programming

Connection for
inspection window
ventilation

Fig.

Laser sensor with bracket

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Procedure

Move cutting table to unloading position (middle position).

Place a 40mm (0, +5mm) metal sheet on the cutting table with
the sensor's laser beam on it
Note:
The sheet defines the minimum distance to the sensor. During
subsequent separating cut detection, no part may protrude
over this limit.

124

Hold down yellow button -> red LED lights up

After approx. 2 seconds, the LED starts to flash red (approx. 2x


per second) -> keep yellow button pressed

After approx. 4 seconds, flashing speed switches to 5x per


second -> release yellow button

Press the button briefly

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

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

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6.2

Servo adjustment and calibration


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

Fig.

Example servo settings

6.2.1 Preparation

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


Press the SE button to enable extended user mode
Select the Settings menu
Select the Administration tab
Start MrAdmin by pressing Start MrAdmin
Enter code and press OK to confirm
Switch to the CNC tab and set the scroll list to Setup.
Edit the values (note down original values first)
feed rate for manual operation, head raised
to 12,000 mm/min
feed rate for manual operation, head lowered
to 1000 mm/min
Switch to the Main tab and quit MrAdmin by pressing Exit
MrAdmin.
Select No when prompted to restart the CNC
Once MMC has started, switch to Manual Mode menu
Note:
Carry out the servo calibration for the X- and Y-axis with the
cutting head raised (Z+)!

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

Fig.

Amcont pcb

To achieve an optimal dynamic trajectory behavior of the axes, the


speed amplification of all axes must be the same magnitude, i.e. the
setpoint value of each axis must be matched. The adjustment has to
be performed according to the description for the X, Y and U axes
and for the Z axis.

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6.2.3

Servo adjustment X and Y axis


1.

Connect the tester to connector X43 on terminals 3 and 4 on


the AMADAP card.

Fig. Amadap pcb

2.

With potentiometer <P1> on the AMADAP card, set the


measured value to 0.000 VDC.

3.

Switch to the <Manual mode> menu.

4.

By means of the manual operation, move the axis to be


adjusted in the plus and minus directions.

5.

With potentiometer <P2> on the AMADAP card, set the


specified adjustment voltage (e.g. 0.8V).

6.

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

7.

Check the adjustment voltage and set it to the exact value


using <P2>.

8.

Repeat step 4 through 7 until the symmetry and level of the


adjustment voltage are precisely matched.

9.

Once servo adjustment is finished, reset the modified setup


values to the original values as per section 6.2.1.

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6.2.4

Servo adjustment Z axis


1. Switch to the <Manual mode> menu.
2. Switch the tool to <OFF>
3. By means of the manual control, move the Z axis in the plus
and minus directions.
4. With potentiometer <P2> on the AMADAP card, set the
specified adjustment voltage (e.g. 0.3V).
5. Check the voltages for the opposite direction (other sign). The
voltage must now be the same in both directions. Using <P1>,
set the forwards and backwards symmetry.
6. Check the adjustment voltage and set it to the exact value
using <P2>.
7. Repeat step 3 through 6 until the symmetry and level of the
adjustment voltage are precisely matched.
8. Note the set adjustment voltage in the new controller record
card.
9. Once servo adjustment is finished, reset the modified setup
values to the original values as per section 6.2.1.

Fig. Amadap pcb

1. Potentiometer P1 Offset setting


2. Potentiometer P2 Control loop amplification
3. Connector X43 CNC setpoint input

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6.3

Adjusting the table height sensors

Fig.

Table height sensors

The limit switches S14 and S15 and used to define the upper and
lower limit of travel, and must be set so that they trip just after the
upper and lower stop position respectively. A slight deflection of the
sensor rollers is permitted.
Sensors S42, S44 and S46 define the braking point before stop
position (cannot be changed).
Sensor S43 must be set to that the upper table position is flush with
the sheet-feed height.
Sensor S45 must be set so that when the parts-removal rake is
moved in, it does not push the parts away ( sensor too low ) or
collide with the table ( sensor too high ). Adjust closer to the cutting
table as the cutting grid wears over time.
Sensor S47 defines the bottom end position (cannot be modified).
Note:
Set the proximity switches to a distance of approx. 0.5...1mm
to achieve correct triggering behavior.

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6.4

Setting sheet clamps and table position


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

Install sheet stops on the cutting table.

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

Fig.

130

Longitudinal stop fixing screws

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

Insert a standard sheet 3000x1500mm (sheet must be perfectly


right-angled)

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

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Fig.

Table stop

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

Launch the MrAdmin program.

Switch to Settings tab.

Close safety door

Activate Manual mode (magenta button)

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

Open safety door

Push the cutting head in Y- direction and check whether the


center of the nozzle is always on the sheet edge.

Fig.

Sheet edge

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Fig.

If the center of the nozzle is not always on the edge of the


sheet, adjust the sheet and the longitudinal stop with the
clamping screw.

Clamping screw

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

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

Push the table stop up to the sheet and tighten.

Fig.

Table stop

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Fig.

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

Right table stop

Push the cutting head by hand exactly to sheet zero point

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

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6.5

Setting sheet zero point and docking position


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

Fig. Settings tab

Place sheet on table and position (push up against installed


stops), close safety door.

Launch the MrAdmin program.

Switch to the Settings tab.

Click the Reference button to move axes to reference position.

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

Press Save sheet zero point, machine moves to reference


position after setting this value.

Setting docking position


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

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Setting docking position

Reduce compressed-air pressure (1st pressure control vale) to 2


bar (the suction-cup frame can be deformed by the pneumatic
posts if the docking position is not exactly right!)

Open the safety door.

Push the cutting carriage to docking position by hand.

Extend pneumatic posts by hand


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

Fig. Valve island

When retracting the cylinders, the suction-cup frame must not


move!
When the suction-cup frame is twisted or even just moved by a
cylinder, adjust the carriers (see overleaf).

Rise the compressed-air pressure to original value (6 bar) and


extend the pneumatic posts by hand again

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

Open safety door

Reset the CNC

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Checking docking position

Close the safety door.

Press the Reference button to move the axes to reference


position.

Open the safety door.

Push the cutting carriage to docking position again. The axis


values on the display must be identical to the values Docking
Position x/y.

Adjusting the carriers


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

Fig. Left carrier

136

The right carrier cannot be adjusted and should be seen as a


reference.

Unscrew set screws B of the left carrier.

Unscrew the four fixing screws A.

Retract docking cylinder.

Tighten fixing screws A, tighten set screws B and secure with


lock nut.

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6.6

Determining Z-axis reference


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

Place sheet on cutting table.

Switch to manual operation menu (MMC).

Select the appropriate parameter for the sheet.

Position the cutting head on the sheet with Tool_Mode enabled.

The value of Z on the display must equal the sum of sheet


thickness and nozzle distance (0.7mm).

If this value is not correct, correct the value of Z-axis:


Reference coordinate by the difference on the CNC tab under
Config in MrAdmin.

Then move to reference on the Settings tab and repeat this


procedure.

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6.7

Testing the vacuum system

6.7.1 Building up a vacuum according to the Venturi principle

Fig. Venturi tube diagram

A Venturi nozzle (also known as a Venturi tube, after Giovanni


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

6.7.2 System test

Fig. Vacuum valve

138

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

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

Using a screwdriver, manually remove the valve (small screw


to side of the right controller)

If working properly, pressure on the manometer drops


approx. 0.5bar and the red pressure sensor LED goes off.

Check air-tightness of the the vacuum system step by step


with blind plugs.

Manometer pressure at rest is approx. 3.5bar.

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7

Repair

7.1

Setting the reference point on the X- and Y-axes


The following adjustment work for the X axis is described. The
procedure also applies to setting Y reference position, only the
direction of movement of rotation may differ.

20mm
Hardlimit X-

Softlimit X-

Ref. X

Fig. Limit switch and reference point (diagram)

Procedure
1. Start the MrAdmin tool
and switch to the
Settings tab.
2. Close safety door and
move to reference
position.
3. Note down axis value
on the display
Example X: 10mm
4. Open safety door
5. Push the axis in minus
direction until the
proximity switch
triggers (red LED on
sensor or appropriate
LED of IO box).

Sensor position X
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6. Note down axis value
on the display
Example X: -15mm
7. Calculate difference
between the two axis
values
Example 25mm
8. Calculate the
difference to 20mm
Example 5mm
9. Open safety door and
trip the small lever on
the bottom door
switch.
10.Open encoder.
11.Unscrew the collet
chuck with an Allen
key and hexagon-head
wrench.
12.Check display and
adjust display value by
the appropriate
amount using a
hexagon-head wrench
Example 5mm
13.Tighten collet chuck to
2.2 Nm.
14.Trip small lever on
bottom door switch.
15.Repeat steps 2
through 7
If the difference is not
20mm, repeat step 8
through 15 with
different direction of
rotation of the
hexagon-head wrench.
16.Screw encoder closed.
17.Set docking position as
per section 6.4

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7.2

Replacing the X motor

7.2.1 Material

New motor, pinion and tensioning ring

7.2.2 Additional tools and equipment required

Fig. Tool kit

Set of Allen keys

Small and large ratchet set

No. 6 screwdriver

8mm hexagon-head wrench

Torque wrench 12Nm, 3mm hex.

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7.2.3 Preparing the machine
1. In Manual operating
mode, move machine
into a suitable
position. Open the
safety door and shut
down the machine
correctly. Switch off
cooling unit. Safeguard
machine against
unauthorized start-up.
2. Remove the orange
motor cover on the
bridge.

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7.2.4 Disassembling the motor

Fig. Motor

1. Feedback connection cable


2. Encoder connection cable
3. Power supply connection cable
4. Set screw for tooth edge play
5. Shaft screw (center of rotation for setting tooth edge play)
6. Fixing screws
Procedure

Remove all electrical connection cables and encoders.

Remove set screw 4 including holder.

Secure motor with crane or place wood underneath.

Remove fixing screws 6 and shaft screw 5.

Remove motor.

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7.2.5 Assembling the pinion
1. Motor shaft
2. Pinion
3. Tensioning ring

Fig. Pinion

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

2. Pish pinion with


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

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7.2.6 Assembling the motor

Fig. Motor

1. Feedback connection cable


2. Encoder connection cable
3. Power supply connection cable
4. Set screw for tooth edge play
5. Shaft screw (center of rotation for setting tooth edge play)
6. Fixing screws
Procedure
1. Install adjustment
block 4 on motor
(unscrew set screw)
Fasten motor with
screws 5 and 6. Only
engage the screws
do not tighten yet!

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2. Setting tooth edge
play:
Jerk bridge to and
fro, adjusting set
screw 4 until you
cannot hear any more
ringing pinion and
rack and pinion.
Secure set screw 4
with lock nut.
3. Tighten motor screws
5 and 6.
Install electrical
connections and
encoders.

7.2.7 Commissioning /Test

146

Start up machine

Function test with 10% switch

Calibrate servo as per section 6.2

Set reference point as per section 7.1

Set docking position as per section 6.4

Cut test part

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7.3

Replacing the Y-axis spindle system

7.3.1 Material

new spindle with recirculating ball nut

possibly new spindle bearings

7.3.2 Additional tools and equipment required

Fig. Tool kit

Set of Allen keys

Large ratchet set containing 8mm Allen insert

Ring wrenches SW 10, 11 and 19

Hook wrench

Circlip pliers

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7.3.3 Preparing the machine
1. In Manual operating
mode, move machine
into a suitable position.
Open the safety door
and shut down the
machine correctly.
Switch off cooling unit.
Safeguard machine
against unauthorized
start-up.
2. Remove the covers
from the rear of the
machine and move the
loading table.

7.3.4

Removing the spindle


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

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

3. Undo the lubrication


line to the spindle nut

4. Unscrew the rear


bellows on the rear side
(4 hex screws M6).
Undo the motor
coupling
(grub screw)
Disconnect the three
motor connection
cables.
Unscrew and remove
the motor
(4 Allen screws M10)
5. Unscrew the two grub
screws on the clamping
nut.
Use a hook wrench and
a size 19 ring wrench
to unscrew and remove
the clamping nut.

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6. Remove the circlip from
the front end of the
spindle.
Unscrew the bearing
flange plus the bearing
and remove (4 Allen
screws M10)
.
Note:
The rear bearing
flange acts as a
fixed bearing and
only needs to be
unscrewed and
removed to
replace the
bearing.
7. Unscrew the screws on
the recirculating ball
nut and remove
(8 Allen screws M10)
8. Slide out the spindle
towards the safety
door, drop it down at
the far end and take it
out towards the rear of
the machine.

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7.3.5

Fitting the spindle


1. If necessary, fit the
fixed bearing to the
rear of the machine
and tighten screws (4
Allen screws M10).
The adjacent
diagram shows the
bridge from below.
Note:
To insert the
spindle, move
the cutting
carriage to its
Y+ limit and if
necessary
move the
recirculating
ball nut on the
spindle.
Caution: the
recirculating
ball nut must
never be
pushed beyond
the threaded
end, because
the balls may
fall out, making
the spindle
unusable.
2. Slide the spacer ring
onto the fixedbearing end.
Insert the spindle
from below through
the detachable
bearing-flange, then
lift up the spindle
and guide the end
through the cutting
carriage into the
fixed bearing.

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3. Fit the detachable
bearing plus flange (4
Allen screws M10) and
attach the circlip.
Only engage the
screws do not
tighten yet!
At the opposite end
(fixed-bearing end),
screw the spacer ring
and the clamping nut
onto the end of the
spindle and screw on
slightly. Do not tighten
the clamping nut.
4. Screw the recirculating
ball nut onto the cutting
carriage
(8 Allen screws M10)
and attach the
lubrication line.
Only insert the screws
do not tighten yet.
5. Move the cutting
carriage as far as
possible in the Y+
direction.
This centers both the
recirculating ball nut and
the fixed bearing.
Tighten the screws on
the recirculating ball nut
(8 Allen screws M10).
6. Move the cutting
carriage as far as
possible in the Ydirection to center the
detachable bearing.
Tighten screws on the
detachable bearing
flange.
7. Tighten the clamping
nut and secure with the
two grub screws.

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8. Install the motor
(4 Allen screws M10)
Tighten the motor
coupling
(grub screw)
Connect the three motor
connection cables.
9. Install lubrication
connection spindle nut,
cover sheets and
bellows.

7.3.6

Commissioning /Test

Start up machine

Function test with 10% switch

Calibrate servo as per section 6.2

Set reference point as per section 7.1

Position sheet-feed table

Fit all covers

Set docking position as per section 6.4

Cut test part

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7.4

Replacing the Z-spindle and guides

7.4.1 Material

Spindle

Guides

Spindle bearing

Bearing grease

7.4.2 Additional tools and equipment required

Fig. Tool kit

154

Set of Allen keys

Small ratchet set

Ring wrenches SW 10,11

Circlip pliers

Loctite type 243

Blanking plugs for water circuit including coupling

Oilstone HF-33

Torque screwdriver 50-500 Ncm

Special hexagonal insert 2.5mm with spherical head and


matching insert

Special wrench for spindle nut

Special wrench for spindle stud

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

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

2. Unscrew the rear


bellows and push out
the way.

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

4. Remove the lower cover


from the spindle brake.
Disconnect the
compressed air line
from the spindle brake
and replace with an M5
screw (used for manual
operation of the spindle
brake).
Brake screw
tighten released
unscrew tightened
Unscrew the bellows on
the Z-axis and move
the Z-axis downwards.
Fix the bellows up at
the top.
5. Remove the limit-switch
tabs at the lower end of
the Z-guides.
Caution
The roller cages can
drop out.

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6. Remove the telescopic
tube plus all
connections and the
cable guide from the
cutting head support.
Unscrew the screws on
the carrier plate
(connection between
cutting head support
and spindle).
Remove the cutting
head support together
with roller cages.
7. Unscrew the bellows
from the Z-axis and
remove.
Remove the two covers
from the Z guides.

8. Disconnect the motor


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

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9. Release the spindle
brake.
Push the spindle
upwards until the
bearings can be
seen; fix in this
position.
Use the special
wrenches to
unscrew the bearing
nut. Remove the
bearing nut and the
bearings.
Move the spindle
downwards.
CAUTION
The spindle
brake must
not be
applied
without the
spindle
inserted:
the brake
cannot be
released
again
afterwards.
10.Unscrew the side
screws on the righthand Z-guide.
Unscrew and
remove the Zguides.
Also remove the
guides from the
cutting head
support.

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7.4.5 Fitting
2. Use an oilstone to hone
the guide contact
surfaces on the cutting
carriage and then clean
them.
Fit the limit-switch tabs
to the upper ends of
the guides.
Fit the new guides but
do not tighten the
screws.
Press the left-hand
guide against the left
face and tighten the
screws to 110 Ncm.
Insert but do not
tighten the top and
bottom screw in the
right-hand guide.
3. Use an oilstone to hone
the guide contact
surfaces on the cutting
head support and then
clean them.
Press the guides
against the inner stop
and tighten the screws
to 110 Ncm.
Fit the limit-switch tabs
to the upper ends of
the guides (not visible
in Fig.), but do not
tighten the screws.

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4. Pre-assemble the new
spindle in the same
way that it was
dismantled.
Only engage the
screws in the carrier
plate do not tighten.
Note:
Approximately
half fill the new
bearings with
grease.
The spindle
must not be
greased to
avoid dirt
adhering to the
surface.
Just spray the
spindle lightly
with oil.
5. Insert the spindle from
below into the hole,
and fix.
Mount the bearings
and spacer rings on
the spindle head in the
order shown on the
right.
Tighten the bearing
nut until the large
intermediate ring is
fully seated.
Note:
Fit the angular
contact ball
bearings with
their labeled
sides facing
each other.

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

7. Slide the cutting head


support plus roller
cages into the guides
on the cutting
carriage. The roller
cages must rest
against the limitswitch tabs at the
upper guide end of the
cutting head support
during this process.
Keep sliding the
cutting head support
along until the roller
cages are fully
inserted. Fix the
cutting head support in
this position.
8. Tighten the side
screws on the righthand cutting-carriage
guide to a torque of
20 Ncm to press the
guide against the
guides on the cutting
head support, working
along half the height of
the guide.
Slide the cutting head
support upwards and
then tighten the
remaining side screws
to a torque of
20 Ncm.
Tighten the screws on
the right-hand guide to
110 Ncm.
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9. Center the limit-switch
tabs at the upper ends
of the guides with
respect to the guide
grooves, and tighten
the screws.
Fit the limit-switch
tabs to the lower ends
of the guides.

10.Screw the cutting head


support onto the
carrier plate of the
spindle. Only engage
the screws slightly
do not tighten yet.
Slide the cutting head
support upwards.
Tighten the fixing
screws on the carrier
plate and spindle nut
through the holes in
the cutting head
support.
Move the cutting head
support up and down
and tighten the screws
on the carrier plate.
11.Fit the motor including
coupling.

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

7.4.6 Commissioning /Test

Start up machine

Function test with 10% switch

Perform servo calibration

Set Z reference and nozzle cleaning height

Re-align the cutting head

Cut test part

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Documentation
Written by:

Reviewed by:

Released by:

Release date:

M.Hug

Changes to the documentation


Any changes must also appear in the English document.
File Name:

Pages:

Change:

Date:

01_06_ByVention_V1_XX.doc every page

New document

06.03.06 mhu

01_06_ByVention_V2_XX.doc every page

New format template, 22.01.07 mhu


documents joined

01_06_ByVention_V3_XX.doc 37, 39-41,


58-59, 66,
82, 130136, 139146

Updated

Please remove this page after printing.

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Signed:

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Input / output overview
(as per S2335-0-A)
A1ST3
Input

Output

X3

X4

X5

X6

I01

UNLOADER SAFETY
COVER CLOSED

I01

LIMIT OF TRAVEL
CARRIAGE

O01

DRIVE RELEASE
CNC

RELEASE
O01 SAFETY
DOOR

I02

CUTTING TABLE
READY / ERROR

I02

LIMIT OF TRAVEL
BRIDGE

O02

DRIVE RELEASE
CUTTING TABLE

O02 -

I03

UNLOADING TABLE
READY / ERROR

I03

LIMIT OF TRAVEL
DRIVE RELEASE
O03
O03 CUTTING TABLE UP
UNLOADING TABLE

I04

SURGE VOLTAGE
PROTECTOR

LIMIT OF TRAVEL
I04 CUTTING TABLE
DOWN

I05

FUSE
LASER MODULE

LIMIT OF TRAVEL
OPERATING
I05 UNLOADING TABLE O05
HOURS COUNTER
RETRACTED

I06

MOTOR CIRCUIT
BREAKER
DRIVE
CUTTING TABLE

LIMIT OF TRAVEL
DUST COLLECTION
I06 UNLOADING TABLE O06 SYSTEM
O06 EXTENDED
ON

LAMP PUSH SHEET


O04 INTO
O04 SHEET STOP
O05 -

MOTOR CIRCUIT
I07 BREAKER DRIVE
UNLOADING TABLE

I07

COMPRESSED AIR
MONITORING

O07 -

O07 -

MOTOR CIRCUIT
I08 BREAKER
CNC DRIVE

I08

MONITORING
ULTRAPAC

O08 -

O08 -

I09

COOLING UNIT AND


CUTTING TABLE
DUST COLLECTION
O09
SYSTEM
RELEASE RESET
READY

O09 -

MOTOR CIRCUIT
I10 BREAKER
24VDC

I10

COOLING UNIT AND


CUTTING TABLE
DUST COLLECTION
O10
FAST
UNIT
WARNING

O10 -

SAFETY DOOR
I11
CLOSED

COOLING UNIT AND


CUTTING TABLE
DUST COLLECTION
O11
I11
SYSTEM
LIFT
ERROR

O11 -

I09

I12

MOTOR CIRCUIT
BREAKER
AIR CONDITIONING
UNIT

CNC DRIVES
ON

I13 NC READY

I12

MODE SELECTOR
SWITCH

O12

CUTTING TABLE
LOWER

I13

NO
APPROVAL

O13

UNLOADING TABLE
O13 RELEASE RESET

O12 -

I14

SEPARATING CUT
MONITORING ERROR

TEMPERATURE
I14 SENSOR
CNC MOTORS

O14

UNLOADING TABLE
O14 FAST

I15

FIRE DETECTION
BELLOWS

I15

CONTINUE
KEY

O15

UNLOADING TABLE
O15 RETRACT

I16

CABINET COOLING
FAULT

I16

CUTTING CARRIAGE
UNLOADING TABLE
O16
O16 UNCOUPLED 2
EXTEND

Bystronic Laser AG, 2006

165

ByAcademy
Business Units Laser & Waterjet
A1ST5
Input
X3
SUCTION-CUP
I01 FRAME
UP

SHEET STOP LONG.


I01 1
EXTEND

X5

X6

O01

CUTTING GAS 1
(O2)

O01 O02 -

I02

CUTTING CARRIAGE
SEPARATING-CUT
I02
UNCOUPLED 1
MONITORING

O02

CUTTING GAS 2
(N2)

I03

VACUUM
MISSING

O03

CUTTING GAS 3
O03 (COMPRESSED AIR)

I03

SEPARATING-CUT
MONITORING

SUCTION UNIT
I04 CARRIER
START POSITION

I04

LOWER SUCTION
SHEET IN POSITION
O04 FRAME
LONG.

O04 -

SUCTION-CUP
I05 FRAME
COUPLED

I05

CUTTING TABLE UP
SLOW

O05

SUCTION UNIT
FIX

O05 -

CUTTING TABLE UP
STOP

O06

SHEET CLAMP
TENSION

O06 -

I06

BRIDGE
REFERENCE

I06

I07

CARRIAGE
REFERENCE

CUTTING TABLE
I07 MIDDLE POSITION
SLOW

SHEET STOP
O07 LONG. 1&2
RETRACT

I08

Z AXIS
REFERENCE

CUTTING TABLE
I08 MIDDLE POSITION
STOP

O08

I09

CUTTING TABLE
SHEET IN POSITION
I09 DOWN
CROSS 1
SLOW

O09 SUCTION FLAP 1

O09 -

I10

CUTTING TABLE
SHEET IN POSITION
I10 DOWN
CROSS 2
STOP

O10 SUCTION FLAP 2

O10 -

I11

SUCTION UNIT
FIXED

I11

UNLOADING TABLE
RETRACT SLOW

O11

I12

SUCTION UNIT
RELEASED

I12

UNLOADING TABLE
RETRACTED

SAFETY COVER
O12 UNLOADER
CLOSED

O12 -

I13

SHEET CLAMP 1
RELEASED

I13

UNLOADING TABLE
EXTEND SLOW

O13 JET COOLING

O13 -

I14

SHEET CLAMP 2
RELEASED

I14

CHECK MATERIAL
REMOVED

O14 -

O14 -

I15

SHEET CLAMP
CLAMP & RELEASE

I15

PROTECTIVE FLAP
OPEN

O15 BLOW-OFF SHEET

O15 -

I16

UNLOADING TABLE
EXTENDED

O16 SUCK ON SHEET

O16 -

SHEET STOP LONG.


I16 1
RETRACTED

166

Output
X4

PROTECTIVE FLAP
OPEN

O07 -

O08 -

CUTTING CARRIAGE
O11 COUPLE

01_06_ByVention_V03_en.doc