Bysprint Ba en PDF

Bysprint
Operating instructions
Issued on: 01.2007
Operating instructions Bysprint_BA_V20_en.fm
Bystronic Laser AG, 2005
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Product identification
These operating instructions apply to the product: Bysprint
Document identification
Operating instructions: Bysprint_BA_V20_en.fm Please specify the document identification and issue date when reordering.
Purpose of the operating instructions

These operating instructions form part of the overall documentation. They provide information on the safe and proper use of the product.
Other documents
The complete set of documentation contains the following documents:

Installation Guide Operating instructions Cutting technology Spare parts catalog Diagrams Supplier documentation Machine documentation Machine logbook
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Target group
These operating instructions are intended for the owner and operator of the machine and for maintenance and repair personnel.
Storage
The operating instructions must always be freely accessible to the specified target group.
Copyright
Dissemination or duplication of this document, or exploitation or communication of its content without the express permission of the author is prohibited. Contravention will result in damages. All rights reserved.
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Argentina
BEHRENDT MAQUINARIAS S.A. Lima 355 - Piso 8 AR-1073 Buenos Aires Tel.: +54 11 5031 5312 Fax: +54 11 5031 5301 Email: info@bmaq.com.ar
Australia
LMC LASER SERVICE PTY. LTD Factory 2 1 Frias Road, Moorabbin AU-3198 Victoria Tel.: +61 3 9555 5525 Fax: +61 3 9555 2970 Email: sales@lmclaser.com.au
Austria
BYSTRONIC AUSTRIA GmbH Wienerstrasse 131 AT-4020 Linz Tel.: +43 732 341 377 0 Fax: +43 732 341 377 11 Email: office@bystronic.at
Brazil
BYSTRONIC DO BRASIL Ltda. Rua Arapongas, 285 BR-83040 200 So Cristvo So Jos dos Pinhais - Paran Tel.: +55 41 3398 2000 Fax: +55 41 3398 1789 Email: bystronic@bystronic.com.br
China
BYSTRONIC CO., LTD Rijing Road 88, Level 1 Part A Waigaoqiao FTZ Pudong CN-200131 Shanghai Tel.: +86 21 5868 0480 Fax: +86 21 5868 0481 Email: byadmin@sh163.net
China
BYSTRONIC MACHINERY CO. LTD. Economic Development Zone Ninghe County CN-301500 Tianjin, PRC Tel.: +86 22 6958 9988 Fax: +86 22 6958 8168 Email: sales@afmtianjin.com
Czech Republic
CANMET s.r.o. Karlova 37 CZ-61400 Brno Tel.: +420 5 4542 4542 Fax: +420 5 4542 4543 Email: info@canmet.cz
England
BYSTRONIC UK LIMITED Maple Park Lowfields Avenue GB-Leeds LS12 6HH Tel.: +44 113 222 8112 Fax: +44 113 271 9862 Email: service.cutting.uk@bystronic.com
France
BYSTRONIC FRANCE SA Parc Technipolis 3 avenue du canada F-91940 Les Ulis Tel.: +33 1 6941 9984 Fax: +33 1 6941 9951 Email: info@bystronic.fr
Germany
BYSTRONIC DEUTSCHLAND GmbH Mollenbachstrasse 33-35 D-71229 Leonberg Tel.: +49 (0)7152 6090 0 Fax: +49 (0)7152 6090 11 Email: info@bystronic.de
Greece
ADECA SA Technical and Commercial Company Ave. Alexandras 56 GR-11473 Athens Tel.: +302 10 822 8503 Fax: +302 10 821 6746 Email: adeca@otenet.gr
Hungary
AUTOREL Kft. Attila ut 131 / III. 12. HU-1012 Budapest Tel.: +36 1 212 7270 Fax: +36 1 212 7271 Email: sales@autorel.hu
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Israel
ALON Laser Services Ltd. 23 Robinzon St. IL-49560 Petach-Tikva Tel.: +972 3 931 0127 Fax: +972 3 931 0128 Email: alon_ch@zahav.net.il
Italy
BYSTRONIC ITALIA SRL Via del Lavoro 30 I-20030 Bovisio Masciago / MI Tel.: +39 0362 59931 Fax: +39 0362 5941 35 Email: services.it@bystronic.com
Netherlands
BYSTRONIC BENELUX BV Stek 8 NL-3371 Hardinxveld-Giessendam Tel.: +31 (184) 611 020 Fax: +31 (184) 617 774 Email: info@bystronic.nl
North America
BYSTRONIC INC. Bystronic North American Headquarters 185 Commerce Drive Hauppauge, NY 11788 Tel.: +1 631 231 1212 Fax: +1 631 231 1040 Email: info@bystronicusa.com
Mexico
Bystronic Mexico S.A. de C.V. Lago Onega No. 424, Col. Granada MX-11520 Mexiko, D.F. Tel: + 52 (0)5 525 815 147 Fax: +52 (0)5 525 815 156 Email: info@bystronicusa.com
Poland
BYSTRONIC POLSKA Sp. z o.o. Al. Krakowska 38 Janki PL-05090 Raszyn Tel.: + 48 22 331 37 70 Fax: + 48 22 331 37 71
Russia / Ukraine and Rest CIS

Bystronic Russia Sales Office c/o United Machinery AG 2. Hutorskaja Street, 38 A RU-127287 Moscow Tel.: +7 (495) 961 21 67 Fax: +7 (495) 961 21 68 Email: sales.ru@bystronic.com
Singapore
BYSTRONIC PTE. LTD. 2 Leng Kee Road #03-05 Thye Hong Centre SG-159086 Singapore Tel.: +65 6472 6300 Fax: +65 6472 2418 Email: bystronicasia@bystronic.com.sg
Slowakei
CANMET s.r.o. Brik 5 SK-811 02 Bratislava Tel.: 00421 245 24 28 96 Fax: 00421 245 24 77 50 Email: info@canmet.sk
South Africa
FOREST ENGINEERING P.O.Box 169 ZA-1600 Isando Tel.: +27 11 397 4050 Fax: +27 11 397 4210 Email: forest@fhmt.co.za
South Korea
BYSTRONIC KOREA, LTD 6Fl, Teleron B/D KR-1459-2 Gwanyang-dong, Dongan-gu Anyang-si Geonggi-do Tel.: +82 314 25 5729 Fax: +82 314 25 0057
Spain / Portugal
BYSTRONIC IBERICA, S.A. Avenida Tenerife No. 2 Edifigo 1 3A Planta Oficina D E-28700 San Sebastian de los Reyes Tel.: +34 91 654 4496 Fax: +34 91 652 4983 Email: info@bystronic.es
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Sweden
BYSTRONIC SCANDINAVIA AB stra Bangatan 18 SE-19560 Arlandastad Tel.: +46 (0)8 5944 1550 Fax: +46 (0)8 5944 1555 Email: info@bystronic.se
Switzerland
BYSTRONIC SALES AG Industriestrasse 21 CH-3362 Niedernz Tel.: +41 (0)62 956 37 83 Fax: +41 (0)62 956 33 81 Email: info.sales@bystronic.com
Taiwan
CHASER C.D. ENTERPRISE CO. LTD 22F, No. 639, Chung Cheng Rd. TW-238 Shuh Lin City - Taipei Hsien Tel.: +886 22 689 7988 Fax: +886 22 689 7986 Email: chaser@tpts5.seed.net.tw
Turkey
LASERPRESS LTD. Kiremitdere Dedeoglu Cad. No. 60 TR-34805 Beykoz Istanbul / Turkiye Tel.: +90 (0)216 413 7677 Fax: +90 (0)216 425 2341 Email: info@laserpress.com.tr
Rest of the World

BYSTRONIC LASER AG Industriestrasse 21 CH-3362 Niedernz Tel.: +41 (0)62 956 3333 Fax: +41 (0)62 956 3386 info.laser@bystronic.com
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Table of contents
1
1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.2 1.2.1 1.2.2 1.2.2.1 1.2.2.2 1.2.2.3 1.2.2.4 1.2.2.5 1.3 1.3.1
Product description
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . Working positions . . . . . . . . . . . . . . . . . . . . . . . . . . Product labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . Product data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Formats and thicknesses that can be cut . . . . . . . . . . Sheet formats that can be cut. . . . . . . . . . . . . . . . Sheet thicknesses that can be cut . . . . . . . . . . . . . Sheet thicknesses that can be cut, 2200 W . . . . . . Sheet thicknesses that can be cut, 3000 W . . . . . . Dust extraction unit . . . . . . . . . . . . . . . . . . . . . . . Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design versions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 14 15 16 18 1 10 1 10 1 11 1 11 1 12 1 12 1 15 1 18 1 19 1 19
Operating instructions Bysprint_BA_V20_enTOC.fm
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Table of contents
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2.1 2.2 2.2.1 2.2.2 2.3 2.3.1 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.5 2.5.1 2.5.1.1 2.5.1.2 2.5.1.3 2.5.1.4 2.5.2 2.5.3 2.5.4 2.5.5 2.5.5.1 2.5.5.2 2.5.6 2.5.6.1 2.5.6.2 2.5.7 2.6 2.7
Safety regulations
Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety devices and monitoring equipment . . . . . . . . . Safety-conscious working . . . . . . . . . . . . . . . . . . . . Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning and advice signs . . . . . . . . . . . . . . . . . . . . Requirements for personnel . . . . . . . . . . . . . . . . . . Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personal protection equipment . . . . . . . . . . . . . . . . . Product-specific hazards. . . . . . . . . . . . . . . . . . . . . Laser radiation hazards . . . . . . . . . . . . . . . . . . . . . . Normal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct laser beam . . . . . . . . . . . . . . . . . . . . . . . . Reflected and stray radiation . . . . . . . . . . . . . . . . High-voltage hazard . . . . . . . . . . . . . . . . . . . . . . . . Electrical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . Hazards arising from the pneumatic system . . . . . . . Hazards arising from gas, dust, vapors, smoke . . . . . Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extraction unit . . . . . . . . . . . . . . . . . . . . . . . . . . Hazards associated with handling the optical system . General information. . . . . . . . . . . . . . . . . . . . . . . Warnings in case of fire or accident . . . . . . . . . . . . Lubricants, coolants and cleaning agents. . . . . . . . . . Additional hazards . . . . . . . . . . . . . . . . . . . . . . . . . Emergency information. . . . . . . . . . . . . . . . . . . . . . 23 25 25 25 26 27 28 28 28 29 29 2 10 2 10 2 10 2 11 2 12 2 13 2 14 2 15 2 16 2 17 2 17 2 18 2 19 2 19 2 19 2 20 2 21 2 22
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3
3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 3.3.1 3.4 3.4.1 3.4.1.1 3.4.1.2 3.4.2 3.4.3 3.4.4 3.5 3.5.1 3.6 3.6.1 3.6.2 3.6.2.1 3.7
Design and operation

Overall view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and monitoring devices . . . . . . . . . . . . . . . . EMERGENCY STOP circuit . . . . . . . . . . . . . . . . . . . Light barrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laser machine safety door. . . . . . . . . . . . . . . . . . . . Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laser module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laser control cabinet (only for 3000 W laser module) . Cabinet base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . STL cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . CNC cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Netbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating terminal . . . . . . . . . . . . . . . . . . . . . . . . . Hand-held controller . . . . . . . . . . . . . . . . . . . . . . . . Base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dust extraction system . . . . . . . . . . . . . . . . . . . . . . Small-parts trays . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic table lock . . . . . . . . . . . . . . . . . . . . . . Cutting bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 35 35 36 37 38 39 3 10 3 11 3 11 3 11 3 12 3 13 3 14 3 16 3 17 3 18 3 19 3 19 3 20 3 21 3 22
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3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.8.4.1 3.8.4.2 3.8.4.3 3.8.5 3.8.5.1 3.8.5.2 3.8.5.3 3.8.5.4 3.8.5.5 3.8.5.6 3.8.5.7 3.8.6 3.8.6.1 3.8.6.2 3.8.7 3.8.7.1 3.8.7.2 3.8.8 3.8.8.1 3.8.8.2 3.8.8.3 3.8.8.4 3.8.8.5 3.8.8.6 3.8.9 3.8.9.1 3.8.9.2 3.8.9.3 Cutting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comparison of focal lengths . . . . . . . . . . . . . . . . . Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Range of nozzles available . . . . . . . . . . . . . . . . . . Labeling of nozzles . . . . . . . . . . . . . . . . . . . . . . . Normal pressure (tactile detection) . . . . . . . . . . . . High pressure (tactile and capacitive detection) . . . Normal pressure (capacitive detection) . . . . . . . . . High pressure (capacitive detection) . . . . . . . . . . . Double nozzles (capacitive detection) . . . . . . . . . . Nozzle cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . CutControl (option). . . . . . . . . . . . . . . . . . . . . . . . . Design and operation. . . . . . . . . . . . . . . . . . . . . . Start-of-cut piercing using CutControl . . . . . . . . . . Crossjet (option) . . . . . . . . . . . . . . . . . . . . . . . . . . Application (without CPP) . . . . . . . . . . . . . . . . . . . Oil to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . Topping up with oil . . . . . . . . . . . . . . . . . . . . . . . Working and parked position . . . . . . . . . . . . . . . . Quantity of oil sprayed. . . . . . . . . . . . . . . . . . . . . Cross-blow facility . . . . . . . . . . . . . . . . . . . . . . . . Sensing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitive detection . . . . . . . . . . . . . . . . . . . . . . Calibrating the capacitive detection . . . . . . . . . . . . Tactile detection (option) . . . . . . . . . . . . . . . . . . . 3 23 3 24 3 25 3 26 3 27 3 28 3 29 3 30 3 31 3 32 3 33 3 34 3 34 3 34 3 34 3 34 3 35 3 35 3 35 3 36 3 36 3 37 3 38 3 39 3 39 3 39 3 39 3 40 3 40 3 41 3 41 3 42 3 42
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3.9 3.10 3.10.1 3.10.2 3.10.3 3.10.4 3.10.4.1 3.10.4.2 3.10.4.3 3.11 3.11.1 3.11.2 3.12 3.13 3.13.1 3.13.2 Shuttle table console . . . . . . . . . . . . . . . . . . . . . . . Beam guidance system . . . . . . . . . . . . . . . . . . . . . . Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiation protection . . . . . . . . . . . . . . . . . . . . . . . . Deflecting mirror . . . . . . . . . . . . . . . . . . . . . . . . . . Adaptive optic (option) . . . . . . . . . . . . . . . . . . . . . . Focal position without adaptive optic (flat mirror) . . Course of focal point with adaptive optic (option) . . Focal position . . . . . . . . . . . . . . . . . . . . . . . . . . . Shuttle table system . . . . . . . . . . . . . . . . . . . . . . . . Shuttle table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote diagnostics (option) . . . . . . . . . . . . . . . . . Cutting gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting gas quality . . . . . . . . . . . . . . . . . . . . . . . . . Cutting gas consumption . . . . . . . . . . . . . . . . . . . . . 3 44 3 45 3 46 3 47 3 48 3 50 3 51 3 52 3 53 3 54 3 54 3 55 3 56 3 58 3 58 3 59
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Table of contents
4
4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.2.2.1 4.2.2.2 4.2.2.3 4.2.2.4 4.2.2.5 4.2.3 4.2.3.1 4.2.3.2 4.2.3.3 4.2.4 4.2.4.1 4.2.4.2 4.2.4.3 4.2.5 4.2.5.1 4.3 4.4 4.4.1 4.4.2 4.5 4.5.1 4.5.1.1 4.5.2 4.5.2.1
Control elements
Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls and indicators . . . . . . . . . . . . . . . . . . . . . . Main power switch . . . . . . . . . . . . . . . . . . . . . . . . . EMERGENCY STOP buttons . . . . . . . . . . . . . . . . . . . Operating terminal . . . . . . . . . . . . . . . . . . . . . . . Hand-held controller . . . . . . . . . . . . . . . . . . . . . . Shuttle-table console . . . . . . . . . . . . . . . . . . . . . . Laser module 2200 . . . . . . . . . . . . . . . . . . . . . . . Control cabinet for laser module 3000 . . . . . . . . . . Operating terminal . . . . . . . . . . . . . . . . . . . . . . . . . Status of illuminated function buttons . . . . . . . . . . Enabling the function buttons . . . . . . . . . . . . . . . . Description of the function buttons . . . . . . . . . . . . Hand-held controller . . . . . . . . . . . . . . . . . . . . . . . . Enabling the hand-held controller . . . . . . . . . . . . . Thumb-wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of buttons on the hand-held controller . Shuttle-table console . . . . . . . . . . . . . . . . . . . . . . . Description of buttons on the shuttle table console . Control cabinet for laser module 3000 . . . . . . . . . . Operating modes of the laser cutting machine . . . . Normal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating modes, Adaptive Optic 1 . . . . . . . . . . . . Operating mode 0 (Service mode) . . . . . . . . . . . . . . Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating mode 1 (production mode) . . . . . . . . . . Working in operating mode 1 . . . . . . . . . . . . . . . . 43 43 44 45 45 46 46 46 47 47 48 49 4 10 4 10 4 10 4 11 4 11 4 12 4 12 4 14 4 14 4 16 4 17 4 17 4 17 4 18 4 18 4 18 4 19 4 19
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5
5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.2.1 5.2.2.2 5.2.3 5.2.3.1 5.2.3.2 5.2.4 5.2.5 5.2.5.1 5.2.5.2 5.3 5.3.1 5.3.2 5.3.2.1 5.3.2.2 5.3.3 5.3.4 5.3.4.1 5.3.4.2 5.3.4.3 5.3.5 5.3.6 5.3.7 5.3.8 5.3.8.1 5.3.8.2 5.3.9 5.3.10 5.3.11 5.3.11.1 5.3.11.2
Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . Operating the machine . . . . . . . . . . . . . . . . . . . . . . Pre start-up check . . . . . . . . . . . . . . . . . . . . . . . . . Starting up the laser cutting machine in normal mode Start-up procedure for laser module 2200 . . . . . . . Start-up procedure for laser module 3000 . . . . . . . Shutting down the laser cutting machine in normal mode Shutdown procedure for laser module 2200 . . . . . . Shutdown procedure for laser module 3000 . . . . . . Switching off in an emergency . . . . . . . . . . . . . . . . . Restarting after an EMERGENCY STOP . . . . . . . . . . Restart procedure for laser module 2200 . . . . . . . . Restart procedure for laser module 3000 . . . . . . . . ByVision user interface . . . . . . . . . . . . . . . . . . . . . . General layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . User logon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User permissions. . . . . . . . . . . . . . . . . . . . . . . . . Access to the individual views . . . . . . . . . . . . . . . . Layout of the views . . . . . . . . . . . . . . . . . . . . . . . . MAIN view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Administration . . . . . . . . . . . . . . . . . . . . . . . . . Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . HAND view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WORK view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOOLS view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System, status and error messages . . . . . . . . . . . . . Message list . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display convention for buttons . . . . . . . . . . . . . . . . . Function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . Online Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Search functions . . . . . . . . . . . . . . . . . . . . . . . . . Printed version . . . . . . . . . . . . . . . . . . . . . . . . . . 53 53 54 54 55 55 56 57 57 58 59 59 59 5 10 5 11 5 11 5 13 5 14 5 15 5 17 5 18 5 19 5 20 5 21 5 22 5 23 5 24 5 25 5 26 5 26 5 27 5 27 5 28 5 29 5 29
Requirements to be met by personnel performing the work 5 3
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Table of contents
5.4 5.4.1 5.4.2 5.4.2.1 5.4.2.2 5.4.3 5.4.4 5.4.5 5.4.5.1 5.4.5.2 5.4.5.3 5.4.6 5.4.6.1 5.4.7 5.4.7.1 5.4.7.2 5.4.7.3 5.4.7.4 5.4.8 5.4.8.1 5.4.9 5.4.9.1 5.5 5.5.1 5.5.2 5.5.3 5.5.3.1 5.5.3.2 5.6 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.6.5.1 5.6.5.2 5.6.6 Handling Operation user interface . . . . . . . . . . . . . Starting the software . . . . . . . . . . . . . . . . . . . . . . . General layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navigation buttons . . . . . . . . . . . . . . . . . . . . . . . Function buttons . . . . . . . . . . . . . . . . . . . . . . . . . Start page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm messages. . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearing alarm messages . . . . . . . . . . . . . . . . . . . Alarm history . . . . . . . . . . . . . . . . . . . . . . . . . . . Info view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the dialog language . . . . . . . . . . . . . . . . Operating the shuttle table system . . . . . . . . . . . . . . Single table interchange. . . . . . . . . . . . . . . . . . . . Resetting job data . . . . . . . . . . . . . . . . . . . . . . . . Advanced operation . . . . . . . . . . . . . . . . . . . . . . . Material status in the cutting and loading position . . Setup functions . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine-specific settings . . . . . . . . . . . . . . . . . . . Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . Moving shuttle tables manually . . . . . . . . . . . . . . . Using the remote diagnostics facility (option) . . . . Connect / Disconnect (Administration) . . . . . . . . . . . Connection status. . . . . . . . . . . . . . . . . . . . . . . . . . Viewing diagnostic data. . . . . . . . . . . . . . . . . . . . . . Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detailed diagnostic data . . . . . . . . . . . . . . . . . . . . Setting up and adjustment tasks . . . . . . . . . . . . . . Initiating an axis movement . . . . . . . . . . . . . . . . . . Changing the cutting head. . . . . . . . . . . . . . . . . . . . Changing the nozzle . . . . . . . . . . . . . . . . . . . . . . . . Centering the nozzle . . . . . . . . . . . . . . . . . . . . . . . . Tactile detection (option) . . . . . . . . . . . . . . . . . . . . Fitting the detection unit . . . . . . . . . . . . . . . . . . . Calibrating the detection unit . . . . . . . . . . . . . . . . Adjusting the focal point on the cutting head (where flat mirror fitted) . . . . . . . . . . . . . . . . . . . . . 5 30 5 30 5 31 5 33 5 34 5 35 5 36 5 37 5 38 5 39 5 39 5 39 5 40 5 42 5 42 5 43 5 44 5 45 5 46 5 47 5 48 5 49 5 50 5 51 5 52 5 53 5 54 5 55 5 56 5 56 5 57 5 59 5 61 5 64 5 65 5 65 5 66
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5.7 5.7.1 5.7.1.1 5.7.2 5.8 5.8.1 5.8.1.1 5.8.1.2 5.8.1.3 5.8.1.4 5.8.2 5.8.2.1 5.8.2.2 5.8.2.3 5.9 5.9.1 5.9.2 5.9.3 5.9.4 5.9.5 5.10 5.10.1 5.10.1.1 5.10.2 5.10.2.1 5.10.3 5.10.3.1 5.10.3.2 5.10.3.3 5.10.4 5.10.4.1 5.10.4.2 5.10.4.3 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . Separating cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine positioning using the hand-wheel . . . . . . . . . . Shifting the zero point of the cutting plan . . . . . . . . . Cutting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual cutting process . . . . . . . . . . . . . . . . . . . . . . Creating a cutting job . . . . . . . . . . . . . . . . . . . . . Importing a cutting plan. . . . . . . . . . . . . . . . . . . . Assigning cutting parameters . . . . . . . . . . . . . . . . Starting the cutting process . . . . . . . . . . . . . . . . . Automatic mode (manual loading and unloading) . . . . Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary steps . . . . . . . . . . . . . . . . . . . . . . . . Starting the cutting process . . . . . . . . . . . . . . . . . Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . Move to service position . . . . . . . . . . . . . . . . . . . . . Move to parked position . . . . . . . . . . . . . . . . . . . . . Calibrate nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special functions. . . . . . . . . . . . . . . . . . . . . . . . . . . Crossjet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Registering the Crossjet . . . . . . . . . . . . . . . . . . . . Edge detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edge detection using CutControl . . . . . . . . . . . . . . CutControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working with CutControl . . . . . . . . . . . . . . . . . . . Measuring the calibration threshold . . . . . . . . . . . . CutControl functional check . . . . . . . . . . . . . . . . . Microjoints / Weld joints . . . . . . . . . . . . . . . . . . . . . Automatic microjoints . . . . . . . . . . . . . . . . . . . . . Programmed microjoints . . . . . . . . . . . . . . . . . . . Weld joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 71 5 71 5 72 5 73 5 74 5 74 5 74 5 77 5 78 5 80 5 81 5 81 5 81 5 84 5 85 5 85 5 85 5 85 5 85 5 86 5 87 5 87 5 87 5 88 5 88 5 89 5 89 5 90 5 93 5 94 5 95 5 96 5 97
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6
6.1 6.1.1 6.1.1.1 6.1.1.2 6.1.1.3 6.1.1.4 6.1.1.5 6.1.1.6 6.1.2 6.2 6.3 6.4 6.5 6.6
Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . Work on live (hot) components . . . . . . . . . . . . . . . Work on gear units . . . . . . . . . . . . . . . . . . . . . . . Remaining in the danger zone . . . . . . . . . . . . . . . Operating materials . . . . . . . . . . . . . . . . . . . . . . . External modules . . . . . . . . . . . . . . . . . . . . . . . . Tools, test equipment and spare parts . . . . . . . . . . Customer service information. . . . . . . . . . . . . . . . . Operating materials . . . . . . . . . . . . . . . . . . . . . . . . Operating hours display . . . . . . . . . . . . . . . . . . . . . Maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . Maintenance record . . . . . . . . . . . . . . . . . . . . . . . . 63 63 63 63 64 64 64 64 65 66 68 69 6 18
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7
7.1 7.1.1 7.1.1.1 7.1.1.2 7.1.1.3 7.1.1.4 7.1.1.5 7.1.1.6 7.1.2 7.2 7.3 7.3.1 7.3.2 7.3.3 7.3.3.1 7.3.3.2
Repair
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . Work on live (hot) components . . . . . . . . . . . . . . . Work on gear units . . . . . . . . . . . . . . . . . . . . . . . Remaining in the danger zone. . . . . . . . . . . . . . . . Operating materials . . . . . . . . . . . . . . . . . . . . . . . External modules . . . . . . . . . . . . . . . . . . . . . . . . Tools, test equipment and spare parts . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety inspection . . . . . . . . . . . . . . . . . . . . . . . . . . EMERGENCY STOP buttons . . . . . . . . . . . . . . . . . . Light barrier on shuttle-table system . . . . . . . . . . . . Limit-of-travel monitoring . . . . . . . . . . . . . . . . . . . . Limit switches on X-axis and Y-axis . . . . . . . . . . . . Limit switch on Z-axis . . . . . . . . . . . . . . . . . . . . . 73 73 73 73 74 74 74 74 76 78 78 79 7 10 7 10 7 11
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7.4 7.4.1 7.4.1.1 7.4.1.2 7.4.2 7.4.2.1 7.4.2.2 7.4.2.3 7.4.2.4 7.4.2.5 7.4.2.6 7.4.3 7.4.3.1 7.4.3.2 7.4.3.3 7.4.4 7.4.4.1 7.4.4.2 7.4.4.3 7.4.5 7.4.5.1 7.4.5.2 7.4.5.3 7.4.5.4 7.4.6 7.4.6.1 7.4.6.2 7.4.6.3 7.4.6.4 7.4.6.5 7.4.7 7.4.7.1 7.4.7.2 7.4.7.3 Lubrication, service and cleaning work . . . . . . . . . Operating terminal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the screen . . . . . . . . . . . . . . . . . . . . . . . Cleaning the keyboard . . . . . . . . . . . . . . . . . . . . . Shuttle table system . . . . . . . . . . . . . . . . . . . . . . . . Roller chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller chain tension . . . . . . . . . . . . . . . . . . . . . . . Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting unit drive and gearing . . . . . . . . . . . . . . . . Table interchange drive . . . . . . . . . . . . . . . . . . . . Rubber buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . Base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extraction system . . . . . . . . . . . . . . . . . . . . . . . . Small-parts trays . . . . . . . . . . . . . . . . . . . . . . . . Safety door . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting bridge and cutting carriage (X-axis and Y-axis) Linear guides . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack-and-pinion . . . . . . . . . . . . . . . . . . . . . . . . . Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water couplings . . . . . . . . . . . . . . . . . . . . . . . . . Cutting head mounting . . . . . . . . . . . . . . . . . . . . Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air drier (adsorption drier) . . . . . . . . . . . . . . . . . . Reset switches . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the muffler . . . . . . . . . . . . . . . . . . . . . . Crossjet oil container, topping up with oil. . . . . . . . Bleeding the Crossjet. . . . . . . . . . . . . . . . . . . . . . Cutting gas, changing gas bottles. . . . . . . . . . . . . . . General instructions . . . . . . . . . . . . . . . . . . . . . . Cutting-gas fittings . . . . . . . . . . . . . . . . . . . . . . . Changing gas bottles during operation . . . . . . . . . . 7 12 7 12 7 12 7 12 7 13 7 13 7 14 7 16 7 17 7 18 7 19 7 20 7 20 7 21 7 22 7 23 7 23 7 25 7 27 7 28 7 28 7 29 7 30 7 31 7 32 7 34 7 35 7 36 7 38 7 40 7 41 7 42 7 43 7 44
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7.5 7.5.1 7.5.1.1 7.5.1.2 7.5.1.3 7.5.2 7.5.3 7.5.3.1 7.5.3.2 7.5.4 7.5.4.1 7.5.4.2 7.5.4.3 7.5.4.4 7.5.4.5 7.5.4.6 7.5.4.7 7.5.4.8 7.5.4.9 7.5.4.10 7.5.4.11 7.5.4.12 7.5.5 7.5.5.1 7.5.5.2 7.6 7.6.1 7.6.1.1 7.6.1.2 7.6.2 7.6.2.1 7.6.2.2 7.6.2.3 7.6.2.4 7.7 7.8 Beam guidance system - optical components. . . . . Optical components . . . . . . . . . . . . . . . . . . . . . . . . Deflecting mirror . . . . . . . . . . . . . . . . . . . . . . . . . Adaptive optic (option) . . . . . . . . . . . . . . . . . . . . Cleaning the deflecting mirrors and lens in the cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning / replacing the deflecting mirrors . . . . . . . . Adaptive optic (option) . . . . . . . . . . . . . . . . . . . . . . Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring the characteristic curve . . . . . . . . . . . . Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the lens . . . . . . . . . . . . . . . . . . . . . . . . Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction of cutting heads . . . . . . . . . . . . . . . . Removing the lens holder . . . . . . . . . . . . . . . . . . . Removing the lens. . . . . . . . . . . . . . . . . . . . . . . . Cleaning lenses and mirrors . . . . . . . . . . . . . . . . . Cleaning in the case of light soiling . . . . . . . . . . . . Cleaning in the case of moderate soiling . . . . . . . . Cleaning in the case of heavy soiling . . . . . . . . . . . Cleaning in the case of stubborn dirt . . . . . . . . . . . Fitting the lens . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting the lens holder . . . . . . . . . . . . . . . . . . . . . Setting the focal point. . . . . . . . . . . . . . . . . . . . . . . Measuring the focal-point zero position using a single pulse (operating mode 0) . . . . . . . . . . . . . Measuring the focal-position reference setting (operating mode 1) . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tactile detection (option). . . . . . . . . . . . . . . . . . . . . Broken sensor in tactile detection system. . . . . . . . Repairing a sensor break . . . . . . . . . . . . . . . . . . . Converting adaptive optic 1 to a flat mirror . . . . . . . . Conversion procedure . . . . . . . . . . . . . . . . . . . . . Cooling circuit before converting to flat mirror . . . . Cooling circuit after converting to flat mirror . . . . . Commissioning after conversion carried out . . . . . . Circuit diagrams, drawings . . . . . . . . . . . . . . . . . . . Customer service information. . . . . . . . . . . . . . . . . 7 45 7 46 7 46 7 47 7 47 7 48 7 52 7 52 7 54 7 60 7 60 7 61 7 62 7 66 7 67 7 73 7 75 7 75 7 78 7 80 7 82 7 86 7 88 7 88 7 91 7 94 7 94 7 94 7 95 7 99 7 100 7 102 7 103 7 105 7 106 7 107
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8
8.1 8.1.1 8.1.2 8.2 8.2.1 8.2.2 8.3 8.3.1 8.4 8.4.1 8.4.2
Disposal
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating resources . . . . . . . . . . . . . . . . . . . . . . . . Components suitable for disposal . . . . . . . . . . . . . . Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal centers, authorities . . . . . . . . . . . . . . . . . Return to manufacturer. . . . . . . . . . . . . . . . . . . . . . Notification of government agencies and manufacturer 83 83 84 84 84 85 85 86 86 86
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Chapter 1
Product description
This chapter contains general information, product data and notes on fitted equipment. Further details are given in the order confirmation.
Operating instructions Bysprint_Kap01.fm
1-1
Product description
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1-2
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1.1
1.1.1
Product description
Introduction
Overall view
Fig. 1.1-1
Overall view of the laser cutting machine
A B C D E F
Laser machine Laser module Shuttle table system Control cabinets Exhaust air filter Cooling unit
1-3
Product description
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1.1.2
Intended use
The laser cutting machine is an industrial cutting and engraving tool for use with sheet metal made of the materials listed below. Operation of the laser cutting machine is manned. Automatic operation is possible with automation modules such as store and handling system.
Tab. 1.1-1
Standard materials and surface treatments
Material
Surface treatment protective film

a)
Structural steel thickness 1 to 10 mm Structural steel thickness 12 to 20 mm Rust and acid-resistant steel thickness 0.8 to 12 mm Aluminum thickness 1 to 8 mm Brass thickness 1 to 4.5 mm Titanium thickness 1 to 5 mm Copper thickness 1 to 3 mm
Stw 22 St 37-2 S235 JRG2 RAEX 420MC QSt 37-2 X5CrNi18 -10
galvanized
none
oiled
b)
AlMg3 CuZn40 Ti Cu
a) Structural steel, galvanized, thickness 1 to 3 mm b) Rust and acid-resistant steel with protective film, thickness 1 to 3 mm
The maximum thickness that can be cut for a material depends on the laser module used (see section 1.2.2.2 Sheet thicknesses that can be cut).
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Product description
The figures given in these operating instructions and the cutting parameters are based on the standard materials listed in Tab. 1.1-1. Other materials or material with a different specification may produce a poorer cutting result or reduce process stability.
Special extraction units or additional filters must be used when machining flammable materials or materials that produce toxic vaporization gases. Please obtain the relevant information from the manufacturer of the material concerned.
1.1.3
Safety precautions
Only those materials approved for the laser cutting machine must be machined. This information can be obtained from the order confirmation, and must be given to the owner's operating personnel.
Any change in the agreed intended use or the agreed general conditions without written approval by the manufacturer is at your own risk.
1-5
Product description
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1.1.4
Working positions
The machine is operated from the following working positions.
Fig. 1.1-2
Working positions for laser module 2200
A B
F C D
A B C D E F
Control cabinets Laser module Operating terminal Shuttle table console Shuttle table system Machining area
1-6
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Fig. 1.1-3 Working positions for laser module 3000
Product description
C B
A G D E F
A B C D E F G
Control cabinets Laser module Laser module control cabinet (MCS) Operating terminal Shuttle table console Shuttle table system Machining area
1-7
Product description
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1.1.5
Product labeling
Fig. 1.1-4
Type plates on the machine frame and cutting bridge
Type plate
Position
Machine frame Cutting bridge
A B C G
D E F H
A B C D E F G H
Machine name Job number Total weight of machine in kg Date of manufacture Machine serial no. Equipment number (technical ID number of the complete laser cutting machine) Maximum weight of a sheet in kg/m2 CE conformity mark
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Fig. 1.1-5 Type plate on the control cabinet
Product description
Type plate
Position
Control cabinet
A B G C H I L
D E F J K
A B C D E F G H I J K L
Machine name Job number Total weight of machine in kg Date of manufacture Machine serial no. Equipment number (technical ID number of the complete laser cutting machine) Mains voltage Mains frequency Electrical power Peak current Rated current CE conformity mark
1-9
Product description
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1.2
1.2.1
Product data
Specification
Cutting area X Y Cutting head travel Max. load-bearing capacity of shuttle table Z 3 000 mm 1 500 mm 70 mm 750 kg 120 inches 60 inches 2.75 inches 1 654 lbs
Positioning variancea) Positioning variancea) Traversing speed X/Y-axis, simultaneous Max. axis acceleration Max. cutting speed Max. laser power
0.1 mm 0.05 mm
140 m/min 8 m/s2 50 m/min 3 000 W
0.004 inches 0.002 inches

460 ft/min 26.25 ft/s2 164 ft/min 3 000 W
a) as per VDI/VDQ 3441. Measurement length 1 m (3.28 ft). The precision achieved for the sheet-metal part depends on the given material, its pre-treatment, overall sheet size and its temperature rise during cutting.
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1.2.2
1.2.2.1
Product description
Formats and thicknesses that can be cut

Sheet formats that can be cut Any sheet formats can be cut on the laser cutting machine up to the maximum dimensions specified for that machine.
Fig. 1.2-1
Maximum dimensions of a metal sheet
Length L
[mm] 3 000 [inches] 120 [mm] 1 500
Width B
[inches] 60
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Product description
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1.2.2.2
Sheet thicknesses that can be cut The thicknesses that can be cut vary according to the material, surface treatment and laser module used. Material Laser module 2200 W
Structural steel Rust and acid-resistant steel Aluminum Brass Titanium Copper Tab. 1.2-7 Tab. 1.2-8 Tab. 1.2-9 Tab. 1.2-10 Tab. 1.2-11 Tab. 1.2-12
3000 W
Tab. 1.2-7 Tab. 1.2-8 Tab. 1.2-9 Tab. 1.2-10 Tab. 1.2-11 Tab. 1.2-12
1.2.2.3
Tab. 1.2-1
Sheet thicknesses that can be cut, 2200 W

Material: structural steel, 2200 W laser module
Thickness
[mm] 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.0 8.0 10.0 12.0 15.0 [inches] 0.040 0.060 0.074 0.104 0.125 0.160 0.187 0.250 0.312 0.375 0.500 0.625 [Gauge No] 19 16 14 12 11 8 7 O2
Cutting gas:
Oxygen Nitrogen N2
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Tab. 1.2-2 Material: Rust and acid-resistant steel, 2200 W laser module
Product description
Thickness
[mm] 0.8 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.0 8.0 [inches] 0.031 0.040 0.060 0.074 0.104 0.125 0.160 0.187 0.250 0.312 19 16 14 12 11 8 7 [Gauge No] O2
Cutting gas:
Oxygen Nitrogen N2
Tab. 1.2-3
Material: aluminum, 2200 W laser module
Thickness
[mm] 1.0 1.5 2.0 3.0 4.0 5.0 6.0 [inches] 0.040 0.060 0.074 0.125 0.160 0.187 0.250 [Gauge No] 19 16 14 11 8 7 O2
Cutting gas:
Oxygen Nitrogen N2
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Product description
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Tab. 1.2-4
Material: brass, 2200 W laser module
Thickness
[mm] 1.0 2.0 3.0 [inches] 0.040 0.074 0.125 [Gauge No] 19 14 11 O2
Cutting gas:
Oxygen Nitrogen N2
Tab. 1.2-5
Material: titanium, 2200 W laser module
Thickness
Cutting gas:
Oxygen Nitrogen N2
Tab. 1.2-6
Material: copper, 2200 W laser module
Thickness
Cutting gas:
Oxygen Nitrogen N2
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1.2.2.4
Tab. 1.2-7
Product description
Sheet thicknesses that can be cut, 3000 W

Material: structural steel, laser module 3000 W
Thickness
[mm] 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.0 8.0 10.0 12.0 15.0 20.0 [inches] 0.040 0.060 0.074 0.104 0.125 0.160 0.187 0.250 0.312 0.375 0.500 0.625 0.750 [Gauge No] 19 16 14 12 11 8 7 O2
Cutting gas:
Oxygen Nitrogen N2
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Product description
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Tab. 1.2-8
Material: Rust and acid-resistant steel, laser module 3000 W
Thickness
[mm] [inches] [Gauge No] Oxygen O2
Cutting gas:
Nitrogen N2 Compressed aira) Air
1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.0 8.0 10.0 12.0
0.040 0.060 0.074 0.104 0.125 0.160 0.187 0.250 0.312 0.375 0.500
19 16 14 12 11 8 7
a) Available as an option
Tab. 1.2-9
Material: aluminum, laser module 3000 W
Thickness
[mm] 1.0 1.5 2.0 3.0 4.0 5.0 6.0 8.0 [inches] 0.040 0.060 0.074 0.125 0.160 0.187 0.250 0.312 [Gauge No] 19 16 14 11 8 7 O2
Cutting gas:
Oxygen Nitrogen N2
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Tab. 1.2-10 Material: brass, laser module 3000 W
Product description
Thickness
[mm] 1.0 1.5 2.0 3.0 [inches] 0.040 0.060 0.074 0.125 [Gauge No] 19 16 14 11 O2
Cutting gas:
Oxygen Nitrogen N2
Tab. 1.2-11
Material: titanium, laser module 3000 W
Thickness
[mm] 1.0 2.0 3.0 5.0 [inches] 0.040 0.074 0.125 0.187 [Gauge No] 19 14 11 7 O2
Cutting gas:
Oxygen Nitrogen N2
Tab. 1.2-12
Material: copper, laser module 3000 W
Thickness
Cutting gas:
Oxygen Nitrogen N2
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Product description
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1.2.2.5
Dust extraction unit For details, please refer to the manufacturer's operating instructions for the dust extraction unit (filed in Supplier documentation).
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1.3
1.3.1
Product description
Equipment
Design versions
The laser cutting machine is designed for both single parts and mass production. For maximum single-part size or cutting plan size see section 1.2.2.1 Sheet formats that can be cut.
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Product description
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Chapter 2
Safety regulations
This chapter describes the safety precautions for the protection of personnel and machine. It also explains the symbols and warnings used in these operating instructions. Nevertheless, despite all safety precautions, there are still risks involved in using the product. Personnel must be aware of these risks at all times. Anyone working with the product must first have read and understood the safety regulations.
2-1
Safety regulations
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2-2
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2.1 Warnings and symbols
Safety regulations
DANGER
Immediate risk of severe injuries or death.
WARNING
Potentially dangerous situation leading to severe injuries or death
CAUTION
Potentially dangerous situation leading to minor injuries or damage to property.
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Safety regulations
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Indicates technical features of the machine or control unit that the operating and maintenance staff must be aware of.
Indicates useful tips on specific topics.
1. 2. 3.
Explains a handling sequence or the steps involved in an activity.
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2.2 Product safety
Safe working is only guaranteed if:

Safety regulations
the operating instructions and warning signs are observed personnel operating, maintaining and repairing the machine have been trained on the machine where several persons are involved in the operation, responsibilities are clearly established and complied with unauthorized persons are kept clear of the work area any working practices that compromise safety are avoided faults that impair safety are rectified immediately maintenance intervals are observed
2.2.1
Safety devices and monitoring equipment

The safety devices and monitoring equipment are provided for personnel protection and must not be dismantled, bridged or bypassed. The machine components are driven automatically by electrical and pneumatic drives. It can be dangerous to remain within the area bounded by the protective devices whilst the machine is in operation.
2.2.2
Safety-conscious working
Work on mechanical, electrical and gas-system equipment must be carried out solely by skilled staff or under their supervision. Improper use and operation can be dangerous and may damage the machine. For this reason it is forbidden to:

use the machine to carry people machine unauthorized materials remain inside the danger zone. It is the duty of the operator to ensure that no unauthorized person is in the danger zone.
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Safety regulations
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2.3
Danger zones
DANGER
Remaining within a danger zone It is prohibited to remain within the machining area while the laser cutting machine is operating. Keep unauthorized persons away from the operating area.
Do not obstruct access to the EMERGENCY STOP buttons. Accidents are most likely to happen during loading and unloading of the shuttle table or stock transfer table or when the tables are moving in and out.
CAUTION
Risk of crushing during loading and unloading of the shuttle table or stock transport table Wear protective gloves and steel-capped boots
The laser cutting machine must be arranged so there is space around it to allow unrestricted access to the shuttle table for bringing in and taking away material.
WARNING
Risk of crushing when the shuttle table or stock transport table is moving in and out When moving the shuttle table or the stock transfer table, ensure that there is no one in the area of movement.
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2.3.1 Warning and advice signs
Safety regulations
Signs must be permanently affixed and easily legible. Signs must be replaced if they are very worn or no longer legible. Do not change the position of the signs when replacing them. The position of each of the signs is shown in chapter 5 Operation and chapter 7 Repair.
Fig. 2.3-1 Warning and advice signs
Symbol
Description
High voltage warning
Position
see laser module operating instructions
Laser radiation warning
Cutting head Laser module (see laser module operating instructions)
Focal length of cutting head in inches
Cutting head
Electrical voltage warning
Control cabinets
Wear a light breathing mask
Dust extraction unit
Warning notice
Dust extraction unit
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Safety regulations
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2.4
Requirements for personnel

Training of operators takes place after the system has been commissioned by the manufacturer's service staff. Please see the order confirmation for further details. The machine owner is responsible for ensuring that operating staff have the correct level of training. A selection of optional training courses are offered for the machines. Further information is available from the Customer Training Center.
2.4.1
Users
All persons who work with or at the machine are designated as a user in these operating instructions. Requirements placed on users vary depending on the actions they must perform. The following user categories are defined:
Owner The term owner is used to describe the signatory to the agreement with the manufacturer, or their representative. The owner is authorized as legally-binding signatory to agreements. He/she procures the laser cutting machine and ensures that it is used correctly and in accordance with regulations.
Operator The term operator refers to a person trained to operate the machine. The operator operates and looks after the machine in normal operation. Relevant training of the operator includes participation in a training course by the manufacturer.
Works engineer Works engineer refers to a skilled person with training in mechanical or electrical engineering. The works engineer maintains the machine, services it and carries out minor repairs as necessary. Relevant training of the works engineer includes participation in a training course by the manufacturer.
2.4.2
Qualifications
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Safety regulations
Only persons instructed and trained by the owner may work on the machine. Personnel are responsible for third persons in the work area. Personnel still requiring training, instruction or teaching are only allowed to work at machine under constant supervision by an experienced person.
2.4.3
Responsibility
Responsibilities for the various activities performed on the machine (operation, setup, maintenance, repair) must be clearly specified and observed. Undefined responsibilities constitute a safety risk. The owner must provide the operator and works engineer with access to the operating instructions, and ensure that they have been read and understood.
2.4.4
Personal protection equipment

Where technical or organizational measures are unable to rule out health risks in full or in part, the owner must provide the operating and maintenance staff with the required personal protection equipment.

Steel-capped boots Protective gloves Laser safety goggles Breathing mask
Personal protection equipment is not provided with the laser cutting machine.
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Safety regulations
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2.5
2.5.1
Product-specific hazards
Laser radiation hazards
A detailed description of the operating modes is given in section 4.4 Operating modes of the laser cutting machine.
2.5.1.1
Normal mode In normal operating mode the laser cutting machine corresponds to a Class 1 laser (fully screened laser radiation). All covers must be fitted. Laser radiation does not pose a risk to eyes or skin if the laser cutting machine is used correctly. The safety door protects you from reflected and stray radiation. There is no need to wear safety goggles to provide protection from reflected and stray radiation.
It is recommended, however, that people wear goggles with an antidazzle filter when exposed to the cutting beam for a prolonged period.
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2.5.1.2 Service mode
Safety regulations
The laser cutting machine is in Service mode when the machining sequence in Normal mode has been interrupted. It makes no difference whether the interruption is for adjustment and inspection tasks, loading and unloading, or is to enable cleaning and maintenance work to be carried out. The machine enters Service mode at the moment when non-contact safety devices (e.g. light barriers) are crossed, safety door(s) are opened or permanent safety devices are removed. Normal mode is restored when the machine is once more ready for use, the safety devices are reset and the process is resumed.
WARNING
In service mode the laser cutting machine corresponds to a Class 4 laser (not fully screened laser radiation). The direct laser beam and reflected or stray radiation is hazardous for eyes and skin.

Fence off laser area Cover or remove reflective objects. Remove combustible objects. Avoid producing explosive solvent fumes Wear laser safety eyewear
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Safety regulations
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2.5.1.3
Direct laser beam
WARNING
Direct laser beam In service mode the laser cutting machine corresponds to a Class 4 laser. The direct laser beam can cause life-threatening injuries to the whole body.
The following points must be observed when working with the laser cutting machine:

Never expose yourself to direct laser radiation. Never modify the fastenings used on optical components. Follow all directions in the operating instructions.
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2.5.1.4 Reflected and stray radiation
Safety regulations
Avoid exposing eyes or skin to reflected or stray radiation. Laser safety glasses must be worn during service mode. These laser safety goggles offer sufficient protection against reflected and stray radiation. Use laser safety goggles of safety grade L5 (for viewing diffuse laser light only OD5+ at 10 600 nm) as per standard EN 207 (DIN 58215). These safety glasses can be obtained from specialist stores or from the manufacturer of the laser cutting machine.
Fig. 2.5-1 Laser safety goggles classed as safety grade L5 (as per EN 207)
Standard designa)
Version for spectacle wearersa)
a) Not included in deliverables
Laser safety goggles are not provided with the laser cutting machine.
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Safety regulations
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2.5.2
High-voltage hazard
A high voltage of 25 000 volts is generated in the laser module. In addition, electrical storage devices such as capacitors store large amounts of energy, which can lead to dangerous electric shocks.
WARNING
High voltage 25 000 VDC Voltages greater than 50 V and currents greater than 20 mA are dangerous and can cause death. Work on high-voltage components must be performed solely by the manufacturers service personnel.
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2.5.3 Electrical hazards
Safety regulations
WARNING
Dangerous electrical voltage Improper or negligent handling of electrical equipment or installations can cause severe injuries or death. Work on electrical equipment or installations must be performed solely by skilled staff or under their supervision. The following points must be observed when working with electrical equipment or installations:

Only use original fuses with the specified amperage. In the event of a fault in the electrical supply, switch off machine immediately. Electrical components undergoing maintenance work must be disconnected from the electrical supply unless otherwise specified. First check that isolated parts are de-energized, then ground and shortcircuit them and also insulate adjacent live (hot) parts. Inspect electrical equipment regularly. Rectify faults such as loose connections or singed cables immediately. When working on live parts, a second person must be present who can operate the EMERGENCY STOP button or power switch in an emergency. Fence off the work area with a red-and-white safety chain and a warning sign. Always use insulated tools.
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Safety regulations
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2.5.4
Hazards arising from the pneumatic system

Inspect loads, valves and hoses regularly for leaks.
WARNING
Risk of injury from flying parts and escaping air Do not perform any assembly or disassembly work, or unscrew or tighten any screw connections, while the system is under pressure. Depressurize sections of systems to be opened before starting maintenance and repair work.
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2.5.5
2.5.5.1
Safety regulations
Hazards arising from gas, dust, vapors, smoke

Gas supply If there are leaks in the gas supply, escaping oxygen can combine with a naked flame to cause deflagrations. Check the lines on the gas supply are connected correctly.
WARNING
Risk of explosion Do not oil or grease oxygen connections. This could lead to an explosion from a chemical reaction.
Further information on the gas supply and its hazards is given in the Laser module operating instructions.
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Safety regulations
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2.5.5.2
Extraction unit The dust and fumes produced during cutting are extracted from the cutting area by a dust extraction unit. The dust is filtered out. Check that the dust extraction unit is running and operating at the correct extraction rate if any smells are noticed during cutting.
WARNING
Risk of fire If extraction levels are inadequate, there is a risk of gases and cutting residues remaining in the extraction ducts and catching fire there.

The extraction rate of the extraction unit must always equal that given in the specification. Observe maintenance intervals as per maintenance plan Do not let stubbed cigarettes or objects that are still alight get into the extraction chambers or piping of the dust extraction system. When changing from steel to aluminum or vice versa, the dust must be kept strictly separate. A separate dust hopper must be used for each material. For flammable, potentially explosive and self-igniting dusts, empty the hopper frequently to minimize the amount of dust held in it.
Ensure that there is sufficient ventilation when working in confined spaces.
If the extracted air is released outdoors, local regulations must be observed.
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2.5.6
2.5.6.1
Safety regulations
Hazards associated with handling the optical system

General information The output coupler in the laser module and the lens in the cutting head are made of zinc selenide. When intact, these components pose no danger. However, toxic fumes are generated if thermal decomposition of a lens occurs. In addition, damage to the coating allows the escape of thorium fluoride, which is slightly radioactive.
2.5.6.2
Warnings in case of fire or accident Zinc selenide is not flammable. Thermal decomposition sets in at temperatures above 400 C, however, at which point toxic fumes and dust particles are released. Wait until dust has settled before starting cleaning work. Do not stir up dust.
CAUTION
Toxic fumes and dust particles Wear a breathing mask and protective gloves during cleaning work. Defective lenses must be returned to the manufacturer of the laser cutting machine in a sealed container. Always ventilate the working environment thoroughly after any damage.
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Safety regulations
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2.5.7
Lubricants, coolants and cleaning agents

When handling working materials, in particular oils, grease and other chemical substances, observe the product's safety regulations from the manufacturer. The supplier documentation folder contains the relevant information.

Avoid prolonged, intensive skin contact with these materials Wear protective gloves, safety glasses and an apron if required Apply a suitable protective skin cream before starting work Change any oil-soaked clothing immediately Do not keep oily cleaning rags in clothing
CAUTION
Poisoning Inhaling oil vapors or oil fumes can lead to nausea and sickness. Avoid contact with oil vapors and oil fumes. Ensure adequate ventilation.
WARNING
Risk of explosion Do not allow sprays or spray cans to come into contact with hot objects, machine parts, gases or vapors. Place working materials on suitable surfaces (e.g. tool trolley).
The owner of the machine is responsible for the proper disposal of lubricants, coolants and cleaning agents and of materials contaminated with these products.
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2.6 Additional hazards
Safety regulations
Unauthorized modifications or additions to the machine are prohibited for safety reasons. It is not permitted to make changes to programmable controllers. Machines must not be integrated with existing systems without the approval of the manufacturer.
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Safety regulations
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2.7
Emergency information
In the event of personal injury

take first-aid measures call a doctor inform immediate supervisor observe national and company regulations
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Chapter 3

This chapter provides information on the position and functions of the various hardware units. The safety and monitoring devices fitted on the product are also described in greater detail.
3-1
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3-2
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3.1
Fig. 3.1-1
Overall view
Laser cutting machine with laser module 2200
A B C D E
Operating terminal Control cabinets Laser machine Laser module Shuttle table system
F G H I J
Shuttle table console Safety fence Dust extraction unit Cooling unit Light barrier
3-3
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Fig. 3.1-2
Laser cutting machine with laser module 3000
A B C D E F
Operating terminal Control cabinets Laser machine Laser module Laser control cabinet (MCS) Shuttle table system
G H I J K
Shuttle table console Safety fence Cooling unit Dust extraction unit Light barrier
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3.2
Safety and monitoring devices
Safety devices that are assigned to an automation module or store system but connected to the laser cutting machine are described in the relevant operating instructions.
3.2.1
EMERGENCY STOP circuit

An EMERGENCY STOP situation can be initiated by an EMERGENCY STOP button on the laser cutting machine or by an internal EMERGENCY STOP from the laser controller.
Fig. 3.2-1
EMERGENCY STOP button
EMERGENCY STOP buttons are fitted:

on the operating terminal on the hand-held controller on the shuttle-table console on the front panel of the laser module 2200 on the laser module 3000 control cabinet
Pressing an EMERGENCY STOP button disconnects all electrical loads from the supply. This does not apply to the controller and the vacuum pump of the loading system (if these are fitted in the laser cutting machine). Operation of the machine can only be resumed once the emergency situation has been cleared and all defects and damage have been rectified (see section 5.2.5 Restarting after an EMERGENCY STOP).
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3.2.2
Light barrier
The light barrier monitors the danger zones around the shuttle table and the swivel loader. As soon as the light beam is interrupted, the drives of the handling systems in question are switched off. The controller stores the last program step.
Fig. 3.2-2
Light barrier
A C
A B C
Laser machine Shuttle table system Safety light-barrier
The light-barrier control states are indicated by the Reset button on the shuttle table console. Reset button
Button flashes
Control state
The light-barrier safety circuit has been broken. A prompt to press the Reset button appears in the status bar of the user interface The light-barrier safety circuit is in working order and enabled.
Button illuminated
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3.2.3 Laser machine safety door
The whole machining area is enclosed by covers and a safety door, which protect the machining area during the work process. A large window ensures a good view of the work piece. The safety door is monitored by a safety switch.
DANGER
Standing within a danger zone Moving parts such as the cutting bridge, cutting carriage or Z-axis pose a risk of crushing which can be fatal. No-one is permitted within the machining area when the safety door is closed.
Fig. 3.2-3 Safety door and covers
The safety door must be locked before a work process can be started on the laser cutting machine. The safety door protects against:

direct laser radiation reflected laser radiation splashes of material during cutting risk of crushing by moving parts
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3.2.4
Safety devices
Protective measures have been put in place at danger spots according to the safety regulations that apply to the machine. It is the operators responsibility to install the appropriate barriers and to check them regularly for proper functioning. It is only permitted to remove, modify or take out of service protective and safety devices if this is absolutely necessary for transport and repair. Suitable precautions must be taken for such work to protect persons and avoid damage or breakage to structural parts. Before putting the system into operation, it must be ensured that all protective devices are in place and that all danger zones are protected according to local safety regulations.
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3.3 Laser module
The laser beam is generated in the upper section of the laser module. The turbine, vacuum pump, gas supply unit, water distributor for the cooling unit and part of the controller are located in the lower section.
Fig. 3.3-1 Laser module 2200 / Laser module 3000
A B C
2200 W laser module 3000 W laser module Control cabinet (only for 3000 W laser module)
Further details on the laser module are given in the operating instructions for the type concerned.
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3.3.1
Laser control cabinet (only for 3000 W laser module)

The laser control cabinet contains the electrical power supply, the laser gasmix unit and the microprocessor controller (MCS).
Fig. 3.3-2
Laser control cabinet (MCS)
Please refer to the operating instructions for the 3000 W laser module for further details on the laser control cabinet.
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3.4
3.4.1
Cabinet base
Control cabinets
The CNC, STL and supply cabinets are mounted on the cabinet base. The control cabinets are joined together. Two air-conditioning doors keep the temperature inside at an optimum level.
Fig. 3.4-1
Control cabinets
A B
STL cabinet CNC cabinet
3.4.1.1
STL cabinet The controller for the table interchange and safety functions is located in the STL cabinet1). An air-conditioning unit is fitted to the cabinet door. The main power switch for the laser cutting machine is located on the STL cabinet. When switched off, it can be locked with a padlock.
1) STL is the abbreviation of the German "Steuerung Tisch Laser" = "Laser table controller"
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3.4.1.2
CNC cabinet The CNC1) cabinet contains the CNC controller. The CNC controller converts cutting plans and process parameters into axis movements. It controls the path of the laser beam over the work piece by means of a combination of movements of cutting bridge, cutting carriage and Z-axis. It automatically adjusts the travel speed and laser power to suit the contours of the parts geometry. The machine works through the programs independently of program input. The operating terminal is available for creating and editing geometries while the machine is in the process of executing a program. The computer for controlling the laser cutting machine is located on the rear side of this cabinet.
1) CNC = Computer Numeric Control
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3.4.2 Computer
The computer is housed in the supply cabinet. The drives can be accessed behind a flap in the side wall. The user interface on the operating terminal provides system visualization.
Fig. 3.4-2 Computer with drives for removable disks
B C D
A B C D
Supply cabinet CD RW drive ZIP drive 31/2 inch disk drive
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3.4.3
Supply unit
The supply unit is located on the cabinet base. It supplies the laser cutting machine with compressed air and filtered air. The filtered air is provided by an air drier1). The supply unit also contains the oil container for the Crossjet and the pressure regulation and gages for the cutting gas.
Fig. 3.4-3
Position of the supply unit
1) The air filter contains two adsorber units. These work reciprocally, i.e. the air is filtered and dried in one element whilst the other regenerates itself.
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Fig. 3.4-4 Supply unit
A H B C D E K F I
G L
A B C D E F G H I J K L
Pressure reduction, beam-path ventilation 2 bar Water filter / pre-filter Compressed-air connection Filter Pressure reduction, main air supply 6 bar Cutting gas pressure gages (N2/O2) Oil container for Crossjet Pressure governor Active charcoal filter Electrical connection Fault indicator for air drier Air drier for filtered air supply (Ultrapac 2000)
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3.4.4
Netbox
The Netbox (B) is housed in the supply cabinet (A). It contains a router and a hub.
Fig. 3.4-5
Position of Netbox
View from the front
View from the rear
A B
Supply cabinet Netbox with router and hub
The Netbox is used for:

creating a clear interface between the machine and the customer network. creating a self-contained, unchanging network that can be handled by the service engineer.
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3.5 Operating terminal
The operating terminal is fixed to the machine frame by a swivel arm. It can be moved horizontally about two axes and is fixed using clamps. The operating terminal includes an EMERGENCY STOP button and the Reset button for enabling the safety circuit.
Fig. 3.5-1 Operating terminal
The machine can be operated via the keyboard, the mouse or the TFT Touch Screen. The operating terminal is described in section 4.2.3 Operating terminal.
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3.5.1
Hand-held controller
The hand-held controller is located in a holder beside the operating terminal. The hand-held controller includes an EMERGENCY STOP button. The controls are described in section 4.2.4 Hand-held controller.
Fig. 3.5-2
The hand-held controller is needed to perform the following tasks:

Setting-up work Operating the laser cutting machine in normal operating mode Cutting off leftover sheets (separating cuts) Trial cuts for working out parameters Alignment of the laser beam
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3.6 Base frame
The machine is constructed so that the machining area is completely enclosed. This ensures safe operation and optimum extraction of cutting emissions.
WARNING
Risk of fire Production of flammable or explosive mixtures. The dust hopper must be emptied when changing material from steel to aluminum or vice versa.
3.6.1
Dust extraction system

The cutting area is divided into a number of extraction chambers. The relevant extraction flaps are opened depending on the given position of the cutting head. The extracted air is passed through a dust removal system and cleaned to remove contaminants.
Fig. 3.6-1
Base frame with extraction system
WARNING
Toxic fumes emitted when cutting plastics The fumes given off on combustion are highly toxic. They cannot be completely removed by the extraction system. Plastics must not be cut on laser cutting machines (without special extraction devices)
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3.6.2
Small-parts trays
Small parts that fall through the support grate reach the small-parts trays via special guides. These trays have handles so that they can be pulled out for emptying. There are four small-parts trays under the base frame of the laser cutting machine, and optionally four more under the shuttle table.
Fig. 3.6-2
Small-parts trays
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3.6.2.1 Pneumatic table lock
A pneumatic table lock fixes the shuttle table in the machining position to ensure exact positioning of the shuttle table during machining.
Fig. 3.6-3 Position-fixing system for the shuttle table
A B
Table lock Locking surface
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3.7
Cutting bridge
The cutting bridge moves along the Y axis. It carries the cutting carriage, which moves along the X axis. The laser beam is deflected from the Y-axis onto the X-axis by the deflecting mirror mounted on the end of the cutting bridge.
Fig. 3.7-1
Cutting bridge
Y+
B
X+
Y-
X-
A B
Cutting bridge Cutting carriage
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3.8 Cutting carriage
The cutting carriage carries the Z-axis, the connection box, the assist-gas valves and the Crossjet (option).
Fig. 3.8-1 Cutting carriage
D Z+ E
Z-
A B C D E
Connection box Adjustment knob, nozzle cooling Cutting carriage Z axis Crossjet
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3.8.1
Connection box
All the lines and connections for the cutting carriage are housed in the connection box.
Fig. 3.8-2
Connection box (safety cover removed)
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3.8.2 Nozzle cooling
When cutting reflective materials such as aluminum and stainless steel, the nozzle is heated by reflections. This can impair the capacitive detection function (the nozzle clearance height changes). In addition, nozzle cooling prevents soiling of the cutting head from fumes produced during low-pressure cutting of steel.
Fig. 3.8-3 Nozzle cooling
The nozzle is cooled by the air flow (A). The adjustment knob (B) can be used to adjust the pressure.
A
Fig. 3.8-4 Adjustment knob, nozzle cooling
A B
Air stream Adjustment knob, nozzle cooling
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3.8.3
Z axis
The Z-axis is the final section of the beam guidance system. It raises the cutting head above the work piece to allow traversing, and ensures that the nozzle clearance height remains constant even when the work piece is uneven.
Fig. 3.8-5
Z-axis design
A B
Z D
ZE
A B C D E
Crossjet Cover for tactile detection connection (option) Cutting head clamping device Cutting head Nozzle
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3.8.4 Cutting head
The laser beam is focused by the lens in the cutting head to achieve the required power density. The nozzle is centered with respect to the laser beam using the two centering screws. The nozzle directs the cutting gas onto the work piece. During the cutting process this drives molten material out of the kerf and prevents the focusing lens from being damaged by splashes of slag.
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3.8.4.1
Fig. 3.8-6
Design
Cutting head (dismantled)
A F B C G
H D I
E J
A B C D E F G H I J
Focal-position scale (6 mm divisions) Locking screw (for locking the focal-position adjusting ring) Measured focal-point zero position / focal position reference setting Focal length in inches Centering screws for nozzle centering Focal-position adjusting ring Scale on adjusting ring (0.1 mm divisions) Clamping device pin (for Z-axis attachment) Anti-rotation element Nozzle
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3.8.4.2 Application
In order to obtain optimum cutting results for a range of material thicknesses, two different focal lengths of 5 or 7.5 are available. The table below shows the possible applications.
Tab. 3.8-1 Suitable applications for the cutting heads
Focal length
Focus Length
Materials
Application Thickness
[mm]
Gas
Gas pressure
[bar]
[inches] 5.0
[m] 130
[mm] 0.6 Structural steel (St 37) Galvanized structural steel Rust and acid-resistant steel (1.4301) Aluminum alloy
3 4 3 4 20 12 8
O2 N2 N2 N2 O2 N2 N2
5 12
8 ... 16 8 ... 16
7.5
190
1.4
Structural steel (St 37) Rust and acid-resistant steel (1.4301) Aluminum alloy
0.5
8 ... 20 8 ... 20
The lens diameter is the same for both focal lengths: 1,5 = 38 mm.
Section 5.6.2 Changing the cutting head describes how to change the cutting head.
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3.8.4.3
Comparison of focal lengths The focal length affects the machining as follows:
Fig. 3.8-7
Comparison of focal lengths (approximate dimensions)
Lens
0.6 mm
5.0
130 m
1.4 mm
190 m
Short focal length 5

small focus diameter higher intensity at focal point higher cutting speed with thin
Long focal length 7.5

larger focus diameter lower intensity at focal point slower cutting speed with thin
sheets
sheets sheets
thick sheets cannot be cut short Rayleigh length sensitive to focal position narrow cut gap lens closer to work piece (soiling) fine cut
higher cutting speed with thick long Rayleigh length not sensitive to focal position wider cut gap lens further away from work piece rough cut
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3.8.5 Nozzles
The shape and diameter of the nozzle depend on:

Fig. 3.8-8
Material type Material thickness Cutting process (fusion cutting / gas cutting) Type of detection
Nozzle mounting on cutting head
A B
Nozzle Plate
The nozzle to be used can be found in the relevant parameter set. Section 5.6.3 Changing the nozzle and section 5.6.4 Centering the nozzle describe how to replace and center a nozzle. The range of nozzles available is the result of optimizing these factors.
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3.8.5.1
Range of nozzles available
Tab. 3.8-2
Nozzle shapes and their applications
Nozzle shape
Area of use
Normal pressure Tactile detection unit All applications for gas cutting (O2) Structural sheet steel up to 20 mm thick
Labeling
10 12 15 17 20 25
Part no.
3-01894 3-01895 3-01896 3-01897 3-01898 3-04272 3-01899 3-01900 3-01901 3-01902 3-01903 3-04276 3-01905 3-01906 3-01907 3-01908 3-01909 3-04274 3-01910 3-01911 3-01912 3-01913 3-01914 3-03854 3-06112
High pressure Tactile detection unit Capacitive detection All applications for fusion cutting (N2) Aluminum and chromium steel Sheets up to 10 mm thick Normal pressure Capacitive detection All applications for gas cutting (O2) Structural sheet steel 0.5 to 25 mm thick
H10 H12 H15 H17 H20 H25 K10 K12 K15 K17 K20 K25
High pressure Capacitive detection Universal nozzles for all applications Steel up to 25 mm (O2 and N2) Stainless steel up to 12 mm (N2) Aluminum up to 8 mm (N2) Various materials (O2 and N2)
HK10 HK12 HK15 HK17 HK20 HK25 HK30
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Nozzle shape Area of use
Double nozzlea) Capacitive detection Structural sheet steel 45 mm (O2) Structural sheet steel 68 mm (O2) Structural sheet steel 1012 mm (O2)
Labeling
Part no.
NK10-15 NK12-15 NK15-15 NK17-15 NK20-15 NK25-15 NK25-20 NK30-17 NK30-20
3-16058 3-16059 3-16060 3-14317 3-14318 3-14319 3-16256 3-16061 3-16257
Structural sheet steel 15 mm (O2) Structural sheet steel 1618 mm (O2) Structural sheet steel 20 mm (O2) Aluminum 58 mm (N2) Structural sheet steel 25 mm (O2) Aluminum 1012 mm (N2)
a) Not suitable for cutting with CutControl
3.8.5.2
Labeling of nozzles H N K High pressure (up to 20 bar) Double nozzles Capacitive detection
10 12 15 17 20 25 30
Nozzle diameter 1.0 mm Nozzle diameter 1.2 mm Nozzle diameter 1.5 mm Nozzle diameter 1.7 mm Nozzle diameter 2.0 mm Nozzle diameter 2.5 mm Nozzle diameter 3.0 mm
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3.8.5.3
Normal pressure (tactile detection) Serial no.
1 20
3.8.5.4
Nozzle diameter 2.0 mm
High pressure (tactile and capacitive detection) High pressure H 20 Nozzle diameter 2.0 mm
3.8.5.5
Normal pressure (capacitive detection) Capacitive detection K 10 Nozzle diameter 1.0 mm
3.8.5.6
High pressure (capacitive detection) High pressure H K 17 Nozzle diameter 1.7 mm Capacitive detection
3.8.5.7
Double nozzles (capacitive detection) Double nozzle Capacitive detection N K 15-10 Nozzle diameter 1.0 mm (inner part) Nozzle diameter 1.5 mm (outer part)
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3.8.6 Nozzle cleaning
A brass brush is fitted on the base frame. It cleans the nozzle head as the nozzle passes over. Nozzle cleaning can be performed automatically after each work cycle, or manually via the Service function of the user interface.
Fig. 3.8-9 Cleaning brush
3.8.6.1
Application Nozzle cleaning is suitable for the following materials:

Structural steel (all thicknesses) Rust and acid-resistant steel (all thicknesses), in particular for rust and acid-resistant steels with protective film Aluminum up to 3 mm
When cutting thicker aluminum sheets, the splashes adhere too firmly to the nozzle. They must be removed manually using a brush or one's hand.
CAUTION
Risk of burns There is a risk of burns when cleaning the nozzle by hand. Wear protective gloves.
3.8.6.2
Replacement The brush no longer cleans effectively once it is full of splashes of metal, and must be replaced.
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3.8.7
3.8.7.1
CutControl (option)
Design and operation CutControl monitors the cutting process during fusion cutting1) of structural steel and rust and acid-resistant steel. The light reflected from the metal sheet during cutting is deflected via an annular mirror and measured by silicon photodiodes. The mirror and photodiodes are integrated in the Z-axis. The CNC controller processes the measurement signals and monitors the cutting process.
Fig. 3.8-10
Cross-sectional diagram of machining head with CutControl
B C
D E A B C D E Photodiode Deflecting mirror Cutting head Reflected light Work piece
The CutControl cutting head (5 and 7.5) can be fitted and used instead of the conventional cutting head. This cutting head only differs externally from a conventional cutting head by its CutControl sticker. It is still handled and adjusted in the same way (e.g. nozzle changing, centering, focal position etc.).
The machine must be fitted with special hardware and software in order to use CutControl.
1) Cutting gas: nitrogen (N2)
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Piercing, pulsing and engraving are now monitored. CutControl is not activated until after the lead-in acceleration. Any deterioration in the quality of the cutting process is detected from a change in the measurement signals, and regulated by the following control functions.
Tab. 3.8-3 Control functions
Control function
Feed rate reduction
Description
If the signal reaches the alarm or plasma threshold then the feed rate is reduced in steps to a predefined percentage level. This reduction continues until the signal falls below the alarm or plasma threshold or until the maximum reduction has been made. The reduced feed rate then remains constant during the Length of time at reduced feed rate. If the alarm stops or the plasma goes out then machining is accelerated again to the original set feed rate (value in cutting parameters).
Stop feed-rate
If the signal no longer drops below the alarm or plasma threshold, or if the stop threshold is exceeded, the feed is stopped and the cut terminated. After machining is stopped and the cut terminated, the head moves back by a specific distance (but no further back than the previous start of cut) and the cut is repeated. The number of re-trace cuts is limited to a maximum value per contour section, after which a normal HALT function is triggered. This prevents uncontrolled endless repetition during imperfect cutting conditions.
3.8.7.2
Start-of-cut piercing using CutControl Piercing in structural steel (cutting gas: oxygen O2) is programmed by default as pulsed piercing (CPP). The piercing process is monitored by CutControl. Movement along the contour starts immediately after the piercing cut is made. In structural steel (cutting gas: oxygen O2), the procedure has the following advantages:

high process reliability short piercing time
For further information see Cutting technology.
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3.8.8
Crossjet (option)
The Crossjet sprays a mixture of air and oil. This prevents the molten material from adhering to the work-piece surface. In addition, it reduces the heat generated during piercing and the size of the piercing crater. The Crossjet can be used in two operating modes:

Oil mist Cross-blow facility
Fig. 3.8-11
Crossjet in working position
B E C
D F F G
A B C D E F G
Cutting head Supply connection Fixing screw Crossjet Set screw for adjusting amount of air Retaining screw Set screw for adjusting amount of oil
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3.8.8.1 Application (without CPP)
The Crossjet should be used for steel and aluminum with a thickness of 6 mm or more. 3.8.8.2 Oil to be used Tab. 6.3-3 shows the oil to be used. 3.8.8.3 Topping up with oil Section 7.4.6.4 Crossjet oil container, topping up with oil explains how to top up the Crossjet with oil. 3.8.8.4 Working and parked position To avoid unnecessary soiling, the unit can be kept in a protected parked position when not in use.
Fig. 3.8-12 Crossjet working and parked position
B A
Working position
Parked position
Suspend the Crossjet unit from (B) and secure with screw (A)
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3.8.8.5
Quantity of oil sprayed The thickness of the oil film depends on the flow rate, the nozzle diameter and the duration of the spraying process.
Fig. 3.8-13
Adjusting the flow rate
A B A B
Use setscrew (A) to regulate the flow rate. First undo the locking screw (B). The flow rate is factory-set to the maximum rate. 3.8.8.6 Cross-blow facility In this operating mode, after the initial piercing cut, a blast of compressed air blows away sideways the material that has been forced upwards. This reduces the adhesion of material to the work piece and nozzle. Enable the Cross-blow after piercing function in the cutting parameters.
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3.8.9 Sensing
The nozzle must be at a constant distance from the workpiece in order to achieve optimum machining quality. The nozzle clearance height is set in the cutting parameters. There are two options available for measuring the distance between the nozzle and the work piece:

capacitive detection tactile detection (optional)
The distance between nozzle and workpiece is adjusted to the preset value by moving the Z-axis.
Both forms of detection cannot be used simultaneously. The tactile detection unit must be removed after use.
3.8.9.1
Capacitive detection In capacitive detection, the electrical capacitance between nozzle and work piece is measured. It can therefore only be used for electrically conducting materials. The capacitive detection system is integrated in the Z-axis.
Fig. 3.8-14
Capacitive detection
X The nozzle and work piece together form the two plates of a variable capacitor. This capacitor is connected to the controller. The controller compares the capacitive charge with the setpoint value, which corresponds to a specific nozzle clearance height X.
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3.8.9.2
Calibrating the capacitive detection When the cutting process is started, the distance is adjusted automatically at the reference point. Further details on calibrating the detection system are given in the Online Help and in the ByVision operating instructions.
3.8.9.3
Tactile detection (option) Tactile (mechanical) detection can be used to detect the clearance for all types of material. Tactile detection is used primarily for materials that are electrical insulators. The tactile detection unit is fitted on the side of the cutting head. The tactile detection sensor is lowered down onto the work piece. The distance from the work piece to the cutting head is measured by the linear potentiometer. The nozzle clearance is then set relative to the sensor.
Fig. 3.8-15
Tactile detection unit
C A B C Knurled screws Housing Ring sensor
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Fig. 3.8-16 Attachment of tactile detection system to the Z-axis
Fig. 3.8-17
Cover
A B C D
Serial port for data transfer Pneumatic connections Locating holes / locating pins Connection plate for tactile detection unit
When the tactile detection unit is removed, the cover supplied (see Fig. 3.8-17) must be fitted (to prevent dirt getting onto the mounting plate).
Section 5.6.5 Tactile detection (option) describes how to fit and calibrate the tactile detection unit.
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3.9
Shuttle table console

The shuttle table system and the swivel loader (option) can be operated manually via the shuttle table console, The console contains the necessary operating buttons and is fitted with an EMERGENCY STOP button.
Fig. 3.9-1
Operating console for shuttle table / swivel loader (option)
The function of each button is described in section 4.2.5 Shuttle-table console.
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3.10 Beam guidance system
The laser beam is guided out of the laser module through the output coupler and onto the work piece via the polarization mirror, a number of deflecting mirrors and the focusing lens. The route traveled by the laser beam between exiting the laser module and arriving at the cutting head on the Z-axis is called the beam path. The bridge and cutting carriage move during operation together with the deflecting mirrors mounted on them. This changes the length of the beam path. This principle of laser-beam guidance is called Flying optics.
WARNING
Risk of fire and explosion The laser beam can cause flammable and explosive fluids and vapors to ignite. Foreign bodies, fluids and gases can also have an adverse effect on the beam quality. Cleaning agents and solvents and their vapors should therefore be kept away from the beam path.
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3.10.1
Components
The beam guidance system basically consists of the following components:
Fig. 3.10-1
Sketch showing the main elements of the beam guidance system
E B A C D
G H I
A B C D E F G H I
Beam shielding tube Beam deflection on cutting bridge Beam deflection on the Z-axis Beam deflection in the laser module Beam deflection, machine frame Cutting carriage Cutting bridge Cutting head Laser beam
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3.10.2 Radiation protection
DANGER
Invisible laser radiation The beam path protective covers must never be removed or modified. The beam shielding tube between the laser module and the machine must not be subjected to mechanical loads. Bending of the beam shielding tube can allow the laser beam to escape unprotected or damage the tube. The beam path is totally sealed by structural parts, bellows and protective covers. Bellows and safety covers protect people from stray radiation and from direct contact with the laser beam. They also double as protection for the optical system from outside influences.
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3.10.3
Deflecting mirror
Deflecting mirrors are used along the machine axes to deflect the laser beam. The mirrors used are flat mirrors, which do not alter the beam quality (for example parallelism) when they deflect the beam.
Fig. 3.10-2
Deflecting mirror
D B C
A B C D E F G H
Cover for coarse adjustment Cover fixing screw Cooling water connections Mirror holder Mirror fixing screw Fine-adjustment set screw Mirror mounting plate Deflector vee-block
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The angle of incidence and the angle of reflection are measured with respect to the normal line. The angles of incidence and reflection are equal. If the deflecting mirror is rotated through a certain angle then the direction of the reflected beam alters by twice that angle.
Fig. 3.10-3 Angle of reflection of a deflecting mirror
C D
E F
A B C
Angle of incidence Angle of reflection Laser beam
D E F
Coating Base material Normal line
When replacing deflecting mirrors, always check the ID of the replacement mirror to ensure it is the correct model. It is particularly important to be aware of the difference between beam-folding, deflecting, telescope and polarization mirrors (see spares catalog). Deflecting mirrors are held in a mirror holder with a clamping ring. The mirror holder can be adjusted by rotating it horizontally and vertically using set screws. The adjustment screws for setting up the beam path are set at commissioning and must not be adjusted again.
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3.10.4
Adaptive optic (option)

The adaptive optic makes it possible to keep the focal point in the same position over the whole cutting table. The adaptive optic employs a deformable mirror to provide a 90 deflection onto the Z-axis. The radius of curvature of the mirror is changed by means of water pressure (3 to 11 bar). The mirror is flat for a pressure of about 7 bar. The pressure of the flowing cooling water is controlled by means of a pressure sensor on the mirror and a proportional valve.
Fig. 3.10-4
Adaptive mirror with holder
A B C D E
Diaphragm Pressure sensor Water circulation Deformation of the mirror Adaptive mirror
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3.10.4.1
Focal position without adaptive optic (flat mirror) In laser cutting machines without an adaptive optic, the position of the focal point varies over the working area of the laser cutting machine. The greater the distance between the output coupler on the laser module and the lens in the cutting head, the lower the focal point. The reason for this is the natural divergence of the laser beam. This results in different cutting qualities over large work areas.
Fig. 3.10-5
Course of focal point with flat mirror
F G
I A J
A B C D E F G H I J
Laser module Deflecting mirror Curved wave front Flat mirror Beam Non-identical wavefronts Lens Work piece Cutting area Course of focal point
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3.10.4.2
Course of focal point with adaptive optic (option) In laser cutting machines fitted with an adaptive optic, the position of the focal point, and hence the cutting quality, is kept constant over the whole cutting area.
Fig. 3.10-6
Course of focal point with adaptive optic
F G
H I A A B C D E F G H I J Laser module Deflecting mirror Curved wave front Deformable mirror Beam Flat wave front Lens Work piece Cutting area Course of focal point J
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3.10.4.3 Focal position
In addition to focus correction, the focal position can be shifted to suit the material to be cut. The value for the focal position is given in the cutting parameters. Depending on the material, the focal point during cutting lies either on the upper face of the work piece, in the work piece or on the underside of the work piece.
Fig. 3.10-7 Focal position of the laser beam
A B C
A B C
Focal point on the upper face of the work piece Focal point in the work piece Focal point on the underside of the work piece
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3.11
Shuttle table system

The shuttle table system consists of a shuttle table drive and two shuttle tables with support grate.
Fig. 3.11-1
The table interchange makes it possible to remove cut parts and to place the next sheet ready for machining while the laser cutting machine works through the current cutting plan. The table interchange can be executed fully automatically, or manually using the Handling Operation application. It is also possible to launch a manual table interchange using the Table interchange button on the shuttle-table console. Section 4.2.5 Shuttle-table console contains information on operating the shuttle table system.
3.11.1
Shuttle table
The shuttle table is used for loading and unloading the laser cutting machine. The nozzle cleaning brush and the detection calibration plate are also fitted on the shuttle table.
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3.11.2 Support grate
The support grate serves as a workpiece support. It can be produced by the machine owner. The required workpiece drawings are saved on the computer as DXF files. The strips can be made from various metals. Copper strips have the longest service life. Slag is easy to remove. The high reflectivity of copper can be a disadvantage, however, for light gage sheets, when cutting small holes or in oxide-free cutting (small holes are imprecise, plasma formation, beam cuts off). Strips made of stainless steel are the most suitable option for cutting steel sheets. The service life of the strips depends on the laser power.
Fig. 3.11-2 Support grates
Support grate for light gage sheets
Support grate for heavy gage sheets
Tab. 3.11-1
Comparison of materials
Materials Steel
Economic, low reflection, short service life
Rust and acid-resistant steel

Splashes from this grid cannot oxidize on stainless materials
Copper
High reflection, long service life
Using oxygen as the cutting gas when cutting the strips can save money.
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3.12
Remote diagnostics (option)

The remote diagnostics facility can be used by the manufacturer's Customer Services and by the owner to access individual machine components such as CNC, laser module, PLC and automation system. TCP/IP and HTTP are used as the communications protocols. The system is operated via a web browser.
Fig. 3.12-1
System design
A B
C D E F G H J M L
A B C D E F G
Internet environment Secure communication (SSH) Owner environment Firewall Router Owner's network Machine network
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H I J K L M Netbox / Router Machines Remote Diagnostics Box (RD box) Manufacturer environment Firewall Remote Diagnostics Server (RD server)
For further information please see the Installation guide and section 5.5 Using the remote diagnostics facility (option).
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3.13
Cutting gases
Nitrogen (N2) and oxygen (O2) are used for laser cutting.
3.13.1
Cutting gas quality

The gas quality has a crucial impact on the cut quality. Nitrogen affects the quality of the cut surface. The following tables show the relationship between quality grade and oxide formation on the cut surface.
Tab. 3.13-1
Quality grade and oxide formation using oxygen as cutting gas
Gas type
Quality
Purity
Proportion nitrogen + argon

N2 + Ar / [ppm]
Proportion of water
H2O / [ppm]
Cut surface
[Vol. %] Oxygen O2 3.5a)
99.95
500
Oxide formation
Tab. 3.13-2
Quality grade and oxide formation using nitrogen as cutting gas
Gas type
Quality
Purity
[Vol. %]
Proportion Oxygen
O2 / [ppm]
Proportion of water
H2O / [ppm]
Cut surface
Nitrogen N2 Nitrogen N2 Nitrogen N2 Nitrogen N2
2.8 3.5a)
99.8 99.95
500 100
20 10
oxide-free, slightly yellowish oxide free, not guaranteed bright oxide-free, guaranteed shiny absolutely oxidefree, guaranteed shiny
4.5 5.0
99.995 99.999
10 3
5 5
a) Recommendation
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3.13.2 Cutting gas consumption
The cutting gas consumption depends on the pressure and the nozzle used. The following diagrams show recommended values for cutting in the low-pressure and high-pressure region.
Fig. 3.13-1 Low pressure up to 6 bar
B
Fig. 3.13-2 High pressure up to 20 bar
B
A B C Cutting gas consumption Gas pressure Nozzle diameter used
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Chapter 4
Control elements
This chapter provides information on warning signals output by the machine. The controls and indicators on the product are also described. The individual modes are also explained.
4-1
Control elements
Bysprint
4-2
Bysprint
4.1
4.1.1
Control elements
Warning signs
Indicator lamps
The indicator lamps signal the operating status of the laser module. They are mounted on the MCS cabinet or on the laser module itself, depending on the type of laser module.
Fig. 4.1-1
Indicator lamp
A B C
The lamps have the following meanings: A Red indicator lamp Provides information on the laser module status.
Lamp not illuminated: shutter is closed Lamp illuminated: shutter is open, the laser beam is being emitted
from the laser module.
Lamp flashing: laser module is in Service mode (class 4 laser), the la-
ser cover is open. Service mode tasks are described in section 4.4.2 Service mode.
Orange indicator lamp Provides information on the high-voltage status.

Lamp illuminated: high-voltage on the laser module is on
White indicator lamp Provides information on the gas-supply pressure.

Lamp flashing: gas pressure
<2 bar, replace laser gas bottle.
Lamp illuminated: gas pressure
<1 bar, laser module high-voltage switches off, cutting process is halted.
This indicator enables the gas supply to be switched to the reserve bottle before the cutting process is stopped. The LaserView laser control software displays which gas is at low pressure.
4-3
Control elements
Bysprint
4.1.2
Error messages
Machine messages are displayed in the status and error-message bars of the ByVision and Handling Operation applications (see section 5.3.8 System, status and error messages and section 5.4.5 Alarm messages). The Online Help provides explanations of the messages.
4-4
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4.2
4.2.1
Control elements
Controls and indicators

Main power switch
The main power switch is located on the STL cabinet. After switching on the main power switch (ON position), all equipment and controllers necessary for operation of the laser cutting machine (gas controller, extraction system, cooling unit, computer, etc.) are started up automatically.
Fig. 4.2-1
Main power switch on the STL cabinet
A B C
STL cabinet Main power switch Reset button(EMERGENCY STOP enable)
4-5
Control elements
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4.2.2
EMERGENCY STOP buttons

There are four EMERGENCY STOP buttons on the laser cutting machine, which can be used to shut down the laser cutting machine and its components in the event of danger.
4.2.2.1
Fig. 4.2-2
Operating terminal
EMERGENCY STOP button on the operating terminal
EMERGENCY STOP
4.2.2.2
Fig. 4.2-3
EMERGENCY STOP button on the hand-held controller
EMERGENCY STOP
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4.2.2.3
Fig. 4.2-4
Control elements
Shuttle-table console
EMERGENCY STOP button on the shuttle-table console
EMERGENCY STOP
4.2.2.4
Fig. 4.2-5
Laser module 2200

EMERGENCY STOP button on the laser module
EMERGENCY STOP
4-7
Control elements
Bysprint
4.2.2.5
Fig. 4.2-6
Control cabinet for laser module 3000

EMERGENCY STOP button on the control cabinet
EMERGENCY STOP
4-8
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4.2.3 Operating terminal
Control elements
The operating terminal has a touch screen, where each program can be opened by touching the relevant button.
Fig. 4.2-7 Operating terminal user interface
A B C D E
EMERGENCY STOP button Screen with touch-screen function Keyboard Function buttons on the membrane keypad Mouse (option)
4-9
Control elements
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4.2.3.1
Status of illuminated function buttons

If the button is illuminated, the button function is enabled If the button is not illuminated, the button function is disabled
4.2.3.2
Enabling the function buttons When the user interface is opened, the relevant function buttons are enabled depending on what equipment is fitted in the machine and the hardware configuration settings.
4.2.3.3
Description of the function buttons Button Description

Enable safety circuit
Release safety door
Stop automatic operation (e.g. table interchange)
No function
No function
Spare
Spare
Spare
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4.2.4 Hand-held controller
Control elements
The hand-held controller is used for setup and adjustment tasks, for separating remaining sheets and for test cuts to determine parameters.
Fig. 4.2-8 Hand-held controller
A B C
EMERGENCY STOP button Thumb-wheel Keypad
4.2.4.1
Enabling the hand-held controller The HAND view must be opened in the user interface to enable the handheld controller. The EMERGENCY STOP button and the STOP and CONT buttons are always enabled (regardless of whether the HAND view is open).
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4.2.4.2
Thumb-wheel Fine positioning of the axes with the JOG button held down.
4.2.4.3
Description of buttons on the hand-held controller Button Description

Software stop. Stops all axis drives. Not an EMERGENCY STOP Holding down this button enables fine positioning using thumbwheel
Function activated (LED on) Capacitive detection is enabled (default) Function deactivated (LED off) Capacitive detection is disabled Move X-axis in positive direction, manual feed
Move X-axis in negative direction, manual feed
Move Y-axis in positive direction, manual feed
Move Y-axis in negative direction, manual feed
Raise cutting head (detection dependent on the TOOL button function)
Lower cutting head (detection dependent on the TOOL button function)
Rotate rotary axis counter-clockwise (ccw), manual feed
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Button Description
Control elements
Rotate rotary axis clockwise (cw), manual feed
Crossjet functions
Single pulse. Open the shutter for the preset time interval. This function is used for aligning the laser beam and centering the nozzle. Open shutter. The shutter stays open for as long as this button is pressed.
Confirm button (continue)
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Control elements
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4.2.5
Shuttle-table console
The shuttle table system and loading equipment (option) can be operated manually via the shuttle table console.
Fig. 4.2-9
Console for shuttle table / loading equipment
A B C
EMERGENCY STOP button Shuttle-table keypad Handling-system keypad (only when an optional handling system is connected)
4.2.5.1
Description of buttons on the shuttle table console Button Description

PLC stop Pressing this button stops all automatic table-interchange and loading actions. Not an EMERGENCY STOP Reset light barrier If the light barrier has tripped, the table-interchange process and the loading/unloading action is stopped. The button light flashes. This button is used to re-enable the light barrier. This button must also be pressed after each restart of the laser cutting machine in order to enable the safety circuit. Table interchange Pressing this button launches an automatic table interchange (provided the light barrier has not tripped).
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Button Description
Material positioned
Control elements
This button must be pressed when raw material to be used for further machining has been placed on the shuttle table in the loading position. This notifies the CNC that further raw material is available for the next cutting plan when machining of the current cutting plan is complete. Once the current cutting plan has been completed, a table interchange is executed automatically and the next cutting plan cut in automatic mode. The following statuses are indicated by this button:
Button illuminated: raw material ready on the loading table Button flashing: waiting for raw material Button off: Function not active
Load raw material When this button is pressed, a handling system conveys the raw material to the shuttle table. Unload raw material When this button is pressed, a handling system conveys the raw material from the shuttle table to a stock transfer table. Unload cut material When this button is pressed, a handling system conveys the cut material from the shuttle table to a disposal position. This button is only enabled if the handling system is fitted with a drop-protection system.
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4.3
Control cabinet for laser module 3000

The controls on the control cabinet are described in the Operating instructions for the laser module.
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4.4
4.4.1
Control elements
Operating modes of the laser cutting machine

Normal mode
The laser cutting machine is in Normal mode when:

all components have been fitted and set up as specified all covers and protective fences have been fitted correctly the laser cutting machine is switched on all safety devices are reset cutting plans and parameters have been imported the machining process has been started
4.4.2
Service mode
The laser cutting machine is in Service mode when the machining sequence in Normal mode has been interrupted. The reason for the interruption is irrelevant - it makes no difference whether machining has stopped for adjustment and checking tasks, loading and unloading or cleaning and maintenance work. The machine enters Service mode at the moment when non-contact safety devices (e.g. light barriers) are crossed, safety door(s) are opened or permanent safety devices are dismantled. Normal mode is restored when the machine is once more ready for use, the safety devices are reset and the process is resumed.
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4.5
4.5.1
Operating modes, Adaptive Optic 1

Operating mode 0 (Service mode)
The predefined mirror deformation remains constant over the entire cutting area irrespective of the beam length. The focal position is not re-corrected in this operating mode. In operating mode 0, Adaptive Optic 11) behaves like a flat mirror, provided the setup value Pressure difference from flat position for operating mode = 0 is set to 0 bar. This corresponds to an actual cooling-water pressure of approx. 7 bar. The technically feasible adjustment range is approx. 4 bar.
4.5.1.1
Insert Operating mode 0 is used for checking the beam shape (mode cube) and measuring the characteristic curve.
Operating mode 0 is not meant to be used in production.
1) Adaptive Optic 1 = Bypos
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4.5.2 Operating mode 1 (production mode)
Control elements
In operating mode 1 the focal position is corrected automatically during cutting and, after importing a new cutting plan, is also adjusted to suit the given material and cutting process. A valid characteristic curve is required for this operating mode. The correction is made in the adaptive optic by changing the cooling-water pressure. The pressure is calculated from the position-dependent characteristic curve value plus an OFFSET.
Tab. 4.5-1 Parameters for OFFSET
OFFSET depends on
focal position focal length Nozzle clearance height Focal length reference setting
held in
Cutting parameters Cutting parameters Cutting parameters Setup values, machine
4.5.2.1
Working in operating mode 1 Follow the procedure below to work in operating mode 1:
1. 2. 3.
Select operating mode 1. Set the cutting head to the reference setting for the focal position. Import cutting plan and cutting parameters. Here it is essential that the focal length in the cutting parameters tallies with that for the cutting head, otherwise the focal point is calculated incorrectly.
4.
Check cutting nozzle, replace if necessary. If several jobs need to be processed automatically one after the other, then the largest of the specified nozzles must be used. Additional parameter adjustments may consequently be necessary. For example, when widely differing sheet thicknesses are cut in automatic mode.
5.
Center the cutting nozzle (see 5.6.4 Centering the nozzle) then start the cutting process.
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Chapter 5
Operation
This chapter provides information on how to operate the product safely, how to set up and adjust it, and also gives details of its various functions.
5-1
Operation
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5-2
Bysprint
5.1
5.1.1
Operation
Introduction
Safety regulations
In order to prevent injuries and damage to property during work on the laser cutting machine, it is essential to observe the safety regulations. In particular, all persons working with the machine must have read and understood Chapter 2 Safety regulations. The machine danger zones that are out of bounds during operation are listed in section 2.3 Danger zones. The machine must only be used for its intended use as described in section 1.1.2 Intended use.
5.1.2
Requirements to be met by personnel performing the work

Operators must understand the operating software and have a technical understanding. Operating personnel must be able to perform the following tasks as a minimum:

Switch the machine or system on and off Operate the machine control system Run and use the operating software Create a cutting job and start the cutting process Perform dimensional corrections Convert the machine for a change in production Clean the machine or system Perform maintenance work required during normal operation
5-3
Operation
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Operating the machine
The laser cutting machine is operated from the operating terminal, the hand-held controller and the shuttle table console.
5.2
5.2.1
Pre start-up check

The following points must be checked before switching on the machine:

All safety equipment, EMERGENCY STOP devices and sound insulation are present and in working order. All EMERGENCY STOP buttons must be enabled. The laser machine and its components show no signs of external damage or faults. Compressed air is connected; pressure and quality meet requirements given in the Installation Guide. Laser-gas bottles are connected and the reducing valves are open. Gas quality for laser gas meet requirements given in the Installation Guide. Cutting gas bottle is connected and reducing valve is open, pressure and quality meet requirements given in the Installation Guide. The shutter remains locked while there is no cutting gas available at the gas controller. Power switches on cooling unit and extraction system are turned on. Check there is no 3 inch disk in the computer floppy-disk drive. The computer cannot boot up automatically if there is a floppy disk in the drive.
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5.2.2
5.2.2.1
Operation
Starting up the laser cutting machine in normal mode

Start-up procedure for laser module 2200 Follow the procedure below to start up the laser cutting machine in normal operating mode.
1. 2. 3.
Switch on the power switch (ON position). Press the Reset button on the operating terminal. This enables the safety circuit. Log onto the operating system if necessary.
z z
The operating system starts up. The ByVision user interface, the Handling Operation application and the LaserView laser control software are started.
4. 5. 6.
The error message Drives disabled is displayed in the status line of the user interface. Log on user (see section 5.3.2 User logon). Press the OPEN DOOR button on the operating terminal. Open and re-close the safety door. If the safety door is already open then it must be closed.
7. 8. 9.
Use the Menu button to select the HAND view in the user interface (see section 5.3.3 Layout of the views). Press the Reference button. Press CONT on the hand-held controller. The axes move to the reference position.
10. Wait until the Ready message for the laser appears in the status bar in the user interface. The orange indicator lamp on the laser module also lights up to show that the laser is ready. 11. The machine is operational.
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Start-up procedure for laser module 3000 Follow the procedure below to start up the laser cutting machine in normal operating mode.
5.2.2.2
1. 2. 3.
Switch on the power switch (ON position). Press the Reset button on the operating terminal. This enables the safety circuit. Turn the key-operated switch on the laser control cabinet (MCS) to ON.
z z
The gas controller for the laser module starts up automatically. The necessary software is started.
4.
Log onto the operating system if necessary.

z z
The operating system starts up. The ByVision user interface and the Handling Operation application are started.
5. 6.
Log on user (see section 5.3.2 User logon). Wait until the Ready message for the laser appears in the status bar in the user interface. The orange indicator light on the laser control cabinet (MCS) also lights up to show that the laser is ready.
7. 8.
The error message Drives disabled is displayed in the status line of the user interface. Press the OPEN DOOR button on the operating terminal. Open and re-close the safety door. If the safety door is already open then it must be closed.
9.
Use the Menu button to select the HAND view in the user interface (see section 5.3.3 Layout of the views).
10. Press the Reference button. 11. Press CONT on the hand-held controller. The axes move to the reference position. 12. The machine is operational.
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5.2.3
Operation
Shutting down the laser cutting machine in normal mode

Before the laser cutting machine can be shut down, active cutting and handling processes must be terminated.
5.2.3.1
Shutdown procedure for laser module 2200 Follow the procedure below to shut down the laser cutting machine in normal operation.
1. 2. 3. 4. 5.
Select the MAIN view of the ByVision user interface and press the Close button. Select the Shut down system option and confirm with OK. As soon as the laser module is flooded, all applications are closed automatically. The computer is shut down. Switch off main power switch (OFF position). All laser cutting machine modules are disconnected from the power supply. Close the cut-off valves to the cutting-gas and laser-gas supply, and to the compressed air.
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Shutdown procedure for laser module 3000 Follow the procedure below to shut down the laser cutting machine in normal operation.
5.2.3.2
1. 2. 3. 4. 5. 6. 7.
Select the MAIN view in the user interface and press the Close button. Select the Shut down system option and confirm with OK. The computer is shut down and the laser module flooded. Wait until the display on the laser control cabinet (MCS) shows at least 980 mbar. Turn the key-operated switch on the laser control cabinet (MCS) to POWER 0. The laser controller is switched off. Switch off main power switch (OFF position). All laser cutting machine modules are disconnected from the power supply. Close the cut-off valves to the cutting-gas and laser-gas supply, and to the compressed air.
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5.2.4 Switching off in an emergency
Operation
The laser cutting machine can be switched off in an emergency using an EMERGENCY STOP button. This immediately stops all movements and processes. Section 3.2.1 EMERGENCY STOP circuit contains further details.

Take appropriate action should anyone be injured during an emergency. Follow the relevant procedures in your company in this case. If the machine is damaged then the manager and the manufacturer must be informed.
5.2.5
Restarting after an EMERGENCY STOP

Operation of the machine can only be resumed once the emergency situation has been cleared and all defects and damage have been rectified.
5.2.5.1
Restart procedure for laser module 2200
1. 2. 3. 4. 5.
Enable the actuated EMERGENCY STOP button by pulling it or turning it clockwise (cw). Press the Reset button on the operating terminal. This enables the safety circuit. Start the LaserView laser control software. Select the Laser Operation view. Clear any errors with the Error reset button. If the laser status has been set to automatic, the laser module starts up automatically.
6.
Wait until the orange indicator lamp on the laser module lights up. You can then continue cutting.
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Restart procedure for laser module 3000
5.2.5.2
1. 2. 3. 4.
Enable the actuated EMERGENCY STOP button by pulling it or turning it clockwise (cw). Press the Reset button on the operating terminal. This enables the safety circuit. Press the STEP button on the membrane keypad. Press the Reset button on the laser control cabinet (MCS). The message Vacuum On? appears on the display.
z
Press the ON button on the membrane keypad.
5.
Wait until the orange indicator lamp on the MCS cabinet lights up. You can then continue cutting.
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5.3 ByVision user interface
Operation
The cutting process of the laser cutting machine is controlled via the ByVision user interface. All controls can be operated via the touch screen.
5.3.1
General layout
The user interface is divided into fixed areas for navigation (J) and operation (H). The screen is divided in this way in all views.
Fig. 5.3-1
Layout of the ByVision user interface
A B C D
Title of the active view Selection of operating mode (Operating mode button) Displays the currently selected operating mode Man. mode, automatic mode or DNC mode Function buttons (CNC, Service, Stop and Help functions)
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E F G H I J Date (set in the System settings of the computer) Time (set in the System settings of the computer) Displays the current cutting plan, material designation and dimensions, and process parameters Function bar (this varies depending on which view is active) Status bar (system, status and error messages) Navigation bar (this varies depending on which view is active)
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5.3.2 User logon
Operation
It is only possible to start production work on the laser cutting machine, modify parameters or import cutting plans once a user has logged on with user name (A) and password (B). Access to the various views is controlled by user permissions. Further information on the user list and user permissions are given in the MMC Online Help.
Fig. 5.3-2 Login / log off dialog window
The following users are defined as standard:

Operator Expert System
Section 5.3.2.1 User permissions explains user permissions and section 5.3.2.2 Access to the individual views gives details of access permissions for the various views.
User administration requires System level user permissions.
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User permissions Action User permissions Operator
Cutting plan import Assigning cutting parameters Starting a cutting job Changing cutting-parameter values Showing/hiding views for WORK parameters and HAND parameters Showing/hiding views for Setup values, machine Showing/hiding views for Configuration, hardware Changing machine setup values Access to the Administration area Interfacing of add-on applications
5.3.2.1
Expert
System
Access No access
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5.3.2.2 Access to the individual views User interface view
Operation
User permissions Operator Expert System
MAIN view Administration

User interface configuration Configuration, hardware User management
Views
WORK view Configuration, hardware Setup values, machine WORK parameters HAND parameters
Diagnostics
User interface Machine Service CNC
Clean screen Information Closing user interface HAND view Setup values, machine Manual-cut parameters
Access No access
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User interface view
User permissions Operator Expert System
WORK view Job list Cutting parameters Potis TOOLS view
Access No access
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5.3.3 Layout of the views
Operation
The user interface is divided into four views. These can be opened using the Menu button in the Navigation bar or the function keys [F5] to [F8] on the keyboard.
Fig. 5.3-3 Main areas of the user interface
[F5] A
[F6] B
C [F7]
D [F8]
MAIN view: User logon and log off, plus opening sub-areas for administration, customizing views and system diagnostics (see section 5.3.4 MAIN view). HAND view: Defining setup values for the machine and parameters for manual operation (see section 5.3.5 HAND view). WORK view: Loading cutting plans, modifying current cutting parameters and starting the cutting process (see section 5.3.6 WORK view). TOOLS view: Starting 5.3.7 TOOLS view). additional applications (see section
B C
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MAIN view
The MAIN view is always displayed when the application is started. It contains sub-areas for administration, customizing views and system diagnostics. A user must be logged on before he/she can use the functions of the user interface (see 5.3.2 User logon).
5.3.4
Fig. 5.3-4
Functions in the MAIN view
MAIN
A B C
Administration functions (MAIN Administration) Customizing views (MAIN Views) Diagnostic functions (MAIN Diagnostics)
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5.3.4.1 Administration
Operation
Configuration settings for the user interface and the CNC can be defined in these views; users can also be managed and their access permissions modified here.
Fig. 5.3-5 Administration functions
MAIN Administration
Configuration settings for the user interface. Integration of add-on applications that can be started from the user interface or brought into the foreground. (MAIN Administration Configuration, ByVision) Configuration settings for the CNC (MAIN Administration Configuration, hardware) User management and modification of their access permissions (MAIN Administration User)
B C
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Views Every user can customize the views available to him. These settings are saved in the user's profile and reloaded when the user next logs on.
5.3.4.2
Fig. 5.3-6
Customizing views
MAIN Views
A B C D E
Customizing the Work view (MAIN Views Work) Showing/hiding parameters for the CNCa) (MAIN Views Configuration, hardware) Showing/hiding Setup values, machinea) (MAIN Views Setup values, machine) Showing/hiding Work parametersa) (MAIN Views Work parameters) Showing/hiding parameters for manual operationa) (MAIN Views Hand parameters)
a) Requires System or Service level user permissions
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5.3.4.3 Diagnostics
Operation
In this view, one can display and check the connection to the CNC and any store system that may be fitted, and display and check the directory paths. In addition, this view can display the CNC and Machine Service diagnostics data.
Fig. 5.3-7 Diagnostics functions
MAIN Diagnostics
A B C
Display of communications and directory data (MAIN Diagnostics ByVision) Machine Service diagnostics data (MAIN Diagnostics Machine Service) CNC diagnostics data (MAIN Diagnostics CNC)
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HAND view
In this view, one can define setup values for the machine and the parameters for manual operation. Those parameters changed during manual operation are not reset when manual operation ends.
5.3.5
Fig. 5.3-8
Functions in the HAND view
HAND
A B
Definition of setup values for the machinea) (HAND Setup values, machine) Definition of parameters for manual operation (HAND Parameters)
a) Requires Expert or System level user permissions
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5.3.6 WORK view
Operation
These views provide functions for loading cutting plans, modifying parameters and starting the cutting process. In addition, information can be displayed on the current cutting plan. When the cutting plan is visualized, those contours already machined are shown in gray, while those contours still to be cut are shown in blue.
Fig. 5.3-9 Functions in the WORK view
WORK
A B
Management of the list of prepared cutting jobs (WORK Job list) Making changes to current values of cutting parameters while a cutting plan is in progress (WORK Parameters) Making dynamic changes to certain cutting-parameter values (e.g. Cutting pressure, Gas type 2 or Feed rate, cutting) while a cutting plan is in progress (WORK Potis)
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TOOLS view
In the TOOLS view, user selectable add-on applications can be started from the user interface or brought into the foreground. These add-on applications can be integrated in the Administration area.
5.3.7
Up to seven add-on applications can be integrated.
Fig. 5.3-10
Functions in the TOOLS view
TOOLS
e.g. LaserView A
e.g. Handling Operation B C
A B C
Application 1 (e.g. LaserView) Application 2 (e.g. Handling Operation) Other applications
Use the [Alt + Tab] hotkeys to toggle between the different applications.
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5.3.8 System, status and error messages
Operation
All system, status and error messages are displayed in the status bar (A). Three dots () are displayed at the end of the text to indicate that further messages are present. Button (B) opens the message list.
Fig. 5.3-11 Display of system, status and error messages
A B
The individual messages are color-coded: Color Class

Error red
Description
Processes already started are interrupted (e.g. stop caused by EMERGENCY STOP). The cause must be fully cleared before operation is resumed.
Warning orange Operator prompt yellow Information light blue
A safety-related element has tripped (e.g. safety door open or light barrier has been crossed). The message prompts for the user to perform an action (e.g. press the CONT or STOP button). Information on the active process (e.g. cutting plan import).
The cause of the fault and the remedial action are described in the ByVision Operating instructions.
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Message list All active messages are listed in the message list, with the most recent message always at the top.
5.3.8.1
Fig. 5.3-12
Message list
5.3.8.2
Quick Help The Quick Help can be opened with button (A). This function displays in the lower section (B) of the message list an explanation of the selected message.
Fig. 5.3-13
Showing Quick Help
Pressing the button (A) once more hides the Quick Help again.
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5.3.9 Display convention for buttons
Display Status
active
Operation
Description
Access permitted
inactive
Access not permitted, either because of user permissions or an inadmissible machine function
5.3.10
Function buttons
Button
Description
Opens a menu from which CNC functions can be selected (e.g. program reference, sensor field or test on/off).
Opens a menu from which service functions can be selected (e.g. move to service position, move to parked position, clean nozzle etc.). Stop before and after processing a cutting plan.
Stop at the zero point of the cutting plan and at the zero point of the individual parts.
Stop before and after a contour (before and after a cut termination).
Programmed stop in the machining process.
Open the Online Help (see section 5.3.11 Online Help). The Help facility can also be opened with the F1 key.
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Online Help
The user interface has an integrated Online Help facility. This contains information on various topics such as functions, views, cutting parameters, setup values etc. The Help facility can be opened with the HELP function button or the F1 key. The Online Help is available in the same language as the user interface.
5.3.11
Fig. 5.3-14
Online Help
J A B C D E F G H I J Navigation window Show table of contents in the Navigation window Hide Navigation window Show keyword search in the Navigation window Show full-text search in the Navigation window Show term definitions in the Navigation window Print out the current contents of the Display window Input field for the search functions Display window Close the Online Help
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5.3.11.1 Search functions The Online Help provides the following search functions: Contents
Operation
In the Contents search, the search is made through the whole table of contents in the Navigation window. The table of contents has a directory structure allowing navigation from main topics to subtopics until the required information is found. Keyword search. Enter the keyword and press Enter to start the search function. The search results are listed in the Navigation window.
Keyword
Full-text search Search for words, word combinations or terms. Enter the search word and press Enter to start the search function. The search results are listed in the Navigation window.
5.3.11.2
Printed version All the information contained in the Online Help is also supplied in hardcopy form in the ByVision Operating instructions.
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Handling Operation user interface
The Handling Operation application is used for operating the shuttle-table system and optional handling systems. The software can be operated via the touch screen, the keyboard or optional mouse. The screens used for operating the shuttle table system and selecting the shuttle-table service functions are described below. Some of the functions are unavailable, depending on the system configuration.
5.4
If a handling system is connected, its functions are described in the operating instructions for the handling system concerned.
5.4.1
Starting the software

When the laser cutting machine starts up, the Handling Operation application is started automatically. Use the [Alt + Tab] hotkeys to toggle between the different applications.
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5.4.2
Fig. 5.4-1
Operation
General layout
Layout of the Handling Operation user interface
H K
I E F
J G
A B C
Title of the active view Alarm field Communication status field If there is an active alarm message, the field flashes red. Green field: present connection to PLC
Red field: connection to PLC lost D E F Title bar Alarm message Status messages Manufacturer and software information The alarm bar is only displayed if there is an alarm active. Current process step of shuttle table system and operating prompts
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G Navigation buttons Buttons for opening the different screens. The button assignment varies depending on which view is active. H I J K Function buttons Date Time Visualization window The button assignment varies depending on which view is active. Setting in the control system settings for the computer Setting in the control system settings for the computer The display varies depending on which view is active
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5.4.2.1
Tab. 5.4-1
Operation
Navigation buttons
Handling Operation navigation buttons
Button
Description
In these views the shuttle table system can be operated by hand (table interchange, specifying material). In these views you can make settings relating to a handling system and machine-specific settings. In these views you can reset the job data and move the shuttle table manually for servicing purposes. The whole machine is configured in these views. These settings are made solely by the manufacturers own staff. Switch to the ByVision application. Open the Main Home start page. These views contain functions and settings relating to the handling system. If a handling system is not connected, then all functions except the dialog language are disabled. These views contain machine-specific functions and settings. Information on the software versions and IP address used for the PLC (see section 5.4.6 Info view). Change the dialog language. User login (Setup login and Service login) User log off Switch to the previous page in the same view. This button is only displayed if a view has more than one page. Switch to the next page in the same view. This button is only displayed if a view has more than one page. Display alarm messages. This button flashes red if there is an active alarm message. To clear an alarm see section 5.4.5 Alarm messages Back to the previous view Close the Handling Operation application
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Function buttons
Handling Operation function buttons
5.4.2.2
Tab. 5.4-2
Button
Description
Move the shuttle tables to the parked position. If the shuttle tables are not in the limit-of-travel position (e.g. light barrier has tripped), they can be moved into the limit-oftravel position (parked position) with the Park button. Enable or disable automatic operation. Function for remote diagnostics (option). See section 5.4.6 Info view. Clear material status for the shuttle tables (see section 5.4.7.2 Resetting job data).
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5.4.3 Start page
Operation
The Main Home start page is displayed automatically when the program is started.
Fig. 5.4-2 Main Home view
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Login
The Manual, Setup, Service or Config views can be opened from the Main Home start page. The Login controls the access options. The Service and Setup views have the same access condition and are enabled with a password. The Manual view can be opened without going through the login procedure. The machine is configured in the Config view. Access to this menu requires a special password (only for the manufacturer's service engineers). Those views currently granted access are represented by symbols on the home page.
5.4.4
Fig. 5.4-3
Symbols for access
The password for these views is valid; access is possible. A valid password has not been entered for this view; no access possible.
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5.4.5 Alarm messages
Operation
If an alarm message is active owing to a fault, button (A) and alarm field (B) flash red alternately. The latest alarm message is also displayed in the alarm bar (C).
Fig. 5.4-4 Home page active alarm message
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Alarm list The ALARM button opens the alarm list. All alarm messages are listed (including secondary faults), with the most recent message at the top.
5.4.5.1
Fig. 5.4-5
Alarm list
Tab. 5.4-3
Active buttons in the alarm list
Button
Description
Close alarm history
Display alarm history (see section 5.4.5.3 Alarm history)
Clear current alarm message
Back to the previous view
Display supplementary text on selected alarm message
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5.4.5.2 Clearing alarm messages
Operation
Once the fault has been rectified, the corresponding alarm message must be cleared with the ACK ALARMS button. If there is more than one active alarm message, each must be dealt with and cleared individually. The messages are color-coded to indicate the different alarm levels.
Tab. 5.4-4 Color-coding of alarm messages
Color
Meaning
Currently active alarm message which stops the machine.
red The alarm message has been cleared but the fault is still present. The fault has been rectified and the alarm message cleared. Pressing the ACK ALARMS button again clears the alarm message from the display.
violet
blue
5.4.5.3
Alarm history All the alarms that have occurred over one day can be listed in a separate window using the HISTORY button.
Fig. 5.4-6
Alarm history
5.4.6
Info view
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Operation
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This view displays information on the software versions and the IP address used for the PLC1).
Fig. 5.4-7
Information on Handling Operation
Handling Operation Machine PLC Machine PLC IP

Tab. 5.4-5 Active buttons in the Info view
Handling Operation software version PLC software version IP-address of the PLC
Button
Description
Function for remote diagnostics (option) Show system bar (for development purposes only) Hide system bar Back to the previous view
5.4.6.1
Changing the dialog language Select the required dialog language using the Panel language button.
1) Programmable Logic Controller
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Fig. 5.4-8 Button for changing the dialog language
Operation
The following languages are available:

German English French Italian Spanish
[DE] [EN] [FR] [IT] [SP]
Close and then restart the application after changing the dialog language.
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Operation
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Operating the shuttle table system
Single table interchange In the Manual General view, button (A) can be used to start a manual table interchange.
5.4.7
5.4.7.1
Fig. 5.4-9
Manual General view
The following conditions must be met:

The axes of the laser cutting machine must be in the reference position The safety door must be closed The light barrier in the loading area must be enabled
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5.4.7.2 Resetting job data
Operation
The function Reset job data clears the material status for both shuttle tables. This is used in association with a store system or before switching to automatic mode.
Fig. 5.4-10 Confirm or cancel the Reset
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Operation
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Advanced operation In the Manual Machine view, you can specify the material status on the shuttle tables (cutting and loading position). For servicing tasks or special functions, it is possible to move both shuttle tables to the loading position.
5.4.7.3
Fig. 5.4-11
Manual Machine view
A B C D
Define the material status on the shuttle table in the cutting position. Define the material status on the shuttle table in the loading position. Perform manual table interchange (see section 5.4.7.1 Single table interchange). Move shuttle table into servicing position. After this action, the two shuttle tables lie one above the other in the loading position.
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5.4.7.4 Material status in the cutting and loading position
Operation
Pressing either of the Mat Pos. buttons opens a dialog box in which you can define the material status on the shuttle table concerned (cutting or loading position).
Fig. 5.4-12 Dialog box for defining the material on the shuttle tables
A B C D
Raw material is on the shuttle table Cut material is on the shuttle table Material that has not finished being cut is on the shuttle table; the cutting job has been interrupted The shuttle table is empty
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Operation
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Setup functions
A valid password is required to access the Setup functions.
5.4.8
Fig. 5.4-13
Main Setup view
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5.4.8.1 Machine-specific settings
Operation
The Setup Machine view contains machine-specific settings. These settings can only affect functions installed on the machine.
Fig. 5.4-14 Setup Machine view
C A
If the axes sit for a prolonged period in the reference position, or if there is a persistent CNC error, then an automatic shutdown is initiated after 1 hour.

The laser module is shut down and flooded Cooling unit is switched off The compressed-air valve is closed The cutting-gas valves are closed
B C D
Disables the table interchange for special applications The extraction flaps are opened when all cutting plans have been completed, and then closed again after the set time period. If an uncut sheet is lying in the cutting position and the loading position when automatic mode is enabled, the lifting unit is automatically raised or lowered into the interchange position.
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Operation
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Service functions
A valid password is required to access the Service functions.
5.4.9
Fig. 5.4-15
Main Service view
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5.4.9.1 Moving shuttle tables manually
Operation
The Service Machine (1/3) view contains the functions for moving the shuttle tables by hand. The shuttle table or lifting unit continues to move while the relevant button is pressed or until it reaches its limit of travel. The following conditions must be met for these functions to work:
Fig. 5.4-16
The safety door must be closed The light barrier in the loading area must be reset
Service Machine (1/3) view
A B C D
Move shuttle table towards the cutting position Move shuttle table towards the loading position Raise lifting unit Lower lifting unit
The Service Machine (2/3) and Service Machine (3/3) views are not enabled for a laser cutting machine that is not fitted with any handling systems.
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Operation
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Using the remote diagnostics facility (option)
The remote diagnostics facility is operated via a web browser (Internet Explorer, Firefox, Opera etc.). Open the home page by entering the IP address of the RD box.
5.5
Fig. 5.5-1
Entering the IP address in the address bar
http://192.168.100.250 (default IP address)
Fig. 5.5-2
Remote diagnostics home page
A B
Viewing diagnostic data Administration area (Connect / Disconnect)
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5.5.1 Connect / Disconnect (Administration)
Operation
The owner can connect the RD-box to the RD server and disconnect it. When connected, the manufacturer's Customer Services department can view diagnostic data for individual machine modules.
Fig. 5.5-3 Administration Connection view
A C B D E
A B C D E
Select the Connection view Administrative functions for the manufacturers Customer Services department Connection status Connect/Disconnect Back to home page
Only the owner can re-connect after a disconnection (see Tab. 5.5-1).
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Operation
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Connection status
The connection status to the RD server is displayed after every refresh. The following table lists the possible connection statuses.
5.5.2
Tab. 5.5-1
Connection status
Connection status
Connected Disconnected try connecting
Description
Connected to server. Use disconnect to end connection. Connection to server lost. Use connect to re-connect. Connection terminated because the network connection has been lost. The system is trying to reconnect. The connection is established as soon as the server can be reached again. Use stop trying to stop trying to connect.
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5.5.3 Viewing diagnostic data
Operation
The status of every machine module can be viewed in the Diagnostics area.
Fig. 5.5-4 Diagnostic data view
A B C
Navigation by tree structure Diagnostic data Back to home page
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Operation
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Navigation Every time the system is interrogated, each connected module transmits its current status, which is color coded in the Navigation view. Table Tab. 5.5-2 shows what the colors mean. The configuration of the machinery is also transmitted at the same time. This is shown in the form of a tree structure in the Navigation view.
5.5.3.1
Fig. 5.5-5
Diagnostic data view
If a module in the subordinate branch has a problem, then the higher-level node is also displayed in red.
Tab. 5.5-2 Status of system modules
Color
Description
The module responds to the query and has no errors.
green The module does not respond to the query. Also flagged Offline. red The module responds to the query but returns an error status. red
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5.5.3.2 Detailed diagnostic data
Operation
Selecting a module in the Navigation view displays detailed diagnostic data for the module.
Fig. 5.5-6 Diagnostic data view
These operating instructions do not describe the detailed diagnostic data.
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Operation
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Setting up and adjustment tasks
Initiating an axis movement
The CONT button on the hand-held controller is normally used to initiate any axis movement. A function that has been started can be stopped or interrupted with the STOP button on the hand-held controller.
5.6
5.6.1
1. 2.
Select the required function (e.g. reference) on the user interface The corresponding message is displayed in the status bar (e.g. CNC: Move to reference, Press CONT to continue, STOP to terminate) Press CONT on the hand-held controller. This confirms the selected function and simultaneously starts the axis movement.
3.
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5.6.2 Changing the cutting head
Operation
When changing the cutting head, the best access is obtained when the head is in the service position.
Fig. 5.6-1 Mounting the cutting head on the Z-axis.
A B C
Clamping lever Mounting plate Cutting head
1. 2. 3. 4.
Close the safety door and move to the Service position. Press the OPEN DOOR button (on the operating terminal). Open safety door. Hold the cutting head with one hand while releasing the clamping lever with the other.
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Operation
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5. 6. Carefully pull the cutting head down out of the holder. With one hand hold the new cutting head against the holder with even pressure while tightening the clamping levers with the other hand to fix the head in place. Close the safety door.
7.
After removing or fitting the cutting head, check that the laser beam is centered in the nozzle. If necessary, center the nozzle.
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5.6.3 Changing the nozzle
The nozzle must be changed:

Operation
if the selected cutting parameter file requires a different nozzle if the machining quality deteriorates and you find on inspection that the nozzle is damaged
Fig. 5.6-2
Cutting head with fitted nozzle
C A
A B C
Jet Unscrewing the nozzle Screwing in a nozzle
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Operation
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1. 2. 3. 4. 5.
Clean the nozzle externally. Unscrew the nozzle by hand. If it is stuck fast, use a ring wrench to unscrew it while taking suitable care. Screw in the new nozzle fully by hand. Check that the laser beam is centered and correct it if necessary (see section 5.6.4 Centering the nozzle). Calibrate nozzle. If a tactile detection unit is being used, it must be calibrated after changing the nozzle (see section 5.6.5.2 Calibrating the detection unit).
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5.6.4 Centering the nozzle
Operation
Optimum cut quality is largely dependent on a properly centered nozzle. If the nozzle is not centered properly, the laser beam may be deflected by hitting the nozzle wall. This reduces the cutting quality and may damage the nozzle.
Using a piece of transparent adhesive tape, center the nozzle by adjusting the centering screws on the cutting head.
Fig. 5.6-3 Nozzle not centered
Fig. 5.6-4
Nozzle centered correctly
A B C
Nozzle aperture Laser burn mark on the adhesive tape Adhesive tape
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Operation
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The two centering screws (D) on the cutting head have right-handed threads.
Turning clockwise (cw) moves the nozzle towards the centering screw.
Turning counterclockwise (ccw) moves the nozzle away from the centering screw.
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Operation
1. 2. 3. 4. 5. 6. 7. 8. 9.
Affix a strip of transparent adhesive tape onto the nozzle in the cutting head. Select the HAND Setup values, machine view of the user interface. Enter a value of about 10 W (recommended value) for the Laser power, single pulse parameter. Enter a value of about 50 ms (recommended value) for the Pulse width, single pulse parameter. Close the HAND Setup values, machine view. The HAND view is active. Enable the hand-held controller using the Manual operation button. Close the safety door. Press PULS on the hand-held controller. Release and open the safety door.
10. Using a mirror, check whether the hole burnt into the adhesive tape is positioned exactly in the center of the nozzle aperture (see Fig. 5.6-4). 11. If necessary, correct the nozzle position using the centering screws. 12. Repeat step 1 to step 11 until the laser beam is fired exactly through the center of the nozzle.
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Operation
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Tactile detection (option)
Tactile detection is used primarily for materials that are electrical insulators. The tactile detection unit is fitted on the side of the cutting head.
5.6.5
Fig. 5.6-5
Tactile detection unit
no tactile detection unit
tactile detection unit fitted
A B D
E F A B C D E F Knurled screw Cover Grub screw Mounting screw Tactile detection unit Ring sensor
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5.6.5.1 Fitting the detection unit
Operation
1. 2. 3.
Undo the knurled screw (A) and remove the cover (B). Unscrew the two grub screws (C) fully. Place the tactile detection unit (E) carefully on the connection plate (check position of locating pins) and secure using the knurled screw (B). Use mounting screws (D) to attach the detection unit housing. The controller automatically detects the tactile detector.
4. 5.
5.6.5.2
Calibrating the detection unit The detection unit must be recalibrated after the following activities.

After changing the nozzle or the cutting head After changing the ring sensor
1.
Select the Calibrate nozzle Service function. The following message is displayed in the status bar: Calibrate, Press CONT to continue, STOP to terminate Press CONT on the hand-held controller. The calibration process is then performed automatically. The nozzle is lowered to the calibration plate and triggers contact. The sensor follows the movement and is also lowered to the calibration plate. The Z-axis then moves upwards until the nozzle clearance height given in the parameters is reached. This position is saved.
2. 3.
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Adjusting the focal point on the cutting head (where flat mirror fitted)
In machines without an adaptive optic, the focal position is set at the cutting head. This can only be done if you know the focal-point zero position of the cutting head. (See section 7.5.5 Setting the focal point for how to set the focal-point zero position).
5.6.6
Fig. 5.6-6
focal position
C H
A B C D E F G
Lens Focal-point zero position Jet Focal position in negative region Reference point for focal position Focal position in positive region Nozzle clearance height
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H Material thickness
Operation
The focal position for each material must be set manually on the cutting head based on the cutting parameter values.
Fig. 5.6-7 Measured focal-point zero position
B C
A B C
Focal-position scale (6 mm divisions) Measured focal-point zero position Adjusting-ring scale (0.2 mm divisions)
Measured focal-point zero position (B). 0 - 34 See label on cutting head (0 - 34 = Value (A) on the focal-position scale Value (C) on the adjusting-ring scale 0 34
34
/10 mm = 3.4 mm)
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1. 2. 3. 4. 5. 6. 7. 8. 9.
Create cutting job (see section 5.8.1.1 Creating a cutting job). Select the WORK view. Use the Info button to retrieve the cutting plan information. Find the cutting-head data. Change the cutting head and nozzle if necessary (find the required focal length and nozzle from the cutting plan information). Add the nozzle clearance height and focal position to the focal-point zero position (see examples below). Set calculated value on the cutting head. Start cutting process (see 5.8.1.4 Starting the cutting process). Assess cut (see Cutting technology folder). If the cutting result is unsatisfactory, correct the focal position on the cutting head until an optimum cut is obtained.
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Example 1:
Operation
Focal position for cutting stainless steel, thickness 3 mm, cutting head with 5 focal length.
Fig. 5.6-8 Calculating the focal position
Focal-point zero position Nozzle clearance (A) Focal position (B)
3.4 mm 1.0 mm 3.1 mm
a) b) b)
Focal position to be set Setting on cutting head

a) Measured value (see label on cutting head)
7.5 mm 6 - 15
c) d)
b) Value found from cutting parameters (cutting head data) c) Calculated focal position d) 7.5 mm = 75/10 mm = 6 + 15/10 mm
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Example 2: Focal position for cutting structural steel, thickness 20 mm, cutting head with 7.5 focal length.
Fig. 5.6-9
Calculating the focal position
Focal-point zero position Nozzle clearance (A) Focal position (B)
3.4 mm 1.0 mm -2.0 mm
a) b) b)
Focal position to be set Setting on cutting head

a) Measured value (see label on cutting head)
2.4 mm 0 - 24
c) d)
b) Value found from cutting parameters (cutting head data) c) Calculated focal position d) 2.4 mm = 24/10 mm = 0 + 24/10 mm
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5.7 Manual operation
Operation
The hand-held controller is a flexible extension to the operating terminal. It is connected to the CNC controller by a cable. The two functions most commonly performed with the hand-held controller are described below.

Separating cuts Shifting the zero point of the cutting plan
5.7.1
Separating cuts
This function is used for removing off-cuts or reducing the size of leftover sheets.
CAUTION
Making separating cuts The cutting head must always be lowered during cutting to prevent severe reflections or stray radiation. After pressing the BURN button, move the cutting head immediately, otherwise the laser beam can damage the trays under the shuttle table or the support grate.
Always make separating cuts using the parameters assigned to the material to be cut.
1. 2. 3.
Select the HAND view on the user interface. Select the Calibrate nozzle Service function and use the CONT button to start the process. Use the Manual operation button to enable the hand-held controller (the illuminated Tool button on the hand-held controller comes on).
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Operation
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4.
Use the buttons for the X- and Y-axes to move the cutting head into the required start position. The separating cut is started from this position. Press and hold the Z- button on the hand-held controller until the cutting head has lowered to the required nozzle clearance height. Then release the button. With the cutting head lowered, traversing is performed at a slower speed, enabling more precise positioning in the start position.
5.
6. 7.
Move the cutting head to about 1 mm beyond the edge of the sheet. Use the BURN button to open the shutter. The shutter stays open for as long as this button is pressed. Use the buttons for the X- and Y-axes to move in the desired direction for cutting the sheet.
8. 9.
Release the BURN button immediately once the separating cut is made. This closes the shutter. Press Z+ on the hand-held controller. The cutting head moves upwards.
5.7.1.1
Fine positioning using the hand-wheel Ideally, fine positioning of the cutting head is performed with the cutting head lowered.
1. 2. 3.
Hold down the JOG button on the hand-held controller. Select the required axis (the travel direction is irrelevant). Move the selected axis by turning the hand-wheel in the plus or minus direction.
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5.7.2 Shifting the zero point of the cutting plan
Operation
The zero point of the cutting plan is offset in order to be able to cut parts in any position on the shuttle table. The main applications are:

Use of leftover sheets Cutting without edge detection Material not located at the machine zero point.
Only use the origin-shift function for cutting single parts (not for large-format cutting plans). There is a risk that the cutting head may move beyond the existing sheet or the axes may travel into the end-stops if the cutting plan extends beyond the sheet as a result of shifting the origin.
To offset the origin of the cutting plan:
1.
Select the WORK view on the user interface and start a cutting job. The following message is displayed in the status bar: CNC: Execute cutting plan, Press CONT to continue, STOP to terminate
2. 3. 4.
The STOP ZERO stop function is actuated. The button is illuminated in yellow. Press CONT on the hand-held controller. The cutting head moves to the machine zero point. Select the Shift origin Service function. The following message is displayed in the status bar: CNC: Shift origin, Press CONT to continue, STOP to terminate Use the hand-held controller buttons for the X- and Y-axes to move the cutting head into the required start position. Press CONT on the hand-held controller. This confirms the new zero point. Press CONT on the hand-held controller. Execution of the cutting plan now starts from the new zero point.
5. 6. 7.
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Cutting process
The cutting process of the laser cutting machine is controlled via the ByVision user interface. Operation is performed from within the different user-interface views. These can be opened using the Menu button in the Navigation bar or the function keys F5 to F8 on the keyboard (see section 5.3 ByVision user interface).
5.8
5.8.1
Manual cutting process

The manual cutting process is the simplest way of starting a cutting process on the laser cutting machine. This process may differ from the process described here depending on whether the laser cutting machine is connected to other automation systems. The manual cutting process includes creating a cutting job (importing a cutting plan and allocating a cutting parameter file) and starting the cutting process.
5.8.1.1
Creating a cutting job A cutting job is always composed of the following information:

Cutting plan Cutting parameters Number of passes
Cutting plan A cutting plan specifies the contours of the parts to be cut. In addition, various technologies can be assigned to the individual contours. Cutting plans are saved with the filename extension .lcc or .ncp. Cutting parameters The cutting parameters depend on the material and thickness. These parameters are used to make the necessary changes to speed and power for the cutting process. Cutting parameters are saved with the .par filename extension.
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Number of passes
Operation
The number of passes defines how often the cutting plan is meant to be executed. Each pass requires a sheet of raw material in the same format as the cutting plan
1. 2. 3. 4.
Open the WORK view on the user interface. Use the Job list button to open the list of cutting jobs. Press the Add button in the job list. This opens the Add job dialog window. Select the root directory in which the cutting plans are saved. Confirm the selected root directory with OK.
Fig. 5.8-1 Selecting the root directory
Cutting plans can also be imported from other drives (floppy disk, CD, ZIP or network drive). See section 5.8.1.2 Importing a cutting plan.
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Operation
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5.
Select the cutting plan. When the Plan preview checkbox is enabled, the selected cutting plan is displayed in the preview window.
Fig. 5.8-2 Selecting the cutting plan
Confirming with OK adds the selected cutting plan to the bottom of the job list. The value Default has automatically been assigned for the cutting parameters. New parameters must be assigned based on the material to be cut. See section 5.8.1.3 Assigning cutting parameters 6. If there is more than one job in the list, the job order can be changed using the functions Prioritize, Move up one place and Move down one place.
All cutting jobs for which the value Default appears in the Parameters column use the cutting parameters from the previously executed cutting job. Further details on creating cutting jobs are given in the Online Help and in the ByVision user manual.
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5.8.1.2 Importing a cutting plan
Operation
A cutting plan import involves reading a cutting plan from any drive (floppy disk, CD, ZIP or network drive) and saving it in the defined destination directory.
1. 2. 3. 4. 5.
Open the WORK view on the user interface. Press the Import / Export button. The individual import and export functions are available. Press the Import job button. This opens the Import job(s) dialog window. Select the source directory and the cutting plan to be imported. More than one cutting plan can also be selected. Select the destination directory.
Fig. 5.8-3 Importing a cutting plan
6.
Press the OK button. The selected cutting plan is imported into the destination directory. If the Add imported job(s) to the job list checkbox is enabled, the cutting plan is placed at the bottom of the job list.
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Operation
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Assigning cutting parameters Each cutting job must be assigned appropriate cutting parameters for the material to be cut. Those cutting parameters available for selection depend on the configuration (laser machine, laser module etc.).
5.8.1.3
1. 2. 3. 4.
Open the WORK Job list view in the user interface. From the Prepared cutting jobs list, select the job to which cutting parameters are to be assigned. Press the Edit button. This opens the Edit job dialog window. Press the Select button. This opens the Parameter selection list dialog window.
Fig. 5.8-4 Parameter selection list
5.
The easiest way to find the required cutting parameter set is to use filter criteria (material, thickness, cutting gas, cutting head and additional information). The cutting parameter set can also be selected directly in the selection list. In this case, however, it is recommended to disable all active filters. If the cutting parameters are grouped in sub-directories (e.g. steel, stainless steel, aluminum etc.), they can be selected with button (A).
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Operation
6.
Confirming with OK assigns the selected cutting parameter set to the cutting job. All cutting jobs for which the value Default appears in the Parameters column use the cutting parameters from the previously executed cutting job.
Tab. 5.8-1
Material names
Material number
1.0161 1.0221 1.0332 1.4301 2.0000 2.1000 3.3535 3.7035
DIN name
St 37-2 QSt 37-2 StW 22 X5CrNi18 9 Cu CuZn40 AlMg3 Ti
Description
Structural steel Cold worked Sheet steel V2A (stainless steel) Copper Brass Peraluman 300 Titanium
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Operation
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Starting the cutting process Before the cutting process is started, the work piece must be placed in the loading position of the shuttle table, the axes must be in the reference position and the safety gate must be closed. Pressing the Shuttle table button on the shuttle table console (see section 4.2.5 Shuttle-table console) moves the shuttle table, together with the material placed on it, from the loading position into the machining area (ensure that the light barrier is enabled). The table interchange can also be actuated in the Handling Operation application (see section 5.4.7.1 Single table interchange).
5.8.1.4
The cutting head and nozzle must match the selected cutting parameters. In addition, the laser beam must be centered in the nozzle (see section 5.6.4 Centering the nozzle). The Info button in the WORK view can be used to open an Information window in order to check whether the cutting data is correct, for instance focal length of the cutting head, type of nozzle, material thickness etc.
1.
Press the Start button in the WORK view. The current job is imported with its assigned parameter file. The following message is displayed in the status bar: CNC: Execute cutting plan, Press CONT to continue, STOP to terminate
2.
Depending on which stop buttons are selected (STOP CYCL, STOP ZERO, STOP WORK or STOP SEL), you are prompted to enter the appropriate confirmation in the status bar with CONT or STOP to continue with the next program step. The stop buttons are used for checking the cutting process (before or after certain program steps). Section 5.3.10 Function buttons describes each of the Stop functions.
3. 4.
Select special functions (nozzle cleaning, Crossjet, edge detection, microjoints). Press CONT on the hand-held controller. This starts the cutting process.
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5.8.2 Automatic mode (manual loading and unloading)
Operation
Automatic mode with manual loading and unloading is understood to mean cutting with automatic table interchange. The cutting process continues until

there is no more material ready in the loading position and the Mat Pos button has not been pressed again all active jobs have been processed from the job list
How the material is loaded onto and unloaded from the shuttle table is not relevant. 5.8.2.1 Requirements

The machine is switched on and started up correctly The axes are sitting in the reference position The machine is in automatic mode There is at least one job in the job list. The correct parameters have been assigned (see section 5.8.1 Manual cutting process). Raw material for cutting is lying on a shuttle table. The buttons STOP CYCL, STOP ZERO, STOP WORK and STOP SEL must not be enabled during the cutting process.
5.8.2.2
Preliminary steps Before the cutting process can be started, the material status on the shuttle table in both the loading and cutting position must be defined. This is done using the Handling Operation application. No Stop buttons must be enabled if several cutting plans are to be processed. If one of these buttons is enabled then the cutting process is interrupted at the relevant point. A message appears in the status bar that must be confirmed with CONT or STOP.
The operator is responsible for ensuring that the correct raw material is placed on the table (material, format and thickness).
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Operation
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1. 2.
Switch to the Handling Operation program. Open the Manual Machine view. The material status of both shuttle tables is displayed in this screen.
Fig. 5.8-5 Manual Machine view
3.
Defining the material status:

z z
Use button (A) for the material status on the shuttle table in the loading position Use button (B) for the material status on the shuttle table in the cutting position
Automatic mode must be enabled (button (D) illuminated in green).
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Operation
4.
The following dialog window opens if the Mat Pos. button is pressed
Fig. 5.8-6 Dialog box for defining the material on the shuttle tables
A B C D
Raw material is on the shuttle table Cut material is on the shuttle table Material that has not finished being cut is on the shuttle table; the cutting job has been interrupted The shuttle table is empty
An automatic table interchange is performed if:

z z
the shuttle table in the cutting position contains cut material or is empty the shuttle table in the loading position contains raw material
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Operation
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Starting the cutting process
5.8.2.3
1.
Press the Start button in the WORK view. The current job is imported with its assigned parameter file. The following message is displayed in the status bar: CNC: Execute cutting plan, Press CONT to continue, STOP to terminate
2. 3. 4.
Select special functions (nozzle cleaning, Crossjet, edge detection, microjoints). Press CONT on the hand-held controller. This starts the cutting process if raw material is lying on the shuttle table (loading or cutting position). Once the cutting plan has finished, a table interchange is performed automatically.
5. 6.
Remove the cut material from the loading position and load new raw material onto the shuttle table. If there is a new uncut sheet on the shuttle table (in the loading position), press the Mat Pos button on the shuttle table console (see section 4.2.5 Shuttle-table console). This tells the controller that there is a new sheet in the loading position and an automatic table interchange can therefore be carried out.
7.
The shuttle table moves into the waiting position.
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5.9 Service functions
Operation
The Service functions are available for selection in every view.
5.9.1
Move to service position

The service position is used for changing the cutting head, replacing the nozzle and centering the nozzle. This function makes the cutting head move to a defined position in the machining area. The location of the service position can be defined in the HAND Setup values, machine view.
5.9.2
Move to parked position

This function makes the cutting head move to the rear left corner of the machining area. This provides unobstructed access to the machining area (e.g. for repair and maintenance work). The location of the parked position can be defined in the HAND Setup values, machine view.
5.9.3
Calibrate nozzle
This function makes the cutting head move over the calibration plate and launches an automatic calibration process. During calibration, the nozzle is lowered to the calibration plate until contact is triggered. Then the Z-axis moves upwards checking various nozzle clearance heights in the process. This function can be used for both the tactile and the capacitive detection system.
5.9.4
Clean nozzle
This function causes the nozzle head to pass several times over the brass brush on the shuttle table. Nozzle cleaning removes dirt, deposits and splashes of metal that have become attached to the nozzle as a result of the cutting process. The Number of cleaning passes is defined in the HAND Setup values, machine view. One can also specify here whether automatic nozzle cleaning should be performed at the end of a cutting plan and after a certain number of start cuts. The detection mechanism is calibrated automatically after each cleaning process.
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Operation
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Shift origin
The zero point of the cutting plan is offset in order to be able to cut parts in any position on the shuttle table (see section 5.7.2 Shifting the zero point of the cutting plan). Only use the origin-shift function for cutting single parts (not for large-format cutting plans). There is a risk that the cutting head may move beyond the existing sheet or the axes may travel into the end-stops if the cutting plan extends beyond the sheet as a result of shifting the origin.
5.9.5
5 - 86
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5.10
5.10.1
Operation
Special functions
Crossjet
The Crossjet prevents escaping slag from adhering to the surface of the work piece during the piercing cut. Section 3.8.8 Crossjet (option) describes the design of the Crossjet and how it works. The Crossjet has the following operating modes:

Oil mist Cross-blow facility
5.10.1.1
Registering the Crossjet Mount the Crossjet on the side of the cutting head and enable it using the Crossjet button in the WORK - Special functions menu.
WARNING
Risk of fire Oil vapor can ignite spontaneously in the laser beam or on hot material. Use only oil intended for Crossjet. The Supplier documentation contains further details. An oil mist is now sprayed onto the material before each piercing operation. The period for which the oil mist is sprayed is controlled using the Oil-mist time prior to piercing cutting parameter. No spraying is used before piercing in pulsed mode or before piercing after lowered positioning. The Crossjet can only be enabled when the cutting parameter Oil-mist time prior to piercing is given a value greater than zero, or the function Cross-blow after piercing is enabled.
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Operation
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Edge detection
Edge detection is used to find the zero point and the angle of the sheet if it is skewed. This enables better use of the raw material, and improves process reliability. The edge detection facility can be switched on or off under Special functions in the WORK view. It is recommended to use detection type 3 (X / Y / angle). The sheet should be placed on the shuttle table in loading position 1 (front left). Further details on the edge detection system are given in the Online Help and in the ByVision Operating instructions.
5.10.2
5.10.2.1
Edge detection using CutControl Edge detection with CutControl1) enables more accurate detection. When CutControl is employed, the following steps are performed in addition to normal capacitive edge detection:
1. 2. 3. 4. 5.
After capacitive edge detection the machine moves approximately 5 mm beyond the edge of the sheet. The laser beam is switched on using the values set for Laser power detection and Gas pressure detection. The cutting head moves towards the sheet edge until the edge is detected by CutControl. The axes stop and the measured detection value is saved. The machine moves to the next detection path and the process is repeated.
1) Only for structural steel and rust and acid-resistant steel using HK and H nozzles
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5.10.3 CutControl
Operation
Section 3.8.7 CutControl (option) describes the CutControl design and operation. 5.10.3.1 Working with CutControl The machine must be operating in perfect condition before you can use the CutControl facility. The cut quality and the cutting parameters must be correct (see Cutting technology folder). To check this, CutControl must be disabled (view HAND Setup values, machine). Input value: 0 = off 1 = on
1. 2.
Enable CutControl (view HAND Setup values, machine). The calibration threshold for the material to be cut is saved in the cutting parameters. Cutting can proceed immediately with these values without needing to find the thresholds manually. During production, the calibration threshold should be measured as a check, and if necessary changed in the cutting parameter file (see section 5.10.3.2 Measuring the calibration threshold).
3. 4.
CutControl is now ready to be used and the cutting plan can be started. CutControl stays enabled until the function is disabled, or the calibration value is set to 0 in the cutting parameter file.
In practice, however, the function must be switched off when cutting material types that CutControl cannot monitor.
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Operation
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Measuring the calibration threshold The calibration threshold is measured during a good cut in cutting mode or manual operation. In cutting mode, the calibration threshold can be measured using the cutting plan Cutcontr.lcc. This cutting plan is saved on the computer. Measure the calibration threshold as follows:
5.10.3.2
1. 2.
Load and run the Cutcontr.lcc cutting plan When cutting contour elements 1 to 5, the function Calibration during cut must be enabled for each contour by entering 1. This activates the calibration process. The measured value is displayed after about 2 seconds. This is the calibration threshold.
Fig. 5.10-1 Cutting plan Cutcontr.lcc
D Y C B A X
A B C D E
Contour element 1 Contour element 2 Contour element 3 Contour element 4 Contour element 5
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Operation
For the calibration, the values are always measured during a straight cut (both axes in positive and negative direction).
Tab. 5.10-1
Cutting sequence for the contour elements
Contour element
1 2 3 4 5
Cut direction
X+ X+ XY+ Y-
Measured values (example)

315 232 212 232 233 mean value: 245
Different values for the calibration thresholds will be obtained in each cutting direction (see Tab. 5.10-1). The mean value needs to be obtained from the values for the contour elements 1 to 5. in order to take into account the directional dependence. The mean value must be entered and saved under the Calibration threshold, gas type 2 cutting parameter. This measured value normally does not vary significantly, and so only needs to be checked occasionally during production. The calibration threshold can vary widely if cutting parameters change, or lenses become splashed or mirrors soiled. CutControl can still operate correctly over a very broad tolerance range however (see Tab. 5.10-2).
If a different type of material, or a known material with a different surface finish is being cut, a new calibration value must be measured. After calibration, or if cutting is stopped prematurely, the setup value is automatically reset.
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Operation
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Recommended values and tolerances for calibration thresholds
Tab. 5.10-2
Material thickness
1 mm 2 mm 3 mm 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm
Stainless steels
350 150 350 150 350 150 300 150 300 150 350 150 450 150 480 150 550 150
Structural steel
350 150 350 150 350 150 350 150 400 150 450 150
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5.10.3.3 CutControl functional check
Operation
The cutting plan Cutcontr.lcc checks that CutControl is working. This cutting plan is saved on the computer. Perform the following steps to check the operation of CutControl:
1. 2. 3. 4. 5. 6. 7.
Load a stainless steel sheet on the shuttle table Make sure that CutControl is enabled. Load the Cutcontr.lcc cutting plan. Assign cutting parameters. Perform a test cut by hand or using a rectangular test piece (to check the cut quality). Start the cutting plan Cutcontr.lcc. The calibration threshold can be checked using the first five contour elements (see section 5.10.3.2 Measuring the calibration threshold) CutControl operation can be checked during cutting of the star shapes. When functioning correctly, the system reacts at the points of the stars as follows:
z
8.
If the laser beam cuts off (welding), the cutting process is stopped and the axes move back to the position prior to where the laser beam cut off. Then cutting is performed slowly over the weld bead before accelerating to the original speed. If just the blue plasma flame appears (the material is still cut through), the machine reduces the cutting speed until the plasma flame disappears and then re-accelerates to normal cutting speed.
Both types of response can occur several times or in combination. A burr appears on those contours where cutting was performed at low speed.
If the machine does not react in the event of plasma formation or laser-beam cut-off, CutControl is not working properly. This means there is a fault.
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Operation
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Microjoints / Weld joints
Microjoints prevent cut parts from tilting or dropping down (see Cutting technology folder). The following types of microjoints are possible:
5.10.4
Automatic microjoints: Programmed microjoints: Weld joints:
These are enabled on the laser cutting machine. These are programmed in Bysoft and enabled on the laser cutting machine. These are programmed in Bysoft and enabled on the laser cutting machine.
Microjoints and weld joints cannot be used in combination within the same cutting plan.

Microjoints are used in thin sheets Weld joints are used in thicker sheets
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5.10.4.1 Automatic microjoints Automatic microjoints are set in a cutting plan as follows:
Operation
1.
Select the HAND Setup values, machine view of the user interface. Select the appropriate function under Setup values, microjoints. Input value: 0 = off 1 = on 2 = automatic 3 = Weld joint
2.
The minimum and maximum parts dimensions for automatic setting of a microjoint are defined using the values for Critical parts (HAND Setup values, machine view). The parameters are only active when automatic microjoints are enabled. The width of the microjoints is defined in the Width of microjoint cutting parameter. The microjoints programmed in Bysoft are also taken into account. The Online Help contains further details on this.
3.
Enable the function using the Microjoints button under Special functions of the WORK view.
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Operation
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Programmed microjoints Programmed microjoints are programmed as Microjoint in Bysoft and are already present in the cutting plan. The microjoints are enabled as follows:
5.10.4.2
1.
Select the HAND Setup values, machine view of the user interface. Select the appropriate function under Setup values, microjoints. Input value: 0 = off 1 = on 2 = automatic 3 = Weld joint All microjoints programmed in Bysoft are enabled. Further information on programming microjoints is given in the Bysoft Online Help.
2.
Enable the function using the Microjoints button under Special functions of the WORK view.
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5.10.4.3 Weld joints
Operation
Weld joints are programmed as Microjoint in Bysoft and are already present in the cutting plan. Unlike the microjoint, the weld joint must be programmed to lie as close as possible to the center of the contour because the weld joint is set on the kerf of an already cut contour. Weld joints are used mainly when cutting sheets greater than 4 mm in thickness, where the thickness of the material makes it difficult or impossible to break out the part. Weld joints are enabled as follows:
1.
Select the HAND Setup values, machine view of the user interface. Select the appropriate function under Setup values, microjoints. Input value: 0 = off 1 = on 2 = automatic 3 = Weld joint Further information on programming microjoints is given in the Bysoft Online Help.
2. 3.
The setup values for the weld joints are defined in the HAND Setup values, machine view. Enable the function using the Microjoints button under Special functions of the WORK view.
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Operation
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5 - 98
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Chapter 6
Maintenance
This chapter contains the maintenance schedule and tables for the maintenance record. Moreover, it lists all operating resources required for maintenance work.
6-1
Maintenance
Bysprint
6-2
Bysprint
6.1
6.1.1
Maintenance
Introduction
Safety regulations
Maintenance staff must be familiar with the technical details of the laser cutting machine. They must have read and understood all operating instructions and safety-related directions in these operating instructions. Always disconnect the machine from the supply when performing maintenance and repair work. Protect the main power switch with a padlock and store the key in a place inaccessible to a third party.
6.1.1.1
Work on live (hot) components
WARNING
Electric shock There is a risk of electric shock when working on live (hot) electrical parts. Electrical components on which maintenance work is being performed must be disconnected from the electrical supply unless otherwise specified.

Check that disconnected components are de-energized. Insulate any adjacent live (hot) parts.
6.1.1.2
Work on gear units
CAUTION
Risk of burns When carrying out maintenance and repair work on gear units still at the operating temperature there is a risk of burns. Allow gear units to cool down.
6-3
Maintenance
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6.1.1.3
Remaining in the danger zone During maintenance and repair work, no unauthorized persons are permitted to remain in the danger zone of the laser cutting machine. Fence off the danger zone.
6.1.1.4
Operating materials Always observe the manufacturers safety instructions when handling operating materials, in particular gear oil, solvents and grease.
6.1.1.5
External modules Always refer to the supplier documentation for all installed external modules (e.g. extraction system, cooling unit etc.).
6.1.1.6
Tools, test equipment and spare parts

Use only the tools and test equipment listed. Use only original spare parts from the manufacturer (see Spare parts catalog).
6.1.2

Maintenance personnel must be able to perform the following tasks as a minimum:

Operation of the machine control system Repair work on pneumatic and hydraulic systems Replacement, repair and adjustment of mechanical components Making mechanical and electrical adjustments to the machine
6-4
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6.2 Customer service information
Maintenance
The manufacturer's Customer Services department is available in the event of problems. Please have the following information ready before calling the department, so that problems and queries can be dealt with as quickly as possible:

Company / Address Contact person Order and equipment number (see type plate)
The contact address appears in the front of this operating manual.
6-5
Maintenance
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6.3
Operating materials
Section 7 Repair specifies the use of resources, lubricants and cleaning materials.
Tab. 6.3-1
Resources and cleaning materials
Description
Usage
Order code
4-10845 10006011
Lubrication set (in tool box) Filter replacement pack Kerosene

Tab. 6.3-2 Lens cleaning kit
Ultrapac 2000 filter system Chapter 7.4.6.1 Chapter 7.4.2.1
Qty
Description
Lens cleaning kit Section 7.5.4.6 / 7.5.4.7 / 7.5.4.8 / 7.5.4.9 / 7.5.4.10
Order code
10006021
1 1 4 1 1 1 1 1 1 1 5 1
Air bulb Bottle of acetone (100 ml) with separate pipette 50 sheet pack of lens cleaning paper 7 12 cm 100 sheet pack of lens cleaning paper 15.2 22.8 cm Pack of 170 Q-Tips cotton buds Pack of makeup-remover cotton-wool pads Bottle of lens polish (60 ml) Bottle of de-ionized water (100 ml) Bottle of (6%) acetic acid (100 ml) with separate pipette Mount for optical elements Pair of disposable latex gloves, size M Cleaning instructions
10003299 500615 500822 10003298 10006017 10003300 10006018 10006016 10006015 90000623 10000925
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Tab. 6.3-3 Lubricants
Maintenance
Lubricant / Supplier
Leybold TST - Oil 22
Make / Type
Special oil
Usage
Leybold turboblower (3000 W only)
Section
(see laser module operating instructions) (see laser module operating instructions) Chapter 7.4.4.1 Chapter 7.4.4.2
Part.no.
1974102
Leybold GS 32
Compressor oil
Vacuum pump in laser module
1973601
Motorex 190 EP Mobilux EP2 Shell Alvania EP 2 Gulf EP 2 BP Energrease LS-EP 2 Castrol LMX Grease Dow Corning Molykote DX Paste
Universal grease
Linear guides, store
1971661
Special grease
Grease for shuttle-table drive (for 3015 format only), rack-and-pinions on cutting bridge and cutting carriage Gears for lifting unit and shuttle table Crossjet Roller chains
Chapter 7.4.2.4
1973609
Motorex Gearsynth 220 Mobil Glygoyle 30 Motorex Proweld 264 Motorex Chainlube 622
Gear oil Welding protection oil Chain lubricant
Chapter 7.4.2.4 Chapter 7.4.2.5 Chapter 7.4.6.4 Chapter 7.4.2.1 Chapter 7.4.3.3
1974002 8861850 1972790
6-7
Maintenance
Bysprint
6.4
Operating hours display

The definitive operating hours for the relevant maintenance tasks are displayed on the laser module operating-hours counter.
Fig. 6.4-1
Position of the operating-hours counter (laser module 2200)
Fig. 6.4-2
Position of the operating-hours counter (laser module 3000)
A B C
Laser module Operating-hours counter Laser control cabinet (MCS)
6-8
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6.5 Maintenance schedule
Maintenance
The following maintenance schedule serves as a reference guide for planning and implementing maintenance work on the laser cutting machine.
Maintenance tasks on the laser module are described in the operating instructions for the type of laser module fitted.
6-9
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Maintenance
Maintenance work Object Notes/Instructions Action Operating resource resources daily
Interval As necessary
X X X X X X X
monthly
1 000 h
3 000 h
Laser cutting machine Safety devices
Chapter 7.3
Check for external damage Complete cleaning Check that the EMERGENCY STOP buttons, light barrier and limit-of-travel monitoring switches are working correctly and effectively Clean screen Clean keyboard Check that the flaps on the extraction sectors are working Clear chambers Empty trays Clean wheels
X X X
Operating terminal Base frame Extraction chambers Small-parts trays
Chapter 7.4.1.1 Chapter 7.4.1.2 Chapter 7.4.3.1 Chapter 7.4.3.1 Chapter 7.4.3.2 Chapter 7.4.3.2
6 - 10
8 000 h
weekly
yearly
500 h
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Maintenance
X
monthly
1 000 h
3 000 h
Extraction unit
Dust removal system; empty dust hopper when full see supplier documentation Empty the dust hopper when changing material from steel to aluminum or vice versa. Clean the oil/water filters Inspect seals on doors visually. Replace if necessary Check connecting pipes for leaks. Repair if necessary Check extraction performance Check filter resistance Visual check of filter elements for caking. Replace if necessary
X X X X X X
6 - 11
8 000 h
weekly
yearly
500 h
Bysprint
Maintenance work Object Notes/Instructions Action Operating resource resources daily Interval
Maintenance
see Supplier documentation
Extraction unit
Inspect dust remover and platform for damage or corrosion, and check that they are fitted securely. Repair or replace if necessary Replace all filter elements Hinged-plate conveyor; check working properly Geared motor; change oil Motorex Gearsynth 220 (VG220 or as specified on type plate) X
Small-parts conveyor (option)
6 - 12
As necessary
monthly
1 000 h
3 000 h
8 000 h
weekly
yearly
500 h
Bysprint
Maintenance
X X WKS chain spray Molykote DX-Paste Motorex Gearsynth 220 (VG220 or as specified on type plate) X X X X X X
monthly
1 000 h
3 000 h
Chapter 7.4.2.3 Chapter 7.4.2.2 Chapter 7.4.2.1 Chapter 7.4.2.4 Chapter 7.4.2.4 Section 7.4.2.5 Chapter 7.4.2.4 Section 7.4.2.5 Chapter 7.4.2.6
Clean guide of any cutting residues and lubricate Check roller-chain tension Clean and lubricate roller chain Clean and lubricate toothed gears (drive and lifting unit) Geared motors for table-interchange and lifting-unit drive; inspect gear oil for soiling. Change oil if necessary Geared motors for table-interchange and lifting-unit drive; change oil Check clearance between shuttle table and end stop
Brush, cloth
6 - 13
8 000 h
X
weekly
yearly
500 h
Bysprint
Maintenance
X X
monthly
1 000 h
3 000 h
Supply unit
Chapter 7.4.6.1 Chapter 7.4.6.1
Air dryer (air filter); check LED display Air dryer (air filter); replace dryingagent cartridge. Indicated by LED display Air dryer (air filter); replace inlet and outlet filters. Indicated by LED display Replace activated charcoal filter Replace filter and inlet filter Crossjet; check oil level, top up if necessary. Moisten seal in cap with a small amount of oil Crossjet; check that safety valve is working Clean muffler if necessary Motorex Proweld 264 Filter replacement pack 10006011
X X
Chapter 7.4.6.1 Chapter 7.4.6.1 Chapter 7.4.6.1 Chapter 7.4.6.4
X X X
X X
6 - 14
8 000 h
X
weekly
yearly
500 h
Bysprint
Maintenance
X X
monthly
1 000 h
3 000 h
Cutting bridge Cutting carriage
Chapter 7.4.4.2 Chapter 7.4.4.1 Chapter 7.4.4.3
Clean and lubricate rack-and-pinion Lubricate linear guides Check bellows for damage. Replace if necessary Check optical components. Clean if necessarya) Check bellows and seals for damage. Replace if necessary Check adaptive optic mirror for soiling. Clean if necessary
Dow Corning Molykote DX Universal grease Motorex 190 EP X Cleaning kit X X
X X
Beam guidance system
Chapter 7.5 Chapter 7.4.4.3 Chapter 7.5.3
a) Dismantled mirrors must be aligned after refitting. The beam guidance system must only be aligned by personnel who have been trained by the manufacturer of the laser cutting machine in performing this task.
6 - 15
8 000 h
weekly
yearly
500 h
Bysprint
Maintenance
X X X
monthly
1 000 h
3 000 h
Cutting head
Chapter 7.4.5.1
Check lens for dirt, metal splashes or scratched surface. Clean or replace if necessary Check coupling (water) for leaks Check condition of seals. Replace missing or damaged O-rings. Check condition of nozzle and copper plate. Clean or replace if necessary Clean cutting head externally Check that tactile detection system is working
Chapter 7.4.5.2 Chapter 7.4.5.3 Chapter 7.4.5.4 Chapter 5.6.5
X X X X
6 - 16
8 000 h
weekly
yearly
500 h
Bysprint
Maintenance
X X
monthly
1 000 h
3 000 h
Pneumatics Safety door
Check all loads, valves and hoses for leaks Guides; check and clean Clean and lubricate roller chain Replace gas bottles Check supply lines for leaks Universal grease Motorex 190 EP WKS chain spray
X X X
Cutting-gas supply
Chapter 7.4.7
6 - 17
8 000 h
weekly
yearly
500 h
Maintenance
Bysprint
6.6
Maintenance record
The following tables can be copied and used as a record of maintenance work carried out. This record must be kept in the machine logbook. Maintenance and repair work must be recorded with the date and signature of the person carrying out the maintenance tasks. The maintenance record forms the basis for any warranty claims.
Warranty is only valid in its entirety if a correctly maintained logbook is produced.
6 - 18
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Maintenance record according to operating hours Operating hours
500 1 000 1 500 2 000 2 500 3 000 3 500 4 000 4 500 5 000 5 500 6 000 6 500 7 000 7 500 8 000
Maintenance
Perform maintenance at following intervals

500 500 / 1 000 500 500 / 1 000 500 500 / 1 000 / 3 000 500 500 / 1 000 500 500 / 1 000 500 500 / 1 000 / 3 000 500 500 / 1 000 500 500 / 1 000 / 8 000
Date
Signed
Comments
6 - 19
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Operating hours
8 500 9 000 9 500 10 000 10 500 11 000 11 500 12 000 12 500 13 000 13 500 14 000 14 500 15 000 15 500 16 000 16 500
Maintenance

500 500 / 1 000 / 3 000 500 500 / 1 000 500 500 / 1 000 500 500 / 1 000 / 3 000 500 500 / 1 000 500 500 / 1 000 500 500 / 1 000 / 3 000 500 500 / 1 000 / 8 000 500
Date
Signed
Comments
6 - 20
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Operating hours
17 000 17 500 18 000 18 500 19 000 19 500 20 000 20 500 21 000 21 500 22 000 22 500 23 000 23 500 24 000
Maintenance

500 / 1 000 500 500 / 1 000 / 3 000 500 500 / 1 000 500 500 / 1 000 500 500 / 1 000 / 3 000 500 500 / 1 000 500 500 / 1 000 500 500 / 1 000 / 3 000 / 8 000
Date
Signed
Comments
6 - 21
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Maintenance record according to calendar Year:
w = weekly m = monthly a = annually
Maintenance
Calendar week
01 02 03 04 05 06 07 08 09 10 11 12 13
Maintenance at following intervals

w w w w/m w w w w/m w w w w/m w
Date
Signed
Comments
6 - 22
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Maintenance
Year:
Calendar week
14 15 16 17 18 19 20 21 22 23 24 25 26

w w w/m w w w w/m w w w w/m w w
Date
Signed
Comments
6 - 23
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Maintenance
Year:
Calendar week
27 28 29 30 31 32 33 34 35 36 37 38 39

w w/m w w w w/m w w w w/m w w w
Date
Signed
Comments
6 - 24
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Year:
Maintenance
Calendar week
40 41 42 43 44 45 46 47 48 49 50 51 52

w/m w w w w/m w w w w/m w w w w/m/a
Date
Signed
Comments
6 - 25
Maintenance
Bysprint
6 - 26
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Chapter 7
Repair
This chapter forms the basis for all maintenance work according to the maintenance schedule. It provides support in locating and rectifying faults. It also contains instructions on how to carry out lubrication, care and cleaning tasks, and how to perform repairs and make adjustments.
7-1
Repair
Bysprint
7-2
Bysprint
7.1
7.1.1
Repair
Introduction
Safety regulations
Maintenance staff must be familiar with the technical details of the laser cutting machine. They must have read and understood all operating instructions and safety-related directions in these operating instructions. Always disconnect the machine from the supply when performing maintenance and repair work. Protect the main power switch with a padlock and store the key in a place inaccessible to a third party.
7.1.1.1
Work on live (hot) components
WARNING
Electric shock There is a risk of electric shock when working on live (hot) electrical parts. Electrical components on which maintenance work is being performed must be disconnected from the electrical supply unless otherwise specified.

Check that disconnected components are de-energized. Insulate any adjacent live (hot) parts.
7.1.1.2
Work on gear units
CAUTION
Risk of burns When carrying out maintenance and repair work on gear units still at the operating temperature there is a risk of burns. Allow gear units to cool down.
7-3
Repair
Bysprint
Remaining in the danger zone When performing maintenance and repair work, no unauthorized persons are permitted to remain in the danger zone of the laser cutting machine. Fence off the danger zone.
7.1.1.3
7.1.1.4
Operating materials Always observe the manufacturers safety instructions when handling operating materials, in particular gear oil, solvents and grease.
7.1.1.5
External modules Always refer to the supplier documentation for all installed external modules (e.g. extraction system, cooling unit etc.).
7.1.1.6
Tools, test equipment and spare parts

Use only the tools and test equipment listed. Use only original spare parts from the manufacturer (see Spare parts catalog).
7-4
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7.1.2
Repair

Maintenance personnel must be able to perform the following tasks as a minimum:

Operation of the machine control system Repair work on pneumatic and hydraulic systems Replacement, repair and adjustment of mechanical components Making mechanical and electrical adjustments to the machine
7-5
Repair
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Troubleshooting
The troubleshooting checklist describes a general procedure for identifying the causes of operating faults. If you do not know why a fault has arisen during operation, follow the troubleshooting steps in the order below.
7.2
1.
Refer to messages issued by the machine. Error messages and remedial actions are described in the Online Help and in the ByVision operating instructions.
2.
Localize the fault. Is the fault mechanical or electrical? Is it a hardware or software fault (error message MMC / CNC / PLC)?
3.
Identify the cause of the fault. One fault often leads to other faults.
4.
Frequency of fault Does the fault occur all the time, or do certain events lead to the fault?
5.
Environmental conditions Check the laser cutting machine:

z z z
Obstruction due to soiling, foreign objects, damage? Supply connections OK ? (power supply, compressed air) Ambient conditions, climatic influences (e.g. heat, storm, etc.)?
6. 7.
Interference from other equipment and loads (voltage spikes)? Check sensors and switches:
z z z
Illuminated pushbuttons on operating terminal and ensure EMERGENCY STOP buttons are enabled. Sensors, limit switches, safety limit switches. Leeds on the input and output modules.
7-6
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Repair
8.
Wiring and terminals Check installations for loose connections and open circuits.
9.
Switches and settings Has an object been replaced, and could the settings now be incorrect?
10. Initialization Shut down the entire system and re-start. 11. Supplier documentation Other operating instructions may contain information on the fault and troubleshooting. 12. Telephone Call the manufacturer's Customer Services department (see section 7.8 Customer service information).
7-7
Repair
Bysprint
Safety inspection
Check safety and monitoring devices such as EMERGENCY STOP buttons and light barrier at the specified maintenance interval to ensure that they are working properly and effectively. Information on the safety components is given in section 3.2 Safety and monitoring devices.
7.3
7.3.1
EMERGENCY STOP buttons

Functional testing of the EMERGENCY STOP circuit must be performed during an active cutting process for each EMERGENCY STOP button on the laser cutting machine.
1. 2.
Set up the machine and start the cutting process. Press EMERGENCY STOP button. The EMERGENCY STOP circuit is working correctly if all electrical loads are disconnected from the power supply. The power supply to the controller is not switched off. EMERGENCY STOP buttons are fitted:
z z z z z
on the operating terminal on the hand-held controller on the shuttle-table console on the front panel of the laser module 2200 on the laser module 3000 control cabinet
3.
Reset the actuated EMERGENCY STOP button and re-start the laser cutting machine. See section 5.2.5 Restarting after an EMERGENCY STOP
7-8
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7.3.2 Light barrier on shuttle-table system
Repair
Follow the procedure below to perform the light-barrier functional test.
1. 2.
Enable the light barrier (Reset light barrier button on the shuttletable console). Start the table interchange (Table interchange button on the shuttle-table console or Handling Operation, Manual Machine view). Trip the light barrier while the table interchange is in progress. The monitoring system for the danger zone on the shuttle table is working correctly if the table interchange stops immediately.
3.
4. 5.
Enable light barrier. Continue the table interchange.
7-9
Repair
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Limit-of-travel monitoring
Limit switches on X-axis and Y-axis Follow the procedure below to perform the functional test on the limit switches on the X-axis and Y-axis.
7.3.3
7.3.3.1
Fig. 7.3-1
Position of the limit switches
1 2 3 4
Limit switch, position X- / Y+ Limit switch, position X- / YLimit switch, position X+ / Y+ Limit switch, position X+ / Y-
1. 2.
Select the HAND view on the user interface. Use the Manual operation button to enable the hand-held controller (the illuminated Tool button on the hand-held controller comes on). Use the buttons for the X- and Y-axes to move the cutting head into the respective limit-of-travel position until the limit switch trips. The actuated limit switch is displayed in the HAND view. If nothing appears on the display for a limit-of-travel position, the limit switch concerned must be replaced by the manufacturer's Customer Service department. Once all limits switches have been tested successfully with no faults, reference the machine.
3. 4.
5.
7 - 10
Bysprint
7.3.3.2 Limit switch on Z-axis
Repair
Follow the procedure below to perform the functional test on the Z-axis limit switches.
1. 2. 3.
Move shuttle tables into servicing 5.4.7.3 Advanced operation).
position
(see
section
Select the HAND view on the user interface. Use the Manual operation button to enable the hand-held controller (the illuminated Tool button on the hand-held controller comes on). Use the buttons for the X- and Y-axes to move the cutting head into approximately the center of the cutting area. Use the Tool button to switch off detection. Use the Z- and Z+ buttons to move the cutting head into the respective limit-of-travel position until the limit switch trips. The actuated limit switch is displayed in the HAND view. If nothing appears on the display for a limit-of-travel position, the limit switch concerned must be replaced by the manufacturer's Customer Service department. Once both limits switches have been tested successfully with no faults, reference the machine.
4. 5. 6. 7.
8.
7 - 11
Repair
Bysprint
Lubrication, service and cleaning work
Operating terminal
Never use a solvent-based cleaning agent for cleaning. Solvents or strong cleaning agents can damage the screen surface or the keyboard.
7.4
7.4.1
7.4.1.1
Cleaning the screen Before cleaning the screen it must be disabled by selecting the Clean screen function (user interface, MAIN view). If necessary, use a soft cloth lightly moistened with water to clean the screen.
Fig. 7.4-1
Operating terminal
7.4.1.2
Cleaning the keyboard Before cleaning the keyboard, shut down the computer and switch off the controller. If necessary, use a soft cloth lightly moistened with soapy water to clean the keyboard.
7 - 12
Bysprint
7.4.2
7.4.2.1
Repair

Roller chain
Clean the roller chain with a kerosene-soaked cleaning cloth, and check for wear or damage. Replace chain if necessary. Lubricate with grease or spray Lubricant: NLGI grade 2 or grade 3 e.g. Motorex 190 EP or WKS chain spray if necessary (See section
Check chain tension. Re-tighten 7.4.2.2 Roller chain tension)
Fig. 7.4-2
Roller chain on shuttle-table system
7 - 13
Repair
Bysprint
Roller chain tension The chain tensioner is located in the machine frame. Overtightened chains load the drive unnecessarily and are subject to increased wear. Chains that are too loose tend to skip teeth.
7.4.2.2
Fig. 7.4-3
Horizontal chain tensioner
A B C
Tensioning screw with nut and lock nut Sprocket Roller chain
The sag (D) in the unloaded roller chain should equal about 1% of the shaft separation (E). Shaft separation: 4867 mm.
Fig. 7.4-4 Roller chain sag
sag = shaft separation x 0.01
7 - 14
Bysprint
Repair
1. 2. 3. 4. 5. 6. 7. 8.
Move tables to the loading position. Switch laser cutting machine off and safeguard against being switched on again. Remove the rear panel. Unscrew locknut. Tighten roller chain firmly. Tighten the locknut. Check roller-chain sag Refit the rear panel.
7 - 15
Repair
Bysprint
Guide
7.4.2.3
Use a cloth or wire brush to remove cutting residues from the hexagonal guide Spray lightly with oil and wipe down with a dry cloth Lubricant: oil spray
Fig. 7.4-5
Hexagonal guide on shuttle-table system
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7.4.2.4 Lifting unit drive and gearing
Repair
Clean and lubricate the toothed gears on the lifting unit every 1 000 operating hours Lubricant: Molykote DX Paste
Check the gear oil for soiling every 3 000 operating hours. Change oil if necessary Check the gear oil every 8 000 operating hours Lubricant: Motorex Gearsynth 220 (VG 220)
Synthetic oil must not be mixed with mineral oil.
Fig. 7.4-6
Lifting unit drive and gearing
A B
Bleeder screw Screw cap
7 - 17
Repair
Bysprint
Table interchange drive
7.4.2.5
Check the gear oil for soiling every 3 000 operating hours. Change oil if necessary Check the gear oil every 8 000 operating hours Lubricant: Motorex Gearsynth 220 (VG 220)
Synthetic oil must not be mixed with mineral oil.
Fig. 7.4-7
Geared motor (protective cover removed)
A B
Bleeder screw Screw cap
7 - 18
Bysprint
7.4.2.6 Rubber buffer
Repair
Check the distance between shuttle table and rubber buffer annually. The distance (X) between shuttle table and rubber buffer must equal at least 50 mm when the roller chain is tensioned. Adjust the length of the roller chain if the distance is less than this value.
Fig. 7.4-8 Distance between shuttle table and rubber buffer
A B
Shuttle table Rubber buffer
7 - 19
Repair
Bysprint
Base frame
Extraction system
7.4.3
7.4.3.1
Remove the cutting residues from the extraction chambers weekly. The extraction chambers must be cleared completely when changing material from steel to aluminum or vice versa. Check monthly that the flaps on the extraction sectors are working. When the cutting head is positioned above a sector, the corresponding extraction-sector flap below must be open.
Fig. 7.4-9
Extraction sector flaps
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7.4.3.2 Small-parts trays

Repair
Empty the small-parts trays daily Clean the wheels weekly
Fig. 7.4-10
Small-parts trays
7 - 21
Repair
Bysprint
Safety door
7.4.3.3
Clean and lubricate the gears every 500 operating hours Lubricant: Motorex 190 EP universal grease
Clean and lubricate the roller chains every 500 operating hours Lubricant: WKS chain spray
Fig. 7.4-11
Guide and roller chain on safety door
B A
A B
Safety-door guide Safety-door roller chain
7 - 22
Bysprint
7.4.4
7.4.4.1
Repair
Cutting bridge and cutting carriage (X-axis and Y-axis)

Linear guides Use a grease gun to lubricate the X- and Y-axis linear guides every 1 000 operating hours Lubricant: Motorex 190 EP universal grease
Fig. 7.4-12
Linear guides
A B
Grease nipple on X-axis linear guide Grease nipple on Y-axis linear guide
7 - 23
Repair
Bysprint
1. 2.
Move to zero point. Disconnect machine from power supply (switch off main power switch, and safeguard against being switched on again). Move the carriage by hand to the center of the bridge. Use grease gun to lubricate the linear guides at grease nipples (A) and (B) (three shots per grease nipple). Move the carriage by 100 mm each time when greasing (to distribute the grease).
3.
4. 5. 6.
Move the carriage backwards and forwards by hand. Switch on the machine. Check that the limit-of-travel monitoring is working correctly and effectively (see section 7.3.3 Limit-of-travel monitoring).
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7.4.4.2 Rack-and-pinion
Repair
Clean and lubricate the rack-and-pinion every 1 000 operating hours Lubricant: Molykote DX
Fig. 7.4-13
Cutting-carriage guide
A B C
Top guide roller Rack-and-pinion Bottom guide roller
7 - 25
Repair
Bysprint
1. 2.
Move to zero point. Disconnect machine from power supply (switch off main power switch, and safeguard against being switched on again). Move the carriage by hand to the center of the bridge. Remove the four screws on the bellows on the side of the cutting carriage. Remove the guard plates. Move the bellows away from the center of the bridge. Remove emergent grease and dirt with a clean cloth. Clean rack-and-pinion with kerosene. Wipe rack-and-pinion with a dry cloth. Grease the rack-and-pinion. Fit bellows and guard plates. Move the bridge back and forth by hand.
3.
4. 5. 6. 7. 8. 9.
10. Switch on the machine. 11. Check that the limit-of-travel monitoring is working correctly and effectively (see section 7.3.3 Limit-of-travel monitoring).
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7.4.4.3 Bellows Check all bellows for damage and replace if necessary.
Fig. 7.4-14 Bellows on X-axis, Y-axis and beam guidance system
Repair
Fig. 7.4-15
Bellows on Z-axis
7 - 27
Repair
Bysprint
Cutting head
Lens Visually inspect lens for dirt, metal splashes or scratched surface. Clean or replace lens if necessary (see section 7.5.4 Cutting head).
7.4.5
7.4.5.1
Fig. 7.4-16
Visual inspection of the lens in the cutting head
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7.4.5.2 Water couplings Check water couplings on the rear of the cutting head for leaks.
Fig. 7.4-17 Water coupling
Repair
A B
Cutting head Water coupling
7 - 29
Repair
Bysprint
Cutting head mounting Check seals. Replace missing or damaged O-rings.
7.4.5.3
Fig. 7.4-18
Seals on the cutting head mounting
A B
Cutting head mounting Seals (O-rings)
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7.4.5.4 Nozzle
Repair
Check nozzle and copper plate for damage or splashes of metal. Clean or replace if necessary. See section 5.6.3 Changing the nozzle for how to replace nozzle
Fig. 7.4-19 Nozzle and copper plate on cutting head
A B
Copper plate Jet
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Repair
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Supply unit
7.4.6
WARNING
Risk of injury from flying parts and escaping air Do not perform any assembly or disassembly work, or unscrew or tighten any screw connections, while the system is under pressure. Before starting any maintenance or repair work on the supply unit, switch off the laser cutting machine and safeguard against being switched on again. Drops in air pressure in the pneumatic system and beam path are monitored by pressostats, and displayed as errors on the operating terminal.
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Bysprint
Fig. 7.4-20 Supply unit
Repair
C D F
A B C D E F
Pressure governor Active charcoal filter Water filter / pre-filter Filter Air drier Fault indicator for air filter
7 - 33
Repair
Bysprint
Air drier (adsorption drier) The air drier issues an error message when the filter or cartridge needs replacing (message on screen: beam path air pressure is missing). This triggers the stop function STOP WORK.
7.4.6.1
Fig. 7.4-21
Ultrapac 2000 air filter
Check the LED display to make sure that the air drier really was the source of the error message. The LEDs (B, C and D) indicate whether the prefilter, post-filter or dryingagent cartridge needs replacing.
Fig. 7.4-22 LED indicator on the air filter
A B C D
A B C D
Operation indicator Replace drying agent cartridge Replace post-filter Replace pre-filter
The precise procedure is given in the Ultrapac 2000 operating instructions in the supplier documentation folder. The filter replacement pack can be obtained from the manufacturer of the laser cutting machine.
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7.4.6.2 Reset switches
Repair
After replacing the drying agent cartridge, you must flip the Reset switch with the machine switched off (resets the last-change counter). The Reset switch is located behind the LED display cover.
Fig. 7.4-23 Reset switch on the control board
Only operate the Reset switch once after each cartridge change. Resetting the last-change counter only works with the machine switched off.
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Repair
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Cleaning the muffler Perform visual inspection monthly. If there are powder residues in the pipe, the muffler must be cleaned.
7.4.6.3
Fig. 7.4-24
Muffler unit
A B C D E
A B C D E F
Pipe Hose clip Clamping screw Clamping plate Machine frame Muffler
7 - 36
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Fig. 7.4-25 Dismantled muffler
Repair
G G H I J K L
Base with casing bolts Mesh sleeve Inner sleeve Mesh Cap Nuts
Use only air, not water, to clean out the inner sleeve
Before starting: the machine casing must be removed from in front of the muffler.
1. 2. 3. 4. 5. 6. 7. 8.
Undo hose clip (B) and take off pipe (A) Unscrew clamping screws (C) and clamping plate (D). Lift out muffler unit (1/4 turn) Undo casing bolts and dismantle muffler (F) Clean parts; use air or water to clean out mesh sleeve (H), but only use air to blow-clean inner sleeve (I) Re-assemble muffler (F) and re-fit Re-connect pipe (A) and tighten hose clip (B) Screw clamping plate (D) back on
7 - 37
Repair
Bysprint
Crossjet oil container, topping up with oil The oil container for the Crossjet oil is located in the supply unit. Check oil level weekly and top up with oil if necessary. Lubricant: Motorex Proweld 264
7.4.6.4
This oil is flame retardant and is therefore suitable for the oil mist.
CAUTION
Risk of fire Oil vapors can ignite spontaneously on the laser beam or on the hot surface of the material. Only use the correct oil for the task and at the correct metering rate. For further information please refer to the safety data sheet (see the supplier documentation folder).
Fig. 7.4-26 Crossjet oil container
C D
A B C D
Safety valve Oil supply coupling Compressed-air supply coupling Oil container cap
7 - 38
Bysprint
Repair
CAUTION
Oil container safety valve The safety valve is set to the correct setting during installation. Changing this setting impairs its operation. Never damage or remove the safety valve seal. Do not change the safety valve setting.
1. 2. 3.
Disconnect the compressed air supply at coupling (C) Disconnect the oil supply at coupling (B) Open safety valve (A) by pulling in the direction of the arrow, and let the compressed air escape. Always make sure that the oil container is not under pressure (check gage).
Fig. 7.4-27 Bleeder valve
4. 5. 6. 7.
Unscrew the oil container cap (D). Top up container with oil (up to max. fill level). Lubricant: Motorex Proweld 264 Moisten seal in cap with a small amount of oil. Replace the cap. Connect compressed air and oil connections
7 - 39
Repair
Bysprint
Bleeding the Crossjet If all the oil has been used up, the line must be bled again after filling.
7.4.6.5
1. 2. 3.
Select the HAND view on the user interface Enable the Oil mist special function Press the JET button on the hand-held controller until oil escapes from the Crossjet.
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Bysprint
7.4.7 Cutting gas, changing gas bottles
Repair
The cutting-gas bottles can be replaced during operation (see section 7.4.7.3 Changing gas bottles during operation).
CAUTION
Handling cutting-gas bottles Make sure that you replace bottles carefully and cleanly to avoid dirt entering the gas pipeline. Secure gas bottles in place. Always screw on safety caps to unconnected bottles being stored.
WARNING
Risk of explosion Do not oil or grease oxygen connections. This could lead to an explosion from a chemical reaction.
7 - 41
Repair
Bysprint
General instructions

7.4.7.1
Never let the bottles empty completely. Always return the bottles with a residual pressure of at least 1 bar. When changing the cutting-gas bottles, make sure that you use the correct gas quality. Never use a lower gas quality than specified. See section 3.13.1 Cutting gas quality. The cutting process is stopped if the cutting gas runs low. The error message GAS JET ERROR is displayed on the screen. The cutting process is stopped and the laser excitation is switched off if the laser gas runs low. The error message GAS ERROR is displayed on the screen. After rectifying the problem of low laser gas, the active error message must be cleared on the laser controller or on the user interface (see section 5.3.8 System, status and error messages).
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Bysprint
7.4.7.2
Fig. 7.4-28
Repair
Cutting-gas fittings
Fittings for cutting-gas supply
F E E
A B C D E F
Gage (high pressure) Gage (reduced pressure) Reducing valve Stop valve (high pressure) Bottle connection Supply to laser cutting machine
7 - 43
Repair
Bysprint
Changing gas bottles during operation
7.4.7.3
CAUTION
Eye injuries from swirling dirt particles The cutting-gas bottles are under pressure (200 bar). Always wear safety glasses when blowing out the valve.
1. 2. 3. 4. 5. 6.
Check that the stop valve (D) to the full bottle is closed. Open the bottle valve on the new bottle briefly to blow out any accumulated dirt. Close stop valve (D) to the empty bottle. Connect line to full bottle. Open stop valve (D) to the full bottle. Adjust reducing valve (C) (25 bar max.).
z z
to 18 bar for oxygen (O2) to 25 bar for nitrogen (N2)
7. 8.
Close the bottle valve on the empty bottle. Remove empty bottle from the cabinet and fit with safety cap. Insert new bottle and secure in place.
The bottle valves must be closed if the system is to be out of operation for a prolonged period (longer than 8 hours). Otherwise pressure builds up if the valves are not completely air-tight. This can ruin the pressure control valve in the cutting carriage.
7 - 44
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7.5
Repair
Beam guidance system - optical components
CAUTION
Damage to optical components and parts Optical components and parts are soiled or damaged by improper handling. Always wear disposable gloves when cleaning, replacing or checking the optical system (type: powdered Latex, non-sterile, EN 455 class 1). Make sure that the work place is clean.
Dismantled mirrors must be aligned after refitting. The beam guidance system must only be aligned by personnel trained to do so by the manufacturer of the laser cutting machine. The relevant documentation is issued during the training course. Check deflecting mirrors monthly or as necessary for damage and soiling. Clean or replace if necessary.
7 - 45
Repair
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Optical components
Deflecting mirror The laser cutting machines use various mirrors that look identical on the outside. The type and properties of the mirrors can only be identified by the order code on the optical element. Either a directly cooled or indirectly cooled mirror is fitted depending on the model.
7.5.1
7.5.1.1
Fig. 7.5-1
Directly cooled deflecting mirror
Fig. 7.5-2
Indirectly cooled deflecting mirror
7 - 46
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7.5.1.2 Adaptive optic (option)
Repair
The adaptive optic basically consists of the mirror and housing. This optic forms a unit that can only be removed as a complete assembly.
Fig. 7.5-3 Adaptive optic
7.5.1.3
Cleaning the deflecting mirrors and lens in the cutting head The lens and mirror surfaces have a special coating. Damage to the coating reduces the beam quality. Special care must therefore be taken when handling optical components. Damage can occur in the following ways:

particles of dirt burnt on by the laser beam particles of dirt that leave scratches on the surface during cleaning removal of the coating from the mirror or lens surface.
7 - 47
Repair
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Cleaning / replacing the deflecting mirrors
Check the following points:

7.5.2
Only remove the cooling-water pipes when replacing a directly cooled deflecting mirror (see Fig. 7.5-4). Do not adjust setscrews (B).
Fig. 7.5-4
Directly cooled deflecting mirror
A D B
F C G H I J
Fig. 7.5-5
Indirectly cooled deflecting mirror
A D E F C G H I J
7 - 48
Bysprint
Repair
A B C D E F G H I J
Mirror mounting Setscrew (do not adjust) Deflecting mirror Cooling water connections Cooler (only in directly cooled deflecting mirror) Fixing screws for mirror holder (4 off) Mirror holder Pressure spring O-ring Deflector vee-block
Repair work on the deflecting mirrors exceeding the specific tasks described must only be performed by specially trained skilled staff from the manufacturer. Contact the manufacturer's Customer Services department (see section 7.8 Customer service information).
When you replace a machine mirror, note down its position, the date and number of operating hours on the back of the mirror.
1. 2. 3. 4. 5.
Switch machine off and safeguard against being switched on again. Remove beam-path cover. Unscrew the fixing screws (F) on the mirror holder (4 off). If a directly cooled deflecting mirror is to be replaced, disconnect cooling-water pipes. Remove the mirror holder (G) from the vee-block and place it with the mirror facing upwards.
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Repair
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6. 7. 8.
Push the mirror out of its holder, i.e.out of the O-ring, by pressing on the cooler (E). You can now hold the exposed mirror around its edge and remove it from the holder. Insert a new or cleaned mirror. Hold the mirror around its edge (avoiding finger marks). Use Kodak paper to insert the mirror into the O-ring.
9.
Make sure that the mirror mounting is absolutely clean before inserting the mirror holder.
10. Insert the mirror holder into the mirror mounting in the correct position, and tighten the four fixing screws evenly. 11. If a directly cooled deflecting mirror has been replaced, connect cooling-water pipes. 12. Fit all covers and switch the machine back on. 13. A trial cut must be performed before proper cutting with the machine is possible. This will establish whether the beam deflection has been altered. To do this: 14. Insert Z-axis alignment gage
Fig. 7.5-6 Alignment gage
7 - 50
Bysprint
Repair
15. Fire onto a cardboard plate in alignment position 4.

Fig. 7.5-7 Alignment positions
Cutting table
16. Check that the burn point lies in the center. Permitted tolerance 0.5 mm. Align beam path if necessary
Fig. 7.5-8 Laser beam not centered
Fig. 7.5-9
Laser beam in correct position
17. Re-center nozzle (see section 5.6.4 Centering the nozzle).
7 - 51
Repair
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Adaptive optic (option)
Cleaning Always remove and fit the adaptive optic as a complete unit (see Fig. 7.53).
7.5.3
7.5.3.1
Fig. 7.5-10
Z-axis deflecting mirror (adaptive optic)
D A C
A B C D
Pressure sensor Fixing screws Water supply line Water return line
1. 2. 3. 4. 5.
Switch machine off and safeguard against being switched on again. Remove beam-path cover. Unscrew the fixing screws (A) on the mirror holder (4 off). Take the adaptive optic out of the vee-block and place it with the mirror facing upwards. Clean the mirror.
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6. 7. 8. 9.
Repair
Make sure that the mirror mounting is absolutely clean before inserting the cleaned optical component. Insert the mirror holder into the mirror mounting in the correct position, and tighten the four fixing screws evenly. Fit all covers and switch the machine back on. A trial cut must be performed before proper cutting with the machine is possible. This will show up any change in the beam deflection. To do this:
10. Insert the alignment gage for the Z-axis and, in alignment position 4, fire onto a cardboard target (see Fig. 7.5-7). 11. Check that the burn point lies in the center. Permitted tolerance 0.5 mm. Align beam path if necessary (see Fig. 7.5-8 and Fig. 7.59). 12. Re-center the laser beam in the nozzle (see section 5.6.4 Centering the nozzle).
7 - 53
Repair
Bysprint
Measuring the characteristic curve The characteristic curve is used to compensate for variations in the position of the focal point (dependent on the beam properties) over the cutting area. The optical components and beam guidance system must be in perfect condition to measure the characteristic curve.
7.5.3.2
Fig. 7.5-11
Position of curve points
Beam entry
Y+
X+
Beam length
3015 format
Curve point 1
600 mm
2
1 425 mm
3
2 250 mm
4
3 075 mm
5
3 900 mm
The measured curve can vary from machine to machine as a result of differing beam-path ventilation. The characteristic curve may need to be re-measured after a change in the optical system of the laser module (especially the output coupler or adaptive optic).
7 - 54
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Repair
Cutting head: Cutting plan: Material:
7.5" focal length see Tab. 7.5-1 (saved on the computer) Rust and acid-resistant steel X5CrNi18-10 DIN 1.4301
Thickness:
see Tab. 7.5-1.
Fig. 7.5-12
Test part, dimensions in [mm]
Tab. 7.5-1
Material thickness based on the laser module used
Laser module
2200 3000
Cutting head
7.5" 7.5"
Material thickness
6 mm 10 mm
Cutting plan
Test_Inox_6mm_22_N2.lcc Test_Inox_10mm_30_N2.lcc
7 - 55
Repair
Bysprint
1. 2.
Select the HANDSetup values, machine view of the user interface. Select Setup values, adaptive optics 1, operating mode 1 and set the values for Characteristic curve, pressure correction 1 to 5 to 0 bar.
Tab. 7.5-2 Pressure correction settings
Curve point 1
0 bar
2
0 bar
3
0 bar
4
0 bar
5
0 bar
3. 4. 5.
Import cutting plan (see Tab. 7.5-1 for file name) and assign cutting parameters. Move to reference position. Move to curve point 1 (minimum beam length). See Fig. 7.5-11 for beam length.
Fig. 7.5-13 Curve point 1
Y+
X+
6.
Set the focal point on the cutting head to 6 - 20. Leave the default value for the focal position in the cutting parameters.
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Repair
7.
Cut test piece at characteristic-curve point 1. Assess the cut quality against the criteria under Cutting technology. Adjust the focal position on the cutting head in steps of 1 mm in the positive and negative direction until the cut quality deteriorates significantly. The optimum value lies in the center of the good range. Set the focal position on the cutting head to this value. Guide value: 6 - 20
3 mm
Do not change the focal position in the cutting parameters.
8.
Move to curve point 5 (maximum beam length). See Fig. 7.5-11 for beam length.
Fig. 7.5-14 Curve point 5
Y+
X+
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Repair
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9.
Under Setup values, adaptive optics 1, correct the values for Characteristic curve, pressure correction 1 to 5 using the table below.
z z
A larger pressure results in a lower focal position A smaller pressure results in a higher focal position
A pressure correction of 0.24 bar is equivalent to a change in the focal position of about 1 mm.
Tab. 7.5-3 Pressure corrections
Curve point 1 2 3 4 5
0 bar 0 bar 0 bar 0 bar 0 bar
0.06 bar 0.03 bar 0 bar -0.03 bar -0.06 bar
10. Cut test piece at characteristic-curve point 5. Assess the cut quality against the criteria under Cutting technology. Correct characteristic curve in steps of 0.12 bar, and cut further test parts at curve point 5. Adjust the characteristic curve in the positive and negative direction until the cut quality deteriorates significantly. The central value between these upper and lower limits can be used to give the best cut quality. This sets the characteristic curve, which is saved. Interpolate along a straight line to obtain the correction values for intermediate points 2 to 4. Do not change the focal position in the cutting parameters.
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Repair
11. Joining curve points 1 and 5 gives a straight line as the characteristic curve. Typical characteristic curves vary between 0 to 0 and 0 to -0.48
Fig. 7.5-15 Examples of typical characteristic curves
Tab. 7.5-4
Values of curve pressure-correction at points 1 to 5
Characteristic curve
A B C
Curve point 1
0 bar 0 bar 0 bar
2
0 bar -0.03 bar -0.06 bar
3
0 bar -0.06 bar -0.12 bar
4
0 bar -0.09 bar -0.18 bar
5
0 bar -0.12 bar -0.24 bar
12. By making test cuts at the intermediate points, the characteristic curve can be checked and corrected if necessary.
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Repair
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Cutting head
Replacing the lens

7.5.4
7.5.4.1
Smoking is strictly forbidden when working with optical elements. Take utmost care, and work to the highest standards of cleanliness when handling optical elements. It is essential to have a clean work environment (if possible an office), a clean work surface and clean materials and tools. Wear latex disposable gloves
WARNING
Damage to a lens Take utmost care if a lens is damaged as the lens contains zinc selenide and thorium. If lenses are intact, no radioactive material can escape. However, if the lens is badly scratched or thermally damaged, radioactive material can escape into the environment. These materials may cause damage to health if inhaled.

Wear breathing mask and gloves. Do not stir up dust. Materials that have come into contact with the broken lens or lens dust must be cleaned thoroughly with water or disposed of as hazardous waste! Return damaged lenses to the manufacturer of the laser cutting machine. After cleaning, wash your hands thoroughly under running water.
Refer to the safety data sheets in the supplier documentation for further measures and safety information.
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7.5.4.2 Equipment
Repair
The following items are required when fitting and removing a lens:
Tool kit (in tool box) Lens wrench Circular rod Lubrication set (in tool box) Cleaning kit (in tool box)
Fig. 7.5-16
Lens wrench and circular rod
A B C
A B C D
Lens wrench Threaded pin (fixes handle extension) Inner piece of circular rod Outer piece of circular rod
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Repair
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Construction of cutting heads The cutting heads (5" and 7.5" focal length) do not differ externally. The difference lies in the lens holder, which defines the focal length of the cutting head.
7.5.4.3
Fig. 7.5-17
5" cutting head
A B
Cutting head 5" lens holder (see Fig. 7.5-18)
The lens holder is different depending on the focal length of the cutting head. Always check the labeling (5", 7.5") when assembling.
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Fig. 7.5-18 5" lens holder
Repair
A B C D E F G
A B C D E F G
Lens holder O-ring Lens holder Lens holder O-ring Lens O-ring Clamping ring Lens nut
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7.5" cutting head
Fig. 7.5-19
A B
A B
Cutting head 7.5" lens holder (see Fig. 7.5-20)
The lens holder is different depending on the focal length of the cutting head. Always check the labeling (5", 7.5") when assembling.
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Fig. 7.5-20 7.5" lens holder
Repair
A B C D E F G
A B C D E F G
Lens holder O-ring Lens holder Lens holder O-ring Lens O-ring Clamping ring Lens nut
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Removing the lens holder
7.5.4.4
1. 2.
Place cutting head on a clean surface. Unscrew fixing screws on lens holder and pull the lens holder out of the cutting head by hand.
Fig. 7.5-21 Removing the lens holder
Do not twist the lens holder as you pull it out.
3.
Check lens holder O-ring. Replace damaged O-rings. Apply minimal grease to O-ring before fitting (Syntheso Proba 270). No residual grease should be visible.
4.
Place the lens holder on a clean surface (with the lens nut facing upwards).
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7.5.4.5 Removing the lens
Repair
1.
Remove handle extension from lens wrench. The handle extension is not needed to exert the required torque to undo/tighten the lens.
Fig. 7.5-22 Removing the handle extension
A B
Lens wrench Handle extension
2.
Clean lens wrench with compressed air.
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3.
Unscrew the lens nut using the lens wrench.

Fig. 7.5-23 Remove the lens nut (5" lens holder)
A B C
5" lens holder Lens wrench for 5" lens nut Lens nut
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Repair
Fig. 7.5-24
Remove the lens nut (7.5" lens holder)
D E F
7.5" lens holder Lens wrench for 7.5" lens nut Lens nut
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4.
Position the outer part of the circular rod in the lens holder.
Fig. 7.5-25 Circular rod in position
A B C
5" lens holder Outer piece of circular rod 7.5" lens holder
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Repair
5.
Rotate the lens holder through 180 and carefully lift it off. If the lens does not come away from the lens holder, press down lightly on the lens from above with a cotton bud (inserted in the inner part of the circular rod).
Fig. 7.5-26 Using a cotton bud to exert gentle pressure if lens is stuck fast
A B C D
Inner piece of circular rod Cotton bud Lens Outer piece of circular rod
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6.
After removal, the clamping ring and the lens are located on the circular rod. Replace scratched or damaged lens. Clean soiled lens.
Fig. 7.5-27 Dismantled lens
A B C
Lens Clamping ring Outer piece of circular rod
7.
Position the dismantled lens in the lens holder1).

Fig. 7.5-28 Lens placed in mount for optical elements
1) Included in cleaning set
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7.5.4.6 Cleaning lenses and mirrors
Repair
The equipment required for cleaning is kept in the cleaning case. Cleaning instructions are placed in the lid of the cleaning case.
Fig. 7.5-29 Lens cleaning kit
A B C D E F G H I J K
Lens cleaning paper 15.2 22.8 cm Makeup-remover cotton wool pads Disposable gloves (type: powdered Latex, non-sterile, EN 455 class 1), size M De-ionized water, 100 ml bottle Acetic acid with separate pipette, 100 ml bottle Q-Tips cotton buds Mount for optical elements Acetone with separate pipette, 100 ml bottle Lens polish, 60 ml bottle Air bulb Lens cleaning paper, 7 12 cm
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The following points must be observed when working with optical elements:

Smoking is strictly forbidden when working with optical elements. Never clean the surface of the mirrors or lenses dry. Never use compressed air on the mirrors or lenses. Contaminants in the compressed air can penetrate the surface. Store cleaning paper, cotton buds and cotton pads in a dust-free environment. Dispose of after use. Always use just the cleaning materials provided. Replace caps on bottles after use. Wear disposable gloves. Finger prints reduce the lifetime of mirrors and lenses. Set up workplace away from the laser module. Do not allow solvent vapor to enter the beam path. Check the labeling on the mirrors and lenses. Re-attach detached labels. Fit cleaned mirrors immediately. Observe direction of installation.
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7.5.4.7 Cleaning in the case of light soiling
Repair
Light soiling means particles that can be removed by blowing them off. Use air bulb to blow off dirt from optical element (dry nitrogen is also allowed). Never use a blow gun. Blowing off deflecting mirrors using the air bulb in very dirty factory shops must be checked on a case-by-case basis. In order to prevent the optical surface ending up even dirtier, you must proceed to the next cleaning step (acetone).
7.5.4.8
Cleaning in the case of moderate soiling If optical elements cannot be cleaned adequately using the air bulb, proceed as follows:
1.
Place optical element in the mount (included in the cleaning kit).

Fig. 7.5-30 Lens placed in mount for optical elements
2.
Place lens cleaning paper (7 12 cm) on the optical component and drop 2 to 3 drops of acetone onto it.
Fig. 7.5-31 Lens cleaning paper with 2 to 3 drops of acetone
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3.
Draw the lens cleaning paper slowly horizontally over the mirror or lens, making sure that no smearing occurs and leaving a dry clean surface. Smears lead to irregular absorption of the laser beam.
Fig. 7.5-32
Draw the lens cleaning paper over the mirror or lens
4. 5.
The procedure can be repeated more than once. Use a fresh lens cleaning paper for each operation. Use cotton buds to clean the mirror surface if soiling is more severe. Take particular care when using this cleaning method. Apply only light pressure. Avoid scratching the mirror from dirt particles adhering to the cotton wool buds. The cotton buds must be prepared before use so that they are as soft as possible for the optical element to be cleaned. Before using each cotton bud, pull the cotton wool apart slightly with your fingers and then re-twist in the opposite direction. Wear disposable gloves.
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Repair
6.
Sprinkle lens cleaner (acetone) on a clean cotton bud and clean the optical element for no longer than 30 seconds, working from the inside out in circular movements. Only exert gentle pressure on the surface of the optical component. Turn the cotton bud steadily about its longitudinal axis so as to remove as much dirt as possible.
Fig. 7.5-33 Lens cleaning using an acetone-soaked cotton bud
A B 7.
Direction of rotation of cotton bud Circular movement to clean mirror
Finally, to remove any smears, clean the optical element again using lens cleaning paper as described in step 2 and step 3.
Fig. 7.5-34 Draw the lens cleaning paper over the mirror or lens
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Cleaning in the case of heavy soiling If optical elements cannot be cleaned adequately using the air bulb, and subsequent cleaning with acetone does not give a satisfactory result, use acetic acid to clean the mirror surface. Take particular care when using this cleaning method. Apply only light pressure. Avoid scratching the mirror from dirt particles adhering to the cotton wool buds. Do not let the edges of an optical element come into contact with the acetic acid.
7.5.4.9
1.
Do not perform the cleaning process for longer than 30 seconds. Apply only light pressure.
Fig. 7.5-35 Lens cleaning using a cotton bud soaked in acetic acid
A B
Direction of rotation of cotton bud Circular movement to clean mirror
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Repair
2.
To remove any residual acetic acid or smears, clean the optical element using lens cleaning paper and acetone as described in section 7.5.4.8 Cleaning in the case of moderate soiling (step 2 and step 3).
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Cleaning in the case of stubborn dirt Polishing has an abrasive action and is only used when all other cleaning attempts described in section 7.5.4.7 to section 7.5.4.9 have failed to give the desired result.
7.5.4.10
CAUTION
Damage to the optical element The polish has an abrasive action and can attack the coating on the optical element if not used properly. Polishing the surface of the optical element for too long, too often or with too high a pressure removes the optical coating. This modifies the properties of the coating, identifiable by a change in color of the surface of the optical element. Polish the surface of the optical element for no longer then 30 seconds maximum. Perform no more than 2 polishing operations. Avoid exerting high pressure.
1. 2. 3.
Shake the polish well before use. Sprinkle a few drops of the lens polish onto a cotton ball (make-up remover cotton-wool pad). Move the cotton ball carefully over the surface, using only the pressure of its own weight and making circular movements, for not longer than 30 seconds. Do not let the polish dry onto the surface of the optical element.
4.
Soak a fresh cotton ball (make-up remover pad) with de-ionized water and use it to carefully remove the polish. Repeat this process with a fresh cotton ball, including the edge of the optical element in the action.
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Repair
5.
Moisten a fresh cotton bud with acetic acid. Use this to remove any polish still remaining by cleaning from the inside out with circular movements (see Fig. 7.5-35). Moisten a fresh cotton bud with acetone. Use this again to clean from inside out using circular movements. Moisten a fresh cotton bud with acetone. Wipe the cotton bud in overlapping movements gently over the surface of the optical element until all polish residues have been loosened.
Fig. 7.5-37 Lens cleaning using an acetone-soaked cotton bud
6. 7.
8.
Place a piece of lens cleaning paper on the optical element; drop 2 3 drops of acetone onto the paper and wipe the element by sliding the paper off sideways to leave a dry and clean surface (see section 7.5.4.8 Cleaning in the case of moderate soiling).
If cleaning with polish is still unsuccessful or if burn marks in the coating are visible, the optical element must be replaced.
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Fitting the lens The lens holder is different depending on the focal length of the cutting head. Always check the labeling (5", 7.5") when assembling.
7.5.4.11
1.
Check O-ring for damage. Replace if necessary. The O-ring must not be greased.
2.
Place clamping ring with O-ring, right side up, on the circular rod.
Fig. 7.5-39 Clamping ring with O-ring
A B
A B C 3.
O-ring Clamping ring Outer piece of circular rod
Place lens on the O-ring with the curvature facing upwards.

Fig. 7.5-40 Clamping ring and lens located on the circular rod
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Repair
C D
Outer piece of circular rod Lens
4.
Slide the lens holder over the prepared package and push it in as far as the end stop.
Fig. 7.5-41 Inserting the lens in the lens holder
5" lens holder
7.5" lens holder
5.
Turn the lens holder through 180 and remove the circular rod.
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6.
Grip the lens holder firmly in one hand. With the other hand, use the lens wrench to screw in the lens nut, applying continuous force to tighten.
Fig. 7.5-42 Screw in the lens nut and tighten
F E
I H
E F G
5" lens holder Lens wrench for 5" lens nut Lens nut
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Repair
H I J
7.5" lens holder Lens wrench for 7.5" lens nut Lens nut
Do not tighten the lens nut with a jerking action. Sharp jerking movements cause jolts to the lens, which can damage it. The clamping ring is tensioned correctly when the four slits are closed (see Fig. 7.5-43).
Fig. 7.5-43 Correct seating of lens
Tightening the clamping ring too severely may damage the lens.
Poorly fitted lens A poorly fitted lens will cause cutting problems and ultimately destroy the lens.
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Fitting the lens holder The lens holder is different depending on the focal length of the cutting head. Always check the labeling (5", 7.5") when assembling.
7.5.4.12
Fig. 7.5-44
Lens holder
C A
A B C
Cutting head Lens holder Fixing screws on the lens holder
1. 2.
Place cutting head on a clean surface. Check lens holder O-ring. Replace damaged O-rings. Apply minimal grease to O-ring before fitting (Syntheso Proba 270). No residual grease should be visible.
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Repair
3. 4. 5.
Slide the lens holder into the cutting head by hand until it reaches the second O-ring. Align the fixing-screw holes on the circle of holes. Push the lens holder in as far as the end stop. Do not twist the lens holder in this position.
6. 7.
Tighten the fixing screws on the lens holder using a ball-end screw driver. Insert the cutting head in the Z-axis and center the nozzle (see section 5.6.4 Centering the nozzle).
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Setting the focal point
The procedure for setting the focal point differs depending on the type of optical component fitted:

7.5.5
In machines with flat mirrors (operating mode 0): measure the focalpoint zero position using a single pulse. In machines with an adaptive optic (operating mode 1): measure the focal-position reference setting using a cutting test.
7.5.5.1
Measuring the focal-point zero position using a single pulse (operating mode 0) In machines fitted with flat mirrors, the focal-point zero position must be re-measured when a new lens is fitted, and then set manually.
Fig. 7.5-45
Focal-point zero position
Focal-point zero position
The focal-point zero position is measured using a single pulse. Self-adhesive notes are needed for this measurement (e.g. Post-it notes, 76 76 mm).
Fig. 7.5-46 Post-it note with burn holes
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Repair
1. 2. 3. 4. 5. 6. 7. 8. 9.
Set the adjusting ring to the focal-point zero position specified on the cutting-head label. Fit nozzle (e.g. HK20). Check that nozzle is centered (see 5.6.4 Centering the nozzle). Set focal position 0-20 on the adjusting ring. Stick a self-adhesive note over the nozzle aperture. Select the HAND Setup values, machine view of the user interface. Enter a value of about 60 W for the Laser power, single pulse parameter. Enter a value of about 20 to 100 ms for the Pulse width, single pulse parameter. Close the HAND Setup values, machine view. The HAND view is active. Enable the hand-held controller using the Manual operation button.
10. Close the safety door. 11. Press PULS on the hand-held controller. Check that the hole created on the note paper is identifiable as a hole and has sharp contours. If not, increase the laser power or the pulse width. 12. Release and open the safety door. 13. Move the note paper slightly. Move the focal position downwards by turning the adjusting ring through 0.5 mm (focal position 0-25). 14. Repeat step 10 to step 13 a number of times, until the smallest possible hole is found. It is then best to use smaller steps (e.g. 0.2 mm) to carry out a fine adjustment.
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15. The setting for which the smallest possible hole was obtained is the focal-point zero position. 16. If this measurement gives a different focal-point zero position, attach a new label with this new measured value on the cutting head.
Fig. 7.5-47 Label showing focal-point zero position
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7.5.5.2
Repair
Measuring the focal-position reference setting (operating mode 1) In machines fitted with an adaptive optic, the focal-position reference setting must be re-measured using a cutting test when a new lens is fitted, and then set manually. Cut the following test part for this test.
Fig. 7.5-48
Test part for measuring the focal-position reference setting
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Specification
Tab. 7.5-5
Laser module used

Bylaser 2200 Bylaser 2200 Bylaser 3000 Bylaser 3000
Cutting head
5 7.5 5 7.5
Material thickness
3 mm 6 mm 3 mm 10 mm
Cutting plan
Test_Inox_3mm_22_52_N2.lcc Test_Inox_6mm_22_N2.lcc Test_Inox_3mm_22_52.lcc Test_Inox_10mm_30_N2.lcc
1.
Set the adjusting ring on the cutting head to the old reference value or the following default value:
z z
Reference value 5: 6 00 Reference value 7.5: 6 50
2.
Load correct raw material onto the machine at table point 1.

Fig. 7.5-49 Raw material at table point 1
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Repair
3. 4. 5. 6. 7.
Create cutting job (see 5.8.1 Manual cutting process). Select and fit the nozzle specified in the cutting parameter file. Check that nozzle is centered (see 5.6.4 Centering the nozzle). Cut contour and assess the result. Correct the focal position at the adjusting ring until you achieve the same cutting quality as before removing and fitting the lens. If the cutting test gives a different focal-position reference setting, attach a new label with this new measured value on the cutting head.
Fig. 7.5-50 Label showing focal-position reference setting
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Repair
Tactile detection (option)
Broken sensor in tactile detection system The sensor is positioned using the pin (A) and fastened with the fixing screw (C). A broken sensor means that the pin, the fixing screw or both parts have broken off.
7.6
7.6.1
7.6.1.1
Fig. 7.6-1
Ring sensor with fixing screw
A B C
Pin with set breaking point Ring sensor Fastening screw with set breaking point
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7.6.1.2 Repairing a sensor break
Repair
1. 2. 3. 4. 5.
Press STOP on the hand-held controller to interrupt the current operation. Use the hand-held controller to raise the cutting head and move it into the service position. Open the safety door and remove the tactile detection unit (including cutting head). Place the cutting head, sensor and spare parts on a clean table top. De-pressurize the pneumatic cylinders by pressing an Allen key onto the tip (D) of the coupling.
Fig. 7.6-2 De-pressurizing the pneumatic cylinders
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6.
Pull the head section forward until the Allen screws (E) are visible. Undo both screws.
Fig. 7.6-3 Undoing the head section
7.
Undo cylinder-head screws (F) and pull the head section out of the guide.
Fig. 7.6-4 Removing the head section
Pull the head section out carefully from the guide. The head section can only be pulled about 5 cm forward because it is connected to the lead to the sensor (see Fig. 7.6-5).
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Repair
Fig. 7.6-5
Head section removed
max.
5 cm
Fig. 7.6-6
Cross-section of tactile detection unit
8.
Force or twist out the broken part of the pin or fixing screw. Disconnect the lead for better access.
Fig. 7.6-7 Connecting lead with head section removed (rear view)
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9.
Fit the connecting lead again, and push the head section into the guide. Tighten the screws.
10. Check that the head section can be moved in the housing without collision. 11. Fit the sensor and tighten the fixing screw. 12. Check whether the sensor is in the center of the nozzle (visual check only).
Fig. 7.6-8 Centering the ring sensor.
13. Fit cutting head (see section 5.6.2 Changing the cutting head). 14. Reference the tactile detection unit (see section 5.6.5 Tactile detection (option)).
X X X X
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7.6.2 Converting adaptive optic 1 to a flat mirror
Repair
The flat mirror needs to be used if one of the following components fails:

Mirror in adaptive optic 1 Pressure sensor Proportional valve Pressure booster station Prescon card
After the flat mirror conversion, the laser cutting machine can continue to be used for cutting as a temporary solution. If the adaptive mirror or the pressure sensor fails then the whole mirror unit (including pressure sensor) is replaced.
CAUTION
Damage to optical components and parts Optical components and parts are soiled or damaged by improper handling. Always wear disposable gloves when cleaning, replacing or checking the optical system (type: powdered Latex, non-sterile, EN 455 class1). Make sure that the work place is clean.
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Adaptive Optic 1 and flat mirror
Fig. 7.6-9
F A B C D E F G H I Vent
Sensor cable connector Pressure sensor Adaptive mirror Flat mirror Cooling water return Fixing screws (4 off) Cooling water supply Protective cap
7.6.2.1
Conversion procedure
1.
Shut down the whole system (laser module, machine, cooling unit) and disconnect from the power supply (switch off main power switch, and safeguard against being switched on again). Take off the cutting head (prevents dirt getting on the lens). Disconnect the sensor cable (B) in the cutting carriage.
2. 3.
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Repair
4. 5. 6. 7.
Disconnect the cooling water supply (H) and return pipes (F) from the adaptive mirror. Unscrew the fixing screws (G) (4 off). Remove the adaptive mirror (D) and affix the protective cap. Fit the flat mirror (E) and connect the cooling water supply and return pipes. Once the flat mirror has been fitted, the cooling-water circuit needs to be converted. See section 7.6.2 Converting adaptive optic 1 to a flat mirror for details of how to convert the cooling-water circuit
8.
Call in the site electrician, and switch off the motor safety switch labeled Pressure booster for adaptive mirror circuit in the cooling-unit control box (see diagram in supplier documentation). Close the cover of the cutting carriage.
9.
10. Select operating mode 0. 11. Ignore error message. 12. Set the focal position manually (see 5.6.6 Adjusting the focal point on the cutting head (where flat mirror fitted)).
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Cooling circuit before converting to flat mirror
7.6.2.2
Fig. 7.6-10
Connectors in the cutting carriage when operating with the adaptive optic
H G
F E D C
A B C D E F G H
T-connector after proportional valve Mirror coupling Extension tube (tube color: brown) Cutting head coupling Return line (tube color: orange) Supply line (tube color: red) Return line from cutting head (tube color: brown) Supply-line coupling
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7.6.2.3 Cooling circuit after converting to flat mirror
Repair
If the pressure booster station fails, the cooling-water return from the cutting head (Z-axis) is diverted into the cooling-water circuit for the flat mirror.
Fig. 7.6-11 Connectors when operating with flat mirror
G I H
E D C J
A B C D E G H I J
T-connector after proportional valve Mirror coupling Extension tube (tube color: brown) Cutting head coupling Return line (tube color: orange) Return line from cutting head (tube color: brown) Supply-line coupling Additional coupling Additional coupling
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1.
Disconnect supply-line coupling (H); use two plugs and an additional coupling taken from the extension tube (C) to close off the supply line. Disconnect couplings (B) and (D). Close off return line (E) with a plug and additional coupling (J). Connect return line from cutting head to connector (A). For model with tank heater: connect return line from cutting head to connector (K) after the bypass valve. Connect return line from mirror (orange) and return line from cutting head (brown) to the extension tube (C). Couplings (B) and (D)
Fig. 7.6-12 Converted cooling-water circuit for model with tank heater
2. 3. 4. 5. 6.
E G K
Return line Return line from cutting head Connector
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7.6.2.4 Commissioning after conversion carried out
Repair
1. 1. 2. 3. 4.
Start up laser cutting machine. Select the HAND Setup values, machine view of the user interface. Select Setup values, adaptive optic 1, operating mode 0. Check the position of the flat mirror using the alignment gage, and align if necessary (see training document). Ignore error message if it appears. Before starting cutting, adjust the focal point manually (see section 5.6.6 Adjusting the focal point on the cutting head (where flat mirror fitted)).
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Circuit diagrams, drawings
Circuit diagrams are held in the Equipment diagram folder, and drawings in the Spare parts catalog.
7.7
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7.8 Customer service information
Repair
The manufacturer's Customer Services department is available in the event of problems. Please have the following information ready before calling the department, so that problems and queries can be dealt with as quickly as possible:

Company / Address Contact person Order and equipment number (see type plate)
The contact address appears in the front of this operating manual.
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Chapter 8
Disposal
This chapter describes the environmentally friendly disposal of the product and its operating resources. It also contains notes on handling replacement assemblies (e.g. replacement parts).
8-1
Disposal
Bysprint
8-2
Bysprint
8.1
8.1.1
Disposal
Introduction
Safety regulations
The country-specific regulations and standards must be observed for all components requiring disposal. Also observe the respective manufacturer's instructions for operating resources and cleaning agents.
8.1.2

Use specially trained personnel for proper disposal.
8-3
Disposal
Bysprint
Disposal
Packing
Packing material accrued on delivery must be disposed of according to country-specific regulations and standards.
8.2
8.2.1
8.2.2
Operating resources
Lubricants must be sent to a treatment plant or disposed of as hazardous waste. The manufacturer's instructions must be observed for all operating resources. Further information can be found in the safety data sheets in the Supplier documentation folder.
Dispose of all operating resources in accordance with national regulations and standards.
8-4
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8.3
8.3.1
Disposal
Components suitable for disposal

Material groups
Separate metals and plastics and send for recycling or disposal. The system and the electrical controls must be dismantled and properly disposed of. The machine contains the following materials:

Cast steel components Steel Nonferrous heavy metals (aluminum, copper) Rubber Plastics
The electrical control system contains the following materials and parts:

Steel Plastics Nonferrous heavy metals (aluminum, copper) Protective varnish on circuit boards Electrical and electronic components Batteries
Dispose of all materials in accordance with national regulations and standards.
8-5
Disposal
Bysprint
Disposal centers, authorities
Return to manufacturer
Various components are accepted back by the manufacturer. This particularly concerns components which are replaced by repaired units within the lifetime of the product.
8.4
8.4.1
8.4.2
Notification of government agencies and manufacturer

The manufacturer should be informed in case of decommissioning.
8-6

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Issued on: 01.2007

Operating instructions Bysprint_BA_V20_en.fm

Bystronic Laser AG, 2005

Purpose of the operating instructions

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_en.fm

Operating instructions Bysprint_BA_V20_en.fm

Bystronic Laser AG, 2005

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_en.fm

Russia / Ukraine and Rest CIS

Operating instructions Bysprint_BA_V20_en.fm

Bystronic Laser AG, 2005

Rest of the World

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_en.fm

Operating instructions Bysprint_BA_V20_enTOC.fm

Bystronic Laser AG, 2005

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_enTOC.fm

Design and operation

Operating instructions Bysprint_BA_V20_enTOC.fm

Bystronic Laser AG, 2005

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_enTOC.fm

Operating instructions Bysprint_BA_V20_enTOC.fm

Bystronic Laser AG, 2005

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_enTOC.fm

Requirements to be met by personnel performing the work 5 3

Operating instructions Bysprint_BA_V20_enTOC.fm

Bystronic Laser AG, 2005

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_enTOC.fm

Operating instructions Bysprint_BA_V20_enTOC.fm

Bystronic Laser AG, 2005

Requirements to be met by personnel performing the work 6 4

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_enTOC.fm

Requirements to be met by personnel performing the work 7 5

Operating instructions Bysprint_BA_V20_enTOC.fm

Bystronic Laser AG, 2005

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_enTOC.fm

Operating instructions Bysprint_BA_V20_enTOC.fm

Bystronic Laser AG, 2005

Requirements to be met by personnel performing the work 8 3

Bystronic Laser AG, 2005

Operating instructions Bysprint_BA_V20_enTOC.fm

Operating instructions Bysprint_Kap01.fm

Bystronic Laser AG, 2005

Bystronic Laser AG, 2005

Operating instructions Bysprint_Kap01.fm

Overall view of the laser cutting machine

Operating instructions Bysprint_Kap01.fm

Bystronic Laser AG, 2005

Standard materials and surface treatments

Surface treatment protective film

Bystronic Laser AG, 2005

Operating instructions Bysprint_Kap01.fm

Operating instructions Bysprint_Kap01.fm

Bystronic Laser AG, 2005