by vent ion 2200 en

ByVentionOperating Instructions

Issued on: 10.2007

0 - 1Operating InstructionsByVention_2200_BA_V04_en.fm

© Bystronic Laser AG, 2006

ByVention

0 - 2 Operating InstructionsByVention_2200_BA_V04_en.fm


ByVention

Product identification

These operating instructions apply to the product:

Document identification

Please specify the document identification and issue date when reorder-ing.

Purpose of the operating instructions

These operating instructions form part of the overall documentation. Theyprovide information on the safe and proper use of the product.

Other documents

The complete set of documentation contains the following documents:

Operating Instructions

Installation Guide

Spare parts catalog

Diagrams

Supplier documentation

Machine documentation

Machine logbook

ByVention with 2 200 W laser module

Operating Instructions: ByVention_2200_BA_V04_en.fm



ByVention

Target group

These operating instructions are intended for the owner and operator ofthe machine and for maintenance and repair personnel.

Storage

The operating instructions must always be freely accessible to the speci-fied target group.

Copyright

Dissemination or duplication of this document, or exploitation or commu-nication of its content without the express permission of the author is pro-hibited. Contravention will result in damages. All rights reserved.



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ArgentinaBEHRENDT MAQUINARIAS S.A.Lima 355 - Piso 8AR-1073 Buenos Aires

Tel.: +54 11 5031 5312Fax: +54 11 5031 5301Email: [email protected]

AustraliaLMC LASER SERVICE PTY. LTDFactory 21 Frias Road, MoorabbinAU-3198 Victoria


AustriaBYSTRONIC AUSTRIA GmbHWienerstrasse 131AT-4020 Linz

Tel.: +43 732 341 377 0Fax: +43 732 341 377 11Email: [email protected]

BrazilBYSTRONIC DO BRASIL Ltda.Rua Arapongas, 285BR-83040 200 São CristóvãoSão José dos Pinhais - Paraná


ChinaBYSTRONIC CO., LTDRijing Road 88, Level 1 Part AWaigaoqiao FTZ PudongCN-200131 Shanghai


ChinaBYSTRONIC MACHINERY CO. LTD.Economic Development ZoneNinghe CountyCN-301500 Tianjin, PRC


Czech RepublicBystronic Czech Republic s.r.o.Slatina, Tuřanka 115/1222PSČ 627 00, BrnoČeská republika


EnglandBYSTRONIC UK LIMITEDMaple ParkLowfields AvenueGB-Leeds LS12 6HH


FranceBYSTRONIC FRANCE SAParc Technipolis3 avenue du canadaF-91940 Les Ulis


GermanyBYSTRONIC DEUTSCHLAND GmbHMollenbachstrasse 33-35D-71229 Leonberg

Tel.: +49 (0)7152 6090 0 Fax: +49 (0)7152 6090 11Email: [email protected]

GreeceADECA SATechnical and Commercial CompanyAve. Alexandras 56GR-11473 Athens


HungaryAUTOREL Kft.Attila ut 131 / III. 12.HU-1012 Budapest




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IsraelALON Laser Services Ltd.23 Robinzon St.IL-49560 Petach-Tikva


ItalyBYSTRONIC ITALIA SRLVia del Lavoro 30I-20030 Bovisio Masciago / MI

Tel.: +39 0362 59931Fax: +39 0362 5941 35Email: [email protected]

NetherlandsBYSTRONIC BENELUX BVStek 8NL-3371 Hardinxveld-Giessendam

Tel.: +31 (184) 611 020Fax: +31 (184) 617 774Email: [email protected]

North AmericaBYSTRONIC INC.Bystronic North American Headquarters185 Commerce DriveHauppauge, NY 11788


MexicoBystronic Mexico S.A. de C.V.Lago Onega No. 424, Col. GranadaMX-11520 Mexiko, D.F.

Tel: + 52 (0)5 525 815 147Fax: +52 (0)5 525 815 156Email: [email protected]

PolandBYSTRONIC POLSKA Sp. z o.o.Al. Krakowska 38JankiPL-05090 Raszyn

Tel.: + 48 22 331 37 70Fax: + 48 22 331 37 71

Russia / Ukraine and Rest CISBystronic Russia Sales Officec/o United Machinery AG2. Hutorskaja Street, 38 ARU-127287 Moscow

Tel.: +7 (495) 961 21 67Fax: +7 (495) 961 21 68Email: [email protected]

SingaporeBYSTRONIC PTE. LTD.2 Leng Kee Road #03-05Thye Hong CentreSG-159086 Singapore

Tel.: +65 6472 6300Fax: +65 6472 2418Email: [email protected]

SlowakeiBystronic Czech Republic s.r.o.Slatina, Tuřanka 115/1222PSČ 627 00, BrnoČeská republika


South AfricaFOREST ENGINEERINGP.O.Box 169ZA-1600 Isando


South KoreaBYSTRONIC KOREA, LTD6Fl, Teleron B/DKR-1459-2 Gwanyang-dong, Dongan-gu Anyang-siGeonggi-do

Tel.: +82 314 25 5729Fax: +82 314 25 0057

Spain / PortugalBYSTRONIC IBERICA, S.A.Avenida Tenerife No. 2Edifigo 1 3A Planta Oficina DE-28700 San Sebastian de los Reyes




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SwedenBYSTRONIC SCANDINAVIA ABÖstra Bangatan 18SE-19560 Arlandastad

Tel.: +46 (0)8 5944 1550Fax: +46 (0)8 5944 1555Email: [email protected]

SwitzerlandBYSTRONIC SALES AGIndustriestrasse 21CH-3362 Niederönz

Tel.: +41 (0)62 956 37 83Fax: +41 (0)62 956 33 81Email: [email protected]

TaiwanCHASER C.D. ENTERPRISE CO. LTD22F, No. 639, Chung Cheng Rd.TW-238 Shuh Lin City - Taipei Hsien


Rest of the WorldBYSTRONIC LASER AGIndustriestrasse 21CH-3362 Niederönz

Tel.: +41 (0)62 956 3333Fax: +41 (0)62 956 [email protected]



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ByVention

Table of contents

1 Product description

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 31.1.1 Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 31.1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 41.1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 51.1.4 Working positions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 6

1.1.4.1 Standard installation . . . . . . . . . . . . . . . . . . . . . . 1 – 61.1.4.2 Special installation . . . . . . . . . . . . . . . . . . . . . . . 1 – 7

1.1.5 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 81.2 Product data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 12

1.2.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 121.2.2 Material formats and thicknesses that can be cut . . . . 1 – 13

1.2.2.1 Standard sheet . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 131.2.2.2 Partly cut standard sheet . . . . . . . . . . . . . . . . . . . 1 – 141.2.2.3 Sheet segment . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 141.2.2.4 Residual sheet . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 151.2.2.5 Cutting area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 161.2.2.6 Cuttable thicknesses . . . . . . . . . . . . . . . . . . . . . . 1 – 17

1.2.3 Combined cooling and filtration unit . . . . . . . . . . . . . 1 – 191.3 Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 20

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Table of contents

2 Safety regulations

2.1 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . 2 – 32.2 Product safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 5

2.2.1 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 52.2.2 Safety-conscious working . . . . . . . . . . . . . . . . . . . . 2 – 6

2.3 Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 72.3.1 Warning and information labels . . . . . . . . . . . . . . . . 2 – 8

2.4 Requirements for personnel . . . . . . . . . . . . . . . . . . 2 – 132.4.1 Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 132.4.2 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 142.4.3 Responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 142.4.4 Personal protection equipment . . . . . . . . . . . . . . . . . 2 – 14

2.5 Product-specific hazards. . . . . . . . . . . . . . . . . . . . . 2 – 152.5.1 Laser radiation hazards . . . . . . . . . . . . . . . . . . . . . . 2 – 15

2.5.1.1 Normal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 152.5.1.2 Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 162.5.1.3 Direct laser beam . . . . . . . . . . . . . . . . . . . . . . . . 2 – 172.5.1.4 Reflected and stray radiation . . . . . . . . . . . . . . . . 2 – 18

2.5.2 High-voltage hazard . . . . . . . . . . . . . . . . . . . . . . . . 2 – 192.5.3 Electrical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 202.5.4 Hazards arising from the pneumatic system . . . . . . . 2 – 212.5.5 Hazards arising from gas, dust, vapors, smoke . . . . . 2 – 22

2.5.5.1 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 222.5.5.2 Handling LASERMIX 312. . . . . . . . . . . . . . . . . . . . 2 – 242.5.5.3 Handling nitrogen (N2). . . . . . . . . . . . . . . . . . . . . 2 – 262.5.5.4 Handling oxygen (O2) . . . . . . . . . . . . . . . . . . . . . 2 – 272.5.5.5 Dust extraction unit. . . . . . . . . . . . . . . . . . . . . . . 2 – 282.5.5.6 Toxic fumes emitted when cutting plastics . . . . . . . 2 – 29

2.5.6 Hazards associated with handling the optical system . 2 – 302.5.6.1 General information. . . . . . . . . . . . . . . . . . . . . . . 2 – 302.5.6.2 Warnings in case of fire or accident . . . . . . . . . . . . 2 – 302.5.6.3 Notes on health protection . . . . . . . . . . . . . . . . . . 2 – 30

2.5.7 Lubricants, coolants and cleaning agents. . . . . . . . . . 2 – 312.6 Additional hazards . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 322.7 Emergency information. . . . . . . . . . . . . . . . . . . . . . 2 – 33

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Table of contents

3 Design and operation

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 33.1.1 Beam path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 43.1.2 Flying optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 43.1.3 Deflecting mirror . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 5

3.2 Layout of the laser cutting machine . . . . . . . . . . . . 3 – 73.2.1 Operating side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 73.2.2 Loading side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 8

3.3 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 93.3.1 Positions of safety devices . . . . . . . . . . . . . . . . . . . . 3 – 103.3.2 Main power switch . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 123.3.3 EMERGENCY STOP circuit . . . . . . . . . . . . . . . . . . . . 3 – 133.3.4 Shutter lock (key-operated switch). . . . . . . . . . . . . . 3 – 143.3.5 Safety door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 15

3.3.5.1 Safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 153.3.5.2 Emergency release . . . . . . . . . . . . . . . . . . . . . . . 3 – 16

3.3.6 Safety cover for cutting area . . . . . . . . . . . . . . . . . . 3 – 173.3.6.1 Safety door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 173.3.6.2 Service opening . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 183.3.6.3 Protective flap on unloader opening. . . . . . . . . . . . 3 – 19

3.3.7 Safety cover on the unloader . . . . . . . . . . . . . . . . . . 3 – 203.3.8 Safety covers on laser module . . . . . . . . . . . . . . . . . 3 – 21

3.3.8.1 Covers and folding doors . . . . . . . . . . . . . . . . . . . 3 – 213.3.8.2 High voltage covers . . . . . . . . . . . . . . . . . . . . . . . 3 – 22

3.3.9 Radiation protection . . . . . . . . . . . . . . . . . . . . . . . . 3 – 233.4 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 243.5 Operator console. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 253.6 Machine stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 26

3.6.1 Clean air supply unit . . . . . . . . . . . . . . . . . . . . . . . . 3 – 273.6.2 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 28

3.6.2.1 Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 293.6.2.2 Cutting gases . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 30

3.7 Travel unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 313.7.1 Cutting bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 313.7.2 Cutting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 323.7.3 Severance-cut monitoring . . . . . . . . . . . . . . . . . . . . 3 – 333.7.4 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 343.7.5 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 36

3.7.5.1 Range of nozzles available . . . . . . . . . . . . . . . . . . 3 – 373.7.5.2 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 38



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Table of contents

3.8 Cutting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 393.8.1 Lifting unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 403.8.2 Cutting grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 413.8.3 Zero point / Sheet stop . . . . . . . . . . . . . . . . . . . . . . 3 – 423.8.4 Nozzle cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 433.8.5 Calibration plate. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 443.8.6 Dust extraction system . . . . . . . . . . . . . . . . . . . . . . 3 – 453.8.7 Waste trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 46

3.9 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 473.9.1 Loading table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 473.9.2 Sheet stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 483.9.3 Sheet feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 49

3.10 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 513.10.1 Unloading table . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 523.10.2 Waste tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 53

3.11 Laser module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 543.11.1 Upper section of laser module . . . . . . . . . . . . . . . . . 3 – 563.11.2 Lower section of laser module . . . . . . . . . . . . . . . . . 3 – 58

3.12 Combined cooling and filtration unit . . . . . . . . . . . 3 – 603.13 Remote diagnostics (option) . . . . . . . . . . . . . . . . . 3 – 613.14 Cutting gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 64

3.14.1 Cutting gas quality . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 643.14.2 Compressed air quality . . . . . . . . . . . . . . . . . . . . . . 3 – 653.14.3 Cutting gas consumption. . . . . . . . . . . . . . . . . . . . . 3 – 66



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Table of contents

4 Control elements

4.1 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 34.1.1 Indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 34.1.2 Loading status . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 44.1.3 System, status and error messages . . . . . . . . . . . . . 4 – 5

4.1.3.1 Color coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 54.1.3.2 Priorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 5

4.2 Controls and indicators. . . . . . . . . . . . . . . . . . . . . . 4 – 64.2.1 Control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 64.2.2 Laser module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 74.2.3 Operator console . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 8

4.2.3.1 Membrane keypad. . . . . . . . . . . . . . . . . . . . . . . . 4 – 94.2.3.2 Function buttons . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 104.2.3.3 Traverse buttons . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 11

4.2.4 Sheet-clamping foot switch . . . . . . . . . . . . . . . . . . . 4 – 124.3 Operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 13

4.3.1 Normal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 134.3.2 Manual operating mode. . . . . . . . . . . . . . . . . . . . . . 4 – 134.3.3 Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 13



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Table of contents

5 Operation

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 35.1.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 35.1.2 Requirements of the operating personnel . . . . . . . . . 5 – 3

5.2 Operating the laser cutting machine . . . . . . . . . . . 5 – 45.2.1 Pre start-up check . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 45.2.2 Switching on in normal operating mode . . . . . . . . . . 5 – 55.2.3 Switching off in an emergency . . . . . . . . . . . . . . . . . 5 – 85.2.4 Switching on again after an EMERGENCY STOP . . . . . 5 – 85.2.5 Switching off in normal mode. . . . . . . . . . . . . . . . . . 5 – 9

5.3 Layout of the user interface . . . . . . . . . . . . . . . . . . 5 – 115.3.1 Standard functions . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 115.3.2 Advanced functions . . . . . . . . . . . . . . . . . . . . . . . . 5 – 12

5.4 Material flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 135.4.1 Cutting standard sheets . . . . . . . . . . . . . . . . . . . . . 5 – 135.4.2 Cutting residual sheets . . . . . . . . . . . . . . . . . . . . . . 5 – 17

5.5 Setting up and adjustment tasks . . . . . . . . . . . . . . 5 – 185.5.1 Initiating a function . . . . . . . . . . . . . . . . . . . . . . . . 5 – 185.5.2 Removing or inserting the cutting head. . . . . . . . . . . 5 – 195.5.3 Adjusting the focal position . . . . . . . . . . . . . . . . . . . 5 – 215.5.4 Changing the nozzle . . . . . . . . . . . . . . . . . . . . . . . . 5 – 235.5.5 Centering the nozzle . . . . . . . . . . . . . . . . . . . . . . . . 5 – 25

5.6 Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 285.6.1 Loading a job. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 28

5.6.1.1 Importing a job from USB memory stick . . . . . . . . 5 – 285.6.1.2 Load job automatically from the network . . . . . . . . 5 – 30

5.6.2 Job selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 325.6.2.1 Order of processing . . . . . . . . . . . . . . . . . . . . . . . 5 – 32

5.6.3 Standard sheet production . . . . . . . . . . . . . . . . . . . 5 – 335.6.3.1 Loading standard sheets or partly cut

standard sheets . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 335.6.3.2 Starting the cutting process . . . . . . . . . . . . . . . . . 5 – 395.6.3.3 Removing the cut parts and skeleton. . . . . . . . . . . 5 – 41

5.6.4 Residual sheet production . . . . . . . . . . . . . . . . . . . . 5 – 425.6.4.1 Loading a residual sheet . . . . . . . . . . . . . . . . . . . 5 – 425.6.4.2 Starting the cutting process . . . . . . . . . . . . . . . . . 5 – 485.6.4.3 Removing the cut parts and skeleton. . . . . . . . . . . 5 – 52



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Table of contents

5.6.5 Start and Stop functions . . . . . . . . . . . . . . . . . . . . . 5 – 535.6.5.1 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 535.6.5.2 Start part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 535.6.5.3 Start job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 535.6.5.4 Stop part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 535.6.5.5 Cancel job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 54

5.6.6 Changing cutting parameters . . . . . . . . . . . . . . . . . . 5 – 555.6.7 Saving cutting parameters. . . . . . . . . . . . . . . . . . . . 5 – 575.6.8 Resetting cutting parameters . . . . . . . . . . . . . . . . . . 5 – 575.6.9 Repeating the cutting process (Restart) . . . . . . . . . . 5 – 58

5.6.9.1 Repeat sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 595.6.9.2 Next part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 595.6.9.3 Contour lock-on . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 595.6.9.4 From stop point. . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 60

5.7 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 615.7.1 Switching to manual mode . . . . . . . . . . . . . . . . . . . 5 – 615.7.2 Laser mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 655.7.3 Tool mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 655.7.4 Cutting parameters for manual operation . . . . . . . . . 5 – 66

5.7.4.1 Laser mode: Burn . . . . . . . . . . . . . . . . . . . . . . . . 5 – 665.7.4.2 Laser mode: Pulsed . . . . . . . . . . . . . . . . . . . . . . . 5 – 675.7.4.3 Distance Z-reference - cleaning height. . . . . . . . . . 5 – 68

5.7.5 Moving the axes manually . . . . . . . . . . . . . . . . . . . . 5 – 695.7.6 Moving the axes to the service position. . . . . . . . . . . 5 – 715.7.7 Manual severance cuts . . . . . . . . . . . . . . . . . . . . . . 5 – 725.7.8 Moving the cutting table manually . . . . . . . . . . . . . . 5 – 745.7.9 Moving the unloading table manually . . . . . . . . . . . . 5 – 765.7.10 Unloading sheets manually . . . . . . . . . . . . . . . . . . . 5 – 78

5.8 Maintenance functions . . . . . . . . . . . . . . . . . . . . . . 5 – 805.8.1 CNC Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 805.8.2 Laser module maintenance . . . . . . . . . . . . . . . . . . . 5 – 82

5.8.2.1 Calibrating the optical power . . . . . . . . . . . . . . . . 5 – 835.8.2.2 Operating status of laser components . . . . . . . . . . 5 – 835.8.2.3 Leak test for gas circuit . . . . . . . . . . . . . . . . . . . . 5 – 84

5.9 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 855.9.1 Changing the dialog language . . . . . . . . . . . . . . . . . 5 – 855.9.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 87

5.9.2.1 Selecting the dimensional units. . . . . . . . . . . . . . . 5 – 885.9.2.2 Defining the PIN code . . . . . . . . . . . . . . . . . . . . . 5 – 89



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5.9.3 Operating-hours counter . . . . . . . . . . . . . . . . . . . . . 5 – 905.9.4 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 925.9.5 Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 93

5.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 945.10.1 System, status and error messages . . . . . . . . . . . . . 5 – 945.10.2 Message list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 955.10.3 Using the Help facility . . . . . . . . . . . . . . . . . . . . . . . 5 – 965.10.4 Resetting errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 98

5.11 Using the remote diagnostics facility (option) . . . . 5 – 995.11.1 Connect / Disconnect (Administration) . . . . . . . . . . . 5 – 1005.11.2 Connection status. . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1015.11.3 Viewing diagnostic data. . . . . . . . . . . . . . . . . . . . . . 5 – 102

5.11.3.1 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1035.11.3.2 Detailed diagnostic data. . . . . . . . . . . . . . . . . . . . 5 – 104



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6 Maintenance

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 36.1.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3

6.1.1.1 Work on live (hot) components . . . . . . . . . . . . . . . 6 – 36.1.1.2 Work on gear units . . . . . . . . . . . . . . . . . . . . . . . 6 – 36.1.1.3 Remaining in the danger zone. . . . . . . . . . . . . . . . 6 – 46.1.1.4 Operating materials . . . . . . . . . . . . . . . . . . . . . . . 6 – 46.1.1.5 External modules . . . . . . . . . . . . . . . . . . . . . . . . 6 – 46.1.1.6 Tools, test equipment and spare parts . . . . . . . . . . 6 – 4

6.1.2 Requirements to be met by personnel performingthe work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 5

6.2 Customer service information. . . . . . . . . . . . . . . . . 6 – 66.3 Operating materials . . . . . . . . . . . . . . . . . . . . . . . . 6 – 76.4 Operating hours display . . . . . . . . . . . . . . . . . . . . . 6 – 96.5 Maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . 6 – 106.6 Maintenance record . . . . . . . . . . . . . . . . . . . . . . . . 6 – 21



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7 Repair

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 37.1.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 3

7.1.1.1 Work on live (hot) components . . . . . . . . . . . . . . . 7 – 37.1.1.2 Work on gear units . . . . . . . . . . . . . . . . . . . . . . . 7 – 37.1.1.3 Remaining in the danger zone . . . . . . . . . . . . . . . 7 – 47.1.1.4 Operating materials. . . . . . . . . . . . . . . . . . . . . . . 7 – 47.1.1.5 External modules . . . . . . . . . . . . . . . . . . . . . . . . 7 – 47.1.1.6 Tools, test equipment and spare parts . . . . . . . . . . 7 – 4

7.1.2 Requirements to be met by personnel performingthe work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 5

7.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 67.3 Safety inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 8

7.3.1 EMERGENCY STOP buttons . . . . . . . . . . . . . . . . . . . 7 – 87.3.2 Limit-of-travel monitoring . . . . . . . . . . . . . . . . . . . . 7 – 9

7.3.2.1 Limit switches on X-axis and Y-axis . . . . . . . . . . . . 7 – 97.3.2.2 Limit switch on Z-axis . . . . . . . . . . . . . . . . . . . . . 7 – 10

7.4 Lubrication, service and cleaning work . . . . . . . . . 7 – 117.4.1 Operator console . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 117.4.2 Safety door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 127.4.3 Travel unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 13

7.4.3.1 X-axis linear guides . . . . . . . . . . . . . . . . . . . . . . . 7 – 137.4.3.2 Y-axis spindle bearings . . . . . . . . . . . . . . . . . . . . 7 – 147.4.3.3 X-axis motor bearings . . . . . . . . . . . . . . . . . . . . . 7 – 157.4.3.4 X-axis rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 167.4.3.5 Y-axis linear guides . . . . . . . . . . . . . . . . . . . . . . . 7 – 177.4.3.6 Y-axis recirculating ball drive . . . . . . . . . . . . . . . . 7 – 187.4.3.7 Z-axis linear guides . . . . . . . . . . . . . . . . . . . . . . . 7 – 197.4.3.8 Cutting-head mount . . . . . . . . . . . . . . . . . . . . . . 7 – 207.4.3.9 Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 217.4.3.10 Severance-cut monitoring . . . . . . . . . . . . . . . . . . 7 – 23

7.4.4 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 247.4.4.1 Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 247.4.4.2 Water couplings . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 257.4.4.3 Nozzle and copper plate . . . . . . . . . . . . . . . . . . . . 7 – 26

7.4.5 Cutting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 277.4.5.1 Extraction system . . . . . . . . . . . . . . . . . . . . . . . . 7 – 277.4.5.2 Extraction duct . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 28



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7.4.5.3 Linear guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 297.4.5.4 Precision screw jack. . . . . . . . . . . . . . . . . . . . . . . 7 – 307.4.5.5 Waste trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 31

7.4.6 Sheet feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 327.4.6.1 Telescopic rails . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 327.4.6.2 Suction-frame linear guides . . . . . . . . . . . . . . . . . 7 – 33

7.4.7 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 347.4.7.1 Fork-system linear guides . . . . . . . . . . . . . . . . . . 7 – 347.4.7.2 Fork-system gears. . . . . . . . . . . . . . . . . . . . . . . . 7 – 35

7.4.8 Clean air supply unit . . . . . . . . . . . . . . . . . . . . . . . . 7 – 367.4.8.1 Air drier (adsorption drier) . . . . . . . . . . . . . . . . . . 7 – 367.4.8.2 Reset switches . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 377.4.8.3 Cleaning the muffler . . . . . . . . . . . . . . . . . . . . . . 7 – 38

7.4.9 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 407.5 Cleaning or replacing the lens . . . . . . . . . . . . . . . . 7 – 41

7.5.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 437.5.2 Construction of cutting head . . . . . . . . . . . . . . . . . . 7 – 447.5.3 Removing the lens holder . . . . . . . . . . . . . . . . . . . . 7 – 467.5.4 Removing the lens . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 487.5.5 Lens cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 53

7.5.5.1 Cleaning in the case of light soiling . . . . . . . . . . . . 7 – 557.5.5.2 Cleaning in the case of moderate soiling . . . . . . . . 7 – 567.5.5.3 Cleaning in the case of heavy soiling . . . . . . . . . . . 7 – 597.5.5.4 Cleaning in the case of stubborn dirt . . . . . . . . . . . 7 – 60

7.5.6 Fitting the lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 627.5.7 Fitting the lens holder . . . . . . . . . . . . . . . . . . . . . . . 7 – 667.5.8 Measuring the focus reference setting. . . . . . . . . . . . 7 – 68

7.6 Laser module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 717.6.1 Check the vacuum-pump oil level. . . . . . . . . . . . . . . 7 – 717.6.2 Top up oil in the vacuum pump . . . . . . . . . . . . . . . . 7 – 72

7.7 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 747.7.1 Cutting gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 75

7.7.1.1 Cylinder pressure reducer . . . . . . . . . . . . . . . . . . 7 – 757.7.1.2 Changing gas cylinders during operation . . . . . . . . 7 – 76

7.7.2 Laser gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 777.7.2.1 Cylinder pressure reducer . . . . . . . . . . . . . . . . . . 7 – 787.7.2.2 Changing gas bottles during operation . . . . . . . . . . 7 – 797.7.2.3 Removing an empty gas cylinder. . . . . . . . . . . . . . 7 – 807.7.2.4 Connecting a full gas cyclinder . . . . . . . . . . . . . . . 7 – 82

7.8 Circuit diagrams, drawings . . . . . . . . . . . . . . . . . . . 7 – 847.9 Customer service information. . . . . . . . . . . . . . . . . 7 – 85



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8 Disposal

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 38.1.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 38.1.2 Requirements to be met by personnel performing

the work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 38.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 4

8.2.1 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 48.2.2 Operating resources . . . . . . . . . . . . . . . . . . . . . . . . 8 – 4

8.3 Components suitable for disposal. . . . . . . . . . . . . . 8 – 58.3.1 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 5

8.4 Disposal centers, authorities . . . . . . . . . . . . . . . . . 8 – 68.4.1 Return to manufacturer. . . . . . . . . . . . . . . . . . . . . . 8 – 68.4.2 Notification of government agencies and

manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 6



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9 Cutting technology

9.1 General information . . . . . . . . . . . . . . . . . . . . . . . . 9 – 39.2 Design guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 4

9.2.1 Sheet formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 49.2.2 Kerf width for laser cutting . . . . . . . . . . . . . . . . . . . 9 – 49.2.3 Orthogonality of the cut surface . . . . . . . . . . . . . . . . 9 – 59.2.4 Roughness of the cut surface . . . . . . . . . . . . . . . . . . 9 – 69.2.5 Contour radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 89.2.6 Sheet thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 99.2.7 Common cut edges. . . . . . . . . . . . . . . . . . . . . . . . . 9 – 99.2.8 Hole as a paint coating aid. . . . . . . . . . . . . . . . . . . . 9 – 109.2.9 Edge deformations . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 109.2.10 Cut-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 119.2.11 Tongues (bent parts only) . . . . . . . . . . . . . . . . . . . . 9 – 129.2.12 Strain relief cuts. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 129.2.13 Discontinuous limb . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 139.2.14 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 149.2.15 Labeling similar parts . . . . . . . . . . . . . . . . . . . . . . . 9 – 15

9.3 Definitions and ranges . . . . . . . . . . . . . . . . . . . . . . 9 – 169.3.1 Minimum distance from sheet edge. . . . . . . . . . . . . . 9 – 169.3.2 Minimum distance of parts from severance cut. . . . . . 9 – 179.3.3 Minimum parts separation . . . . . . . . . . . . . . . . . . . . 9 – 189.3.4 Minimum hole diameters . . . . . . . . . . . . . . . . . . . . . 9 – 199.3.5 Minimum web width . . . . . . . . . . . . . . . . . . . . . . . . 9 – 20

9.4 Laser cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 229.4.1 Laser fusion cutting . . . . . . . . . . . . . . . . . . . . . . . . 9 – 239.4.2 Laser gas cutting . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 249.4.3 Laser sublimation cutting . . . . . . . . . . . . . . . . . . . . 9 – 259.4.4 Cutting process . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 269.4.5 Gas parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 27

9.5 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 289.5.1 Technology wizard . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 289.5.2 Technology table in Bysoft. . . . . . . . . . . . . . . . . . . . 9 – 309.5.3 Piercing and lead-ins. . . . . . . . . . . . . . . . . . . . . . . . 9 – 32

9.5.3.1 Outer contour . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 339.5.3.2 Inside contour (cut-outs) . . . . . . . . . . . . . . . . . . . 9 – 34

9.5.4 Programming process macros . . . . . . . . . . . . . . . . . 9 – 35



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9.5.5 Machining strategies . . . . . . . . . . . . . . . . . . . . . . . . 9 – 369.5.5.1 Strategy A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 369.5.5.2 Strategy B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 36

9.5.6 Cutting-time calculation . . . . . . . . . . . . . . . . . . . . . 9 – 389.6 Cutting parameters . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 39

9.6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . 9 – 399.6.2 Adjusting cutting parameters . . . . . . . . . . . . . . . . . . 9 – 41

9.6.2.1 Reasons for adjusting parameters . . . . . . . . . . . . . 9 – 429.6.2.2 Conditions to be met before adjusting parameters . 9 – 42

9.6.3 Procedure for optimizing the cutting parameters . . . . 9 – 439.6.4 Cutting parameters on the laser cutting machine . . . . 9 – 44

9.6.4.1 Focal position, cutting . . . . . . . . . . . . . . . . . . . . . 9 – 459.6.4.2 Feed rate, cutting . . . . . . . . . . . . . . . . . . . . . . . . 9 – 479.6.4.3 Laser power, cutting . . . . . . . . . . . . . . . . . . . . . . 9 – 489.6.4.4 Gas pressure, cutting. . . . . . . . . . . . . . . . . . . . . . 9 – 499.6.4.5 Width of microjoints . . . . . . . . . . . . . . . . . . . . . . 9 – 519.6.4.6 Tool radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 529.6.4.7 Pulse width, piercing . . . . . . . . . . . . . . . . . . . . . . 9 – 539.6.4.8 Laser power, engraving . . . . . . . . . . . . . . . . . . . . 9 – 549.6.4.9 Protective film vaporization . . . . . . . . . . . . . . . . . 9 – 56

9.6.5 Cutting parameters for different dimensional units . . . 9 – 579.6.6 Structure of saved default parameters . . . . . . . . . . . 9 – 58

9.7 Cutting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 609.7.1 Summary of the various technologies . . . . . . . . . . . . 9 – 609.7.2 Cutting structural steel with oxygen (O2) . . . . . . . . . 9 – 619.7.3 Oxide-free cutting of structural steel with

nitrogen (N2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 629.7.4 Cutting structural steel with normal pulse . . . . . . . . . 9 – 63

9.7.4.1 Pulsed cutting (application examples) . . . . . . . . . . 9 – 639.7.4.2 Pulsed piercing (application examples). . . . . . . . . . 9 – 639.7.4.3 Programming for pulsed contours . . . . . . . . . . . . . 9 – 65

9.7.5 Oxide-free cutting of rust and acid-resistant steel . . . 9 – 679.7.5.1 Technology table for rust and acid-resistant steel . . 9 – 679.7.5.2 Rust and acid-resistant steel with protective film . . 9 – 689.7.5.3 Protective film vaporization . . . . . . . . . . . . . . . . . 9 – 719.7.5.4 Recommended protective films . . . . . . . . . . . . . . . 9 – 71

9.7.6 Oxide-free cutting of aluminum alloys. . . . . . . . . . . . 9 – 729.7.7 Laser cutting using compressed air. . . . . . . . . . . . . . 9 – 73

9.7.7.1 Providing the compressed air . . . . . . . . . . . . . . . . 9 – 73



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9.7.8 Engraving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 759.7.8.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 759.7.8.2 Assessment of engraving quality . . . . . . . . . . . . . . 9 – 75

9.7.9 Machining with process macros . . . . . . . . . . . . . . . . 9 – 769.7.9.1 Process macro 1 . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 769.7.9.2 Example with process macro . . . . . . . . . . . . . . . . 9 – 77

9.7.10 Microjoints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 789.8 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 81

9.8.1 Material properties . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 819.8.2 Alloy components . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 819.8.3 Microstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 829.8.4 Sheet surface finish . . . . . . . . . . . . . . . . . . . . . . . . 9 – 82

9.8.4.1 Unwanted surface finishes . . . . . . . . . . . . . . . . . . 9 – 829.8.4.2 Preferred surface finishes . . . . . . . . . . . . . . . . . . . 9 – 82

9.8.5 Surface treatment . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 839.8.5.1 Oiled surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 83

9.8.6 Beam reflection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 849.8.7 Thermal conductivity . . . . . . . . . . . . . . . . . . . . . . . 9 – 849.8.8 Heat affected zone . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 85

9.9 Cut evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 869.9.1 Cutting with oxygen (O2). . . . . . . . . . . . . . . . . . . . . 9 – 86

9.9.1.1 Structural steel St 37-2, 4 mm thick . . . . . . . . . . . 9 – 869.9.2 Cutting with nitrogen (N2) . . . . . . . . . . . . . . . . . . . . 9 – 88

9.9.2.1 Structural steel, hot galvanized, 2 mm thick. . . . . . 9 – 889.9.2.2 Rust and acid-resistant steel 1.4301, 6 mm thick . . 9 – 899.9.2.3 Aluminum AlMg3, 3 mm thick . . . . . . . . . . . . . . . . 9 – 90

9.9.3 Piercing with oxygen (O2) . . . . . . . . . . . . . . . . . . . . 9 – 929.9.3.1 Structural steel St 37-2, 6 mm thick . . . . . . . . . . . 9 – 92

9.9.4 Piercing with nitrogen (N2) . . . . . . . . . . . . . . . . . . . 9 – 939.9.4.1 Rust and acid-resistant steel 1.4301, 2 mm thick . . 9 – 93

9.9.5 Quality of the cut edge . . . . . . . . . . . . . . . . . . . . . . 9 – 949.9.5.1 Structural steel . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 949.9.5.2 Rust and acid-resistant steel. . . . . . . . . . . . . . . . . 9 – 949.9.5.3 Aluminum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 95

9.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 969.10.1 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 96



ByVention



ByVention

Chapter 1

1 Product description

This chapter contains general information, product data and notes on fit-ted equipment. Further details are given in the order confirmation.

1 - 1Operating InstructionsByVention_2200_Kap01.fm


ByVentionProduct description

1 - 2 Operating InstructionsByVention_2200_Kap01.fm


ByVention Product description

1.1 Introduction

1.1.1 Overall view

Fig. 1.1-1 Overall view of the laser cutting machine

A Control cabinet

B Loading table

C Combined cooling and filtration unit

D Laser module

E Unloader

F Machining area

D

A

E

CB

F




1.1.2 Intended use

The laser cutting machine is used for the industrial cutting and engravingof sheets of the materials listed below. Operation is manned.

Tab. 1.1-1 Permitted materials and surface treatments

Material Surface treatment

no

ne

oil

ed

galv

an

ized

sin

gle

-sid

ed

pro

tect

ive f

ilm

Structural steel

Thickness 1 to 8 mm

St 37-2

Stw 22a)

a) Structural steel, galvanized, thickness 1 to 3 mm

⎯

Rust and acid-resistant steel

Thickness 1 to 6 mm

X5CrNi18 -10 ⎯ ⎯

b)

b) Rust and acid-resistant steel with single-sided protective film, thickness 1 to 3 mm

Aluminum

Thickness 1 to 4 mm

AlMg3 ⎯ ⎯ ⎯

The information given in these operating instructions and thecutting parameters apply to the permitted materials specified inTab. 1.1-1.Other materials or material with a different specification mayproduce a poorer cutting result or reduce process stability.




1.1.3 Safety precautions

Only those materials approved for the laser cutting machine may be ma-chined.

Any use in addition to that specified without written approvalby the manufacturer is at your own risk.




1.1.4 Working positions

1.1.4.1 Standard installation

Fig. 1.1-2 Working positions at the laser cutting machine (safety door opened)

A Control cabinet

B Machining area

C Operator console

D Loading table

E Unloader

F Combined cooling and filtration unit

A

E

C

D

B

F




1.1.4.2 Special installation

Fig. 1.1-3 Working positions at the laser cutting machine (safety door opened)

A Control cabinet

B Machining area

C Operator console

D Loading table

E Unloader

F Combined cooling and filtration unit

A

E

C

D

B

F




1.1.5 Labeling

Fig. 1.1-4 Position of type plates

A Machine type plate (see Fig. 1.1-5)

B Control box type plate (see Fig. 1.1-6)

C Laser module type plate (see Fig. 1.1-7)

B

A

C




Fig. 1.1-5 Type plate on the machine

A Machine name

B Job number

C Total weight of machine in [kg]

D Year of manufacture

E Machine number

F Equipment number (technical ID number of the complete laser cut-ting machine)

G Maximum weight of a sheet in [kg/m2]

H CE conformity mark

A DEF

B

CG H




Fig. 1.1-6 Type plate in the control cabinet

A Equipment number of controller

B Wiring diagram number

C Year of manufacture

D Electrical power supply. Supply ratings as specified in the Installa-tion Guide, chapter 4 ›Power supply‹

E Degree of protection provided by electrical equipment enclosure(contact, foreign bodies, water)

F Standard on which it is based

G CE conformity mark

AB C

G

D

EF




Fig. 1.1-7 Type plate on the laser module

A Machine name

B Job number

C Total weight of laser module in [kg]

D Year of manufacture

E Laser module number

F Equipment number (technical ID number of the complete laser cut-ting machine)

G Laser medium

H Emitted wavelength in [NM]

I Beam diameter [mm]

J Maximum output power in [W]

K Beam divergence in [mrad]

L CE conformity mark

A DEF

BCGH J

I K

L




1.2 Product data

1.2.1 Specification

Positioning accuracy Paa)

a) as per VDI/VDQ 3441. Measurement length 1 m (3.28 ft). The precision of the finished part depends on the given material, its thickness and quality.

±0,10 mm ±0,004 inches

Repeatability Psa) ±0,05 mm ±0,002 inches

Positioning speed in X-direction 100 m/min 3940 in/min

Positioning speed in Y-direction 100 m/min 3940 in/min

Simultaneous positioning speed 140 m/min 5510 in/min

Max. axis acceleration 8 m/s2 315 in/s2

Max. cutting speed 20 m/min 788 in/min

Max. laser power 2 200 W 2 200 W

Maximum cutting areaX-axis 1 562 mm 61.50 inches

Y-axis 772 mm 30,40 inches

Vertical range of cutting head

Z-axis 100 mm 4 inches

Max. load-bearing capacity of loading table 300 kg 660 lbs

Max. load-bearing capacity of cutting table 80 kg 176 lbs




1.2.2 Material formats and thicknesses that can be cut

1.2.2.1 Standard sheet

Standard sheets have the following commercial sheet sizes:

Fig. 1.2-1 Standard sheet dimensions

Length L Width B

[mm] [inches] [mm] [inches]

Standard sheet 1 3 000 ⎯ 1 500 ⎯

Standard sheet 2 ⎯ 120 ⎯ 60





Y+

X+

L

B

0+20

0+20

0+1.5

0+1.5

0+20

0+20

0+1.5

0+1.5

0+20

0+20

0+1.5

0+1.5




1.2.2.2 Partly cut standard sheet

A partly cut standard sheet is a sheet with a standard width and a lengthof at least 1 200 mm.

1.2.2.3 Sheet segment

A sheet segment is a piece cut off a standard sheet. A segment can be cutby the machine without moving the standard sheet.

Fig. 1.2-2 Sheet segment dimensions

Length Width

L1

[mm]

L2

[mm]

B1

[mm]

B2

[mm]

Sheet segment min. 250

max. 772

⎯ max. 1 562 ⎯

Parts size ⎯ max. 752 ⎯ max. 1 542

Y+

X+

B1

B210 mm1) 10 mm1)L

1

L2

10

mm

1)

10

mm

1)

1) Recommended edge distance (default setting)




1.2.2.4 Residual sheet

A residual sheet is a small-size sheet that is placed on the cutting tableand removed from it from the front.

Fig. 1.2-3 Residual sheet dimensions

Length L Width B


Residual sheet max. 772 max. 30.40 max. 1 562 max. 61.50

See section 9.3 ›Definitions and ranges‹ for minimum distancesfrom sheet edge.

Y+

X+

B

L




1.2.2.5 Cutting area

Fig. 1.2-4 Cutting area dimensions

X range Y range


Cutting area max. 1 562 max. 61.50 max. 772 max. 30.40

Cutting plans that lie outside this area cannot be processed.

X+

Y+




1.2.2.6 Cuttable thicknesses

The following conditions must be met in order to be able to cut the maxi-mum thicknesses.

Laser cutting machine must be in optimum condition with optimum set-tings and adjustments

Materials must meet the quality standards specified by the machinemanufacturer (laser materials)

Tab. 1.2-1 Material: Structural steel

Structural steel, galvanized, thickness 1 to 3 mm can be cut (hot-galva-nized or electro-galvanized). Cutting gas: Nitrogen N2

Thickness Cutting gas

[mm] [inches] [Gauge No] Oxygen

O2

Nitrogen

N2

Com-pressed air

Air

1.0 0,040 19

1.5 0,060 16

2.0 0,074 14

2.5 0,104 12 ⎯

3.0 0,125 11 ⎯

4.0 0,160 8 ⎯ ⎯

5.0 0,187 7 ⎯ ⎯

6.0 0,250 ⎯ ⎯ ⎯

8.0 0,312 ⎯ ⎯ ⎯




Tab. 1.2-2 Material: Rust and acid-resistant steel

Rust and acid-resistant steel, thickness 1 to 3 mm, with well-bonded pro-tective film, can be cut. Cutting gas: Nitrogen N2

See section 9.7.5.2 ›Rust and acid-resistant steel with protective film‹

Tab. 1.2-3 Material: Aluminum



O2

Nitrogen

N2

Com-pressed air

Air

1.0 0,040 19 ⎯

1.5 0,060 16 ⎯

2.0 0,074 14 ⎯

2.5 0,104 12 ⎯ ⎯

3.0 0,125 11 ⎯ ⎯

4.0 0,160 8 ⎯ ⎯

5.0 0,187 7 ⎯ ⎯

6.0 0,250 ⎯ ⎯ ⎯



O2

Nitrogen

N2

Com-pressed air

Air

1.0 0,040 19 ⎯

1.5 0,060 16 ⎯

2.0 0,074 14 ⎯

2.5 0,104 12 ⎯ ⎯

3.0 0,125 11 ⎯ ⎯

4.0 0,160 8 ⎯ ⎯




1.2.3 Combined cooling and filtration unit

Please refer to the manufacturer's operating instructions for informationon the combined cooling and filtration unit.




1.3 Equipment

Freestanding laser cutting machine with integral laser module. Manualloading and unloading of material by the operator.

The laser cutting machine is designed both for single parts and mass pro-duction. Please see 1.2.2.5 ›Cutting area‹ for the maximum sizes of singlepieces or cutting plans.



ByVention

Chapter 2

2 Safety regulations

This chapter describes the safety precautions for the protection of person-nel and machine.

It also explains the symbols and warnings used in these operating instruc-tions.



ByVentionSafety regulations



ByVention Safety regulations

2.1 Warnings and symbols

DANGERImmediate risk of severe injuries or death

WARNINGPotentially dangerous situation leading to severe injuriesor death

CAUTIONPotentially dangerous situation leading to minor injuriesor damage to property




1. Explains a handling sequence or the steps involved in an activity.

2.

3.

Indicates technical features of the machine or control unitthat the operating and maintenance staff must be aware of.

Indicates useful tips on specific topics.




2.2 Product safety

Those persons whose job requires them to work within the danger zone ofthe laser cutting machine are, despite all safety measures, exposed to anacceptable level of risk.

Read the operating instructions before starting up the laser cutting ma-chine.

Safe working is only guaranteed if:

directions in the operating instructions are observed

operating, maintenance and repair personnel have been trained on themachine

where several persons are involved in the operation, responsibilities areclearly 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

The safety devices must never be removed, bridged or bypassed.

Before starting up the laser cutting machine, defective safety devicesmust be replaced and checked for correct operation.




2.2.2 Safety-conscious working

Work on mechanical, electrical and gas-system equipment must be carriedout solely by skilled staff1) or under their supervision.

Improper use and operation can be dangerous and may damage the ma-chine.

For this reason it is forbidden to:

process materials that are not approved

remain inside the danger zone. It is the operator's responsibility to en-sure that no unauthorized persons remain within the danger zone.

1) Skilled staff: a skilled member of staff means someone who, on the basis of his/her technical education, knowledge and experience, plus knowledge of the relevant regulations, can assess the work given to him/her and recognize the potential hazards.




2.3 Danger zones

Do not obstruct access to the EMERGENCY STOP buttons on the operatorconsole and the laser module.

It is particularly dangerous when loading or unloading the laser cuttingmachine.

The laser cutting machine must be arranged so that there is space aroundit to allow unrestricted access to the loading and unloading tables forbringing in and taking away material.

DANGERRemaining within a danger zone

While the laser cutting machine is operating it is forbid-den to stay within the machining area.

Keep unauthorized persons away from the work area.

CAUTIONRisk of pinch/crushing injury when loading or un-loading the laser cutting machine

Wear protective gloves and steel-capped boots




2.3.1 Warning and information labels

Signs must be permanently affixed and easily legible. Signs must be re-placed if they are very worn or no longer legible.

Do not change the original position of the signs when replacing them.

Fig. 2.3-1 Warning and information labels on the laser cutting machine

A Label for key-operated switch

B Electrical voltage warning

C Label for main power switch

D Label for EMERGENCY STOP enable button

B

C

D

A




Fig. 2.3-2 Warning and information labels on the laser cutting machine

A Electrical voltage warning

B Warning of external voltage supply (power supply for dehumidifier)

C Electrical voltage warning

Please refer to the manufacturer's operating instructions for de-tails on the position and meaning of the Warning and informa-tion labels on the combined cooling and filtration unit.

C

B

A




Fig. 2.3-3 Warning and information labels on the laser module

A High voltage warning

B Warning of external voltage supply (power supply for dehumidifier)

C High voltage warning

Warning and information labels inside the laser module mustonly be replaced by the manufacturer's service personnel.

B

C

A

A

C




Fig. 2.3-4 Warning and information labels on the laser module

A Invisible laser radiation warning

B Laser radiation warning

C Warning of external voltage supply (power supply for dehumidifier)

D Warning that the capacitors carry dangerous voltages

E High voltage warning

Warning and information labels inside the laser module mustonly be replaced by the manufacturer's service personnel.

B

A

C D

E




Fig. 2.3-5 Warning and information labels on the cutting head

A Focus reference setting

B Laser radiation warning

C Focal length of cutting head in inches

B

C

A




2.4 Requirements for personnel

Training of operators takes place after the system has been commissionedby the manufacturer's service staff. Please see the order confirmation forfurther details.

It is the responsibility of the owner of the machine to ensure that operat-ing staff are properly trained.

A selection of optional training courses are offered for the machines. Fur-ther 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 inthese operating instructions.

The demands placed on users vary according to the activity they mustperform.

Users are classified as follows:

Owner

The term owner is used to describe the signatory to the agreement withthe manufacturer, or their representative. The owner is authorized aslegally-binding signatory to agreements.

He/she procures the laser cutting machine and ensures that it is usedcorrectly 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 trainingcourse by the manufacturer.

Works engineer

Works engineer refers to a skilled person with training in mechanical orelectrical engineering. The works engineer maintains the machine, ser-vices it and carries out minor repairs as necessary.

Training of the work's engineer includes participation in a course held bythe manufacturer.




2.4.2 Qualifications

Only persons instructed and trained by the owner may work on the ma-chine. Personnel are responsible for third persons in the work area.

Personnel still requiring training, instruction or teaching are only allowedto operate the machine under constant supervision by an experienced per-son.

2.4.3 Responsibility

Responsibilities for the various activities performed on the machine (oper-ation, setup, maintenance, repair) must be clearly specified and observed.

Undefined responsibilities are a safety risk.

The owner must provide operating and maintenance personnel with ac-cess to the operating instructions and ensure that they have read and un-derstood them.

2.4.4 Personal protection equipment

Where technical or organizational measures are unable to rule out healthrisks in full or in part, the owner must provide the operating and mainte-nance staff with the required personal protection equipment.

Steel-capped boots

Protective gloves

Laser protective eyewear

Breathing mask

Personal protection equipment is not included in the deliver-ables of the laser cutting machine.




2.5 Product-specific hazards

2.5.1 Laser radiation hazards

Laser devices are classified according to the potential danger of the laserradiation. The applicable laser class depends on the operating mode of thelaser cutting machine (see section 4.3 ›Operating modes‹).

2.5.1.1 Normal mode

In normal operating mode the laser cutting machine corresponds to aClass 1 laser (i.e. fully screened laser radiation). All safety covers must bein place.

Laser radiation does not pose a risk to eyes or skin if the laser cutting ma-chine is used correctly.

The safety door protects against reflected and stray radiation. There is noneed to wear safety goggles to provide protection from reflected and strayradiation.

It is recommended, however, that people wear goggles withan antidazzle filter when exposed to the cutting beam for aprolonged period.




2.5.1.2 Service mode

The laser cutting machine is in Service mode when Normal operatingmode has been interrupted. It makes no difference whether the interrup-tion is for adjustment and inspection tasks, or for cleaning and mainte-nance work.

The machine enters Service mode at the moment when the safety door isopened or permanent safety devices are dismantled.

Normal mode is restored when the laser cutting machine is made readyfor use, the safety devices are reset and the process is started up again.

WARNINGIn Service mode the laser cutting machine corre-sponds to a Class 4 laser (i.e. not fully screened la-ser radiation).

The direct laser beam and reflected and stray radiationare very dangerous 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




2.5.1.3 Direct laser beam

The following points must be observed when working with the laser cut-ting machine:

Never expose yourself to direct laser radiation.

Never modify the fastenings used on optical components.

Follow all instructions in the operating instructions.

WARNINGDirect laser beam

In service mode the laser cutting machine correspondsto a Class 4 laser.

The direct laser beam can cause life-threatening injuriesto the whole body.




2.5.1.4 Reflected and stray radiation

Avoid exposing eyes or skin to reflected or stray radiation.

Laser protective eyewear must be worn during Service mode. These lasersafety glasses offer sufficient protection against reflected and stray radia-tion.

Use laser protective eyewear of protection grade L5A (for viewing dif-fuse laser light only OD 5 + at 10 600 nm) as per standard EN 207 (DIN58215).

Fig. 2.5-1 Laser protective eyewear providing L5 protection (as per EN 207)

Reflected and stray radiation is also possible if the waste trays happen tobe pulled forwards during a cutting process.

Before every cutting process, make sure that the waste trays are insertedcorrectly.

Standard design Version for spectacle wearers

Laser protective eyewear is not included in the deliverables ofthe laser cutting machine.

WARNINGRisk of injury from reflected and stray radiation

The laser cutting machine must only be used when thewaste trays are inserted.




2.5.2 High-voltage hazard

A high voltage of 25 000 volts is generated in the laser module. In addi-tion, electrical storage devices such as capacitors store large amounts ofenergy, These can deliver dangerous electric shocks if touched.

WARNINGHigh voltage 25 000 VDC

Voltages greater than 50 V and currents greater than20 mA are dangerous and can cause death.

Work on high-voltage components must be performedsolely by the manufacturer’s service personnel.




2.5.3 Electrical hazards

The following points must be observed when working with electrical instal-lations or equipment:

Only use original fuses with the specified amperage.

Switch the machine off immediately in the event of a fault in the electri-cal supply.

Electrical components on which maintenance work is being performedmust be disconnected from the electrical supply unless otherwise speci-fied.

First check that isolated parts are de-energized, then earth and short-circuit them and also insulate adjacent live parts.

Inspect electrical equipment regularly. Rectify faults such as loose con-nections or singed cables immediately.

When working on live (hot) parts, a second person must be presentwho can operate the EMERGENCY STOP button or power switch in anemergency. Fence off the work area with a red-and-white safety chainand a warning sign.

Always use insulated tools.

WARNINGDangerous electrical voltage

Improper or negligent handling of electrical installationsor equipment can result in severe injuries or death.

Work on electrical installations or equipment must beperformed solely by skilled staff or under their supervi-sion.




2.5.4 Hazards arising from the pneumatic system

Inspect loads, valves and hoses regularly for leaks.

WARNINGRisk of injury from flying parts and escaping air

Do not perform any assembly or disassembly work, orunscrew or tighten any screw connections, while thesystem is under pressure.

Depressurize all subsystems which require opening, be-fore commencing maintenance and repair work.




2.5.5 Hazards arising from gas, dust, vapors, smoke

2.5.5.1 Gas supply

If there are leaks in the gas supply, escaping oxygen can combine with anaked flame to cause deflagrations. Check the lines on the gas supply areconnected correctly.

Further information on the gas supply and its hazards is given in the in-stallation instructions.

DANGERDanger to life and limb of the operator or thirdparty

Impaired respiration and cardiac functions if containersor lines are leaking.

Check connections and lines for leaks.

WARNINGRisk of explosion

Do not oil or grease gas-bottle connections.

This could lead to an explosion from a chemical reaction.




Where air is recirculated, ventilate rooms well with fresh air after everyshift. Prevent gas collecting in enclosed accessible areas (e.g. shaftsand ducts).

Select fire extinguishers to suit the flammable materials present in theroom. Signpost the location of extinguishers and escape routes.

Perform leak tests regularly. Leave the room immediately if there is amajor leak or equipment failure, and do not re-enter unless using self-contained breathing apparatus. At least two people must be present inthis case.

Keep gas bottles away from naked flames and heat sources (>50°C).Protect bottles from direct sunlight if stored outside.

Always transport bottles with safety cap fitted. Secure bottles againstfalling over.

Look out for leaks from bottles during storage and when in use. Store ina well-ventilated location away from combustible materials. Do notstore in escape routes or work areas, or in their immediate vicinity. Donot fill bottles in storerooms.

Only use original parts. Close bottle valves before handling. Whenchanging the bottles, check the valves on full and empty bottles forleaks. Never adjust safety valves. Do not release gases in enclosedspaces.

Repairs must be performed by specialists.

Wear protective clothing and gloves made of leather or thick material. Ifthe gas escapes into enclosed spaces, self-contained breathing appara-tus must be worn.

Observe additional national directives, for example vehicle labeling dur-ing transport, regular staff training etc.

Observe national directives on bottle licensing and test periods.




2.5.5.2 Handling LASERMIX 312

LASERMIX 312 is composed of the gases helium (He), nitrogen (N2) andcarbon dioxide (CO2). The main constituent is helium at > 60%. Carbondioxide forms the smallest component at < 5%.

Note on its chemical and physical behavior and usage

Warnings in case of fire or accident

LASERMIX 312 itself (and its constituent gases) is not flammable. Fireleads to an increase in pressure and can cause the bottle to burst /explode. Select fire-extinguishing measures to suit the surroundings.From a safe position, cool down nearby containers and bottles thoroughlywith plenty of water. Risk of suffocation, particularly in enclosed and low-lying areas. Keep on the up-wind side.

Wear self-contained breathing apparatus, and full protective clothing.

LASERMIX 312 itself (and its constituent gases) is not a water contami-nant.

Helium

He

Helium is a noble gas that does not form chemical bonds. It is also used as an inert gas in arc welding of steel, aluminum, magnesium and titanium, as it pre-vents oxidation and nitride formation by displacing the air. It has low solubility in water and organic solvents.

Nitrogen

N2

Nitrogen reacts with only a very few substances at room temperature, for example lithium and calcium to form nitrides. Even at high temperatures nitrogen does not react easily. This is why it is used as an inert gas in tech-nical processes, and for conveying and storing flamma-ble fluids.

Carbon dioxide

CO2

Carbon dioxide can react strongly with various substanc-es, particularly at higher temperatures, and is therefore not suitable for universal extinguishing purposes. Dan-gerous reactions may occur when mixed with ammoniac, ethylamine, methylamine, dimethylamine and trimethy-lamine. When liquid carbon dioxide expands rapidly to atmospheric pressure, it freezes to dry ice as it cools to -79 °C, then quickly vaporizes without passing through the fusion stage.




Notes on health protection

The nature of effect of LASERMIX 312 and its toxicity depends on the na-ture of effect and toxicity of each of the constituent gases. As heliumforms the largest part by volume, its properties are dominant, while theproperties of carbon dioxide as the smallest component are least promi-nent.

First aid

if carbon dioxide has been inhaled, remove the victim from the hazard ar-ea. Provide sufficient fresh air. In enclosed spaces, first-aid personnelmust wear self-contained breathing apparatus. Victims need rest, warmthand possibly artificial respiration. Keep air passages clear, monitor bloodcirculation, perform cardiac massage if necessary. If patient loses con-sciousness, place and transport him in a stable lateral position. Consultdoctor.

Helium

He

Nature of effect and toxicity: insufficient oxygen, de-pending on length of inhalation, may cause drowsiness, indisposition, increased blood pressure, breathlessness. The speed of sound in helium is different from that in air, so that inhalation of helium in low, breathable concen-trations can be detected by the breathing noise or al-tered voice frequency. A pure helium atmosphere will cause immediate loss of consciousness and suffocation without obvious symptoms. Owing to its low solubility in blood, forced inhalation of helium is less hazardous than nitrogen.

Nitrogen

N2

Nature of effect and toxicity: nitrogen has no physiologi-cal effect; in concentrations of more than 88%, however, it prevents vital respiration and thus leads to suffoca-tion. It does not cause irritation and has no warning symptoms.

Carbon dioxide

CO2

Nature of effect and toxicity: carbon dioxide paralyzes the respiratory center in high concentrations. At low con-centrations, an adequate supply of oxygen or the lack of it determines the severity of injury or the extent of car-bon dioxide poisoning.

Depending on the length of inhalation, insufficient oxy-gen supply at about 8 to 10 % by vol. causes headache, buzzing in the ears, dizziness, raised blood pressure, ac-celerated heart rate, accelerated breathing or breath-lessness, blue skin tinge, excited state, nausea, sickness.

Above 10 % by vol. problems occur with proper func-tioning and coordination of muscle movements, includ-ing convulsions similar to an epileptic fit, loss of consciousness, drop in blood pressure.

Rapid recovery if supplied with fresh air in good time, otherwise suffocation. Above 18 to 20 % by vol. stroke.




2.5.5.3 Handling nitrogen (N2)


Nitrogen reacts with only a very few substances at room temperature, forexample lithium and calcium to form nitrides. Even at high temperaturesnitrogen does not react easily. This is why it is used as an inert gas intechnical processes, and for conveying and storing flammable fluids.


Nitrogen is not flammable. Fire leads to an increase in pressure and cancause the bottle to burst / explode. In case of fire use water spray, or gasor powder-type extinguishers. If gas escapes do not spray the bottle withwater. Cool down nearby containers and bottles thoroughly with plenty ofwater. Large amounts of escaping gas mixed with moist air form a cold fogthat is heavier than air.

Wear self-contained breathing apparatus, and full protective clothing.

Nitrogen is not a water contaminant.


Nature of effect and toxicity: nitrogen has no physiological effect; in con-centrations of more than 88%, however, it prevents vital respiration andthus leads to suffocation. It does not cause irritation and has no warningsymptoms.

First aid

if carbon dioxide has been inhaled, remove the victim from the hazard ar-ea. Provide sufficient fresh air. In enclosed spaces, first-aid personnelmust wear self-contained breathing apparatus. Victims need rest, warmthand possibly artificial respiration. Keep air passages clear, monitor bloodcirculation, perform cardiac massage if necessary. If patient loses con-sciousness, place and transport him in a stable lateral position. Consultdoctor.




2.5.5.4 Handling oxygen (O2)


Oxygen is not flammable, but does assist combustion. Although it is 11%heavier than air at ambient temperatures, the air does not separate outand hence the oxygen concentration near the ground does not increase.

Liquid oxygen has a very low temperature (minus 183°C at atmosphericpressure). At this temperature, skin that comes into contact with oxygenwill suffer "cold burns" extremely rapidly. These low temperatures can alsomake some materials brittle.


Increasing the oxygen content of the air (even by just a few percent) sig-nificantly increases the risk of fire. Materials that are not flammable in air(including materials impregnated with fire retardants) may burn briskly oreven spontaneously combust in oxygen-enriched air. The flames are muchhotter and spread very quickly.


Oxygen is naturally present in air in the proportion 21 % by volume.Hence if oxygen escapes into the atmosphere, it does not have a pollutingeffect. Inhaling pure oxygen or air with a raised oxygen content normallyproduces no detrimental effects on the human body.

Any clothes worn in an atmosphere that may have a raised oxygen con-centration must be aired very carefully. Oxygen adheres very strongly toclothing. An ignition source such as a cigarette could cause clothes tocatch fire.

If cryogenic liquid oxygen is accidentally spilt, the soil will not be contami-nated because cryogenic liquid oxygen vaporizes and hence does not pen-etrate the soil, or only to a small degree. The temporary local frost formedon the ground leaves no permanent damage to the soil.




2.5.5.5 Dust extraction unit

The dust and fumes produced during cutting are extracted from the cut-ting area by a dust extraction unit. The dust is filtered out.

Check that the dust extraction unit is running and operating at the correctextraction rate if any smells are noticed during cutting.

Ensure that there is sufficient ventilation when working in confined spac-es.

WARNINGRisk of fire

If extraction levels are inadequate, there is a risk of gas-es and cutting residues remaining in the extraction ductsand catching fire there.

The extraction rate of the extraction unit must alwaysequal that given in the specification.

Observe maintenance intervals as per maintenanceschedule

Do not let stubbed cigarettes or objects that are stillalight get into the extraction chambers or piping ofthe dust extraction system.

When changing from steel to aluminum or vice versa,the dust must be kept strictly separate. A separatedust hopper must be used for each material.

For flammable, potentially explosive and self-ignitingdusts, empty the hopper frequently to minimize theamount of dust held in it.

If the extracted air is released outdoors, local regulationsmust be observed.




2.5.5.6 Toxic fumes emitted when cutting plastics

The fumes given off on combustion are highly toxic. They cannot be com-pletely removed by the extraction system.

Plastics must not be cut on the laser cutting machine.




2.5.6 Hazards associated with handling the optical system

2.5.6.1 General information

The output coupler of the laser module and the lens in the cutting headare made of zinc selenide. When intact, these components pose no dan-ger.

However, toxic fumes are generated if thermal decomposition of a lens oc-curs. In addition, damage to the coating allows the escape of thorium flu-oride, 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 temper-atures above 400°C, releasing toxic fumes and dust particles.

Wait until dust has settled before starting cleaning work. Do not stir updust.

2.5.6.3 Notes on health protection

For further details on first aid measures refer to the safety data sheetson zinc selenide and thorium contained in the supplier documentationfolder.

CAUTIONToxic fumes and dust particles

Wear a breathing mask and protective gloves duringcleaning work.

Defective lenses must be returned to the manufacturerof the laser cutting machine in a sealed container.

Always ventilate the working environment thoroughlyafter any damage.




2.5.7 Lubricants, coolants and cleaning agents

When handling working materials, in particular oils, grease and otherchemical substances, observe the product's safety regulations from themanufacturer. The supplier documentation folder contains the relevantinformation.

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 carry oily cloths about your person.

CAUTIONPoisoning

Inhaling oil vapors or oil fumes can lead to nausea andsickness.

Avoid contact with oil vapors and oil fumes. Ensure ade-quate ventilation.


Do not allow sprays or spray cans to come into contactwith hot objects, machine parts, gases or vapors.

Place working materials on suitable surfaces (e.g. tooltrolley).

The owner of the machine is responsible for the proper dis-posal of lubricants, coolants and cleaning agents and of mate-rials contaminated with these products.




2.6 Additional hazards

Unauthorized modifications or additions to the machine are prohibited forsafety reasons.

It is not permitted to make changes to programmable controllers.

The machine must not be integrated with existing systems without the ap-proval of the manufacturer.




2.7 Emergency information

In the event of personal injury

take first-aid measures

notify a doctor

inform immediate supervisor

observe national and company regulations



ByVention

Chapter 3

3 Design and operation

This chapter provides information on the position and functions of the var-ious hardware units. The safety and monitoring devices fitted on the prod-uct are also described in greater detail.



ByVentionDesign and operation



ByVention Design and operation

3.1 Introduction

For laser cutting, a focused laser beam is directed at the sheet metal to becut on the cutting table.

The laser beam is directed from the laser module via a number of deflect-ing mirrors to the focusing lens in the cutting head.

Fig. 3.1-1 Beam guidance system (shown without safety covers)

A Laser module

B Laser beam

C Cutting-bridge deflecting mirror

D Cutting-carriage deflecting mirror

E Cutting head

F Focused laser beam

G Cut part

A

BC

D

F

E

G




3.1.1 Beam path

The route taken by the laser beam from the output of the laser module tothe cutting head is called the beam path.

3.1.2 Flying optics

The cutting bridge and carriage move during operating, together with thedeflecting mirrors mounted on them. This changes the length of the beampath.

This principle of laser-beam guidance is called Flying optics.

WARNINGRisk of fire and explosion

The laser beam can cause flammable and explosive flu-ids and vapors to ignite. Foreign bodies, fluids and gasescan also have an adverse effect on the beam quality.

Cleaning agents and solvents and their vapors shouldtherefore be kept away from the beam path.




3.1.3 Deflecting mirror

Deflecting mirrors are used along the machine axes to deflect the laserbeam. These mirrors are flat.

The beam quality (the parallelism, for example) is maintained with flatmirrors.

Fig. 3.1-2 Deflecting mirror

A Deflecting mirror

B Laser beam

A

B

A




The angle of incidence and the angle of reflection are measured with re-spect to the normal line. The angles of incidence and reflection are equal.

If the deflecting mirror is rotated through a certain angle then the direc-tion of the reflected beam alters by twice that angle.

Fig. 3.1-3 Angle of reflection of a deflecting mirror

A Angle of incidence α

B Angle of reflection β

C Laser beam

D Coating

E Base material

F Normal line

A B

C

D

E

F




3.2 Layout of the laser cutting machine

3.2.1 Operating side

Fig. 3.2-1 Laser cutting machine, safety door open

A Control cabinet

B Machine stand

C Laser module

D Unloader

E Operator console

F Travel unit

G Cutting table

H Sheet feed

I Safety door

B

A

I

F

GC

DE

H




3.2.2 Loading side

Fig. 3.2-2 Laser cutting machine, loading table empty

A Safety covers

B Loading table

C Combined cooling and filtration unit

B

AC

A




3.3 Safety devices

Protective measures have been put in place at danger spots according tothe safety regulations that apply to laser cutting machines.

It is the operator’s responsibility to install the appropriate barriers and tocheck them regularly for proper functioning.

It is only permitted to remove, modify or take out of service protectiveand safety devices if this is necessary for transport and repair. Beforework commences, appropriate measures must be taken to protect per-sons, and to prevent damage to machine parts.

Before putting the system into operation, it must be ensured that all pro-tective devices are in place and that all danger zones are protected ac-cording to local safety regulations.




3.3.1 Positions of safety devices

Fig. 3.3-1 Safety devices on the laser cutting machine viewed from the operating side

A Safety cover for cutting area

B Safety door

C EMERGENCY STOP button on the operator console

D Safety cover on unloader

E Shutter lock (key-operated switch)

F EMERGENCY STOP button on the laser module

C

DE

F

A

B




Fig. 3.3-2 Safety devices on the laser cutting machine viewed from the loading side

G Safety covers on laser module

H EMERGENCY STOP button on the control cabinet

I Main power switch

The laser cutting machine must only be used when safety de-vices are operating correctly.

G

H

I




3.3.2 Main power switch

After the power is switched on (ON position), all the units and controllersrequired for operating the laser cutting machine are started automatically.

The main switch can be secured in the OFF position with a padlock to pre-vent unauthorized switch-on.

Fig. 3.3-3 Main power switch

The combined cooling and filtration unit is fitted with a separatepower switch.Please refer to the manufacturer's operating instructions for de-tailed information.




3.3.3 EMERGENCY STOP circuit

Pressing an EMERGENCY STOP button triggers an EMERGENCY STOPsituation.

There are three EMERGENCY STOP buttons on the laser cutting machine,which can be used to shut down the laser cutting machine and its compo-nents in an emergency.

Control cabinet

Operator console

Laser module

Fig. 3.3-4 EMERGENCY STOP button

Pressing an EMERGENCY STOP button disconnects all electrical loadsfrom the supply apart from the controller and the combined cooling andfiltration unit.

Operation of the machine can only be resumed once the emergency situa-tion has been cleared and all defects and damage have been rectified (seesection 5.2.4 ›Switching on again after an EMERGENCY STOP‹).




3.3.4 Shutter lock (key-operated switch)

The shutter lock is used to protect service personnel working on the beampath against accidental opening of the shutter.

In normal operating mode, the shutter switch is always in the UNLOCKposition.

Fig. 3.3-5 Shutter switch in UNLOCK position

Service work on the beam path and the associated locking ofthe shutter must only be performed by the manufacturer'sservice staff.




3.3.5 Safety door

3.3.5.1 Safety switch

When the safety door is open, the emission of laser power, movement ofmachine parts and a machine restart are prevented.

The laser cutting machine can only be put into operation with the safetydoor shut.

Fig. 3.3-6 Safety switch

A Safety position switch

B Safety interlock

In the event of damage or wear, the complete switch or com-plete interlock must be replaced.

A

B




3.3.5.2 Emergency release

When no power is supplied, the safety interlock is engaged, locking thesafety door. In a fault or emergency situation, the safety interlock can bereleased manually.

Fig. 3.3-7 Releasing the safety interlock manually

A Safety interlock

B Switch

C Switch in home position

D Safety interlock released manually

X

A

C D

Detail X

B




3.3.6 Safety cover for cutting area

The whole machining area is enclosed by covers and a safety door, whichprotect the machining area during the work process. The safety door posi-tion is monitored by safety switches.

Fig. 3.3-8 Safety covers with safety door

3.3.6.1 Safety door

The closed safety door blocks access to the cutting area. It protectsagainst:

reflected laser radiation

sparks

injury from moving parts

The safety door must be closed and locked before a work process can bestarted on the laser cutting machine.

DANGERStanding within a danger zone

Moving parts such as the cutting bridge, cutting carriageor Z-axis pose a risk of crushing, which can be fatal.

No-one is permitted within the machining area when thesafety door is closed.




3.3.6.2 Service opening

The service opening gives access for maintenance work (e.g. access toclean air filter). In normal operating mode, the service opening is closed.

Fig. 3.3-9 Service opening

DANGERStanding within a danger zone

Moving parts such as the cutting bridge, cutting carriageor Z-axis pose a risk of crushing, which can be fatal.

Before removing the cover, shut down the machine, turnoff the main power switch and secure it in this positionwith a padlock.

A Safety cover for cutting area

B Service opening

A

B




3.3.6.3 Protective flap on unloader opening

A protective flap is fitted on the unloader opening, which opens automati-cally when the cut sheet segments are moved out.

When moving the unloading table into the machining area, the protectiveflap checks whether the cut sheet segment has been completely removed.The skeleton or parts left on the table press against the shutter plate, ac-tuating a limit switch. Movement of the unloading table is interrupted andthe safety cover opens.

Fig. 3.3-10 Unloader

A Pneumatic cylinder

B Telescopic rail

C Diaphragm

A

C

B

B




3.3.7 Safety cover on the unloader

The unloader is enclosed by covers and a safety cover. The safety coveropens automatically as soon as a cut sheet segment is ready to be re-moved.

The safety cover can also be released manually by pressing the relevantbutton on the operator console (see section 4.2.3.2 ›Function buttons‹).

Closing the safety cover confirms that the unloading table is empty.

Fig. 3.3-11 Unloader, safety cover closed

Fig. 3.3-12 Unloader, safety cover open




3.3.8 Safety covers on laser module

3.3.8.1 Covers and folding doors

The covers and folding doors on the laser module are mechanically locked.The main power switch must always be in the OFF position before remov-ing covers or opening the folding doors.

Use a padlock to secure the main power switch against unauthorizedswitch-on.

Fig. 3.3-13 Safety covers on the laser module

CAUTIONExternal supply

Turning off the main power switch does not cut off thesupply to the dehumidifier.

To turn off the dehumidifier, pull out the mains plug.

A Folding doors

B Covers

To prevent dirt entering the laser module, ensure that thecovers and folding doors are always properly closed andlocked.

BB B

A A




3.3.8.2 High voltage covers

The covers prevent accidental contact with high-voltage parts. The coversare screwed on and fitted with a safety switch.

When a cover is removed, the high voltage is immediately switched off.

Fig. 3.3-14 High voltage covers on the laser module

DANGERHigh voltage -25 000 VDC

Touching live (hot) high-voltage parts may result indeath.

The covers must only be removed by the manufacturer’sservice personnel.

A Folding doors

B High voltage covers

A

BB




3.3.9 Radiation protection

The beam path is totally sealed by structural parts, bellows and protectivecovers.

Bellows and safety covers protect people from stray radiation and from di-rect contact with the laser beam. They also double as protection for theoptical system from outside influences.

DANGERInvisible laser radiation

The beam path protective covers must never be re-moved or modified.

The beam shielding tube between the laser module andthe machine must not be subjected to mechanical loads.

Bending of the beam shielding tube can allow the laserbeam to escape unprotected or damage the tube.




3.4 Control cabinet

The control cabinet contains electrical components such as power-supply,CNC controller and fuses / circuit-breakers etc.

The temperature in the control cabinet is maintained at an optimum levelby an air conditioning unit.

Fig. 3.4-1 Control cabinet

A Control cabinet

B Air conditioning unit

C Doors

D Controls (see section 4.2.1 ›Control cabinet‹.)

B

D

C

A




3.5 Operator console

The operator console is inserted in the holder on the safety cover. For op-eration, this can be removed from the holder and carried around by theuser.

Fig. 3.5-1 Operator console

The controls on the operator console are described in section4.2.3 ›Operator console‹.

If the touch screen is not operated using the finger, the use of asuitable touch stylus is recommended.




3.6 Machine stand

The machine stand provides the support for the laser cutting machine. As-semblies, including travel unit, cutting table and unloader are built ontothe machine stand.

The clean air supply and power supply are housed in the machine stand.

Fig. 3.6-1 Machine stand (shown without safety covers)

A Bridge

B Clean air supply unit (behind cover)

C Cutting table

D Travel unit

E Unloader

F Supply unit (behind cover). See section 3.6.2 ›Supply unit‹

G Supply connections (see installation instructions)

B

C

D

E

A F

G




3.6.1 Clean air supply unit

The air drier (adsorption drier) supplies the laser cutting machine withclean air for ventilation of the beam path.

The air drier contains two adsorber units. These work reciprocally, i.e. theair is filtered and dried in one element whilst the other regenerates itself.

Fig. 3.6-2 Air supply system

A Air filter for filtered air

B Muffler

C Operation indicator

D Replace drying agent cartridge

E Replace post-filter

F Replace pre-filter

B

C

D

E

F

A




3.6.2 Supply unit

The pressure regulators and the compressed-air and cutting-gas pressuregages are located on the supply unit.

Fig. 3.6-3 Position of the supply unit (shown without safety covers)




3.6.2.1 Compressed air

See the installation instructions for details of the quality and pressureof the compressed air supply.

Fig. 3.6-4 Pressure regulator and compressed-air pressure gage

A Beam-path ventilation pressure reducer

B Beam-path ventilation pressure gage

C Inlet pressure to the pressure reducer

D Tap

E Water trap / prefilter

F Inlet pressure gage

G Fine filter

A

B

D

C

E

F

G




3.6.2.2 Cutting gases

See the installation instructions for details of the quality and pressureof the cutting gas supply.

Fig. 3.6-5 Pressure regulators and cutting-gas pressure gages

A Pressure reducer, Nitrogen N2

B Pressure reducer, Oxygen O2

C Pressure gage, Nitrogen N2

D Pressure gage, Oxygen O2

E Pressure reducer, compressed air (Air)1)

E Pressure gage, compressed air (Air)1)

N2

O2

Air

1)

A

B

C

DE

F

1) only when option fitted




3.7 Travel unit

The travel unit hangs from linear guides in the X direction.

3.7.1 Cutting bridge

The cutting bridge moves along the X-axis. It carries the cutting carriage,which moves along the Y-axis.

The laser beam is deflected from the X-axis onto the Y-axis by the deflect-ing mirror mounted on its rear side (see Fig. 3.1-1).

Fig. 3.7-1 Travel unit (shown without safety covers)

A Bridge

B Cutting bridge

C Cutting carriage

D Laser beam

D

A

B

C




3.7.2 Cutting carriage

The cutting carriage moves along the Y axis. It carries the Z-axis on whichthe cutting head is mounted.

On the Z-axis, the cutting head moves in a vertical direction. It raises thecutting head when traversing between different figures on the work piece,and ensures that the nozzle clearance height remains constant even whenthe work piece is uneven.

In the cutting carriage, the laser beam is deflected from the Y-axis ontothe Z-axis.

Fig. 3.7-2 Cutting carriage (shown without safety covers)

A Cutting carriage

B Cutting head

C Laser beam

D Severance-cut monitoring

A

BC

D




3.7.3 Severance-cut monitoring

The light sensor scans the severance cut before removing a cut sheet seg-ment. It detects if a severance cut is not made properly.

If the severance cut is OK, the cut sheet segment is transferred to theunloading area.

If the severance cut is not OK, an error message is issued and produc-tion halted.

Fig. 3.7-3 Severance-cut monitoring (shown without safety covers)

A Reflection light sensor

B Window

C Laser diode

D Compressed-air nozzle (aimed at laser diode)

E Cutting carriage

BA

E

C

D




3.7.4 Cutting head

The cutting head is the final element of the beam guidance system. Thelaser beam is focused in the cutting head to achieve the power density re-quired for cutting.

The cutting gas is fed through the cutting head. During the cutting processthis drives molten material out of the cut gap and prevents the focusinglens from being damaged by splashes of slag.

The stream of cutting gas is shaped by the nozzle so that the greatestpossible percentage of the gas flows through the kerf.

The two centering screws center the laser beam in the nozzle (see section5.5.5 ›Centering the nozzle‹).

Fig. 3.7-4 Cutting head (dismantled)

A

C

B

D

E E

J

F

G

H

I

X




Detail X

A Focal-position scale (6 mm divisions)

B Measured focus reference setting

C Locking screw (for locking the focal-position adjusting ring)

D Focal length in inches

E Centering screws for nozzle centering

F Focal-position adjusting ring

G Adjusting-ring scale (0.2 mm divisions)

H Clamping device pin (for Z-axis attachment)

I Anti-rotation element

J Nozzle

See section 5.5.2 ›Removing or inserting the cutting head‹ forhow to change the cutting head.

A




3.7.5 Nozzles

During the cutting process, there is a controlled supply of cutting gasthrough the nozzle. The shape and diameter of the nozzle depend on:

Focal position

Gas pressure

volume flow rate

gas-jet shape

range of uses

Fig. 3.7-5 Nozzle mounting on cutting head

A Cutting head

B Nozzle

The nozzle to be used can be found in the selected job (param-eter set). Sections 5.5.4 ›Changing the nozzle‹ and5.5.5 ›Centering the nozzle‹ describe how to change and centerthe nozzle.

A

B




3.7.5.1 Range of nozzles available

Tab. 3.7-1 Nozzle shape and area of use

Nozzle shape

Area of use Labeling

Normal pressure

All applications for gas cutting (O2)

Structural steel, 0.5…8 mm thick

K10

K12

K15

K17

High pressure

Universal nozzles for all applications

Structural steel to 8 mm (O2 and N2)

Rust and acid-resistant steel up to 6 mm (N2)

Aluminum up to 4 mm (N2)

Various materials (O2 and N2)

Rust and acid-resistant steel up to 2 mm (Air)

HK10

HK12

HK15

HK17

HK20

HK25

HK30




3.7.5.2 Labeling

Normal pressure (capacitive detection)

High pressure (capacitive detection)

H High pressure (up to 20 bar)

K Capacitive detection

10 Nozzle diameter 1.0 mm







Capacitive detection

Nozzle diameter 1.0 mm

High pressure

Nozzle diameter 1.7 mm

Capacitive detection

K 10

H K 17




3.8 Cutting table

The cutting table is equipped with plug-in cutting grates on which thesheet to be cut is laid.

Fig. 3.8-1 Cutting table (shown without safety covers)

CAUTIONRisk of pinch/crushing injury when loading or un-loading material


A Cutting grate E Scrap hoppers

B Dust extraction system F Scrap trolley

C Nozzle cleaning G Sheet stop

D Calibration plate H Sheet stop

D

C

BA

FEF

G

H




3.8.1 Lifting unit

During the unloading procedure, the unloading table moves under the cutsheet segment. The lifting unit lowers the cutting table until the cut sheetsegment comes to rest on the unloading table.

Fig. 3.8-2 Lifting unit (shown without safety covers)

A Guide

B Lifting unit

B

A

A




3.8.2 Cutting grate

The cutting grate supports the sheet to be cut. The slats are made ofsteel.

Steel slats impair the cutting process less than other materials. The dura-bility of these slats depends on the laser power used for cutting.

Fig. 3.8-3 Cutting grate

A Sheet

B Cutting grate

A

B




3.8.3 Zero point / Sheet stop

Two sheet stops are provided for positioning leftover sheets at the zeropoint. One of the sheet stops can be moved in the X-direction to fit thesize of the sheet.

The sheet stops are set up initially by the manufacturer’s service person-nel.

Fig. 3.8-4 Sheet stops

Before cutting a standard sheet (Standard sheet produc-tion), both sheet stops must be removed.

A Fixed sheet stop

B Movable sheet stop

C Leftover sheet

D Zero point

B

A

C

D




3.8.4 Nozzle cleaning

During the cleaning procedure, the nozzle head passes several timesacross the brass brush on the cutting table, removing any dirt, depositsand metal splashes.

Fig. 3.8-5 Nozzle cleaning

The nozzle cleaning procedure is carried out at the end of a cutting plan orafter a certain number of piercing cuts.

This function cannot be controlled by the machine operator. Seesection 5.7.4.3 ›Distance Z-reference - cleaning height‹ for howto adjust the cleaning height.




3.8.5 Calibration plate

During calibration, the nozzle is lowered to the calibration plate until con-tact is made. Then the Z-axis moves upwards checking various nozzleclearance heights in the process.

Fig. 3.8-6 Calibration position

The calibration procedure is carried out at the beginning of a cutting planor after nozzle cleaning.

This function cannot be controlled by the machine operator.




3.8.6 Dust extraction system

The cutting area is divided into two extraction sectors. The appropriate ex-traction flaps are opened depending on the position of the cutting head.

The extracted air is cleaned by the air filtration unit.

Fig. 3.8-7 Cutting table (shown without cutting grate and safety covers)

A Air extraction sector 1

B Air extraction sector 2

C Extracted air

WARNINGRisk of fire

Production of flammable or explosive mixtures.

The extraction chambers, waste trays and swarf in thecutting area must be cleared completely when changingmaterial from steel to aluminum or vice versa.

CA

B




3.8.7 Waste trays

Small parts or cutting waste fall through the support grate and are collect-ed in waste trays. The waste trays can be moved out to the front for emp-tying.

There are two waste trays under the cutting table and one under the un-loader.

Fig. 3.8-8 Waste trays under the cutting table

Before every cutting process, make sure that the waste trays are insertedcorrectly.

WARNINGRisk of injury from reflected and stray radiation

The laser cutting machine must only be used when thewaste trays are inserted.




3.9 Unloader

3.9.1 Loading table

The loading table is fitted with roller balls on which the standard sheet orpartly cut standard sheet can be pushed up to the stops (see section5.4.1 ›Cutting standard sheets‹).

Fig. 3.9-1 Loading table




3.9.2 Sheet stop

The stops are located between the loading table and the cutting area.

The correct position of the standard sheet or partly cut standard sheet ismonitored by inductive proximity switches in the stops. The loading statusis shown by an indicator lamp (see section 4.1.2 ›Loading status‹).

The sheet can only be clamped and pulled in if it is correctly positioned.

Fig. 3.9-2 Standard sheet or partly cut standard sheet against sheet stop.

A Longitudinal stop

B Transverse stop

C Sheet clamping

D Standard sheet or partly cut standard sheet

A B C

B

D




3.9.3 Sheet feed

For the subsequent cutting process, the standard sheet or partly cut stan-dard sheet is pulled into the cutting area by the sheet feed.

The sheet is held by the suction unit by a vacuum. To pull the sheet in, thecutting carriage couples to the suction unit and pulls the sheet in the Y di-rection onto the cutting table.

Once the sheet has been pulled in, the feed unit is returned to its homeposition by the cutting carriage.

Fig. 3.9-3 Sheet feed

A Coupling

B Suction unit

C Telescopic rail

D Standard sheet or partly cut standard sheet

A

B

C

D

X




The rows of suction cups must be switched on or off manually using vacu-um switches depending on the size of the sheet placed on the table. Whenusing standard sheets 1 and 2, both vacuum switches must be in the ONposition.

View X

Tab. 3.9-1 Switch settings based on standard sheet

E Vacuum switch 1 (switch suction-cup row 5 on/off manually)

F Vacuum switch 2 (switch suction-cup row 4 on/off manually)

F

E

Standard sheet Switch position

Vacuum switch1 Vacuum switch2

1 3 000 mm × 1 500 mm ON ON

2 120 inches × 60 inches ON ON

3 2 500 mm × 1 250 mm OFF ON

4 96 inches × 48 inches OFF ON

5 2 000 mm × 1 000 mm OFF OFF

6 72 inches × 40 inches OFF OFF




3.10 Unloader

The unloader enables the cut sheet segment to be removed while the nextsheet segment is being cut.

The cut sheet segment is automatically transported to the unloading table.

Fig. 3.10-1 Unloader

If a cut sheet segment is ready for removal, the safety cover opens auto-matically. If the safety cover is closed by the operator, this is treated asconfirmation that the cut sheet segment has been removed.




3.10.1 Unloading table

The cut sheet segment is transported from the cutting area on the unload-ing table.

Fig. 3.10-2 Unloader (shown without safety covers)

A Protective flap

B Unloading table

C Linear guides

D Synchronous belt

B

A

C

D




3.10.2 Waste tray

During removal of the cut parts, small parts and cutting waste fall into thewaste tray. The waste trays can be moved out to the front for emptying.

Fig. 3.10-3 Waste tray under the unloading table




3.11 Laser module

The laser module is where the laser beam is generated. The operatingstate of the laser module is shown by an indicator lamp (see section4.1.1 ›Indicator lamp‹).

The safety covers and folding doors must only be removed and/or openedfor servicing purposes, with the main power switch in the OFF position.

To prevent dirt entering the laser module, ensure that the covers and fold-ing doors are always properly closed and locked.

CAUTIONExternal supply

Turning off the main power switch does not cut off thesupply to the dehumidifier.

To turn off the dehumidifier, pull out the mains plug.




Fig. 3.11-1 Laser module (viewed from operating side)

A Beam outlet

B Lower section of laser module with safety covers

C Upper section of laser module with folding doors

D Indicator lamp

A

D

C

B




3.11.1 Upper section of laser module

The upper section of the laser module houses the optical system. Theseare protected from accidental contact by the high-voltage covers.

Fig. 3.11-2 Laser module viewed from operating side (folding doors open)

The high-voltage covers must only be removed by the manu-facturer’s service personnel.




The optical components are important and sensitive components of the la-ser module. They require special handling and care.

Fig. 3.11-3 Schematic diagram of the optical system

Work on the optical components must only be performed bythe manufacturer’s service personnel.

A End mirror

B Horizontal beam-folding mirror

C Vertical beam-folding mirror

D Output coupler

E Shutter

F 90o deflecting mirror

G 45o deflecting mirror

H Convex telescopic mirror

I Concave telescopic mirror

J Polarizing mirror

A

B B

B

B

C

C

D

E

F

G

H

J

I




3.11.2 Lower section of laser module

The lower section of the laser module houses the excitation modules andthe laser controller.

Fig. 3.11-4 Laser module viewed from operating side (shown without safety covers)

A Frequency converter

B Dehumidifier

C Vacuum pump

D Central gas cooler

E Gasmix unit

A

B C

D

E




Fig. 3.11-5 Laser module viewed from loading side (shown without safety covers)

F Laser controller

G High-voltage excitation

H Turboblower

F

F

G

H




3.12 Combined cooling and filtration unit

The purpose of the combined cooling and filtration unit is to cool waterand filter out metal cutting dusts, and is used in conjunction with a lasercutting machine.

The combined cooling and filtration unit is ready for connection, and con-sists chiefly of the housing, the components for the cooling-agent, cool-airand water circuits, the air filtration unit, the control cabinet and all thecontrol and monitoring units required for automatic operation.

Fig. 3.12-1 Combined cooling and filtration unit

Please refer to the manufacturer's operating instructions for de-tailed information on the combined cooling and filtration unit.




3.13 Remote diagnostics (option)

The remote diagnostics facility can be used by the manufacturer's Cus-tomer Services and by the owner to access individual machine compo-nents such as the CNC, MachineService, laser module and SysInfo.

TCP/IP and HTTP are used as the communications protocols. The system isoperated via a web browser.

For further information please see the Installation guide andsection 5.11 ›Using the remote diagnostics facility (option)‹.




Fig. 3.13-1 System layout with machine network

A Internet environment

B Secure communication (SSH)

C Owner environment

D Firewall

E Router

F Owner's network

G Machine network

H Netbox / Router

I Machines

J Remote Diagnostics Box (RD box)

K Manufacturer environment

L Firewall

M Remote Diagnostics Server (RD server)

A

B

C

D

EF

H

I

JM

G

L

K




Fig. 3.13-2 System layout without machine network

A Internet environment

B Secure communication (SSH)

C Owner environment

D Firewall

E Router

F Owner's network

G Machines

H Remote Diagnostics Box (RD box)

I Manufacturer environment

J Firewall

K Remote Diagnostics Server (RD server)

A

B

C

D

EF

G

H

K

J

I




3.14 Cutting gases

Nitrogen (N2), oxygen (O2) and optionally compressed air (Air) are usedfor laser cutting. See section 9 ›Cutting technology‹

3.14.1 Cutting gas quality

The gas quality has a crucial impact on the cut quality. Nitrogen affectsthe quality of the cut surface. The following tables show the relationshipbetween quality grade and oxide formation on the cut surface.

Tab. 3.14-1 Quality level and oxide formation

Gas

typ

e

Qu

ali

ty

Pu

rity

[Vol. %

]

Pro

po

rtio

n o

fn

itro

gen

+arg

on

N2 +

Ar

/ [p

pm

]

Pro

po

rtio

n o

f w

ate

rH

2O

/ [

ppm

]

Cu

t su

rface

Oxygen

O2

3.5a) ≥ 99.95 ≤ 500 ≤ 5 Oxide formation

Nitrogen

N2

2.8 ≥ 99.8 ≤ 500 ≤ 20 oxide-free, slightly yel-lowish

3.5a)

a) Recommendation

≥ 99.95 ≤ 100 ≤ 10 oxide free, not guaran-teed bright

4.5 ≥ 99.995 ≤ 10 ≤ 5 oxide-free, guaranteed shiny

5.0 ≥ 99.999 ≤ 3 ≤ 5 absolutely oxide-free, guaranteed shiny




3.14.2 Compressed air quality

A suitable solution for the low-cost production of compressed air is an as-sembly with compressor and filter units capable of producing the requiredvolume and quality of compressed air.

Tab. 3.14-2 Compressed-air quality to ISO 8573-1

Maximum particle diameter(Class 1 or better)

0.01 μm

Maximum particle density(Class 1 or better)

0.01 mg/m3

Maximum residual oil content(Class 1 or better)

0.003 mg/m3

Compressed-air dew point(Class 2r)

-40 °C (-40 °F)




3.14.3 Cutting gas consumption

The cutting gas consumption depends on the pressure and the nozzleused. The following diagrams show recommended values for cutting in thelow-pressure and high-pressure region.

Fig. 3.14-1 Low pressure up to 6 bar (nozzle diameter 0.8 ... 3.0 mm)

Fig. 3.14-2 High pressure up to 20 bar (nozzle diameter 0.8 ... 3.0 mm)

A

B

C

A Cutting gas consumption

B Gas pressure

C Nozzle diameter used

A

B

C



ByVention

Chapter 4

4 Control elements

This chapter provides information on warning signals output by the lasercutting machine. It also describes the controls and indicators and the indi-vidual operating modes.



ByVentionControl elements



ByVention Control elements

4.1 Warning signs

4.1.1 Indicator lamp

The indicator lamp is mounted on the laser module. The various colors in-dicate the operating status of the laser module.

Fig. 4.1-1 Indicator lamp on the laser module

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 safety door is open. Service mode tasks are described in section 4.3.3 ›Service mode‹.

B Orange indicator lamp

Provides information on the high-voltage status.

Lamp illuminated: high voltage switched on

C White indicator lamp

Provides information on the laser gas supply.

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.

A

B

C




4.1.2 Loading status

The loading status is indicated by an indicator lamp.

Fig. 4.1-2 Position of indicator lamp

Lamp flashing No standard sheet against sheet stop

Lamp illuminated Standard sheet against sheet stop

Lamp not illuminated Standard sheet clamped

or

No sheet clamped and sheet stop re-tracted




4.1.3 System, status and error messages

All system, status and error messages are shown in the user interface(see section 5.10 ›Troubleshooting‹).

4.1.3.1 Color coding

The individual messages are divided into classes and color-coded.

Tab. 4.1-1 Message colors

4.1.3.2 Priorities

All messages are listed in the message list with the highest priority mes-sage always at the top. See section 5.10.2 ›Message list‹

paint Priority / Class Description

1 Operator prompt The message requires operator in-tervention (e.g. press the CONT or STOP button).yellow

2 Fault Processes already started are inter-rupted (e.g. stop caused by EMER-GENCY STOP).

The cause must be fully cleared be-fore operation is resumed.

red

3 Warning A safety-related element has tripped (e.g. safety door open).

orange

4 Information Information on the active process (e.g. cutting plan import).

light blue




4.2 Controls and indicators

4.2.1 Control cabinet

Fig. 4.2-1 Controls on the control cabinet

In normal operating mode, the key-operated switch is always in the Oper-ation position.

Remove the key when in the Operation position and give to theowner for safekeeping.

A Main power switch (see section 3.3.2 ›Main power switch‹).

B EMERGENCY STOP button (see section 3.3.3 ›EMERGENCY STOPcircuit‹)

C Reset button (safety circuit enable)

D Key-operated switch Operation / Adjustment laser beam

The key must only be issued to the manufacturer's Servicepersonnel.

D

C

B

A




4.2.2 Laser module

Fig. 4.2-2 Operating and display elements on the laser module

The shutter lock is used to protect service personnel working on the beampath against accidental opening of the shutter.

In normal operating mode, the shutter switch is always in the UNLOCKposition.

A Indicator lamp (see section 4.1.1 ›Indicator lamp‹)

B EMERGENCY STOP button

C Shutter lock (key-operated switch)

Service work on the beam path and the associated locking ofthe shutter must only be performed by the manufacturer'sservice staff.

A

C B




4.2.3 Operator console

The laser cutting machine is operated from the operator console. The op-erator console is designed as a touch screen. This means that the user in-terface can be operated by touching the relevant on-screen buttons orkeys.

Fig. 4.2-3 Controls on the operator console

A EMERGENCY STOP button

B Rotary knob

C CONT button

D USB port

E Dead-man button (back of console)

F Screen (touch screen)

G Membrane keypad

D

CB

A

E

F

E

G




4.2.3.1 Membrane keypad

Fig. 4.2-4 Membrane keypad on operator console

A Status indicator of operator console

B Shutter status. When the LED is on, the shutter is open.

C Function keys

D X-, Y-, Z-axis traverse buttonsa)

a) Function is only available if Deadman button is held pressed at the same time.

DC

C

A

B




4.2.3.2 Function buttons

Tab. 4.2-1 Function buttons on the membrane keypad

Button Description

Toggles between standard and advanced functions. Access to the advanced functions can be protected by a PIN code. See section 5.9.2.2 ›Defining the PIN code‹

Changes the user interface language See section 5.9.1 ›Changing the dialog language‹

Dual function, depending on the laser mode defined. See section 5.7.2 ›Laser mode‹

Pulsed laser mode: emit one laser pulse each time the but-ton is pressed (deadman button must also be pressed)

Burn laser mode: open shutter while button is pressed (deadman button must also be pressed)

Stops any functions that have been started

Release safety door

Releases safety cover on unloader




4.2.3.3 Traverse buttons

Tab. 4.2-2 Traverse buttons on the membrane keypad

Button Description

Moves X-axis in plus or minus direction in manual mode, while deadman button also pressed.

Moves Y-axis in plus or minus direction in manual mode, while deadman button also pressed.

Moves Z-axis in plus or minus direction in manual mode, while deadman button also pressed.

No function




4.2.4 Sheet-clamping foot switch

Once the standard sheet is lying correctly against the sheet stop (loadingstatus indicator lamp lit), it can be clamped or released by pressing thefoot switch.

Fig. 4.2-5 Foot switch

At the start of a job, the sheet stop can be retracted/extended by pressingthe foot switch.




4.3 Operating modes

4.3.1 Normal mode

The laser cutting machine is in Normal mode when:

all components have been fitted and set up as specified

all covers correctly fitted

the laser cutting machine is switched on

all safety devices have been initialized

cutting plans and parameters have been imported

the cutting process has been started

4.3.2 Manual operating mode

Manual operation is only available from the advanced functions. While cut-ting is in progress, manual operation is blocked.

In manual operation, axes can be moved manually and the laser beam canbe switched on for a single pulse or continuously to make a manual sever-ance cut. Only with the safety door closed and deadman buttonheld pressed.

4.3.3 Service mode

The laser cutting machine is in Service mode when Normal operatingmode has been interrupted. It makes no difference whether the interrup-tion is for adjustment and inspection tasks, or for cleaning and mainte-nance work.

The machine enters Service mode at the moment when the safety door isopened or permanent safety devices are dismantled.

Normal mode is restored when the laser cutting machine is made readyfor use, the safety devices are reset and the process is started up again.



ByVention

Chapter 5

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.



ByVentionOperation



ByVention Operation

5.1 Introduction

5.1.1 Safety regulations

In order to prevent injuries and damage to property during work on thelaser cutting machine, it is essential to observe the safety regulations. Inparticular, all persons working with the machine must have read and un-derstood Chapter 2 ›Safety regulations‹ .

The machine danger zones that are out of bounds during operation arelisted in section 2.3 ›Danger zones‹.

The machine must only be used as intended, as described in section1.1.2 ›Intended use‹.

5.1.2 Requirements of the operating personnel

Operators must understand the operating software and have a technicalunderstanding. Operating staff must be able to perform the followingtasks:

Switch the laser cutting machine on and off

Operate the machine control system

Use the control software

Import a cutting job and start the cutting process

Perform dimensional corrections

Convert the machine for a change in production

Clean the laser cutting machine

Perform maintenance work required during normal operation



ByVentionOperation

5.2 Operating the laser cutting machine

The laser cutting machine is operated from the operator console, and atthe loading and unloading table.

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 insulationpresent and in working order.

The safety door must be closed.

All EMERGENCY STOP buttons must be enabled.

The ByVention machine and its components show no external signs ofdamage or defects.

Compressed air is connected with pressure and quality in accordancewith the requirements in the installation instructions. The shut-off valveis open.

The laser gas bottle is connected and the reducing valve open withpressure and quality in accordance with the requirements in the instal-lation instructions.The high voltage remains off during start-up if no laser gas is availableat the gas controller.

Cutting gas bottles are connected and the pressure reducing valvesopen. The shutter remains locked while there is no cutting gas availableat the gas controller.



ByVention Operation

5.2.2 Switching on in normal operating mode

Follow the procedure below to start up the laser cutting machine in normaloperating mode.

1. Switch on at the main power switch (ON position).

2. Press the reset button on the control cabinet. This enables the safetycircuit.

3. Switch on the main power switch on the combined cooling and filtra-tion unit (ON position).

4. The display on the operator console shows the required start-upsteps in the order they are to be performed.

Fig. 5.2-1 Manual start-up steps

Color-coding:

red Start-up step not carried out

green Start-up step carried out

The remaining start-up procedure remains blocked untilall start-up steps are carried out.



ByVentionOperation

5. Press the Unlock safety door button on the operator console. Openand re-close the safety door.

If the safety door is already open then it must be closed.

6. Move the axes to the reference positions. The operator console dis-plays the relevant operating prompt.

Fig. 5.2-2 Operating prompt: Move to reference

7. Press CONT on the hand-held controller. The axes move to the refer-ence position.

8. Wait until the Ready message for the laser appears in the status barin the user interface.

The orange indicator lamp on the laser module also lights up to showthat the laser is ready.

CONT



ByVention Operation

The machine is operational. The display shows the main view with thestandard functions.

Fig. 5.2-3 Main view showing standard functions



ByVentionOperation

5.2.3 Switching off in an emergency

The laser cutting machine can be switched off in an emergency by press-ing an EMERGENCY STOP button.

Error message: Stop - external emergency stop

All movements and processes are stopped immediately. Section3.3.3 ›EMERGENCY STOP circuit‹ contains further details.

Take appropriate action should anyone be injured during an emergency(observe operating regulations).

If the machine is damaged then the manager and the manufacturermust be informed.

5.2.4 Switching on again after an EMERGENCY STOP

Operation of the machine can only be resumed once the emergency situa-tion has been cleared and all defects and damage have been rectified.

1. Enable the actuated EMERGENCY STOP button by pulling it or turn-ing it clockwise (cw).

2. Press the reset button on the control cabinet. This enables the safetycircuit.

3. Reset error (see section 5.10.4 ›Resetting errors‹).

4. Wait until the laser module is ready (orange indicator lamp on the la-ser module comes on). You can then continue cutting.



ByVention Operation

5.2.5 Switching off in normal mode

Before the laser cutting machine can be switched off, the active cuttingprocesses must be completed.

1. Press button (A) in the main view showing standard or advancedfunctions.


2. Confirm prompt with yes.

Fig. 5.2-5 Confirmation prompt

Yes Continue shutdown procedure

No Cancel shutdown procedure

A

Yes No



ByVentionOperation

3. The display on the operator console shows the required switch-offsteps in the order in which they are performed.

Fig. 5.2-6 Manual shutdown functions

4. Wait until the laser module is flooded. As soon as the laser module isflooded, all applications are automatically closed and the controller isshut down.

5. Close shut-off valves for cutting gas, laser gas and compressed air.

6. Switch off the main power switch on the machine (OFF position).

7. Switch off the main power switch on the combined cooling and filtra-tion unit (OFF position).

Once started, the shutdown procedure cannot be inter-rupted.

Do not switch off the combined cooling and filtrationunit if there is a risk of frost.



ByVention Operation

5.3 Layout of the user interface

5.3.1 Standard functions

After starting up the laser cutting machine, the display shows the mainview with the standard functions.


A System, status and error messages. See section5.10 ›Troubleshooting‹

B Start standard sheet production. See section 5.6.3 ›Standardsheet production‹

C Import job. See section 5.6.1.1 ›Importing a job fromUSB memory stick‹

D Start shutdown procedure. See section 5.2.5 ›Switching off in nor-mal mode‹

B

C

D

A



ByVentionOperation

5.3.2 Advanced functions

The user can switch to the advanced functions at any time (function keyon operator console).

Fig. 5.3-2 Main view with advanced functions

Access to the advanced functions can be protected by a PINcode (see section 5.9.2.2 ›Defining the PIN code‹).

A Start residual sheet production. See section 5.6.4 ›Residual sheetproduction‹

B Select hand-held controller. See section 5.7 ›Manual operation‹

C Make settings. See section 5.9 ›Settings‹

D Select maintenance functions for the CNC or laser module. Seesection 5.8 ›Maintenance functions‹

E Symbol indicating advanced functions

No symbol: standard functions active

Symbol displayed: advanced functions active

E

C

D

A

B



ByVention Operation

5.4 Material flow

The material flow differs depending on whether it is a standard sheet(Standard sheet production) or a residual sheet (Residual sheet pro-duction) that is being cut.

5.4.1 Cutting standard sheets

Whole or partly cut standard sheets (length greater than 1 200 mm) arealways loaded or removed at the loading table.

The operator is responsible for loading sheets of the correct material.

1. Loading a standard sheet onto the loading table.

Fig. 5.4-1 Standard sheet on loading table



ByVentionOperation

2. Push a standard sheet against the sheet stops by hand and clamp.

Fig. 5.4-2 Standard sheet against sheet stop

3. The standard sheet will be pulled into the cutting area by the sheetfeed and travel unit.

Fig. 5.4-3 Standard sheet pulled into place



ByVention Operation

4. Make severance cut and cut first sheet segment.

Fig. 5.4-4 Cut sheet segment

5. The sheet segment is transported from the cutting area to the un-loading area. Manually remove the cut parts and skeleton.

Fig. 5.4-5 Cut sheet segment on the unloading table



ByVentionOperation

6. To cut the next segment, the standard sheet is again pulled into thecutting area.

Fig. 5.4-6 Standard sheet pulled into place

The following points must be observed:

If the current job requires further standard sheets, the operator consolewill display an operating prompt.

To remove a partly cut standard sheet (length less than 1 200 mm), itmust be cut into smaller pieces using severance cuts and shifted out tothe unloading table in several repeat operations.



ByVention Operation

5.4.2 Cutting residual sheets

Residual sheets are loaded and removed through the open safety door (formaximum dimensions see section 1.2.2.4 ›Residual sheet‹).

The operator is responsible for loading the correct material. He/she mustensure that the cutting plan fits the loaded residual sheet.



ByVentionOperation

5.5 Setting up and adjustment tasks

5.5.1 Initiating a function

Usually each selected function (e.g. Service position, Laser pulse etc.)is initiated by pressing the CONT button on the operator console. Thesafety door must be closed.

A started function can be stopped or aborted at any time using the STOPbutton on the operator console.

1. Select the desired function on the user interface (e.g. Service posi-tion).

2. Look at operating prompt on the user interface (e.g. to press theCONT or STOP button).

3. Press CONT on the operator console. The selected function is con-firmed and executed.



ByVention Operation

5.5.2 Removing or inserting the cutting head

When changing the cutting head, the best access is obtained when thehead is in the service position.

Fig. 5.5-1 Mounting the cutting head on the Z-axis.

1. Release and open the safety door.

2. Hold the cutting head with one hand while releasing the two clamp-ing levers with the other.

3. Carefully pull the cutting head down out of the holder.

A Clamping lever

B Mounting plate

C Cutting head

C

B

A



ByVentionOperation

4. With one hand hold the new cutting head against the mount witheven pressure while tightening the two clamping levers with the oth-er hand to fix the head in place.

5. Close the safety door.

After removing or fitting the cutting head, check that the laserbeam is centered in the nozzle. If necessary, center the noz-zle.



ByVention Operation

5.5.3 Adjusting the focal position

The focal position for the material to be cut and the cutting gas used mustbe set manually on the cutting head to the value shown.

Fig. 5.5-2 Step 2 of 4: Tool preparation

A Focal position to be set

B Focal-position scale (6 mm divisions)

C Scale on adjusting ring (0.2 mm divisions)

D Locking screw (for locking the focal-position adjusting ring)

A

B

D C



ByVentionOperation

1. Read off value shown on user interface (e.g. 0 - 55).

2. Undo locking screw.

3. Adjust the focal position at the adjusting ring. One revolution of theadjusting ring moves the foal position by 60/10 mm (6 mm).

Fig. 5.5-3 Changing the focal position

4. Check the focal position setting (focal-position scale and adjusting-ring scale)

5. Lock the adjusting ring with the locking screw.

Turning counterclockwise movesthe focal point downwards.

Turning clockwise moves thefocal point upwards.

Every cutting head has its own focus reference setting which isused by the controller as a basis for calculation.After cleaning or fitting a new lens, the focus reference settingmust be re-measured and saved in the parameters (see section7.5.8 ›Measuring the focus reference setting‹).



ByVention Operation

5.5.4 Changing the nozzle

The nozzle must be changed under the following circumstances:

if a different nozzle is required for processing a job (message displayedon user interface during tool preparation)

if the machining quality deteriorates and you find, on inspection, thatthe nozzle is damaged

Fig. 5.5-4 Cutting head with fitted nozzle

A Nozzle

B Unscrewing the nozzle

C Screw in nozzle

A

B

C



ByVentionOperation

1. Clean the nozzle externally.

2. Unscrew the nozzle by hand. If it is stuck fast, use a ring wrench withsuitable care.

3. Screw in the new nozzle fully by hand.

Whenever the nozzle is changed, check that the laser beam iscentered in the nozzle. If necessary, center the nozzle.



ByVention Operation

5.5.5 Centering the nozzle

Optimum cut quality is largely dependent on a properly centered nozzle.

If the nozzle is not centered properly, the laser beam can touch the nozzleand be distorted. So precision is essential when centering the nozzle.

Fig. 5.5-5 Nozzle not centered

Fig. 5.5-6 Nozzle centered correctly

A B

C

A Nozzle aperture

B Laser burn mark on the adhesive tape

C Adhesive tape

A B

C



ByVentionOperation

1. Affix a strip of transparent adhesive tape onto the nozzle in the cut-ting head.


3. Press button (D) to select laser pulse.


4. Press CONT to trigger laser pulse.


6. Using a mirror, check whether the hole burnt into the adhesive tapeis positioned exactly in the center of the nozzle aperture (seeFig. 5.5-6).

7. If necessary, use the centering screws on the cutting head (E) and(F) to correct the laser beam in the appropriate direction.

Turning clockwise (cw) moves the nozzle towards the centeringscrew (see Fig. 5.5-8).

Turning counterclockwise (ccw) moves the nozzle away from thecentering screw (see Fig. 5.5-9).

D



ByVention Operation

Fig. 5.5-8 Turning centering screws clockwise (cw)

Fig. 5.5-9 Turning centering screws counterclockwise (ccw)

8. Repeat step 1 to step 7 until the laser beam is fired exactly throughthe center of the nozzle (see Fig. 5.5-6).

E F

E F



ByVentionOperation

5.6 Production

5.6.1 Loading a job

The system recognizes whether the loaded job needs to be cut from astandard sheet or a residual sheet. The job is automatically added to theend of the appropriate job list (Standard sheet production or Residualsheet production).

5.6.1.1 Importing a job from USB memory stick

Plus the memory stick into the USB port of the operator console (see sec-tion 4.2.3 ›Operator console‹).

This function appears both in the standard functions and the advancedfunctions.

Fig. 5.6-1 Importing a job

The list can be scrolled up or down line by line (rotary knob on operatorconsole).

A

B C



ByVention Operation

A Open selected directory / import selected job

B Back to the previous view

C Cancel import function



ByVentionOperation

5.6.1.2 Load job automatically from the network

The created jobs can be copied automatically from the source directory tothe destination directory of the laser cutting machine.

The source directory can be defined on the local hard disk or on a server inthe network. The NcpMachineDistributor software module must be in-stalled for this function.

Fig. 5.6-2 Copying jobs from the source directory to the laser cutting machine

A A

E

B

C

F

D



ByVention Operation

The NcpMachineDistributor software module has the role of a job allo-cator. It looks for new jobs in the defined source directory at regular inter-vals. Any new jobs present are copied to the destination directory of thelaser cutting machine. Back up files of the copied jobs are created in thesource directory and then deleted afterwards.

A Programmer workstation

B Local hard disk

C Server in the network

D Installed NcpMachineDistributor software module

E Jobs created in Bysoft

F Laser cutting machine



ByVentionOperation

5.6.2 Job selection

In the Select job window, all available jobs are listed. The list can bescrolled up or down line by line (rotary knob on operator console).

The job at the top of the list can be processed. If another job is to be pro-cessed, it must first be moved to the top of the list.

Fig. 5.6-3 Job selection

5.6.2.1 Order of processing

The order of processing can be changed using the Prioritize and Movedown functions.

Pressing button (B) moves the selected job to the top position in thejob list.

Pressing button (C) moves the job down one position in the list.

A Job list

B Prioritize job

C Defer (Move down) job

A

B

C



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5.6.3 Standard sheet production

The formats specified in section 1.2.2.1 ›Standard sheet‹ and section1.2.2.2 ›Partly cut standard sheet‹ are permitted for Standard sheetproduction. Processing can be carried out with both standard and ad-vanced functions.

5.6.3.1 Loading standard sheets or partly cut standard sheets

1. Select the Standard sheet production function on the user inter-face.

Fig. 5.6-4 Step 1 of 4: Select job

CAUTIONRisk of pinch/crushing injury when loading or un-loading sheets




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2. Select job. If the correct job is not at the top of the list, it must firstbe moved there (see section 5.6.2 ›Job selection‹).

3. Enter number of Remaining runs if required. The number of Re-maining runs defines how often the cutting plan is worked through.

Fig. 5.6-5 Changing the number of runs

4. Press button (A) to confirm the entry.

A



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5. Start the job that appears at the top of the list.


6. Move axes to service position. The safety door must be closed to dothis. Select the function by pressing button (B) and use the CONTbutton to start the process.

7. Release the safety door and carry out adjustment work.

Check nozzle and change if necessary (see section5.5.4 ›Changing the nozzle‹).

Set the focal point on the cutting head (see section5.5.3 ›Adjusting the focal position‹).

Center the nozzle (see section 5.5.5 ›Centering the nozzle‹).

B



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8. Provide sheet according to the required specification (C). For severalrepeat runs of the cutting plan, provide the correct number of stan-dard sheets.

Fig. 5.6-7 Step 3 of 4: Place on material

Ensure that the sheets provided meet the required spec-ification (C).

C



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9. Place a standard sheet on the loading table and push it against thesheet stop (see section 5.4.1 ›Cutting standard sheets‹).

Fig. 5.6-8 Loading the sheet and pushing it against the stop

The loading status is indicated by the indicator lamp (D).

Lamp flashing No standard sheet against sheet stop

Lamp illuminated Standard sheet against sheet stop

Lamp not illuminated Standard sheet clamped

or

No sheet clamped and sheet stop re-tracted

D



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10. Once the standard sheet is correctly against the sheet stop, clamp itby pressing the foot switch.

Fig. 5.6-9 Foot switch

11. Press button (E) to confirm that sheet is loaded. The machine isready for cutting.

Fig. 5.6-10 Step 4 of 4: Cut plan

12. Start cutting process (see section 5.6.3.2 ›Starting the cutting pro-cess‹).

E



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5.6.3.2 Starting the cutting process

If the machine has been set up correctly and the correct material with thecorrect dimensions has been loaded, the cutting process can be started.


A Start and Stop functions (see section 5.6.5 ›Start and Stop func-tions‹)

Cancel job

Start part

Start job

Stop part

B Manual operatingmode

Switch to manual mode. While cutting is inprogress, manual operation is blocked.

See section 5.7 ›Manual operation‹

C <Param

Param>

Switch between the individual cutting pa-rameter views

See section 5.6.6 ›Changing cutting param-eters‹

D Restart Run through cutting plan again

See section 5.6.9 ›Repeating the cuttingprocess (Restart)‹

E

D

C

A

B



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1. Press the Start job or Start part button. See section 5.6.5 ›Startand Stop functions‹ for how to start or stop processing.

2. Press CONT on the hand-held controller. The following functions arecarried out automatically:

pulling in the sheet (first sheet segment in cutting area)

calibration of Z-axis

Starting the cutting process

3. Make a severance cut and then cut the parts on the sheet segment.

4. The cut sheet segment is transported to the unloading area.

5. The sheet feed pulls the next sheet segment into the cutting area.The machine continues to work through the cutting plan.

6. If a job includes several Remaining runs, the operator console dis-plays an operating prompt when another standard sheet needs to beloaded.

The nozzle is cleaned after every run through a cutting plan.

7. If the complete job has been worked through, it is deleted from thejob list. The following functions are carried out automatically:

Clean nozzle

Move to reference

E Cutting plan Show current cutting plan. The cutting planview can be scrolled up or down (rotaryknob on operator console).



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5.6.3.3 Removing the cut parts and skeleton

After transport of the cut sheet segment to the unloading position, thesafety cover on the unloader opens automatically allowing removal of cutparts and skeleton.

Fig. 5.6-12 Removing material in the case of mass production

Closing the safety cover confirms that the unloading table is empty.

CAUTIONRisk of burns

There is a risk of burns when removing the cut sheetsegment.

Wear protective gloves.

Before the next cut sheet segment can be transported to theunloading table, a check is made to ensure that it is empty. Ifthis is not the case then the unloading table moves back to theunloading position. The safety cover opens automatically.



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5.6.4 Residual sheet production

The formats specified in section 1.2.2.4 ›Residual sheet‹ are permitted forresidual sheet production. Processing is possible only with the advancedfunctions.

5.6.4.1 Loading a residual sheet

1. Switch to advanced functions (button on operator console).

2. Select the Residual sheet production function on the user inter-face.

Fig. 5.6-13 Step 1 of 4: Select job

CAUTIONRisk of pinch/crushing injury when loading or un-loading sheets




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3. Select job. If the correct job is not at the top of the list, it must firstbe moved there (see section 5.6.2 ›Job selection‹).

4. Enter number of Remaining runs if required. The number of Re-maining runs defines how often the cutting plan is worked through.

Fig. 5.6-14 Changing the number of runs

5. Press button (A) to confirm the entry.

A



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6. Start the job that appears at the top of the list.


7. Move axes to service position. The safety door must be closed to dothis. Select the function by pressing button (B) and use the CONTbutton to start the process.

8. Release the safety door and carry out adjustment work.

Check nozzle and change if necessary (see section5.5.4 ›Changing the nozzle‹).

Set the focal point on the cutting head (see section5.5.3 ›Adjusting the focal position‹).

Center the nozzle (see section 5.5.5 ›Centering the nozzle‹).

B



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9. Provide sheet according to the required specification (C). For severalrepeat runs of the cutting plan, provide the correct number of residu-al sheets.

Fig. 5.6-16 Step 3 of 4: Place on material

Ensure that the sheets provided meet the required spec-ification (C).

C



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10. Load the cutting table with a residual sheet and position it roughly atthe machine zero point (see section 5.4.2 ›Cutting residual sheets‹).

Fig. 5.6-17 Loading the material

Fig. 5.6-18 Residual sheet positioned at the zero point

Residual sheets are loaded and removed through the opensafety door.



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11. Press button (D) to confirm that sheet is loaded. The machine isready for cutting.


12. Start cutting process (see section 5.6.4.2 ›Starting the cutting pro-cess‹).

D



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5.6.4.2 Starting the cutting process

If the machine has been set up correctly and the correct material with thecorrect dimensions has been loaded, the cutting process can be started.


A Start and Stop functions (see section 5.6.5 ›Start and Stop func-tions‹)

Cancel job

Start part

Start job

Stop part

B Manual operatingmode

Switch to manual mode

See section 5.7 ›Manual operation‹

C Saveparameters

Save modified cutting parameters

See section 5.6.7 ›Saving cutting parame-ters‹

D Loaddefault

Resets cutting parameters to default values

See section 5.6.8 ›Resetting cutting param-eters‹

A

G

F

E

D

C

B



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1. Press the Start job or Start part button. See section 5.6.5 ›Startand Stop functions‹ for how to start or stop processing.

2. Press CONT on the hand-held controller. The following functions arecarried out automatically:

calibration of Z-axis

move to reference

3. Use the X+, X-, Y+ and Y- buttons while pressing the dead-man but-ton to move the axes manually to the start position. Note direction oftravel (see Fig. 5.6-21).

E <Param

Param>

Switch between the individual cutting pa-rameter views

See section 5.6.6 ›Changing cutting param-eters‹

F Restart Run through cutting plan again

See section 5.6.9 ›Repeating the cuttingprocess (Restart)‹

G Cutting plan Show current cutting plan. The cutting planview can be scrolled up or down (rotaryknob on operator console).

H Confirm selected start position

step 3 is not needed if the residual sheet has been posi-tioned correctly at the zero point using the end stops. Con-tinue with step 4



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Fig. 5.6-21 Directions of travel

4. Press button (H) to confirm the start position.

Fig. 5.6-22 Shifting the zero point

H



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5. Press CONT on the hand-held controller. The zero-point offset is cal-culated, and machining of the residual sheet starts.

6. If a job includes several Remaining runs, the operator console dis-plays an operating prompt when another residual sheet needs to beloaded.

The nozzle is cleaned after every run through a cutting plan.

7. If the complete job has been processed, it is deleted from the job list.The following functions are carried out automatically:

Clean nozzle

move to reference



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5.6.4.3 Removing the cut parts and skeleton

After the cutting process, manually remove cut parts and skeleton fromthe cutting table.

Fig. 5.6-23 Removing material in the case of residual sheet production


There is a risk of burns when removing the cut residualsheet.

Wear protective gloves.



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5.6.5 Start and Stop functions

5.6.5.1 Stop

A started function can be stopped at any time using the STOP button onthe operator console.

Fig. 5.6-24 Button on the operator console

5.6.5.2 Start part

Cut first part in the cutting plan. On pressing the Start part button again,the next part in the processing sequence is cut. Processing stops aftereach cut part.

5.6.5.3 Start job

Process whole job. If a job includes several Remaining runs, the opera-tor console displays an operating prompt when another standard or resid-ual sheet needs to be loaded.

5.6.5.4 Stop part

Execution of the cutting plan stops before the next part is started. Pressthe Start job or Start part button to resume processing.



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5.6.5.5 Cancel job

Before a job that has been started can be canceled it must be stopped(Stop part or STOP button).

Canceled jobs remain in the job list and are marked with a symbol (A).

On restarting a canceled job, processing continues after the last complete-ly cut standard sheet. Incompletely cut standard sheets are repeated.

Fig. 5.6-25 Canceled job

A



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5.6.6 Changing cutting parameters

The cutting parameters are not optimized for maximum process reliability.This means that adjustments can be needed for an optimum cutting result(see section 9 ›Cutting technology‹).

The values of the individual cutting parameters are changed as percentag-es of the default value. The default value is always 100%.


Cutting parameters can only be changed once processing of the cuttingplan has started.

A Next cutting-parameters view

B Previous cutting-parameters view

B

A



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1. Select cutting-parameter views by pressing button (A) or (B).

2. Select cutting parameter to be changed.

Fig. 5.6-27 Selected cutting parameter

3. Increase or decrease parameter value by turning rotary knob.

Fig. 5.6-28 Rotary knob on the operator console

The parameter is highlighted as it is changed.

Fig. 5.6-29 Parameter value when being changed

4. Wait for a few seconds. The modified parameter is automaticallytransferred to the controller and takes immediate effect.

Fig. 5.6-30 Modified parameter value

Changes in parameter values remain active until a new job isstarted.



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5.6.7 Saving cutting parameters

Modified cutting parameters can be saved. The modified parameters thentake effect for all jobs that use the same material.

A modified cutting parameter set can be given a new file name.

The function is only available from the advanced functions (see section5.3.2 ›Advanced functions‹).


5.6.8 Resetting cutting parameters

It is possible to reset the cutting parameters to the default values definedby the manufacturer.

Resetting is only possible when the loaded job is being processed (when atleast one cut has been made). Confirm prompt with Yes or No.

The function is only available from the advanced functions (see section5.3.2 ›Advanced functions‹).

A Save modified cutting parameters

B Resets cutting parameters to default values

A

B



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5.6.9 Repeating the cutting process (Restart)

If the cutting process has to be aborted (e.g. following a fault or collision),repeat functions are available for restarting the cutting process.


A Repeat sheet Repeat entire standard or residual sheet

B Next part Skip current part

C Contour lock-on Manually shift starting point for continuedprocessing of the cutting plan

D From stop point Continue processing from the positionwhere cutting was stopped

A

B

C

D



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5.6.9.1 Repeat sheet

Repeat entire standard or residual sheet. Individual sheet segments orparts of a residual sheet cannot be repeated.

This function requires that the standard or residual sheet on which cuttinghas been started is removed and another standard or residual sheet isloaded. Confirm prompt with Yes or No.

5.6.9.2 Next part

The part in processing when the cutting process was interrupted by press-ing the STOP or Stop part button is skipped.

On resuming the cutting process with Start part or Start job, the axesmove to the zero point of the next part in the cutting sequence.

5.6.9.3 Contour lock-on

After the cutting process is interrupted with the STOP or Stop part but-ton, the starting point for further processing of the cutting plan can beshifted manually (see Fig. 5.6-22 and Fig. 5.6-21).

On resuming the cutting process with Start part or Start job, the axesmove to the part nearest to the starting point. The cutting sequence con-tinues from this part.

This function is only possible within the same sheet segment orthe same residual sheet.

Moving the starting point may lead to parts being skipped.These will not be cut.



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5.6.9.4 From stop point

The machine continues to work through the cutting plan from the positionat which cutting stopped.



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5.7 Manual operation

Manual operation is only available from the advanced functions. While cut-ting is in progress, manual operation is blocked.

5.7.1 Switching to manual mode

Manual operation can be selected only when a cutting parameter file hasbeen selected. This is required for a manual severance cut, for example.The cutting parameter file depends on the material of the loaded sheet.

1. Select the Manual operation function on the user interface.

Fig. 5.7-1 Selecting the cutting parameter file



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2. Select cutting parameter. The list can be scrolled up or down line byline (rotary knob on operator console).

The names of the cutting parameter sets are structured according tothe following coding scheme.

Fig. 5.7-2 Structure of parameter set names.

A Material number using DIN convention

B Sheet thickness in [mm]

C Focal length of cutting head in inches

D Cutting gas

E Additional information

Material number using DIN convention

1.0161 St 37-2 Structural steel

1.0332 Stw 22 Sheet steel

1.4301 X5CrNi18 -10 Rust and acid-resistant steel

3.3535 AlMg3 Peraluman 300

Sheet thickness

1 1.0 mm 4 4.0 mm

1.5 1.5 mm 5 5.0 mm

2 2.0 mm 6 6.0 mm

2.5 2.5 mm 8 8.0 mm

3 3.0 mm

1.0161 1.5 5 N2 GALVANIZED

A B C D E



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Focal length of cutting head

5 Focal length 5 inches

Cutting gas

N2 Nitrogen

O2 Oxygen

Air Compressed air

Additional information

HOT DIP GALVANIZED hot galvanized

GALVANIZED electro-galvanized

PLASTIC FOIL film-coated



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3. Select manual operation by pressing button (F).

Fig. 5.7-3 Selecting manual operation

F Selecting manual operation

G Select cutting parameter file for manual operation (see sec-tion 5.7.4 ›Cutting parameters for manual operation‹).

F G



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5.7.2 Laser mode

The laser mode defines which function is actuated when the Laser button(on the operator console) is pressed. Only with safety door closed anddeadman button held pressed.

Tab. 5.7-1 Laser mode

5.7.3 Tool mode

Tool mode can be used to switch capacitive detection on/off in order toraise and lower the Z-axis.

Tab. 5.7-2 Tool mode

Laser mode Description

Burn Pressing the Laser button opens the shutter. The laser beam is emitted continuously, in accordance with the se-lected cutting parameter set. The shutter stays open for as long as this button is pressed.

This function is used for a making a manual severance cut.

Pulsed Pressing the Laser button emits a laser pulse, in accor-dance with the selected cutting parameters.

This function is used for centering the nozzle.

Tool mode Description

On Capacitive detection is enabled (default)

Off Capacitive detection is disabled

CAUTIONCollision risk

The nozzle may be damaged when detection is disabled.

Only switch off detection for maintenance work.



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5.7.4 Cutting parameters for manual operation

The cutting parameters only apply during manual operation. See section5.6.6 ›Changing cutting parameters‹ and section 9.6 ›Cutting parame-ters‹ for how to change parameters.

5.7.4.1 Laser mode: Burn

On the user interface, three different parameters can be changed for CWcutting.

Fig. 5.7-4 Cutting parameters in manual operation, Laser mode: Burn

In addition, the focal position for each material type andsheet thickness must be set manually on the cutting head.

A Cutting parameters in manual operation, Laser mode: Burn

B Cleaning height for nozzle cleaning This is used as a setup valuefor nozzle cleaning.

See section 5.7.4.3 ›Distance Z-reference - cleaning height‹

A

B



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5.7.4.2 Laser mode: Pulsed

On the user interface, two different parameters can be changed for thesingle pulse mode.

Fig. 5.7-5 Cutting parameters in manual operation, Laser mode: Pulsed

A Cutting parameters in manual operation, Laser mode: Pulsed

B Cleaning height for nozzle cleaning This is used as a setup valuefor nozzle cleaning.

See section 5.7.4.3 ›Distance Z-reference - cleaning height‹

A

B



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5.7.4.3 Distance Z-reference - cleaning height

The cleaning height (Z) defines how far the cutting head is lowered fromthe Z-axis reference position in order to clean the nozzle.

max. adjustment range 90 ... 105 mm

Adjustment step 1 mm

The value (Z) may need to be increased as the cleaning brush wearsdown. The optimum depth for the nozzle tip to extend into the brushequals 2 ... 3mm.

Fig. 5.7-6 Cleaning height

Z



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5.7.5 Moving the axes manually

When moving the axes manually, care must be taken to ensure that thereare no obstructions within the range of travel.

This function is available only with safety door closed and deadman buttonheld pressed.

Fig. 5.7-7 Directions of movement and buttons

Y+Y-

Z +Z -

X+X-



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Information on the individual axes is shown on the user interface.

Fig. 5.7-8 Manual operation, axis positions

A Current axis positions (X, Y and Z axes)

B Ref. (reference position of the X, Y and Z axes)

C End.+ (End of travel in positive direction of X, Y and Z axes)

D End.- (End of travel in negative direction of X, Y and Z axes)

A B C D

Axis in reference position

Axis not in reference position

Axis at limit of travel

Axis not at limit of travel

Axis at limit of travel

Axis not at limit of travel



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5.7.6 Moving the axes to the service position

The cutting head is moved to a defined position that is readily accessiblefor the operator. The following work is carried out in the service position:

changing the cutting head

adjusting the focal position

changing the nozzle

Center nozzle


2. Press button (A) to select the function.

Fig. 5.7-9 Manual operating mode

3. Press CONT on the hand-held controller. The axes travel to the ser-vice position.


A



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5.7.7 Manual severance cuts

Manual severance cuts are used to cut off waste or cut up residual sheetsinto smaller pieces. This function is available only with safety door closedand deadman button held pressed.

1. Place residual sheet on the cutting table.

2. Select manual operation (see section 5.7.1 ›Switching to manualmode‹).

3. Set Laser mode to Burn.

4. Switch Tool mode to On.

5. Move the cutting head manually to the desired starting position (seesection 5.7.5 ›Moving the axes manually‹). The severance cut isstarted from this position.

6. Press the Z- button on the operator console and hold until the cuttinghead has been lowered to the appropriate nozzle clearance height.Then release the button.

When the cutting head is lowered, traversing is performed at a slow-er speed enabling more precise positioning in the starting position.

CAUTIONMaking separating cuts

The cutting head must always be lowered during cuttingto prevent severe reflections or stray radiation.

Move the cutting head immediately after pressing theLaser button. Otherwise, the laser beam can damagethe trays under the cutting table or the support grate.

Always make severance cuts using the parameters assignedto the material of the loaded residual sheet.



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Fig. 5.7-10 Starting position for severance cut

7. Move the cutting head about 1 mm beyond the edge of the sheet.

8. Open the shutter by pressing the Laser button. The shutter staysopen for as long as this button is pressed.

Use the buttons for the X and Y-axes to move immediately in the de-sired direction for cutting the sheet.

9. Release the Laser button immediately once the severance cut ismade. This closes the shutter.

10. Press Z+ on the operator console The cutting head moves upwards.



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5.7.8 Moving the cutting table manually

The cutting table can be moved into defined positions (top, center or bot-tom). The current position is displayed.


2. Press button (B) or (C) to select the function.


A Current position of cutting table

B Move cutting table up

C Move cutting table down

A

B

C



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3. Press CONT on the hand-held controller. The cutting table moves inthe selected direction to the next position. The position with respectto the unloading table is monitored.




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5.7.9 Moving the unloading table manually

The unloading table can be moved into the limits of travel (cutting area orunloading area). The current position is displayed.


2. Press button (B) or (C) to select the function.


A Current position of unloading table

B Move unloading table into the cutting area

C Move unloading table into the unloading area

A

B

C



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3. Press CONT on the hand-held controller. The unloading table movesin the selected direction to the limit of travel. The position with re-spect to the cutting table is monitored.

4. If the unloading table is in the unloading position, the safety cover onthe unloader opens automatically.



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5.7.10 Unloading sheets manually

The sheet is transported from the cutting table to the unloading area. Themachine does not make a severance cut in this case. The following pointsmust be observed:

Check that the length of a sheet segment or residual sheet does not ex-ceed the maximum length (see section 1.2.2 ›Material formats andthicknesses that can be cut‹). If necessary, use manual severance cutsto reduce the sheet size.

Unloading is only possible when the unloading table is empty

This function is executed whether or not the cutting table contains ma-terial


2. Press button (A) to select the function.


A



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3. Press CONT on the hand-held controller. The sheet on the cutting ta-ble is transported to the unloading area.

4. If the unloading table is in the unloading position, the safety cover onthe unloader opens automatically.



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5.8 Maintenance functions

The maintenance functions can only be selected when the cutting processis not running.

5.8.1 CNC Maintenance

Fig. 5.8-1 Maintenance functions, CNC controller

A Execute RamDump. Save log files in a defined directory on theoperator console. The log files are used solely for fault analysis bythe manufacturer.

B Copy RamDump. Copy log files from the source directory on theoperator console to the destination directory on the USB memorystick. The files in the source directory are deleted after copying.

C Reset Terminal. Shut down and restart the operating system onthe operator console.

D Reset CNC. Shut down and restart the CNC controller.

B

A D

E

F

C



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E Edit saved focus reference setting (see section 7.5.8 ›Measuringthe focus reference setting‹)

F Saved value for the focus reference setting



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5.8.2 Laser module maintenance

Fig. 5.8-2 Maintenance functions, Laser module

A Start calibration process

B Abort calibration process

C Time remaining for calibration process

D Start leak test

E Stop leak test

F Results of leak test

G Operating status of laser components

A

D

B

E

C

F

GG



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5.8.2.1 Calibrating the optical power

The optical power of the laser module is monitored (comparison of actualand setpoint values). Wear and soiling of individual components can leadto a difference between the two values.

Warning message when difference exceeds 5 % of the setpoint value.

Error message and shut down of laser module when difference exceeds10 % of the setpoint value

If the warning message is displayed, run the calibration. This takes about12 minutes. After calibration, the actual value returns to within the per-mitted tolerance of the setpoint value.

5.8.2.2 Operating status of laser components

The operating status of each laser component is displayed on the user in-terface.

Only run the calibration after the laser module has warmed up(after about 2 h).

If the calibration establishes that too much current is requiredfor the specified power, then another error message is dis-played. Contact the manufacturer’s Customer Services depart-ment.

Operating status paint Meaning

Turbine running red Turboblower off

green Turboblower on

Excitation active red Excitation modules off

green Excitation modules on

Vacuum pump red Vacuum pump off

green Vacuum pump on

Laser module flooding red Laser module not flooded

green Laser module flooding



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5.8.2.3 Leak test for gas circuit

If the laser module is not supplying the required power, or there are prob-lems with generating the vacuum, the cause may be a leak in the gas cir-cuit.

The leak test will identify a leak in the gas circuit. A leak rate is displayedas the result. This must not exceed 1 hPa/h.

The leak rate is only displayed once the evacuation process has finished(approx. 10 ... 15 minutes after starting). Watch the operating status ofthe laser components.

The started leak test can be stopped at any time.

min. length of leak test 75 minutes

max. length of leak test 720 minutes

If the leak test produces a leak rate >1 hPa/h, there is a leak inthe gas circuit. Contact the manufacturer’s Customer Servicesdepartment.



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5.9 Settings

5.9.1 Changing the dialog language

The interface language can be changed without having to restart the lasercutting machine.

1. Select the Settings function on the user interface or press the Lan-guage select button on the operator console.

Fig. 5.9-1 Settings ⎯ Default language

A Current interface language

B Available interface languages

C Close view

C

A

B



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2. Change the interface language by selecting the appropriate button(B). Changes are effective immediately.

The list can be scrolled up or down line by line (rotary knob on oper-ator console).

3. Press button (C) to close the language-setting window.

The new interface language will be the default language whenthe the laser cutting machine is next started.



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5.9.2 Configuration

Fig. 5.9-2 Settings ⎯ Machine settings

A Length units ([mm] or [inches])

B Define PIN code

C Close view

C B

A



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5.9.2.1 Selecting the dimensional units

The setting for the dimensional units applies to the display of the materialdimensions (length, width, thickness) and to the display of the axis posi-tions (X, Y and Z axes).

Tab. 5.9-1 Dimensional units

Units Description

Millimeters Display material dimensions and axis positions in metric units

Inches Display material dimensions and axis positions in im-perial units



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5.9.2.2 Defining the PIN code

Access to the advanced functions can be protected by a PIN code (8 digitsmaximum). The default setting is no PIN code.

Fig. 5.9-3 Settings ⎯ Change PIN

Tab. 5.9-2 Set, change or de-activate PIN code

A Enter old PIN code

B Enter new PIN code

C Enter new PIN code again to confirm

D Confirm entry

E Delete entry

F Cancel change

ABC

ED

F

PIN code Input field

A B C

Set PIN code for the first time

Change existing PIN code

De-activate PIN code

No entry

Required entry



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5.9.3 Operating-hours counter

Maintenance is carried out on the basis of operating hours.

The operating hours listed below are displayed on the user interface.

Fig. 5.9-4 Settings ⎯ Operating-hours counter

A Operating-hours counter: Power switch on

B Operating-hours counter: Machine ready for cutting

C Operating-hours counter: Production time

D Operating-hours counter: Turboblower on

Figure used to assess when to carry out maintenance

E Close view

E

A

B

C

D



ByVention Operation

Tab. 5.9-3 Operating-hours counter

Hours counter Description

Power switch on Total duration, in hours, for which the main switch has been on.

Machine ready for cutting

Total duration, in hours, for which the laser cutting machine has been started up and referenced.

Production time Total duration, in hours, for which jobs have been processed.

Turboblower on Total duration, in hours, for which the turboblower in the laser module has been running.



ByVentionOperation

5.9.4 Versions

Display of installed software versions, protocols used and product infor-mation.

Fig. 5.9-5 Settings ⎯ Versions

A Installed software versions (user interface, machine service andCNC)

B Protocols for internal communication

C Machine type

D Machine version

E Rated power of laser module in [W]

F Installed version of the CNC operating system

G Software-image version on operating terminal

H Software version installed in laser module

I Close view

I

A

B

CDE

FGH



ByVention Operation

5.9.5 Administration

The manufacturer’s service personnel make machine-specific settings inthe Administration area. The functions are protected by a PIN code.

Fig. 5.9-6 Settings ⎯ Administration

A Close (Exit) application

B Start Administrator

C Close view

C

A B



ByVentionOperation

5.10 Troubleshooting

5.10.1 System, status and error messages

All system, status and error messages are displayed in the status bar (A).

Fig. 5.10-1 Error message

The individual messages are divided into classes and color-coded.

Tab. 5.10-1 Message colors

A

paint Priority / Class Description

1 Operator prompt The message requires operator in-tervention (e.g. press the CONT or STOP button).yellow

2 Fault Processes already started are inter-rupted (e.g. stop caused by EMER-GENCY STOP).

The cause must be fully cleared be-fore operation is resumed.

red

3 Warning A safety-related element has tripped (e.g. safety door open).

orange

4 Information Information on the active process (e.g. cutting plan import).

light blue



ByVention Operation

5.10.2 Message list

Touch the status bar to open the message list. All active messages are list-ed in the message list, with the highest priority message always at thetop.

If a number of messages are active simultaneously, the list can be scrolledup or down line by line (rotary knob on operator console).

Fig. 5.10-2 Message list

A List of active messages

B Reset error (see section 5.10.4 ›Resetting errors‹)

C Close dialog

B

C

A



ByVentionOperation

5.10.3 Using the Help facility

Press button (A) to display details of the selected message.

Fig. 5.10-3 Details

A Display details

B Detailed information on the selected system message, status mes-sage or error message

C Close dialog

C

A

B



ByVention Operation

Press button (D) to open the Online Help for the selected message. TheOnline Help contains a description of the cause of the error and its correc-tion.

Fig. 5.10-4 Online Help

D Open the Online Help

E Online Help for the selected system message, status message orerror message

F Close dialog

D

F

E



ByVentionOperation

5.10.4 Resetting errors

Most messages are automatically reset once normal conditions are re-stored.

There are, however, certain fault conditions for which the message mustbe reset by the operator after clearance of the fault.

Fig. 5.10-5 Message list

Press button (A) to reset the message. Press button (B) to close the mes-sage list.

Messages can be reset only after the causes have been com-pletely cleared.

A

B



ByVention Operation

5.11 Using the remote diagnostics facility (option)

The remote diagnostics facility is operated via a web browser (Internet Ex-plorer, Firefox, Opera etc.).

Open the home page by entering the IP address of the RD box.

Fig. 5.11-1 Entering the IP address in the address bar

Fig. 5.11-2 Remote diagnostics home page

http://192.168.100.250 (default IP address)

A Viewing diagnostic data

B Administration area (Connect / Disconnect)

A

B



ByVentionOperation

5.11.1 Connect / Disconnect (Administration)

The owner can connect the RD-box to the RD server and disconnect it.

When connected, the manufacturer's Customer Services department canview diagnostic data for individual machine modules.

Fig. 5.11-3 Administration – Connection view

A Select the Connection view

B Administrative functions for the manufacturer’s Customer Servicesdepartment

C Connection status

D Connect/Disconnect

E Back to home page

Only the owner can re-connect after a disconnection (seeTab. 5.11-1).

A

C D

EB



ByVention Operation

5.11.2 Connection status

The connection status to the RD server is displayed after every refresh.The following table lists the possible connection statuses.

Tab. 5.11-1 Connection status

Connection status Description

Connected Connected to server.

Use disconnect to end connection.

Disconnected Connection to server lost.

Use connect to re-connect.

try connecting Connection terminated because the network con-nection has been lost. The system is trying to re-connect.

The connection is established as soon as the server can be reached again.

Use stop trying to stop trying to connect.



ByVentionOperation

5.11.3 Viewing diagnostic data

The status of every machine module can be viewed in the Diagnostics ar-ea.

Fig. 5.11-4 Diagnostic data view

A Navigation by tree structure

B Diagnostic data

C Back to home page

CB

A



ByVention Operation

5.11.3.1 Navigation

Every time the system is interrogated, each connected module transmitsits current status, which is color coded in the Navigation view. TableTab. 5.11-2 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.


If a module in the subordinate branch has a problem, then the higher-lev-el node is also displayed in red.

Tab. 5.11-2 Status of system modules

paint 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



ByVentionOperation

5.11.3.2 Detailed diagnostic data

Selecting a module in the Navigation view displays detailed diagnosticdata for the module.


These operating instructions do not describe the detailed diag-nostic data.



ByVention

Chapter 6

6 Maintenance

This chapter contains the maintenance schedule and instructions on howto carry out lubrication, care and cleaning tasks and forms for the mainte-nance record. Materials required for maintenance work are also listed.



ByVentionMaintenance



ByVention Maintenance

6.1 Introduction


Maintenance staff must be familiar with the technical details of the lasercutting machine. They must have read and understood all operating in-structions and safety-related directions in these operating instructions.

Always disconnect the machine from the supply when performing mainte-nance and repair work. Protect the main power switch with a padlock andstore the key in a place inaccessible to a third party.

6.1.1.1 Work on live (hot) components

6.1.1.2 Work on gear units

WARNINGElectric shock

When working on live (hot) components there is a dan-ger of electric shock.

Electrical components on which maintenance work is be-ing performed must be disconnected from the electricalsupply unless otherwise specified.

Check that disconnected components are de-ener-gized.

Insulate any adjacent live (hot) parts.


Risk of burns if maintenance and repair work is per-formed on the gears when they are still at working tem-perature.

Allow gear units to cool down.




6.1.1.3 Remaining in the danger zone

During maintenance and repair work, no unauthorized persons are permit-ted to remain in the danger zone of the laser cutting machine. Block offdanger zone.

6.1.1.4 Operating materials

Always observe the manufacturer’s safety instructions when handlingworking materials, in particular gear oil, solvents and grease.

6.1.1.5 External modules

Always refer to the supplier documentation for all installed third-partyassemblies (e.g. combined cooling and filtration unit).

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 partscatalog).




6.1.2 Requirements to be met by personnel performing the work

Maintenance personnel must be capable of performing the following tasks:

Operation of the machine control system

repair work on pneumatic systems,

Replacement, repair and adjustment of mechanical parts

Making mechanical and electrical adjustments to the machine




6.2 Customer service information

The manufacturer's Customer Services department is available in theevent of problems. Please have the following information ready beforecalling the department, so that problems and queries can be dealt with asquickly as possible:

Company / Address

Contact person

Order and equipment number (see type plate)

The contact address appears in the front of these operating instructions.




6.3 Operating materials

Section 7 ›Repair‹ specifies the use of resources, lubricants and cleaningmaterials.

Tab. 6.3-1 Resources and cleaning materials

Tab. 6.3-2 Lubricants

Description Usage Order code

Lubrication set (in tool box)

4-10845

"Ultrapac" set of spares Air drier (adsorption drier) Section 7.4.8

10006011

Resin Amberlite MB-5 Combined cooling and filtra-tion unit

1991000

Kerosene Section 7.4.3.7 / 7.4.6.1

Description Usage Order code

Motorex 190 EP univer-sal grease

Section 7.4.3.1 / 7.4.3.3 /7.4.3.5 / 7.4.3.6 / 7.4.5.3 /7.4.5.4 / 7.4.6.2 / 7.4.7.1

1971661

Syntheso Proba 270 Chapter 7.5.7 1971659

Motorex Gearsynt ISO 460

Chapter 7.4.3.4 10010453

Chain oilChainlube 622

Section 7.4.3.7 / 7.4.6.1 1972790

Pump-action spray bot-tle

1972791

Compressor oil G32 Chapter 7.6.2 1973601




Tab. 6.3-3 Lens cleaning kit

Qty Description Order code

Lens cleaning kit

Section 7.5.5 / 7.5.5.1 / 7.5.5.2 / 7.5.5.3 / 7.5.5.4

10006021

1 Air bulb 10003299

1 Bottle of acetone (100 ml) with separate pipette 500615

4 50 sheet pack of lens cleaning paper 7 × 12 cm 500822

1 100 sheet pack of lens cleaning paper 15.2 × 22.8 cm

10003298

1 Pack of 170 Q-Tips cotton buds 10006017

1 Pack of makeup-remover cotton-wool pads 10003300

1 Bottle of lens polish (60 ml) 10006018

1 Bottle of de-ionized water (100 ml) 10006016

1 Bottle of (6%) acetic acid (100 ml) with separate pipette

10006015

1 Mount for optical elements 90000623

5 Pair of disposable latex gloves, size M 10000925

1 Cleaning instructions




6.4 Operating hours display

The reading from the Turboblower on operating-hours counter is used toassess when to carry out maintenance work (see Section5.9.3 ›Operating-hours counter‹).

Fig. 6.4-1




6.5 Maintenance schedule

The following maintenance schedule serves as a reference guide for plan-ning and implementing maintenance work on the laser cutting machine.

Maintenance of other modules (e.g. combined cooling and filtra-tion unit) is described in the operating instructions for that mod-ule.




ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Laser cutmachine

X

X

Safety dees

X

Operatorsole

X

Safety do grease90 EP

X

Gas supp X

X

X


ntion

Maintenance work

Notes/In-structions

Action Operatinsourceresource

ting ⎯ Check for external damage

⎯ Complete cleaning

vic- Chapter 7.3 Check EMERGENCY STOP buttons and end position monitoring for correct func-tioning and effectiveness.

con- Chapter 7.4.1 Clean operator console

or Chapter 7.4.2 Clean and lubricate guides Universal Motorex 1

ly Chapter 7.7.1 Cutting gas supply, change gas cylinder

Chapter 7.7.2 Laser gas supply, change gas cylinder

⎯ Check supply lines for leaks


ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Travel un X

grease90 EP

X

grease90 EP

X

grease90 EP

X

SO 460X

grease90 EP

X

grease90 EP

X


ntion

Maintenance work

Notes/In-structions


it Chapter 7.4.3.9 Check bellows for damage.

Chapter 7.4.3.1 Grease X-axis linear guides Universal Motorex 1

Chapter 7.4.3.2 Grease Y-axis spindle bearings Universal Motorex 1

Chapter 7.4.3.3 Grease X-axis motor bearings Universal Motorex 1

Chapter 7.4.3.4 Grease X-axis rack MotorexGearsynt I

Chapter 7.4.3.5 Grease Y-axis linear guides Universal Motorex 1

Chapter 7.4.3.6 Grease Y-axis recirculating ball drive Universal Motorex 1


ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Travel un622

X

X

Severanccut moniing

X X


ntion

Maintenance work

Notes/In-structions


it Chapter 7.4.3.7 Clean and lubricate Z-axis linear guides Chain oilChainlube

Chapter 7.4.3.8 Check for leakage at the cutting head mount. Replace missing or damaged O-rings.

e-tor-

Chapter 7.4.3.10 Check laser diode and window for soiling. Clean if necessary.


ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Cutting t

a) The extr or vice versa.

X X

X

grease90 EP

X

grease90 EP

X

SO 460X

X

X


ntion

Maintenance work

Notes/In-structions


able Chapter 7.4.5.1 Clear extraction chambersa)

action chambers must be cleared completely when changing material from steel to aluminum

Chapter 7.4.5.1 Check functioning of exhaust air sector flaps.

Chapter 7.4.5.3 Lubricate linear guides Universal Motorex 1

Chapter 7.4.5.4 Precision screw jack, grease spindle nut Universal Motorex 1

Manufacturer's Customer Ser-vice

Precision screw jack, change the gear oil.

Check spindle for soiling. Clean and lubri-cate if necessary.

MotorexGearsynt I

Chapter 7.4.5.5 Empty waste trays

Chapter 7.4.5.5 Clean waste tray wheels


ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Sheet fee622

X

grease90 EP

X

Unloader X

grease90 EP

X

X

Cutting h ing kit X X

X

X X


ntion

Maintenance work

Notes/In-structions


d Chapter 7.4.6.1 Clean and lubricate telescopic rails Chain oilChainlube

Chapter 7.4.6.2 Grease suction frame linear guides Universal Motorex 1

Chapter 7.4.5.5 Empty waste tray

Chapter 7.4.7.1 Grease fork system linear guides Universal Motorex 1

Chapter 7.4.7.2 Check gears for oil loss

ead Chapter 7.4.4.1 Check lens for dirt, metal splashes or scratched surface. Clean or replace if nec-essary.

Lens clean

Chapter 7.4.4.2 Check water couplings for leaks. Replace leaky couplings.

Chapter 7.4.4.3 Check nozzle and copper plate for damage or splashes of metal. Clean or replace if necessary.


ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Clean airply unit

X

X X

X X

X

Supply u X

X

X


ntion

Maintenance work

Notes/In-structions


sup- Chapter 7.4.8.1 Check LED display on air drier

Chapter 7.4.8.1 Air direr; replace drying agent cartridge. Indicated by LED display

Spares kitUltrapac

Chapter 7.4.8.1 Air drier; replace inlet and outlet filters. Indicated by LED display

Chapter 7.4.8.3 Cleaning the muffler

nit Chapter 7.4.9 Replace coarse filter

Chapter 7.4.9 Replace fine filter

Manufacturer's Customer Ser-vice

Filter on cutting-gas pressure reducer, clean or replace if necessary.


ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Laser mo or oil G32 X X

X

X

X

X

X


ntion

Maintenance work

Notes/In-structions


dule Chapter 7.6.1

Chapter 7.6.2

Check the vacuum pump oil level. Top up with oil if necessary.

Compress

Man

ufa

cture

r's

Cust

om

er S

ervi

ce

Visual inspection for soiling, corrosion and water leaks

Check contact pin on the Shutter circuit-breaker

Adhesive safety labels. All labels and safe-ty notices are fitted and legible Clean or replace if necessary.

Check mirrors in beam-expansion unit for soiling. Clean or replace if necessary.

Inspect pneumatic elements (loads, valves and hoses) for leaks. Clean or replace if necessary.


ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Laser mo X

X

X

X


ntion

Maintenance work

Notes/In-structions


dule

Manufa

cture

r's

Cust

om

er S

ervi

ce Vacuum pump, change oil

Vacuum pump, replace the air oil-filter el-ement (oil-mist filter) and seals

Turboblower, replace bearing cartridges

Replace turboblower


ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Combinecooling afiltration

a) When ch utting aluminum, the dust hopper must be emptied when 25% full.

X

X

X

X

X

ized wa-S/cm2

X X

X


ntion

Maintenance work

Notes/In-structions


d nd unit

see

oper

ating inst

ruct

ions

Com

bin

ed c

oolin

g a

nd

filtra

tion u

nit

Empty dust hopper when 75% fulla)

anging material from steel to aluminum or vice versa, empty dust separator hopper. When c

Check cleaning of filter unit

Check spark trap. Clean if necessary.

Clean air filter mats. Replace defective or very heavily soiled filter mats.

Clean condensers

Check water level in tank. Top up if neces-sary.

Demineralter < 20 μ

Replace resin


ByVe Maintenance

Interval

Object g re-

s

dail

y

50

h

15

0h

50

0h

10

00

h

30

00

h

80

00

h

16

00

0h

32

00

0h

As

nece

ssary

Combinecooling afiltration

X

X

X

X

X

X

Extractioduct

X


ntion

Maintenance work

Notes/In-structions


d nd unit

see

oper

atin

g inst

ruct

ions

Com

bin

ed c

oolin

g a

nd

filtra

tion u

nit

Check oil / water trap

Inspect seals on doors visually. Replace if necessary.

Check connecting pipes for leaks. Repair if necessary.

Dust extraction system, check that there is no caking at the entrance to the spiral hose. Clean if necessary.

Dust extraction system, check for leaks in the spiral hose. Replace if necessary.

Check combined cooling and filtration unit for damage or corrosion and ensure it is fitted securely. Repair or replace if neces-sary.

n Chapter 7.4.5.2 Check for deposits. Clean if necessary.


6.6 Maintenance record

The forms below may be copied and used as maintenance records forproof of maintenance work carried out. This record must be kept in themachine logbook.

Maintenance and repair work must be recorded with the date and signa-ture 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 maintainedlogbook is produced.




ByVe Maintenance

Maintena

Operatinhours

mments

50

100

150

200

250

300

350

400

450

500

550

600

650

700

750

800


ntion

nce record according to operating hours

g Maintenance atinterval

Date Signed Co

50

50

50 / 150

50

50

50 / 150

50

50

50 / 150

50 / 500

50

50 / 150

50

50

50 / 150

50


ByVe Maintenance

850

900

950

1 000

1 050

1 100

1 150

1 200

1 250

1 300

1 350

1 400

1 450

1 500

1 550

1 600

1 650

Operatinhours

mments


ntion

50

50 / 150

50

50 / 500 / 1 000

50 / 150

50

50

50 / 150

50

50

50 / 150

50

50

50 / 150 / 500

50

50

50 / 150


Date Signed Co


ByVe Maintenance

1 700

1 750

1 800

1 850

1 900

1 950

2 000

2 050

2 100

2 150

2 200

2 250

2 300

2 350

2 400

2 450

2 500

Operatinhours

mments


ntion

50

50

50 / 150

50

50

50 / 150

50 / 500 / 1 000

50

50 / 150

50

50

50 / 150

50

50

50 / 150

50

50 / 500


Date Signed Co


ByVe Maintenance

2 550

2 600

2 650

2 700

2 750

2 800

2 850

2 900

2 950

3 000

3 050

3 100

3 150

3 200

3 250

3 300

3 350

Operatinhours

mments


ntion

50 / 150

50

50

50 / 150

50

50

50 / 150

50

50

50 / 150 / 500 / 1 000 / 3 000

50

50

50 / 150

50

50

50 / 150

50


Date Signed Co


ByVe Maintenance

3 400

3 450

3 500

3 550

3 600

3 650

3 700

3 750

3 800

3 850

3'900

3 950

4 000

4 050

4 100

4 150

4 200

Operatinhours

mments


ntion

50

50 / 150

50 / 500

50

50 / 150

50

50

50 / 150

50

50

50 / 150

50

50 / 500 / 1 000

50 / 150

50

50

50 / 150


Date Signed Co


ByVe Maintenance

4 250

4 300

4 350

4 400

4 450

4 500

4 550

4 600

4 650

4 700

4 750

4 800

4 850

4 900

4 950

5 000

5 050

Operatinhours

mments


ntion

50

50

50 / 150

50

50

50 / 150 / 500

50

50

50 / 150

50

50

50 / 150

50

50

50 / 150

50 / 500 / 1 000

50


Date Signed Co


ByVe Maintenance

5 100

5 150

5 200

5 250

5 300

5 350

5 400

5 450

5 500

5 550

5 600

5 650

5 700

5 750

5 800

5 850

5 900

Operatinhours

mments


ntion

50 / 150

50

50

50 / 150

50

50

50 / 150

50

50 / 500

50 / 150

50

50

50 / 150

50

50

50 / 150

50


Date Signed Co


ByVe Maintenance

5 950

6 000

6 050

6 100

6 150

6 200

6 250

6 300

6 350

6 400

6 450

6 500

6 550

6 600

6 650

6 700

6 750

Operatinhours

mments


ntion

50

50 / 150 / 500 / 1 000 / 3 000

50

50

50 / 150

50

50

50 / 150

50

50

50 / 150

50 / 500

50

50 / 150

50

50

50 / 150


Date Signed Co


ByVe Maintenance

6 800

6 850

6 900

6 950

7 000

7 050

7 100

7 150

7 200

7 250

7 300

7 350

7 400

7 450

7 500

7 550

7 600

Operatinhours

mments


ntion

50

50

50 / 150

50

50

50 / 150

50

50

50 / 150

50

50

50 / 150

50

50

50 / 150 / 500

50

50


Date Signed Co


ByVe Maintenance

7 650

7 700

7 750

7 800

7 850

7'900

7 950

8 000

Operatinhours

mments


ntion

50 / 150

50

50

50 / 150

50

50

50 / 150

50 / 500 / 1 000 / 8 000


Date Signed Co

ByVention

Chapter 7

7 Repair

This chapter provides support in locating and rectifying faults. It also con-tains instructions for carrying out maintenance and making adjustments.



ByVentionRepair



ByVention Repair

7.1 Introduction


Maintenance staff must be familiar with the technical details of the lasercutting machine. They must have read and understood all operating in-structions and safety-related directions in these operating instructions.

Always disconnect the machine from the supply when performing mainte-nance and repair work. Protect the main power switch with a padlock andstore the key in a place inaccessible to a third party.

7.1.1.1 Work on live (hot) components

7.1.1.2 Work on gear units

WARNINGElectric shock

When working on live (hot) components there is a dan-ger of electric shock.

Electrical components on which maintenance work is be-ing performed must be disconnected from the electricalsupply unless otherwise specified.

Check that disconnected components are de-ener-gized.

Insulate any adjacent live (hot) parts.


Risk of burns if maintenance and repair work is per-formed on the gears when they are still at working tem-perature.

Allow gear units to cool down.



ByVentionRepair

7.1.1.3 Remaining in the danger zone

During maintenance and repair work, no unauthorized persons are permit-ted to remain in the danger zone of the laser cutting machine. Block offdanger zone.

7.1.1.4 Operating materials

Always observe the manufacturer’s safety instructions when handlingworking materials, in particular gear oil, solvents and grease.

7.1.1.5 External modules

Always refer to the supplier documentation for all installed third-partyassemblies (e.g. combined cooling and filtration unit).

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 partscatalog).



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Maintenance personnel must be capable of performing the following tasks:

Operation of the machine control system

repair work on pneumatic systems,

Replacement, repair and adjustment of mechanical parts

Making mechanical and electrical adjustments to the machine



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7.2 Troubleshooting

The following section show the step-by-step procedure for determining thesources of problems.

1. Refer to messages issued by the machine.

Error messages and remedial actions are described in the Onlinehelp.

2. Localizing faults

Is the fault mechanical or electrical?

Is it a hardware or software fault?

3. Finding source of problem

One fault often leads to other faults.

4. Frequency of fault

Does the fault always occur or do certain events trigger it?

5. Checking the laser cutting machine

Obstruction due to soiling, foreign objects, damage?

Supply connections OK ? (power supply, compressed air)

Ambient conditions, climatic influences (e.g. heat, storm, etc.)?

6. Interference from other equipment and loads (voltage spikes)?

7. Check sensors and switches

Buttons on operator console and release of EMERGENCY STOPbuttons

Sensors, limit switches, safety limit switches

LEDs on the input and output modules

8. Wiring and terminals

check installation for loose connections and broken conductors.



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9. Switches and settings

have components been changed but not correctly set?

10. Initialization

Shut down the entire system and re-start.

11. Supplier documentation

Other operating instructions may contain information on the faultand troubleshooting.

12. Telephone

Call the manufacturer's Customer Services department (see section7.9 ›Customer service information‹).



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7.3 Safety inspection

Check safety and monitoring devices such as EMERGENCY STOP buttonsand limit switches at the specified maintenance intervals to ensure thatthey are operating correctly and effectively.

Information on the safety components is given in section 3.3 ›Safety de-vices‹.

7.3.1 EMERGENCY STOP buttons

Functional test of all EMERGENCY STOP buttons on the laser cutting ma-chine during an active cutting process.

1. Set up the machine and start the cutting process.

2. Press EMERGENCY STOP button. The EMERGENCY STOP circuit isworking correctly if all electrical loads are disconnected from thepower supply. The power supply to the controller is not switched off.

EMERGENCY STOP buttons are fitted:

on the operator console

on the control cabinet

on the laser module

3. Reset the actuated EMERGENCY STOP button and re-start the lasercutting machine.

See section 5.2.4 ›Switching on again after an EMERGENCY STOP‹



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7.3.2 Limit-of-travel monitoring

7.3.2.1 Limit switches on X-axis and Y-axis

Follow the procedure below to perform the functional test on the limitswitches on the X-axis and Y-axis.

Fig. 7.3-1 Position of the limit switches

1. Select manual operation (see section 5.7 ›Manual operation‹).


3. Move the axes manually to the end position in question until the limitswitch is actuated (see section 5.7.5 ›Moving the axes manually‹).

4. The actuated limit switch is shown in the Axis positions view.

If it not possible to actuate the X-axis limit switch and/or Y-axis limitswitch, the limit switch concerned must be must be replaced by themanufacturer's Customer Service department.

5. Once the limits switches have been tested successfully with no faults,reference the machine.

A Cutting table

B Limit switch, position X-

C Limit switch, position Y-

A

B

C

Y+

X+



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7.3.2.2 Limit switch on Z-axis

Follow the procedure below to perform the functional test on the Z-axislimit switches.

1. Select manual operation (see section 5.7 ›Manual operation‹).


3. Lower the cutting table as far as possible (see section 5.7.8 ›Movingthe cutting table manually‹).

4. Switch Tool mode to Off to turn off the capacitive sensing. SeeChapter 5.7.3 ›Tool mode‹.

5. Move the manually, roughly to the middle of the cutting area.

6. Move the Z-axis manually to the Z+ limit of travel until the limitswitch is actuated (see section 5.7.5 ›Moving the axes manually‹).

7. The actuated limit switch is shown in the Axis positions view.

If it is not possible to actuate the limit switch, it must be replaced bythe manufacturer's Customer Service department.

8. Move Z-axis in Z- direction. As soon as the Z-axis reaches the Z- lim-it of travel, the Z-axis automatically moves upwards again.

Error message: Stop - limit switch Z- tripped

9. Once both limits of travel have been tested successfully with nofaults,

move the cutting table up to its topmost position.

Switch Tool mode to On to turn on the capacitive sensing.



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7.4 Lubrication, service and cleaning work

7.4.1 Operator console

Before cleaning the operator console, shut down the laser cutting machineand switch off at the main switch.

Fig. 7.4-1 Operator console

Never use a solvent-based cleaning agent for cleaning. Solvents or strongcleaning agents can damage the screen surface and the membrane key-board.

If necessary, use a soft cloth lightly moistened with soapy water to cleanthe keyboard.



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7.4.2 Safety door

Clean and grease the guides every 500 operating hours.

Fig. 7.4-2 Guides, safety door

Lubricant: Motorex 190 EP universal grease

A Safety door

B Guides

B

B

A



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7.4.3 Travel unit

7.4.3.1 X-axis linear guides

Every 500 operating hours, grease the X-axis linear guides. Lubricationnipples 1 to 6

Fig. 7.4-3 Grease nipples on X-axis linear guides


Quantity: 1,7 cm3 (2 shots with the grease gun)per lubricating nipple

64

2

1

3

5



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7.4.3.2 Y-axis spindle bearings

Every 3 000 operating hours, grease the Y-axis spindle bearings. Greasenipple No. 7

Fig. 7.4-4 Grease nipples on Y-axis spindle bearings


Quantity: 2,5 cm3 (2 shots with the grease gun)

7



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7.4.3.3 X-axis motor bearings

Every 3 000 operating hours, grease the X-axis motor bearings. Greasenipple No. 8

Fig. 7.4-5 X-axis motor bearings lubrication nipple



8



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7.4.3.4 X-axis rack

Every 1 000 operating hours, grease the X-axis rack. Grease nipple No. 9

Fig. 7.4-6 X-axis rack lubrication nipple

Lubricant: Motorex Gearsynt ISO 460


9



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7.4.3.5 Y-axis linear guides

Every 500 operating hours, grease the Y-axis linear guides. Lubricationnipples 1 to 4

Fig. 7.4-7 Lubrication nipples on Y-axis linear guides


Quantity: 0,6 cm3 (1 shot with the grease gun)per lubricating nipple

12

3

4



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7.4.3.6 Y-axis recirculating ball drive

Every 150 operating hours, grease the Y-axis recirculating ball drive (spin-dles and bearings). Grease nipple No. 5

Fig. 7.4-8 Lubrication nipples on Y-axis linear guides


Quantity: 5 cm3 (4 shots with the grease gun)

5



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7.4.3.7 Z-axis linear guides

Every 500 operating hours, clean the Z-axis linear guides with kerosenesoaked cloths. Lubricate with chain oil.

Fig. 7.4-9 Linear guides, Z-axis

Lubricant: Chain oil Chainlube 622 (in pump-action spray bottle)



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7.4.3.8 Cutting-head mount

Check condition of seals daily. Replace missing or damaged O-rings.

Fig. 7.4-10 Seals on the cutting head mounting

A Cutting-head mount

B Seals (O-rings)

A

B

B



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7.4.3.9 Bellows

Check all bellows for damage every 500 operating hours. Replace defec-tive bellows.

Fig. 7.4-11 Bellows on the laser cutting machine



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The laser bellows have a multi-layer construction. So any external damagein the corners does not necessarily mean the bellows are not sealed. Theflexible inner material remains intact considerably longer than the toughouter cover.

A thin probe (e.g. pen refill or wire) can be used to investigate any exter-nal corner damage to see whether the inner material is also damaged(e.g. contains holes). If damage is clearly present, the bellows must bereplaced.



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7.4.3.10 Severance-cut monitoring

Check laser diode and window for soiling daily (visual inspection). Cleanwith a dry, clean cloth as necessary.

Fig. 7.4-12 Reflection light sensor, severance-cut monitoring

A Window

B Laser diode

A

B



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7.4.4 Cutting head

7.4.4.1 Lens

Check lens for dirt, metal splashes or scratched surface daily (visual in-spection).

Clean or replace lens if necessary (see section 7.5 ›Cleaning or replacingthe lens‹).

Fig. 7.4-13 Visual inspection of the lens in the cutting head



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7.4.4.2 Water couplings

Check water couplings on cutting head daily for leaks.

Fig. 7.4-14 Water coupling

A Cutting head

B Water coupling

A

B



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7.4.4.3 Nozzle and copper plate

Check nozzle and copper plate daily for damage and splashes of metal.Clean or replace if necessary. See section 5.5.4 ›Changing the nozzle‹ forhow to replace nozzle.

Fig. 7.4-15 Nozzle and copper plate on cutting head

A Copper plate

B Jet

A

B



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7.4.5 Cutting table

7.4.5.1 Extraction system

Every 50 operating hours, remove the cutting residues from the extrac-tion chambers.

Every 150 operating hours, check that the flaps on the extraction sec-tors are working. If the cutting head is located over sector (A) or (B),the corresponding air extraction sector flap must be open.

Fig. 7.4-16 Extraction sector flaps

The extraction chambers must be cleared completely whenchanging material from steel to aluminum or vice versa.

A Air extraction sector 1

B Air extraction sector 2

A

B



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7.4.5.2 Extraction duct

Check the extraction duct for deposits every 1 000 operating hours. Cleanif necessary.

Fig. 7.4-17 Extraction duct between machine and the combined cooling and filtration unit (cover re-moved)

Remove extraction duct and clean internally. Check sealing tape for dam-age. Replace if necessary.



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7.4.5.3 Linear guides

Every 500 operating hours, grease the cutting table linear guides.

Fig. 7.4-18 Cutting table linear guides





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7.4.5.4 Precision screw jack

Every 500 operating hours, grease the spindle nuts.Grease nipple No. 5

Fig. 7.4-19 Precision screw jack, cutting table


Quantity: 1,4 cm3 (1 shot with the grease gun)

5



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7.4.5.5 Waste trays

Empty the waste trays daily

Every 150 operating hours, clean the wheels.

Fig. 7.4-20 Waste trays on cutting table and unloading table

A Waste trays under the cutting table

B Waste tray under the unloader

A

A

B



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7.4.6 Sheet feed

7.4.6.1 Telescopic rails

Every 500 operating hours, clean the sheet-feed telescopic rails with kero-sene soaked cloths. Lubricate with chain oil.

Fig. 7.4-21 Sheet-feed telescopic rails

Lubricant: Chain oil Chainlube 622 (in pump-action spray bottle)

Clean and lubricate telescopic rails when fully extended.



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7.4.6.2 Suction-frame linear guides

Every 500 operating hours, grease the suction-frame linear guides. Lubri-cation nipples no. 1 and 2

Fig. 7.4-22 Lubrication nipples on suction-frame linear guide

Detail X



X

1

2



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7.4.7 Unloader

7.4.7.1 Fork-system linear guides

Every 500 operating hours, grease the fork-system linear guides.

Fig. 7.4-23 Lubrication nipples on fork-system linear guide





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7.4.7.2 Fork-system gears

Check the gears for oil loss every 1 000 operating hours. If they are losingoil, contact the manufacturer’s Customer Services department.

Fig. 7.4-24 Fork-system worm-gear



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7.4.8 Clean air supply unit

7.4.8.1 Air drier (adsorption drier)

Every 8 000 operating hours or if there is a relevant error message,change the filter or cartridge.

The air drier displays an error message when a filter or cartridge needschanging. The error message stops the cutting process.

Error message on the operator console: Beam path air pressure ismissing

Fig. 7.4-25 LED indicator on the air drier

Check the LED display to make sure that the air drier really was the sourceof the error message.

The LEDs (B, C and D) indicate whether the pre-filter, post-filter or drying-agent cartridge needs replacing.

The precise procedure is given in the manufacturer's operating manual, inthe supplier documentation folder. The filter replacement pack can beobtained from the manufacturer of the laser cutting machine.

A Operation indicator

B Replace drying agent cartridge

C Replace post-filter

D Replace pre-filter

A

B

C

D



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7.4.8.2 Reset switches

After replacing the drying agent cartridge, you must flip the Reset switchwith the machine switched off (resets the last-change counter).

The Reset switch is located behind the LED display cover.

Fig. 7.4-26 Reset switch on the control board

Only operate the Reset switch once after each cartridgechange.

Resetting the last-change counter only works with the ma-chine switched off.



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7.4.8.3 Cleaning the muffler

Every 150 operating hours, check the muffleers for deposits (visual in-spection). If there are powder residues in the pipe, the muffler must becleaned.

Fig. 7.4-27 Muffler unit

1. Undo hose clip (B) and pull off hose (A).

2. Unscrew elbow joint (C).

3. Remove muffler (D).

A Tube

B Hose clip

C Elbow joint

D Muffler

A

B

D

C



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4. Undo casing bolts and dismantle muffler (D).

Fig. 7.4-28 Dismantled muffler

5. Clean parts

Blow off or wash out mesh sleeve (F).

Blow off inner sleeve (G).

6. Assemble the muffler.

7. Insert muffler and fit elbow joint (C).

8. Re-connect pipe (A) and tighten hose clip (B)

E Base with casing bolts

F Mesh sleeve

G Inner sleeve

H Mesh

I Cap

J Nuts

Use only air, never water, to clean the inner sleeve.

E F G H I

J



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7.4.9 Supply unit

Every 1 000 operating hours, replace the coarse filter (40 μm).

Every 1 000 operating hours, replace the fine filter (5 μm)

Fig. 7.4-29 Coarse and fine filters on the supply unit

A Coarse filter (40 μm)

B Fine filter (5 μm)

A

B



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7.5 Cleaning or replacing the lens

The lens surfaces are specially coated. Damage to the coating reduces thebeam 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

erosion of the coating from the lens surface.

CAUTIONDamage to optical components and parts

Improper handling will soil or damage optical compo-nents.

Always wear disposable gloves when cleaning, replacingor checking the lens (type: powdered Latex, non-sterile,EN 455 class 1). Make sure that the work place is clean.



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Smoking is strictly forbidden when working with optical elements.

Take utmost care, and work to the highest standards of cleanlinesswhen handling optical elements. It is essential to have a clean work en-vironment (if possible an office), a clean work surface and clean materi-als and tools.

Wear latex disposable gloves

WARNINGDamage to a lens

Take utmost care if a lens is damaged as the lens con-tains zinc selenide and thorium. If lenses are intact, noradioactive material can escape. However, if the lens isbadly scratched or thermally damaged, radioactive ma-terial can escape into the environment. These materialsmay cause damage to health if inhaled.

Wear breathing mask and gloves.

Do not stir up dust.

Materials that have come into contact with the brokenlens or lens dust must be cleaned thoroughly with wa-ter or disposed of as hazardous waste!

Return damaged lenses to the manufacturer of the la-ser cutting machine.

After cleaning, wash your hands thoroughly underrunning water.



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7.5.1 Equipment

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. 7.5-1 Lens wrench and circular rod

A Lens wrench

B Threaded pin (fixes handle extension)

C Inner piece of circular rod

D Outer piece of circular rod

C

D

A

B

B



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7.5.2 Construction of cutting head

Fig. 7.5-2 Cutting head

A Cutting head

B 5" lens holder (see Fig. 7.5-3)

The lens holder is different depending on the focal length ofthe cutting head. Note the engraving (5") when assembling.

AB



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Fig. 7.5-3 Lens holder

A Lens holder O-ring

B Lens holder

C Lens holder O-ring

D Lens

E O-ring

F Clamping ring

G Lens nut

A

B

C

D

E

GF



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7.5.3 Removing the lens holder

1. Place cutting head on a clean surface.

2. Unscrew fixing screws on lens holder and pull the lens holder out ofthe cutting head by hand.

Fig. 7.5-4 Removing the lens holder

A Lens holder

B Fixing screws

Do not twist the lens holder as you pull it out.

A

B



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3. Check lens holder O-ring. Replace damaged O-rings.

4. Place the lens holder on a clean surface (with the lens nut facing up-wards).

Apply minimal grease to O-ring before fitting (Synthe-so Proba 270).

No residual grease should be visible.



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7.5.4 Removing the lens

1. Remove handle extension from lens wrench. The handle extension isnot needed to exert the required torque to undo/tighten the lens.

Fig. 7.5-5 Removing the handle extension

2. Clean lens wrench with compressed air.

A Lens wrench

B Handle extension

B

A



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3. Unscrew the lens nut using the lens wrench.

Fig. 7.5-6 Remove the lens nut

A Lens holder

B Lens wrench for 5" lens nut

C Lens nut

B

A

C



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4. Position the outer part of the circular rod in the lens holder.

Fig. 7.5-7 Circular rod in position

A Lens holder

B Outer piece of circular rod

B

A



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5. Rotate the lens holder through 180° and carefully lift it off. If the lensdoes not come away from the lens holder, press down lightly on thelens from above with a cotton bud (inserted in the inner part of thecircular rod).

Fig. 7.5-8 Using a cotton bud to exert gentle pressure if lens is stuck fast

A Inner piece of circular rod

B Cotton bud

C Lens

D Outer piece of circular rod

A

B

C

D



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6. After removal, the clamping ring and the lens are located on the cir-cular rod. Replace scratched or damaged lens. Clean soiled lens.

Fig. 7.5-9 Dismantled lens

7. Position the dismantled lens in the lens holder1).

Fig. 7.5-10 Lens placed in mount for optical elements

A Lens

B Clamping ring

C Outer piece of circular rod

1) Included in cleaning set

B

A

C



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7.5.5 Lens cleaning

The equipment required for cleaning is kept in the cleaning case. Cleaninginstructions are placed in the lid of the cleaning case.

Fig. 7.5-11 Lens cleaning kit

A Lens cleaning paper 15.2 × 22.8 cm

B Makeup-remover cotton wool pads

C Disposable gloves (type: powdered Latex, non-sterile, EN 455class 1), size M

D De-ionized water, 100 ml bottle

E Acetic acid with separate pipette, 100 ml bottle

F Q-Tips cotton buds

G Optical component holder

H Acetone with separate pipette, 100 ml bottle

I Lens polish, 60 ml bottle

J Air bulb

K Lens cleaning paper, 7 × 12 cm

A B C D E F

G H I J K



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The following points must be observed when working with op-tical elements:

Smoking is strictly forbidden when working with optical ele-ments.

Never clean the surface of the lens dry.

Never treat the lens with compressed air. Contaminants inthe compressed air can penetrate the surface.

Store cleaning paper, cotton buds and cotton pads in adust-free environment. Dispose of after use.

Always use only the cleaning materials provided. Replacecaps on bottles after use.

Wear disposable gloves. Finger prints reduce the lifetime oflenses.

Set up workplace away from the laser module. Do not allowsolvent vapor to enter the beam path.

Check the labeling on the lenses. Re-attach detached la-bels.

Fit cleaned lenses immediately. Observe direction of instal-lation.



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7.5.5.1 Cleaning in the case of light soiling

Light soiling means particles that can be removed by blowing them off.

Use air bulb to blow off dirt (dry nitrogen is also allowed). Never use ablow gun.

Blowing dirt from lenses using an air bulb in heavily contaminat-ed workshops must be tried 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).



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7.5.5.2 Cleaning in the case of moderate soiling

If lenses cannot be cleaned adequately using the air bulb, proceed as fol-lows:

1. Place lens in the mount (included in the cleaning kit).

Fig. 7.5-12 Lens placed in mount for optical elements

2. Place lens cleaning paper (7 × 12 cm) on the lens and drop 2 to 3drops of acetone onto it.

Fig. 7.5-13 Lens cleaning paper with 2 to 3 drops of acetone

3. Draw the lens cleaning paper slowly and horizontally over the lens,avoiding smears and leaving a dry clean surface.

Fig. 7.5-14 Draw the lens cleaning paper over the lens.

Smears lead to irregular absorption of the laser beam.



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4. The procedure can be repeated more than once. Use a fresh lenswipe each time.

5. Use cotton buds to clean the lens surface if soiling is more severe.

The cotton buds must be prepared before use so that they are as softas possible for the optical element to be cleaned.Before using each cotton bud, pull the cotton wool apart slightly withyour fingers and then re-twist in the opposite direction. Wear dispos-able gloves.

6. Sprinkle lens cleaner (acetone) on a clean cotton bud and clean thelens for no longer than 30 seconds, working from the inside out.

Only exert gentle pressure on the surface of the lens. Turn the cottonbud steadily about its longitudinal axis so as to remove as much dirtas possible.

Fig. 7.5-15 Lens cleaning using an acetone-soaked cotton bud

Take particular care when using this cleaning method.Apply only light pressure.

Avoid scratching the surface with dirt particles that ad-here to the cotton buds.

A Direction of rotation of cotton bud

B Circular movement to clean lens

A

B



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7. Finally, to remove any smears, clean the lens again using lens clean-ing paper as described in step 2 and step 3.




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7.5.5.3 Cleaning in the case of heavy soiling

If lenses cannot be cleaned adequately using the air bulb, and subsequentcleaning with acetone does not give a satisfactory result, use acetic acid toclean the lens surface.

1. Do not perform the cleaning process for longer than 30 seconds. Ap-ply only light pressure.

Fig. 7.5-17 Lens cleaning using a cotton bud soaked in acetic acid

2. To remove any residual acetic acid or smears, clean the optical ele-ment using lens cleaning paper and acetone as described in section7.5.5.2 ›Cleaning in the case of moderate soiling‹ (step 2 andstep 3).


Take particular care when using this cleaning method. Applyonly light pressure.

Avoid scratching the surface with dirt particles that adhere tothe cotton buds.

Do not let the edges of the lens come into contact with theacetic acid.

A Direction of rotation of cotton bud

B Circular movement to clean lens

A

B



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7.5.5.4 Cleaning in the case of stubborn dirt

Polishing has an abrasive action and is only used when all other cleaningattempts described in section 7.5.5.1, 7.5.5.2 and 7.5.5.3 have failed togive the desired result.

1. Shake the polish well before use.

2. Sprinkle a few drops of the lens polish onto a cotton wool pad (eyemake-up remover pad).

3. Move the cotton pad carefully over the surface, using only the pres-sure of its own weight and making circular movements, for not long-er than 30 seconds.

4. Soak a fresh cotton pad (make-up remover pad) with de-ionized wa-ter and use it to remove the polish carefully. Repeat this process witha fresh cotton ball, including the edge of the optical element in theaction.

CAUTIONDamage to the lens

The polish has an abrasive action and can attack thelens coating if not used properly.

Polishing the surface of the optical element for too long,too often or with too high a pressure wears away the op-tical coating. This modifies the properties of the coating,identifiable by a change in color of the surface of thelens.

Polish the lens surface for no more than 30 seconds.

Perform no more than 2 polishing operations.

Avoid exerting high pressure.

Do not let the polish dry onto the surface of the lens.



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5. Moisten a fresh cotton bud with acetic acid. Use this to remove anypolish still remaining by cleaning from the inside out with circularmovements (see Fig. 7.5-17).

6. Moisten a cotton bud with acetone. Use it to clean again in circularmovments, working from the center outwards.

7. Moisten a fresh cotton bud with acetone. Wipe the cotton bud inoverlapping movements gently over the surface of the lens until allpolish residues have been loosened.

Fig. 7.5-19 Lens cleaning using an acetone-soaked cotton bud

8. Place a piece of lens cleaning paper on the lens; drop 2 to 3 drops ofacetone onto the paper and wipe the element by sliding the paper offsideways to leave a dry and clean surface (see section7.5.5.2 ›Cleaning in the case of moderate soiling‹).


If cleaning with polish is still unsuccessful or if burn marks inthe coating are visible, the optical element must be replaced.



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7.5.6 Fitting the lens

The lens holder is different depending on the focal length of the cuttinghead. Note the engraving (5") when assembling.

1. Check O-ring for damage. Replace if necessary.

2. Place clamping ring with O-ring, right side up, on the circular rod.

Fig. 7.5-21 Clamping ring with O-ring

3. Place lens on the O-ring with the curvature facing upwards.

Tab. 7.5-1 Clamping ring and lens located on the circular rod

The O-ring must not be greased.

A O-ring

B Clamping ring


A

B

C

D

C



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4. Slide the lens holder over the prepared package and push it in as faras the end stop.

Fig. 7.5-22 Inserting the lens in the lens holder

5. Turn the lens holder through 180° and remove the circular rod.


D Lens



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6. Grip the lens holder firmly in one hand. With the other hand, use thelens wrench to screw in the lens nut, applying continuous force totighten.

Fig. 7.5-23 Screw in the lens nut and tighten

E Lens holder

F Lens wrench for 5" lens nut

G Lens nut

Do not tighten the lens nut with a jerking action. Sharpjerking movements cause jolts to the lens, which candamage it.

E

G

F



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The clamping ring is tensioned correctly when the four slits are closed (seeFig. 7.5-24).

Fig. 7.5-24 Correct seating of lens

Poorly fitted lens

A poorly fitted lens will cause cutting problems and ultimately destroy thelens.

Tightening the clamping ring too severely may damage thelens.



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7.5.7 Fitting the lens holder

The lens holder is different depending on the focal length of the cuttinghead. Note the engraving (5") when assembling.

Fig. 7.5-25 Lens holder

1. Place cutting head on a clean surface.

2. Check lens holder O-ring. Replace damaged O-rings.

A Cutting head

B Lens holder

C Fixing screws on the lens holder

C

B

A

Apply minimal grease to O-ring before fitting (Synthe-so Proba 270).

No residual grease should be visible.



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3. Slide the lens holder into the cutting head by hand until it reachesthe second O-ring.

4. Align the fixing-screw holes on the circle of holes.

5. Push the lens holder in as far as the end stop.

6. Tighten the fixing screws on the lens holder using a ball-end screwdriver.

7. Insert the cutting head in the Z-axis and center the nozzle (see sec-tion 5.5.5 ›Centering the nozzle‹).

Do not twist the lens holder in this position.



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7.5.8 Measuring the focus reference setting

After cleaning or fitting a new lens, the focus reference setting must be re-measured. This is done by cutting a test part.

Fig. 7.5-26 Test part for measuring the focus reference setting

Fig. 7.5-27 Cutting plan: Test_Stahl_2mm_22M_O2.ncp

Material: Structural steel

Thickness: 2 mm

Cutting gas: Oxygen O2

80 mm

80

mm

500

mm

1 000 mm



ByVention Repair

1. Select Residual sheet production (see section 5.6.4 ›Residual sheetproduction‹).

2. Set the focal position on the cutting head to 6 - 00.

3. Load a residual sheet onto the cutting table. See Fig. 7.5-27 for min-imum dimensions.

4. Start cutting process using Start part function.

5. Adjust the focal position up and down in steps of 0.5 mm (in total± 3 mm).

6. Cut a part after each adjustment. Note the focal position on the re-spective part.

7. Assess the optimum focal position by looking at the cut surface (seesection 9.9 ›Cut evaluation‹).

Tab. 7.5-2 Example for assessing the cut quality

Do not change the cutting parameters.

Focal position Assessment of cut quality

0 - 30 Cut no longer possible


0 - 40 Sheet no longer cut through

0 - 45 Course cut and burring

0 - 50 Fine bead formation on the underside of the sheet


6 - 00 Good

6 - 05 Good

6 - 10 Excellent

6 - 15 Good


6 - 25 Coarse bead formation on the underside of the sheet




ByVentionRepair

8. If the measurement results in a new focus reference setting:

Select Maintenance functions, enter the measured value for the fo-cus reference setting in the Focal default setting input field, andsave

Attach a new label to the cutting head showing the measured val-ue

Fig. 7.5-28 Measured focus reference setting

A new focus reference setting must be entered This isused as a basis for cutting other materials.



ByVention Repair

7.6 Laser module

7.6.1 Check the vacuum-pump oil level.

Check the oil level at the level indicator every 150 operating hours.. Theoil level must lie between the two markings on the level indicator. Top upwith oil if necessary.

Fig. 7.6-1 Level indicator on the vacuum pump

A Laser module

B Vacuum pump

C Level indicator

A

B

C



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7.6.2 Top up oil in the vacuum pump

Always use the compressor oil G32 supplied (order code 1973601).

Instructions for use and the safety data sheet are kept in the Supplierdocumentation folder.

Fig. 7.6-2 Vacuum pump

A Vacuum pump

B Cap

C Level indicator

B

C

A



ByVention Repair

1. Shut down the laser cutting machine and switch off at the main pow-er switch.

2. Allow vacuum pump to cool down.

3. Remove cap from top-up hole.

4. Clean rim of top-up hole and filling funnel.

5. Top up with oil. Check oil level (level indicator).

6. Refit cap on top-up hole.

Make sure that no particles of dirt fall into the top-uphole.



ByVentionRepair

7.7 Gas supply

The gas cylinders can be replaced during operation. It is essential to usegas of the correct quality. Never use a lower gas quality than specified(see installation instructions).

Never completely empty gas bottles. Always return the bottles with aresidual pressure of at least 1 atmosphere above atmospheric pressure.

The cutting process is stopped if the cutting gas runs low. An error mes-sage is shown on the operator console.

The cutting process is stopped and the laser excitation is switched off ifthe laser gas runs low. An error message is shown on the operator con-sole.Also signaled by the indicator lamp on the laser module (see section4.1.1 ›Indicator lamp‹).

CAUTIONHandling gas bottles

Make sure that you replace bottles carefully and cleanlyto avoid dirt entering the gas pipeline.

Secure gas bottles in place.

Always screw on safety caps to unconnected bottles be-ing stored.

Close bottle valves before handling.

Always open stop valves slowly.

Observe guidelines for handling gas.


Do not oil or grease oxygen connections.

This could lead to an explosion from a chemical reaction.



ByVention Repair

7.7.1 Cutting gas

7.7.1.1 Cylinder pressure reducer

Fig. 7.7-1 Cylinder pressure reducer for cutting gas

A Gage (high pressure)

B Gage (reduced pressure)

C Pressure reducing valve

D Stop valve (high pressure)

E Bottle connection

F Supply to laser cutting machine

D

B

C

D

FE

A

F

E



ByVentionRepair

7.7.1.2 Changing gas cylinders during operation

1. Check that the stop valve (D) to the full bottle is closed.

2. Open the cylinder valve on the new cylinder briefly to blow out dirtfrom the valve.

3. Close stop valve (D) to the empty bottle.

4. Connect line to full bottle.

5. Open stop valve (D) to the full bottle.

6. Adjust reducing valve (C) (25 bar max.).

to 18 bar for oxygen (O2)

to 25 bar for nitrogen (N2)

7. Close the bottle valve on the empty bottle.

8. Remove the empty bottle from the cabinet and fit the protective cap.Insert new bottle and secure in place.

CAUTIONEye injuries from swirlingdirt particles

The cutting-gas cylinders are under pressure (200 bar).

Always wear safety goggles when blowing off a valve.

The bottle valves must be closed if the system is to be out ofoperation for a prolonged period (longer than 8 hours).

Otherwise, a pressure build-up can result from leaky valves.This can destroy the pressure regulator valve in the cuttingcarriage.



ByVention Repair

7.7.2 Laser gas

Fig. 7.7-2 Location of laser gas bottle

A Laser module

B Combined cooling and filtration unit

C Laser gas bottle

B

C

A



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7.7.2.1 Cylinder pressure reducer

Fig. 7.7-3 Cylinder pressure reducer for laser gas

A Gas bottle connection

B Gage (cylinder pressure)

C Pressure gage (operating pressure)

D Stop valve

E Laser module supply

F Safety valve

G Pressure reducing valve

H Purge valve

E

C

D

F

B

A

G

H



ByVention Repair

7.7.2.2 Changing gas bottles during operation

If the white indicator lamp is flashing, the pressure in the laser gas bottlehas dropped to 2 bar. An error message is shown on the operator console.

Finish working through a cutting plan already in progress and then changethe laser-gas bottle.

CAUTIONEye injuries from swirlingdirt particles

The laser gas cylinders are under pressure (200 bar).

Always wear safety goggles when blowing off a valve.



ByVentionRepair

7.7.2.3 Removing an empty gas cylinder

Fig. 7.7-4 Laser gas bottle with bottle pressure regulator

A Bottle valve

B Hexagonal nut

C Stop valve

D Purge valve

E Cap nut

F Protective cap

G Safety chain

A B

F

G

G

E

C

D



ByVention Repair

1. Close cylinder valve (A) of empty cylinder.

2. Close shut-off valve (C) to laser module.

3. Open purge valve (D) to release residual pressure.

4. Close purge valve (D).

5. Unscrew cylinder pressure reducer from bottle valve. Hex nut (B) SW32 mm

6. Screw on cap nut (E).

7. Screw on protective cap (F).

8. Undo safety chains (G).

9. Remove empty gas cylinder.



ByVentionRepair

7.7.2.4 Connecting a full gas cyclinder

Fig. 7.7-5 Laser gas bottle with bottle pressure regulator

A Bottle valve

B Hexagonal nut

C Stop valve

D Purge valve

E Cap nut

F Protective cap

G Safety chain

H Pressure gage (operating pressure)

AB

F

G

G

E

C

D

H



ByVention Repair

1. Put full laser gas bottle in place (see Fig. 7.7-2).

2. Secure bottle with safety chains (G).

3. Screw on protective cap (F).

4. Unscrew cap nut (F).

5. Screw cylinder pressure reducer onto the bottle valve. Hex nut (B)SW 32 mm

6. Fully open bottle valve (A) and re-close again immediately.

7. Check bottle connection for leaks using leak detection spray.

8. Purge bottle pressure regulator to remove any air that may have en-tered when changing the bottle.

Slowly open bottle valve (A) briefly and re-close again immediate-ly.

Slowly open purge valve (D) briefly to release the pressure, andre-close again immediately. There must be minimum residualpressure.

9. Repeat step 8 at least five times. Close the purge valve (D) afterpurging.

10. Open the bottle valve (A).

11. Slowly open the stop valve (C) to the consumer.

12. Check the operating pressure at the pressure gage (H).

Operating pressure: 5 bar (72.50 psi)

After changing the laser gas bottle, the laser module must becalibrated (see section 5.8.2.1 ›Calibrating the optical pow-er‹).

The bottle valve must be closed if the system is to be out ofoperation for a prolonged period (longer than 8 hours).



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7.8 Circuit diagrams, drawings

Circuit diagrams are held in the Equipment diagram folder, and drawingsin the Spare parts catalog.



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7.9 Customer service information

The manufacturer's Customer Services department is available in theevent of problems. Please have the following information ready beforecalling the department, so that problems and queries can be dealt with asquickly as possible:

Company / Address

Contact person

Order and equipment number (see type plate)

The contact address appears in the front of these operating instructions.



ByVentionRepair



ByVention

Chapter 8

8 Disposal

This chapter describes the environmentally friendly disposal of the productand its operating resources. It also contains notes on handling replace-ment assemblies (e.g. replacement parts).



ByVentionDisposal



ByVention Disposal

8.1 Introduction


The country-specific regulations and standards must be observed for allcomponents requiring disposal.

Also observe the manufacturer’s regulations for working materials andcleaning agents.


Use specially trained personnel for proper disposal.



ByVentionDisposal

8.2 Disposal

8.2.1 Packing

Packing material accrued on delivery must be disposed of according tocountry-specific regulations and standards.

8.2.2 Operating resources

Lubricants must be sent to a treatment plant or disposed of as hazardouswaste.

Observe the manufacturer’s regulations for all working materials. Furtherinformation can be found in the safety data sheets in the Supplier docu-mentation folder.

Dispose of all operating resources in accordance with country-specific regulations and standards!



ByVention Disposal

8.3 Components suitable for disposal

8.3.1 Material groups

Metals and plastics must be separated and taken for recycling or disposal.

Dismantle the machine and electrical controls and provide for correct dis-posal.

The machine contains parts in the following materials:

Mineral casting

Steel casting

Steel

Nonferrous metals (aluminum, copper etc.)

Rubber

Plastics

The electrical controls contain parts in the following materials:

Steel

Plastics

Non-ferrous metals (aluminum, copper)

Protective varnish on circuit boards

Electrical and electronic components

Batteries

Dispose of all materials in accordance with national regula-tions and standards.



ByVentionDisposal

8.4 Disposal centers, authorities

8.4.1 Return to manufacturer

The manufacturer takes back various components. This particularly con-cerns components which are replaced by repaired units within the lifetimeof the product.

8.4.2 Notification of government agencies and manufacturer

The manufacturer should be informed when you decommission the sys-tem.



ByVention

Chapter 9

9 Cutting technology

This chapter provides information on the fundamentals of cutting with thelaser cutting machine. In addition, it contains information on special appli-cations, material coatings and alloys.



ByVentionCutting technology



ByVention Cutting technology

9.1 General information

This chapter describes laser cutting technology. It gives information on thefactors that influence the cutting result.

Design options and limits

The influence of working methods and procedures

The effects of various factors and parameters on the cutting result

The influence of programming

Rules, advantages and tips

An optimum cutting result is largely determined by following certain de-sign rules for ideal cutting back at the part design stage. It is importantthat the designer knows the capabilities of the laser cutting machine.

The person responsible for creating the cutting plans must have a thor-ough knowledge of the laser cutting machine. Only then can cutting plansbe designed optimally to suit the laser cutting machine and its procedures.

Practice has also shown that it is best to locate the programming worksta-tion close to the laser cutting machine. This encourages a constant trans-fer of knowledge between the operator and the programmer.

This chapter builds upon the basic knowledge of machine opera-tion and programming.




9.2 Design guidelines

When designing the parts to be cut the following guidelines should be ob-served. This can greatly simplify manufacture.

9.2.1 Sheet formats

The main sheet formats are:

3 000 x 1 500 mm

2 500 x 1 250 mm

2 000 x 1 000 mm

120 x 60 inches

96 x 48 inches

72 x 40 inches

9.2.2 Kerf width for laser cutting

The width of the cutting kerf is a function of the focal length and the sheetthickness. The width cannot be altered. However, the tool radius cuttingparameter can be used to compensate for it (to guarantee dimensionaltolerances).

Tab. 9.2-1 Guide values for the kerf width

Sheet thicknessin [mm]

1 3 5 8

Width of cutting kerf

in [mm]

0.15 0.20 0.25 0.40

It is possible just to make a cut in the width of the cutting kerf.This is used for strain relief cuts in the region of bends, for ex-ample.




9.2.3 Orthogonality of the cut surface

In laser cutting, the cut face does not lie exactly square to the sheet sur-face. Per 10 mm of sheet thickness, the cut plane can be up to 0.1 mmout of square.

Fig. 9.2-1 Orthogonality when cutting with oxygen O2

Fig. 9.2-2 Orthogonality when fusion cutting with nitrogen N2

The above geometries (Fig. 9.2-1 and Fig. 9.2-2) result from the selectedcutting process and cannot be altered.

The orthogonality is assessed according to DIN EN ISO 9013 (Classifica-tion of thermal cuts).

As a rule, the orthogonality with laser cutting is significantly better thanwith plasma cutting or thermal cutting.

0.1 mm

10

mm

0.1 mm

10

mm

10

mm

0.1 mm




9.2.4 Roughness of the cut surface

The roughness of the cut surface increases with increasing material thick-ness.

As a general guide, roughness values of tolerance class 2 as perDIN EN ISO 9013 are achieved with laser cutting.

The roughness of the cut surface can be influenced by changing the cut-ting parameters.

The following diagrams (Fig. 9.2-3, Fig. 9.2-4 and Fig. 9.2-5) show asimple summary. For more precise information, measurements must becarried out on the actual workpiece.

Fig. 9.2-3 Guide values for structural steel with Laser 2200

Roughness curves in structural steel

A DIN EN ISO 9013 tolerance class 1

B DIN EN ISO 9013 tolerance class 2

C DIN EN ISO 9013 tolerance class 3

I Cutting gas nitrogen N2

II Cutting gas oxygen O2

Mean

ro

ug

hn

ess

Rz

in [

μm]

Sheet thickness in [mm]

II

I

A

B

C




Fig. 9.2-4 Guide values for rust and acid resistant steel with Laser 2200

Fig. 9.2-5 Guide values for aluminum with Laser 2200

Mean

ro

ug

hn

ess

Rz

in [

μm]


A

B

C

A ISO tolerance class 1

B ISO tolerance class 2

C ISO tolerance class 3

Mean

ro

ug

hn

ess

Rz

in [

μm]


A

B

C




9.2.5 Contour radii

Always avoid acute contours in laser cutting. It is far simpler to cut a radi-us of 1 ... 2 mm, for example, when changing direction. This has the fol-lowing advantages:

corners do not burn

time saving thanks to continuous process,

clean laser part

reduced risk of injury by the part.

Tab. 9.2-2 Guide values for minimum radii in [mm]

The radii can be set to be greater than the minimum values in the table. Ifthe design does not allow for a radius, the corner is meant to be pointed.Radii smaller than 0.8 mm are more difficult to manufacture than pointedcorners.

Parts quality may suffer or parts may be rejected if radii are less than theminimum radii.

Material Cutting gas


... 4 5 ... 6 8

Structural steel Oxygen

O2

0.8 1.0 1.2

Rust and acid-resistant steel Nitrogen

N2

0.8 1.2 ⎯

Aluminum 0.8 ⎯ ⎯

Structural steel 0.8 ⎯ ⎯

Bysoft provides an easy method for rounding corners.




9.2.6 Sheet thickness

Select small sheet thicknesses

As far as rigidity allows, the most effective material saving is achieved byreducing the sheet thickness. Not only does this lead to less weight, butcutting and handling times are also shortened drastically.

However, the reduction in material thickness is only justified if it is notachieved at the cost of additional manufacturing effort, such as welded re-inforcements.

Select identical sheet thicknesses

For single piece production it is expedient to fabricate all sheet compo-nents of an assembly from as few different sheet thicknesses as possible.Production times can be vastly reduced in this manner.

9.2.7 Common cut edges

Common cut edges are not possible. The minimum parts separation for areliable process is 10 mm. See section 9.3.3 ›Minimum parts separation‹

Fig. 9.2-6 Single piece production (each piece is cut separately)

10

mm




9.2.8 Hole as a paint coating aid

A hole enables the part to be hung for painting. Care should be taken thatthese holes are made near the edge of the workpiece, so that hooks canbe inserted easily.

9.2.9 Edge deformations

On the edge faces of sheets, deformation of the edges can occur due tocompression of the material during bending. A corner relief must thereforebe cut when:

The face needs to lie flat

A slot will accommodate a flat plate after bending

Fig. 9.2-7 Corner reliefs

Min. hole diameter for lightweight parts: ∅4 mm

Min. hole diameter for heavy parts: ∅6 mm


Radius and corner reliefin [mm]

r t

up to 3.0 8.0 1.0

3.0 ... 8.0 15.0 2.0

rr

tt




9.2.10 Cut-outs

For limbs bent together or offset limbs, a relief is provided in the corner.Radius r = sheet thickness

Fig. 9.2-8 Corner relief for limbs bent against each other

Fig. 9.2-9 Corner relief for offset limbs r

Bysoft provides a straightforward tool for making cut-outs.

r




9.2.11 Tongues (bent parts only)

Incisions for tongues should always be drawn as continuous lines made atthe correct gap width. This ensures simple manufacture.

The tongue width should not be less than 50 mm. Gap width x = sheetthickness

Fig. 9.2-10 Incisions for tongues

9.2.12 Strain relief cuts

Holes and slots located too close to the bent edge are deformed duringbending. If the minimum limb length cannot be achieved even with asmaller bottom tool, a strain-relief slot must be cut.

Fig. 9.2-11 Strain-relief cut

poor design good design

x50

A Strain-relief cut

B Bend edge

A

B




9.2.13 Discontinuous limb

In profiles with discontinuous limbs, the edge must be set back by at least1.5 × sheet thickness s.

Fig. 9.2-12 Set-back edge in profiles with discontinuous limbs

s1.5

×s

incor-correct




9.2.14 Connections

Aligning, centering and crimping prior to welding can be saved by usingtongue and groove joints.

Ensure that the tongue and groove joint is manufactured with approx.0.5 mm play, so that individual parts can be easily fitted together.

Examples

Fig. 9.2-13 Straight joint

Fig. 9.2-14 Right-angled joint

Fig. 9.2-15 Multipart holder




9.2.15 Labeling similar parts

Labeling is performed using the Engrave function. This is a simple way toadd part numbers, positioning aids and the like to parts in the same workcycle as the laser cutting (also see section 9.7.8 ›Engraving‹).

Examples

Fig. 9.2-16 Engraved part number

Fig. 9.2-17 Engraved positioning aid

laser engraved

Making engraved markings and labels increases the productiontime.

laser engraved




9.3 Definitions and ranges

9.3.1 Minimum distance from sheet edge.

The minimum distance from the sheet edge for a reliable process is10 mm. The distance should not be set lower than this.

Fig. 9.3-1 Distance from sheet edge.

10 mm 10 mm 10

mm

Y+

X+




9.3.2 Minimum distance of parts from severance cut

The minimum distance from the severance cut for a reliable process is10 mm. The distance should not be set lower than this.

Fig. 9.3-2 Distance from severance cut

10

mm

Y+

X+

10

mm




9.3.3 Minimum parts separation

The minimum parts separation for a reliable process is 10 mm. The dis-tance should not be set lower than this.

Fig. 9.3-3 Parts separation

10

mm

10 mm




9.3.4 Minimum hole diameters

Parts quality may suffer or parts may be rejected if hole diameters areless than the minimum hole diameters.

Tab. 9.3-1 Minimum hole diameters

Sheet thick-ness[mm]

Minimum hole diameter[mm]

Structural steel

Oxygen O2 Nitrogen N2

1.0 1.00 1.00

1.5 1.00 1.00

2.0 1.00 1.00

2.5 1.25 1.25

3.0 1.50 1.50

4.0 2.00 ⎯

5.0 2.50 ⎯

6.0 3.00 ⎯

8.0 4.00 ⎯


Minimum hole diameter[mm]


Aluminum

1.0 1.00 1.00

1.5 1.00 1.50

2.0 1.00 2.00

2.5 1.25 2.50

3.0 1.50 3.00

4.0 2.00 4.00

5.0 2.50 ⎯

6.0 3.00 ⎯

8.0 ⎯ ⎯




9.3.5 Minimum web width

Parts quality may suffer or parts may be rejected if web widths are lessthan the minimum web widths.

Fig. 9.3-4 Web width

x = minimum web width

Tab. 9.3-2 Minimum web width

x x


Minimum web width[mm]

Structural steel

Oxygen O2 Nitrogen N2

1.0 2.00 2.00

1.5 3.00 2.00

2.0 4.00 3.00

2.5 5.00 3.00

3.0 6.00 4.00

4.0 8.00 ⎯

5.0 10.00 ⎯

6.0 12.00 ⎯

8.0 16.00 ⎯





Minimum web width[mm]


Aluminum

1.0 2.00 2.00

1.5 2.00 2.00

2.0 3.00 3.00

2.5 3.00 3.00

3.0 4.00 4.00

4.0 5.00 5.00

5.0 6.00 ⎯

6.0 8.00 ⎯

8.0 ⎯ ⎯




9.4 Laser cutting

In laser cutting, a focused laser beam is directed at the sheet to be cut.The energy density at the focal point rapidly raises the temperature of thematerial to be cut to its melting point.

Basically, we can divide laser cutting into three areas.

Fig. 9.4-1 Laser cutting areas

Laser cutting

Lasergas cutting

Lasersublimation cutting

Laserfusion cutting




9.4.1 Laser fusion cutting

In the fusion cutting process the work piece is melted locally and the meltis blown out by a gas jet (nitrogen N2). The material is only transported inthe liquid or molten phase, which is why the process is called fusion cut-ting.

Fig. 9.4-2 Focal position for fusion cutting

Characteristics:

A very pure, inert cutting gas is supplied to the laser beam, which ejectsthe melted material from the cutting gap, but does not itself participate inthe cutting process.

Laser fusion cutting is suitable for producing oxide-free cuts in ferrousmaterials.

A Laser beam

B Approximate location of the focal point

C Upper face of sheet

D Lower face of sheet

Cutting gas: Nitrogen (N2) or argon

Laser power: 80 ... 100% of maximum power

Gas pressure: 10 ... 20 bar

Focal position: Approximately on the lower face of the sheet

B

AC

D




9.4.2 Laser gas cutting

Laser gas cutting differs from laser fusion cutting by the use of oxygen ascutting gas. The interaction of oxygen with the heated metal causes a re-action that heats up the material even more.

Thanks to this effect, speeds can be achieved when cutting structural steelthat are much greater than for fusion cutting in sheet thicknesses fromapprox. 6 mm upwards.

Fig. 9.4-3 Focal position for gas cutting

Characteristics:

However, this process can lead to diminished cut quality compared to fu-sion cutting. The result may be wider cuts, increased surface roughness,deeper heat affected zones and diminished cut edge quality. The cut edgeoxidizes heavily.

Oxygen cutting is critical when cutting fine contours and acute geometries(risk of burn-off). However, the amount of heat input can be limited bypulsing.

A Laser beam

B Approximate location of the focal point

C Upper face of sheet

D Lower face of sheet

Cutting gas: Oxygen O2

Laser power: 25 ... 80% of maximum power

Gas pressure: 0.5 ... 5 bar

Focal position: Approximately on the upper face of the sheet

B

A

C

D




9.4.3 Laser sublimation cutting

With laser sublimation cutting, the material is vaporized directly in the cut,without a liquid phase.

Laser sublimation cutting is not used in the present laser cuttingmachine and is therefore only mentioned here for the sake ofcompleteness.




9.4.4 Cutting process

A machining process is undrestood to mean the interaction between laserbeam, cutting gas and workpiece.

Fig. 9.4-4 Process parameters

The zone in which this process occurs is known as the cutting front or cutfront. The laser power applied at the cutting front must heat up the mate-rial to the temperature required for phase transition of the material tomelt and vapor.

The cutting front is a practically perpendicular surface heated and meltedby the absorbed laser beam.

In laser gas cutting, this melt zone is heated up further by the flow ofoxygen blown into the kerf and reaches temperatures close to the boil-ing point of the material. This causes strong vaporization and ablationof the material. The jet of cutting gas is used simultaneously to blowout molten material from the underside of the workpiece.

In fusion cutting the gas blows out the molten material and protects thekerf from oxidization.

The molten zone progresses in the direction of cutting. This ensures a con-tinuous kerf.

Many important processes in laser cutting occur in this zone. Analyzingthese processes provides important information on laser cutting. For ex-ample, it is possible to estimate cutting speed and explain the formationof characteristic striation marks.

Process parameters for

Laser Cutting gasMaterial Axis movement




9.4.5 Gas parameters

Gas type

Gas purity

Gas pressure

Nozzle diameter

Nozzle geometry

Gas pressure and nozzle geometry affect the roughness of the cut edgeand the creation of whiskers.

Cutting gas consumption depends on the nozzle diameter and the gaspressure.

For low-pressure cutting applications gas pressure is up to 5 bar, andup to 20 bar in the high-pressure range.

The conventional cutting nozzle has a circular, conical aperture.

The distance between the nozzle orifice and the workpiece surface mustbe as small as possible. The smaller the distance, the greater the vol-ume of gas actually entering the kerf. Clearance distances typicallyrange from 0.5 to 1.5 mm.




9.5 Programming

Optimum programming makes the cutting process far simpler and reducesmanufacturing times while retaining maximum part quality. It is thereforeimportant that the programmer is familiar with the laser cutting machineand exchanges experiences with the operating personnel.

9.5.1 Technology wizard

The technology wizard provides support when programming parts. Thismeans that the programmer requires less knowledge of the technology.An optimum cutting result is achieved substantially faster.

The following technologies are set up automatically for each laser type,sheet type, sheet thickness and geometry:

Type of lead-in and lead-out (straight cut / straight cut with arc)

Length of lead-in and lead-out

Piercing type (CW / pulse)

Cutting type (CW / pulse / process macro 1) as a function of the sheettype, thickness and the area to be cut

Bysoft version 6.7.x or higher is used for programming. Thisversion contains the range of functions required for the lasercutting machine.

The cutting parameters of the laser cutting machine are opti-mized for the wizard technologies. In general, the technologywizard should be used. This allows optimum exploitation of thevarious options.Changes to the Technology Wizard are not allowed.




Fig. 9.5-1 Specifying the technology (in Bypart)

A Select material

B Select sheet thickness

C Select laser cutting machine

D Select technology table

C

B

A

D




9.5.2 Technology table in Bysoft

A column is reserved for each material type and thickness. In the col-umns, the technologies and the ranges of validity are defined.

Tab. 9.5-1 Technology table

Thickness 8

Lead-in 1 up to and including hole diameter 5.5

Piercing open contours Pulsed

Lead-in 1 settings

Type Straight orthogo-nal

Length 4

Radius 0

Operating mode Follow-on element

Piercing Pulsed

Standard lead-in settings

Type Straight with arc

Length 8

Radius 1

Operating mode Follow-on element

Piercing normal

Lead-out settings

Type Directly on con-tour

Length 0

Radius 0

Cutting

Conditions

Pulsed up to and including hole diameter 5.5

Process macro 1 up to and including hole diameter 30





Tool correction Normala)

a) Generally applicable for cutting

Operating mode for open contours Cutting

= Selection




Fig. 9.5-2 Example of using technology table for structural steel, 8 mm thick

Setting Meaning

Lead-in 1 Define lead-ins (initial cuts) for pulsed holes or small contours.

Standard lead-in Define standard lead-ins (standard initial cuts). All lead-ins that do not meet the criteria for lead-in 1 are standard lead-ins. The boundary between lead-in 1 or a standard lead-in is determined in the sec-ond row of the technology table.

Lead-out Define lead-out (final cut). Lead-outs are not nor-mally used for laser cutting.

Cutting The technology is selected according to the area. A value of zero (0) means that the technology is not selected.

Detail X

Detail Y




9.5.3 Piercing and lead-ins

The lead-ins will always be made as long as specified and must be placedaccordingly.

Piercing causes the sheet to heat up very strongly. Careful positioning ofpiercing points and adequate lead-in lengths can help prevent heat build-up.

Fig. 9.5-3 Poor choice of lead-in position

Fig. 9.5-4 Good choice of lead-in position with additional radius lead-in

Heat build-up; cut quality may deteriorate




9.5.3.1 Outer contour

The pierce hole is generally located outside of the contour (see Fig. 2 andFig. 3). The path between the pierce and the contour is referred to as thelead-in line or lead-in for short.

A change in direction of the laser beam between the end of the lead-in andcontour, and the end of a cut, are visible on the workpiece as an irregular-ity in the cut edge.

Fig. 9.5-5 The lead-in can be seen as an irregularity in the cut

The lead-in to the outer contour should therefore be programmed as anextension of a geometry elements (see Fig. 3).

Tab. 9.5-2 CW pierce hole

Parts requiring fin-ishing

Normal case Thick sheet option

Fig. 1 Fig. 2 Fig. 3

CW pierce hole in con-tour

Corner damaged

CW pierce outside con-tour.

CW pierce outside con-tour.

Move into contour in a line.

Minor markings on part




Various types of lead-in can be employed within a part. This allows anacute corner (A), for example, to be cut optimally.

Fig. 9.5-6 Various types of lead-in

9.5.3.2 Inside contour (cut-outs)

With small inside contours it is important that the heat input during pierc-ing can flow away before cutting begins. The lead-in line must not be pro-grammed in tight corners and should be designed with the largest possibleangle to the contour. This helps the heat to flow away more easily.

Fig. 9.5-7 Small inner contours

A

not suitable suitable




9.5.4 Programming process macros

Contours assigned a process macro during programming with Bysoft canbe cut with other cutting parameters. This has the advantage that difficultparts or sections of contour (e.g. gear teeth) can be optimized.

Fig. 9.5-8 Gear teeth, cut with process macro 1

One process macro is available (macro 1). The Bysoft technology wizardautomatically assigns process macro 1 to small contours (based on thetechnology table). The cutting parameters are adapted accordingly.

Process macro 1 is assigned automatically based on the area.For contour cuts such as the gear teeth in Fig. 9.5-8, processmacro 1 must be assigned manually.




9.5.5 Machining strategies

9.5.5.1 Strategy A

The sheet segment to be cut is separated from the main sheet by a con-tinuous severance cut at the start of the cutting plan. Then the parts onthe sheet segment are cut.

Fig. 9.5-9 Continuous severance cut

9.5.5.2 Strategy B

Parts in the sheet segment to be cut extend into the main sheet. Thismeans that, depending on the parts geometry, more parts may be nestedon the sheet. It also reduces the size of off-cuts.

The severance cut is divided into several steps. These are performed be-fore cutting the parts. The sheet segment is severed from the main sheetas the parts are cut.

Not all parts are suitable for using machining strategy B. If it is difficult toseparate the sheet segment from the main sheet when the cutting table islowered, machining strategy A must be used. This may be the case, for

A Sheet

B Cut sheet segment

C Continuous severance cut

Y+

X+

B

AC




example, when complicated parts geometries get caught in the mainsheet when the cutting table is lowered.

Machining process B works best with flat sheets having minimum internalstresses. Other sheet qualities may prevent a reliable process or lead to alarger number of rejects.

Fig. 9.5-10 Discontinuous severance cut

A Sheet

B Cut sheet segment

C Discontinuous severance cut

It is up to the parts programmer to ensure that the lead-in ispositioned on the parts in the current sheet segment.

Otherwise the automatic setting of microjoints prevents thecut sheet segment from being severed correctly from themain sheet.

Y+

X+

B

AC




9.5.6 Cutting-time calculation

The result of the cutting-time calculation is only a rough guide to the ex-pected process time on the laser cutting machine. The effective processtime can differ significantly from this however.

The result from the cutting-time calculation must not be usedas a basis for quotations.




9.6 Cutting parameters

Cutting parameters are provided for authorized materials and cuttablesheet thicknesses.

The user cannot create new cutting parameters.

The default parameters are given for metric sheet thicknesses. Countriesusing different dimensional units (e.g. inches, Gauge No.) must use thenext closest metric cutting parameters (see section 9.6.5 ›Cutting param-eters for different dimensional units‹).

The cutting parameters assume a minimum radius for each geometry (seesection 9.2.5 ›Contour radii‹). Parts quality may suffer or parts may be re-jected if parts have a smaller radius.

9.6.1 General information

For selective editing of the cutting parameters, it is vital to know how apart is programmed and where a particular technology is employed. Theexample below shows a part for which the technologies selected by thetechnology wizard are highlighted.

Fig. 9.6-1 Example: Structural steel, 8 mm thick

B

C

D

E

A




It is important to observe carefully during cutting to identify those opera-tions for which a parameter needs to be edited. Only in this way can im-mediate and targeted changes be made.

A Text Engraving

B Hole ∅ 4 mm Pulsed piercing, pulsed cutting

C Banana hole Pulsed piercing, cutting with processmacro 1

D Gear teeth Pulsed piercing, cutting with processmacro 1

E Outer contour Pulsed piercing, CW cutting




9.6.2 Adjusting cutting parameters

Cutting parameters are parameters which have a direct influence on thecutting process. These parameters are not optimized for maximum cuttingspeed, but for process reliability.

A set of cutting parameters is supplied with every laser cutting machine.They are optimized to cut certain materials. Nevertheless, the parametersmay not deliver satisfactory cutting results. Below, the requirements andthe procedure for obtaining better cutting results in such cases are de-scribed.

For laser cutting, there are numerous parameters that influence one an-other to some extent. The five main parameters that can be used to opti-mize the cut quality are listed here:

Focal position

Feed rate

Laser power, cutting

Gas pressure

Changes considered here apply only to simple contours such as straightlines.

The cutting quality is only evaluated in a cut-out comprisingstraight lines (directions X+, X-, Y+ and Y-). Interpolated cut di-rections such as radii, diagonal cuts or lead-ins are not included.Changes to cutting parameters for complex contours such asacute-angled corners, radii, small contours, lead-ins/lead-outsand holes are not included in this chapter.




9.6.2.1 Reasons for adjusting parameters

Differences in alloys

Tolerance variation in the sheet thickness

Differing nature of surfaces

Different composition of material

Large temperature differences in the material used(reference temperature = +20 °C)

9.6.2.2 Conditions to be met before adjusting parameters

The following conditions must be met in order to obtain a good cut qualityby adjusting the main parameters:

laser cutting machine is in a fault-free condition

lens in cutting head must be in perfect condition (see section7 ›Repair‹)

cutting head and nozzle must match the details given in the respectivecutting parameters

Changed cutting parameters can be saved (see section5.6.7 ›Saving cutting parameters‹).




9.6.3 Procedure for optimizing the cutting parameters

Before a new material is cut, a cutting test must be carried out. If prob-lems with the cutting quality occur in this test, they can be rectified by ad-justing the original cutting parameters.

When optimizing, change only one cutting parameter at a time and thenobserve the effect on the cut part (see also section 9.9 ›Cut evaluation‹).Follow the order given below.

Tab. 9.6-1 Order in which to adjust the cutting parameters

Ste

p

Cutting withoxygen (O2)

Cutting withnitrogen (N2)

Cutting withcompressed air

(Air)

1 Focal position Focal position Focal position

2 Laser power Feed rate ± 10% OK Feed rate ± 10% OK

3 Gas pressure Laser power Laser power

4 Feed rate ± 10% OK Gas pressure Gas pressure




9.6.4 Cutting parameters on the laser cutting machine

On the user interface, seven different cutting parameters can be changed.

The standard functions contain the cutting parameters for CW cutting.

Fig. 9.6-2 Cutting parameters, standard functions

The advanced functions contain the cutting parameters for CW, Macroand Pulsed.

Fig. 9.6-3 Cutting parameters, advanced functions

In addition, the focal point must be set manually on the cut-ting head according to the material type and sheet thickness.




9.6.4.1 Focal position, cutting

The focal position is the position of the point where the laser beam reach-es its smallest diameter and thus its highest power density.

The laser beam is focussed by the lens in the cutting head. Depending onthe material being cut, the focal point is located:

On the workpiece (A)

In the workpiece (B)

Below the workpiece (C)

Fig. 9.6-4 Focal position of the laser beam

The focus position basically depends on the cutting gas used.

Focal position A Focal position B Focal position C

Gas type Laser cuttingmethoda)

a) Information on the laser cutting methods can be found in section 9.4 ›Laser cutting‹.

Focal position

Oxygen O2 laser cutting Focal position in the upper region of the material to be cut.

Focal position A

Compressed air Fusion cutting Focal position in the center of the material to be cut.

Focal position B

Nitrogen N2 Fusion cutting Focal position in the lower region of the material to be cut.

Focal position C




Altering the focal position

The focusing must be adjusted manually, by turning the setting ring.

Fig. 9.6-5 Changing the focal position

The focal position alters with the condition of the lens. Soiling or an oldlens shifts the focal position upwards. This shift can reach several millime-ters. It is therefore important to clean the lens regularly.

Turning counter-clockwise movesthe focal point lower.

Turning clockwise moves the fo-cal point higher.

A Setting Ring

B Focal position

See section 9.9 ›Cut evaluation‹ for details of the effect of thefocal position on different materials.

A

B

A

B




9.6.4.2 Feed rate, cutting

This parameter defines the feed rate during cutting in continuous opera-tion (CW).

The Feed rate, cutting parameter can be altered as follows:

1. On the user interface, select the cutting parameter view.

2. Select the parameter Feed rate, cutting and increase or decreasethe value by turning the rotary knob.

The change will be shown in [%].


3. Wait for a few seconds. The changed parameter is automaticallytransferred to the controller and takes immediate effect.

By reducing the feed rate by 10…20% the quality or process reliability canbe greatly improved in almost all cases.

See section 9.9 ›Cut evaluation‹ for details of the effect of thecutting feed rate on various materials.




9.6.4.3 Laser power, cutting

This parameter defines the laser power during cutting in continuous oper-ation (CW).

The Laser power, cutting parameter can be altered as follows:


2. Select the parameter Laser power, cutting and increase or de-crease the value by turning the rotary knob.




See section 9.9 ›Cut evaluation‹ for details of the effect of thelaser power on various materials.




9.6.4.4 Gas pressure, cutting

The gas pressure depends on the cutting gas used.

For oxygen (O2), a higher value produces a higher cutting temperatureand a rougher cut face.

With nitrogen (N2) and compressed air (Air) the material is ejected betterand cooled more.

The Cutting pressure parameter can be altered as follows:


2. Select the appropriate parameter for the cutting gas pressure (Gastype 1, Gas type 2 or Gas type 3) and increase or decrease thevalue by turning the rotary knob.




Parameter Used for

Cutting pressure, Gas type 1 Cutting with oxygen (O2)

Maximum pressure 10 bar

Cutting pressure, Gas type 2 Cutting with nitrogen (N2)


Cutting pressure, Gas type 3 Cutting with compressed air





See section 9.9 ›Cut evaluation‹ for details of the effect of thegas pressure on various materials.




9.6.4.5 Width of microjoints

Microjoints prevent cut parts from tilting up or dropping down. The micro-joints are automatically inserted by the control system (see section9.7.10 ›Microjoints‹). The width of the microjoints can be varied.

The Width of microjoints parameter can be altered as follows:


2. Select the parameter Width of microjoints and increase or de-crease the value by turning the rotary knob.




Increasing the width: the parts are more firmly attached.

Reducing the width: the parts are easier to detach. When processingstandard sheets, it must always be ensured thatthe width of the mcrojoint is sufficient to preventparts tipping up or falling.




9.6.4.6 Tool radius

The tool radius is used to alter the position of the kerf relative to the con-tour. The tool radius equals half the width of the kerf.

Tab. 9.6-2 Guide values for the tool radius in [mm].

Usage

To optimize the dimensional accuracy for precision parts.

If the tool radius is increased, the outer contour becomes larger and theinner contours smaller (assuming that the tool correction was correctlyprogrammed in Bysoft).

When the tool radius is decreased, the outer contour becomes smallerand the inner contour larger.

The Tool radius can be changed as follows:


2. Select the parameter Tool radius and increase or decrease the valueby turning the rotary knob.

The change will be shown in [mm].



Material thickness Tool radius

1…5 mm 0.10 mm

6…8 mm 0.15 mm




9.6.4.7 Pulse width, piercing

The Pulse width, piercing can only be changed for pulsed piercing. CWpiercing cannot be changed.

Increasing the Pulse width, piercing parameter increases the amount ofenergy input during piercing. This speeds up piercing but increases thepiercing hole size.

With larger pierced holes, a large amount of material from the piercing isdeposited on the sheet. This can lead to problems with feeding the sheet.The Pulse width, piercing parameter must therefore be optimized sothat the pierced hole appears as shown in Fig. 9.9-14.

The Pulse width, piercing parameter can be altered as follows:


2. Select the parameter Pulse width, piercing and increase or de-crease the value by turning the rotary knob.







9.6.4.8 Laser power, engraving

The Laser power, engraving parameter determines the contrast of anengraving. In structural steel, this parameter can be used to control thedepth of the engraving.

Fig. 9.6-12 Fine engraving on structural steel with reduced laser power

Fig. 9.6-13 Deep engraving on structural steel with increased laser power

The Laser power, engraving parameter must be adjusted to suit thesurface finish of the sheet and the desired visibility.




The Laser power, engraving can be altered as follows:


2. Select the parameter Laser power, engraving and increase or de-crease the value by turning the rotary knob.







9.6.4.9 Protective film vaporization

This parameter is used to define the laser power for vaporizing protectivefilms from rust and acid-resistant steel.

This parameter is only active when Vaporization has been programmed inBysoft.

The Laser power, vaporization parameter can be altered as follows:


2. Select the parameter Laser power, vaporization and increase ordecrease the value by turning the rotary knob.




The thickness of the protective film may vary. Optimum vapor-ization can be achieved by adjusting the Laser power, vapor-ization parameter.




9.6.5 Cutting parameters for different dimensional units

The default parameters are given for metric sheet thicknesses. Countriesusing different dimensional units (e.g. inches, Gauge No.) must use thenext closest metric cutting parameters as shown in Tab. 9.6-3.

Tab. 9.6-3 Cutting parameters to use for different dimensional units

Sheet thickness

in [mm] in [inches] in [Gauge No]

1.0 0.040 19

1.5 0.060 16

2.0 0.074 14

2.5 0.104 12

3.0 0.125 11

4.0 0.160 8

5.0 0.187 7

6.0 0.250 ⎯

8.0 0.312 ⎯




9.6.6 Structure of saved default parameters

The default parameters are saved using the following code.

Fig. 9.6-16 Structure of parameter set names.

Material number using DIN convention

A Machine type and sheet format

B CNC version

C Laser power in [W]

D Material number using DIN convention

E Sheet thickness in [mm]

F Focal length of cutting head

G Cutting gas

H Additional information

I File extension for cutting parameters

1.0161 St 37-2 Structural steel

1.0332 Stw 22 Sheet steel

1.4301 X5CrNi18 -10 Rust and acid-resistant steel

3.3535 AlMg3 Peraluman 300

A B C D E

F

G

H

I




Sheet thickness

Focal length of cutting head

Cutting gas

Additional information

1 1.0 mm 4 4.0 mm

1.5 1.5 mm 5 5.0 mm

2 2.0 mm 6 6.0 mm

2.5 2.5 mm 8 8.0 mm

3 3.0 mm

5 Focal length 5 inches

N2 Nitrogen

O2 Oxygen

Air Compressed air

HOT DIP GALVANIZED hot galvanized

GALVANIZED electro-galvanized

PLASTIC FOIL film-coated




9.7 Cutting process

9.7.1 Summary of the various technologies

Tab. 9.7-1 Operating modes and applications

Operating mode Usage Example

Continuous wave (CW)

Low-pressure cutting

High-pressure cutting

Structural steel cut with oxygen (O2)

Aluminum cut with nitro-gen (N2)

Rust and acid-resistant steel cut with nitrogen (N2)

Continuous cutting pro-duces a relatively fine cut

Continuous operation (Process macro 1)

Low-pressure cutting

High-pressure cutting

Small and medium-size con-tours

Continuous operation (Process macro 5)

Protective film vaporiza-tion

Rust and acid-resistant steel with protective film

Thickness 1 to 3 mm

Cutting gas: Nitrogen N2

Normal pulsed (NP) Piercing

Cutting tight contours

Mild steel example:

Small piercing point on contour (after microjoint)

small holes down to ∅ 1/2 material thickness

Fine contours

Engraving Labeling and marking See 9.7.8 ›Engraving‹.




9.7.2 Cutting structural steel with oxygen (O2)

This material can be cut with oxygen to produce good quality cuts. The la-ser is operated in CW mode.

If oxygen is used as the cutting gas the cut face is slightly oxidized.

Complex contours and holes (diameter smaller than material thickness)are cut in pulsed mode. This prevents burn-off on acute-angled cornersand thin webs.

The higher the carbon content of the steel, the greater the hardening ofthe cut edge and the more sharp corners are burnt off.

Sheets with higher alloy content are more difficult to cut than sheetswith low alloy content.

An oxidized or sand-blasted surface will produce a far poorer cut quali-ty.

Colored marks on the surface of the sheet have a negative effect on thecutting result.

Use only fully killed steel where possible. Contaminants in un-killedsteel significantly impairs the cutting result. Dress rolling and internalstresses also influence the cutability.




9.7.3 Oxide-free cutting of structural steel with nitrogen (N2)

Structural steel is also cut using nitrogen (N2) for the following reasons:

Oxide-free cut edge. This is particularly important if the parts are to bepowder coated, varnished or painted. This guarantees that the coatingadheres to the cut face. This is not guaranteed on a cut edge oxidizedby oxygen (O2).

Trouble-free cutting of high-alloy steels, which cannot be cut to a goodquality using oxygen.

Higher cutting speeds. Much faster cutting is possible up to a thicknessof 1.5 mm.

Reducing the heat input.

Fig. 9.7-1 Example: Gear teeth in structural steel, thickness 3 mm, cut using nitrogen

Optimum cut quality thanks to strong cooling effect of nitrogen. The pro-duction time is only 1/4 of the pulsed time using oxygen.

When using nitrogen (N2), gas consumption is substantiallyhigher than with oxygen (O2).




9.7.4 Cutting structural steel with normal pulse

In pulsed cutting the laser is switched on and off at short intervals. Theadvantage of this is that, on average, there is less heat input to the mate-rial. Higher quality is achieved in small holes and difficult shapes.

Because the cutting and piercing process is interrupted during the pulseinterval, the cutting and piercing speed is slower than for continuous CWcutting and piercing.

Fig. 9.7-2 Sequence during pulsed cutting

9.7.4.1 Pulsed cutting (application examples)

Holes and openings smaller than sheet thickness, e.g. a hole with∅3 mm in a steel sheet, thickness 6 mm

Cutting sharp tips and corners without radii

9.7.4.2 Pulsed piercing (application examples)

Piercing with lower heat input

Piercing without piercing crater

Piercing directly on the contour, so that both inner and outer part canbe used

A Laser power in [W]

B Cycle

C Pulse pause

D Pulse width

E Pulse frequency in [Hz]

B C D

E

A




Tab. 9.7-2 Difference between pulsed and continuous cutting

criterion Pulsed cutting or piercing

Continuous cutting (CW)

Cutting speed Low High

Heat input to the sheet

Low High

Cut quality Rough, brown color Fine

Piercing Small, fine, within the kerf width

Large, with crater




9.7.4.3 Programming for pulsed contours

There are two ways of defining whether pulsed mode is used to cut/piercecontours:

Automatically: using the Technology Wizard. This contains the most im-portant rules on how to machine which contour (exception: gear teethare not automatically recognized).This has the advantage of shortening the programming time.

Manually ⎯ the programmer selects the individual contours based onpersonal experience of the machine.

If only portions of the contour are cut pulsed, e.g. the teeth in the follow-ing figures, the programming must be carried out so that there as fewchangeover points as possible (A).

Fig. 9.7-3 Poor programming (two changeover points)

Fig. 9.7-4 Good programming (one changeover point)

One changeover point

Because of the optimum positioning of the initial cut, only one changeoverpoint from normal to pulsed cutting is necessary. This improves the partquality.

Two changeover points (A)

Normal — pulse — normal

AA

A




Parts programming has a major impact on good pulsed results:

Pulsing should, where possible, be switched on after CW cutting (notthe other way round). This improves the transitions on the cut face.

Changeover points from CW to pulsed mode should be positioned sothat the changeover takes place at a change of direction or in a corner.Do not changeover on straight edges or in curves. Changing over fromone mode to another causes a small chip.

Fig. 9.7-5 Cutting in CW and pulsed mode

not suitable suitable

A Changeover point

B CW cutting

C Pulsed cutting

The cutting sequence should be selected so that the complexcontours on a part are always cut first, i.e. the smallest first(usually the pulsed ones). Bysoft selects this strategy automat-ically.

A

A

B

B B

BC

CA A

A

A

B

B

B B

C

C

A

A




9.7.5 Oxide-free cutting of rust and acid-resistant steel

The following points should be noted when cutting rust and acid-resistantsteel.

Cutting with nitrogen to achieve oxide-free and burr-free cut edges forpost-processing without further treatment.

An oiled sheet surface improves piercing without reducing the machin-ing quality (see Fig. 9.9-17).

9.7.5.1 Technology table for rust and acid-resistant steel

The default parameters refer to the most commonly used alloy(X5CrNi 18-10) with material number 1.4301.

Suitable adjustment of the focal position, feed rate, laser power andgas pressure allow almost all rust and acid-resistant steels to be cut. Tobegin with, the default parameters (1.4301) should always be used.

Adjust the cutting parameters based on the information given in section9.6.3 ›Procedure for optimizing the cutting parameters‹. Compare thecutting results achieved with the figures in section 9.9 ›Cut evaluation‹.

When cutting rust and acid-resistant steel, rust and acid-re-sistant steel support grids must be used.

If steel grids are used, steel splashes can fuse with the cutpart at the support points. These will subsequently oxidize.




9.7.5.2 Rust and acid-resistant steel with protective film

In order to protect brushed, polished or processed surfaces, protectivefilms are stuck onto the surface of sheets up to thickness 3 mm.

Fig. 9.7-6 Metal sheet with protective film

The process reliability when cutting sheets protected by a film basicallydepends on the adhesive strength of the bond between film and sheet.

The pressure of the cutting gas detaches poorly bonded films from thesheet, stopping the cutting process.

Nitrogen N2 must be used as the cutting gas.

Only cut sheets that have a protective film on one side. Theprotective film must always lie uppermost during cutting.

A Cutting grate

B Sheet

C protective film

The adhesive strength of the protective film diminishes overtime. Do not store sheets with protective films over prolongedperiods.

Only use sheets protected by films specifically designed forlaser cutting.

B

A

C




Vaporization of the protective film is programmed in Bysoft (see section9.7.5.3 ›Protective film vaporization‹).

Example 1: protective film with good adhesion

The parts can be cut directly using the optimized parameters for rust and acid-resistant steel with protective film (additional information: PLASTIC FOIL). The protective film is only vaporized on the lead-in cuts.

Ensure that the correct nozzle is used.

Fig. 9.7-7 Protective film with good adhesion

Example of a suitable cutting parameter set:

VENTION3015_8120_2200_1.4301_2_5_N2_PLASTIC FOIL.PAR

Example 2: protective film with moderate adhesion

The protective film comes away from the sheet in places. Process reliability is not guaranteed using the optimized cutting parameters (as used in example 1).

In a first pass, the protective film is vaporized on the lead-in cuts and over the whole parts contour. This is performed at maximum machine speeds.

The parts are actually cut in the second pass using the standard cutting pa-rameters for rust and acid-resistant steel. These parameters include the pa-rameters for film vaporization.

Ensure that the correct nozzle is used.


VENTION3015_8120_2200_1.4301_2_5_N2.PAR




Example 3: protective film with poor adhesion

The protective film must be removed by hand before cutting. The standard cut-ting parameters for rust and acid-resistant steel are used for cutting the parts.

Disadvantage: the sheet surface is not protected.

Fig. 9.7-8 Protective film with poor adhesion


VENTION3015_8120_2200_1.4301_2_5_N2.PAR




9.7.5.3 Protective film vaporization

Vaporization is enabled in Bysoft, in the Postprocessor 2 tab of the Jobparameters menu.

The following options are available depending on the adhesive strength ofthe protective film:

No vaporization

complete part

Lead-in only

Fig. 9.7-9 Enabling protective film vaporization

9.7.5.4 Recommended protective films

Laserguard 3100H5 and Laserquard 3100H3 Light from the Nitto Denkocompany, which have the following excellent properties for laser cutting:

Excellent adhesion during cutting. No need to pre-vaporize the protec-tive film before cutting.

Parts look cleanly cut without black discoloration around the edges.

No fraying of the protective film near the edges.

High tear strength when detaching from the sheet (even after a bend-ing operation)1)

Minimal adhesive residues on the sheet

A Postprocessor 2 tab

B Selection of vaporization type

AB

1) This is a very important property. Approximately 80% of parts cut with a laser undergo subsequent bending.




9.7.6 Oxide-free cutting of aluminum alloys

The default parameters refer to the most commonly used alloy (AlMg3)with material number 3.2323. This alloy is also good for bending.

The cutting gas employed is nitrogen.

With suitable adjustment to the focal position, feed rate, laser powerand gas pressure, almost all aluminum alloys can be cut. To begin with,the default parameters (3.2323) should always be used.

Adjust the cutting parameters based on the information given in section9.6.3 ›Procedure for optimizing the cutting parameters‹. Compare thecutting results achieved with the figures in section 9.9 ›Cut evaluation‹.

Aluminum is a highly reflective material. If the laser beam is no longercutting the sheet, the laser power will be reflected. This can shorten thelife of the lens. It is recommended to monitor the production processwhen cutting aluminum and its alloys.

The softer and purer an aluminum alloy is, the more difficult it is to cutwith a laser. This can be recognized by the presence of burrs, even onsheets under 3 mm thick. In addition, the feed rate must be drastically re-duced. With pure aluminum (Al 99.5%), the feed rate must be reduced byup to 40% of the default value.




9.7.7 Laser cutting using compressed air

Laser cutting using compressed air is a mixture of fusion cutting with ni-trogen (N2) and gas cutting with oxygen (O2).

However, since air contains more nitrogen than oxygen, the cutting be-havior is more like fusion cutting with nitrogen (N2).

9.7.7.1 Providing the compressed air

For occasional cutting with compressed air, this can be obtained from thegas supplier (for specification, see section 3.14.2 ›Compressed air quali-ty‹). The price in this case, however, is often higher than for nitrogen froma tank. There is thus no production cost advantage.

A suitable solution for the low-cost production of compressed air is an as-sembly with compressor and filter units capable of producing the requiredvolume and quality of compressed air (for specification, see section3.14.2 ›Compressed air quality‹). This system should preferably be placedimmediately adjacent to the laser cutting machine. It has its own line, di-rectly to the connection point on the laser cutting machine. The gas sup-plier or the manufacturer's Customer Services is available in the event ofproblems.

Applications: Up to a material thickness of 2 mm, it is possible tocut structural steel, rust and acid-resistant steeland aluminum with compressed air.

Advantages: With economically produced compressed air, theproduction costs can be reduced.

Sometimes the cutting performance is higherthan with oxygen (O2) or nitrogen (N2).

Disadvantages: Because of the oxygen content, the cut edge isoxidized, This is usually undesirable, especiallyin the case of rust and acid-resistant steel.

The underside of the sheet can be burred.




Standard compressors and in-house compressed air supplies are not suit-able for laser cutting. These installation do not deliver the required air pu-rity.

Cutting with dirty compressed air can damage the machine.

Compressed air quality must comply with the specifications insection 3.14.2 ›Compressed air quality‹.




9.7.8 Engraving

9.7.8.1 General points

Engraving is available as an auxiliary function of every machine. Examplesof use are:

labeling parts

marking positions (hole centers),

marking bending edges

pre-positioning of sheets or parts

Engraving is chiefly used on sheets of rust and acid-resistant steel andstructural steel. It is possible to engrave using nitrogen or oxygen. Thesame gas should be used for engraving as for cutting to avoid the need forpurging.

Highly reflective materials such as copper, brass or shiny surfaces are notsuitable for engraving.

The cutting parameters supplied by the laser cutting machine manufactur-er include engraving data. Engraving is easy to program in Bysoft.

9.7.8.2 Assessment of engraving quality

The depth and quality of the engraving is determined partly by the param-eter settings, partly by the sheet surface finish. Moreover, each personjudges the quality of an engraving differently.

Thus, the saved parameters should be considered simply as guidelines.Using them as a starting point, the values can be changed to adjust thedepth of the engraving. See Chapter 9.6.4.8 ›Laser power, engraving‹.

The depth of engraved contours or lettering should not be lessthan a minimum height of 8 mm. This ensures good legibility.




9.7.9 Machining with process macros

Process macros are additional parameters to assist optimum cutting ofcomplex contours. The process macros are programmed in Bysoft. Thecutting parameters must be altered on the laser cutting machine. A pro-cess macro is available.

Fig. 9.7-10 Example with process macros

9.7.9.1 Process macro 1

Process macro 1 is automatically called by the Bysoft technology wizardaccording to the rules for small contours.

The cutting parameters are also determined for small contours (e.g. thesmall hole in Fig. 9.7-10).

A Small contour (hole) using process macro 1

A




9.7.9.2 Example with process macro

In the following example, the individual sections are cut using differenttechnologies (process macro 1 and CW).

Fig. 9.7-11 Structural steel, 6 mm thick, with different technologies

A Holes, ∅6,5 mm, cut with process macro 1

B Banana holes and outer contour cut with CW

The part can thus be cut at optimum quality and in minimumtime.

A

A A

A BB

B B

B




9.7.10 Microjoints

Parts must not tip up on end, otherwise there will be problems removingthe cut parts using the unloading table. This problem is prevented by mi-crojoints.

The microjoints are automatically placed in accordance with the rules be-low.

Tab. 9.7-3 Rules for automatic microjoints

Rule Description

If the part contour in the X and Y directions is smaller than 40 mm, no microjoints are set.

If the part size in the X and Y directions is between 40 mm and 140 mm, microjoints are set.

If the part size in the X or Y directions is between 40 mm and 140 mm, microjoints are set.

If the parts in the X and Y directions are larger than 140 mm, no microjoints are set.




If, despite the rules according to Tab. 9.7-3, cut parts do tip up, additionalmicrojoints (from Bysoft) must be programmed to secure them. Thisneed would mainly arise for parts with an offset center of gravity.

Fig. 9.7-12 Programmed microjoints

A Programmed microjoint

B Common axis of rotation for twisting out the part

When cutting a new cutting plan, it must be ensured that thecut parts remain lying flat. If cut parts tip up, the cut sheetsegment cannot be removed with the unloading table.

When cutting leftover sheets, microjoints do not need to beset (cut material is removed manually). To omit microjoints,set the microjoint width to zero (0) in the cutting parameters.

AA

B




Fig. 9.7-13 Application example

Geometries without microjoints

Geometries with microjoints

Cut part

Rules for placing microjoints in accordance with Tab. 9.7-3

Y

X




9.8 Materials

9.8.1 Material properties

The cutting result on the work piece is either a clean cut or a frayed cutedge with a burr. The main factors influencing cut quality are:

Alloy elements

Microstructure

Material surface

Surface treatment

Beam reflection

Thermal conductivity

Melting point

9.8.2 Alloy components

Alloy constituents have a substantial influence on the strength, weldabili-ty, oxidation resistance and acid resistance of the materials.

The main alloy constituents of steels are carbon, chromium, nickel, mag-nesium and zinc.

The higher the carbon content, the more difficult is the material to cut(critical limit at about 0,8% carbon). The following carbon steels can becut well with the laser:

St 37-2, Stw 22

Cutting quality and cutting performance depend on alloy constituents. Instructural steel, a greater content of Si creates a rough cut edge and in-creases slag formation and burring. Carbon contents > 0.16% can lead topoor results on sharp edges and small holes.

Recommendation: use laser sheets having controlled alloy constituentswhen working at the extreme sheet-thickness range.

Tab. 9.8-1 C and Si content

Material C content Si content

RAEX 250 0.12% 0.01%

RAEX 420 0.13% 0.01%




9.8.3 Microstructure

Generally speaking, the finer the grain of the material structure, the bet-ter the quality of the cut edge.

9.8.4 Sheet surface finish

The surface finish of a sheet has a major impact on cutting results and cutquality.

9.8.4.1 Unwanted surface finishes

Loose rolling skin

Rust

Scale

Uneven surface with troughs and irregularities

General soiling

Steel stamping, scrap marks

Colored marks

Example:

cheap ST52 sheets that have been exposed to weathering.

9.8.4.2 Preferred surface finishes

Fine, even surfaces with microscale

Sheet lightly oiled

Pickled sheets

Hot-rolled oiled sheets

Sandblasted and shot-blasted surfaces are only suitable to a limited ex-tent but still better than rusty surfaces.




9.8.5 Surface treatment

The sheet may have the following surface treatments:

protective film

protective zinc coating

anodic coating

paint

primer

lacquer

etc.

All these and similar surface treatments usually have a negative impact oncutting results. Oxygen and e.g. paint react in the kerf during cutting. Thisresults in a very rough, frayed cut. Another problem is the difference inlayer thickness in one sheet. Different thicknesses of protective coatingcause errors in the capacitive detection.

Solution:

9.8.5.1 Oiled surfaces

Piercing splashes adhere less well to oiled surfaces. This means that ca-pacitative scanning is disrupted less. Oiling can be carried out in a numberof ways:

Purchase oiled sheets

Oil dry sheets by hand

Thicknesses ... 3 mm: Cut with nitrogen (N2)

WARNINGRisk of fire

The oil on the sheet surface can be ignited by the laserbeam.

Flammable oils should not be used.

Always use welding protection oil(MOTOREX PROWELD 264)




9.8.6 Beam reflection

The beam reflection from the workpiece surface is dependent on the ma-terial, surface roughness, focusing and surface treatment. The beam re-flection is higher for rust and acid-resistant steel, pure aluminum andaluminum alloys. The higher the reflectance, the more difficult to cut thematerial.

Fig. 9.8-1 Comparison of beam reflectance for focal position

9.8.7 Thermal conductivity

Materials with low thermal conductivity require less energy to melt themthan materials with high thermal conductivity.

For example, the power required for stainless steel is less than the valuesfor structural steel, despite the lower absorption at the process tempera-ture.

On the other hand, copper, aluminum and brass, for example, conductaway a large amount of the heat generated by absorption of the laserbeam. The heat is quickly conducted away from the focal point of the laserbeam, making it harder to melt the material at this spot.

Higher beam reflectance due tolower focal point. Setting the focustoo low can increase the outputcoupler temperature.

Low beam reflection due to higherfocal point (lower output couplertemperature)

Large area Small area




9.8.8 Heat affected zone

During laser cutting, material alterations can occur at the boundaries ofthe material being cut.

Tab. 9.8-2 Guide values for the extent of the heat-affected zone as a function of the base material andthe sheet thickness

In low-carbon and rust and acid-resistant steels the hardening of theheat-affected zone is minor.

In high-carbon steels (e.g. Ck60) the boundary zones are hardened.

In hard-rolled aluminum alloys, the heat affected zone is slightly softerthan the rest of the material.


Heat affected zonein [mm]

Structural steel


Aluminum

1 0.05 0.05 0.10

2 0.10 0.10 0.20

3 0.15 0.15 0.30

4 0.20 0.25 0.40

5 0.25 0.35 ⎯

6 0.30 0.55 ⎯

8 0.40 ⎯ ⎯




9.9 Cut evaluation

The following images are enlarged up to 10x. This is why striations and ir-regularities can even be seen on the optimum cuts.

The measures taken can also be extrapolated to other sheet thicknesses

9.9.1 Cutting with oxygen (O2)

9.9.1.1 Structural steel St 37-2, 4 mm thick

Fig. 9.9-1 Optimum CW cut

Fig. 9.9-2 Nozzle diameter too large

Cut:

Cut:

Situation: Very coarse cut surface in approximately the upperthird of the cut.

Action: Use smaller nozzle (∅1.7 mm was used instead of∅1.2 mm).

The correct nozzle is shown on the user interfacewhen starting a job.




Fig. 9.9-3 Laser power and gas pressure too low, nozzle diameter too small

Fig. 9.9-4 Optimum pulsed cut surface

Cut:

Situation: Cut parts do not fall out of the sheet independently. Abead of slag is found on the underside of the sheet.Good cut face except the lower third.

Action: Increase the laser power for cutting. Increase the gaspressure for cutting. Use larger nozzle.

Cut:

Situation: Rough, but regular cut surface (brown discoloration inthe lower third). Pulsed cut.

Action: The figure shows an optimum pulsed cut surface. It isalways rougher than the cut surface of a CW cut.




9.9.2 Cutting with nitrogen (N2)

9.9.2.1 Structural steel, hot galvanized, 2 mm thick

Fig. 9.9-5 Optimum cut

Fig. 9.9-6 Feed rate too great

Fig. 9.9-7 Laser power too high

Cut:

Situation: The cut face is always considerably rougher thanwithout zinc. The cut changes with varying zinc layerthickness. The thicker the zinc layer, the rougher isthe cut surface.

Slight burr on the underside of the sheet. Electro-gal-vanized sheets produce a much finer cut.

Cut:

Situation: Irregular, deep fissures in the cut face.Brown discol-oration from the middle of the cut down.

Action: Reduce feed rate.

Cut:

Situation: Irregular, heavy cracks in the cut surface.

Action: Reduce the laser power for cutting.




9.9.2.2 Rust and acid-resistant steel 1.4301, 6 mm thick

Fig. 9.9-8 Optimum oxide-free cut

Cut:




9.9.2.3 Aluminum AlMg3, 3 mm thick

Fig. 9.9-9 Optimum cut

Fig. 9.9-10 Gas pressure too high

Fig. 9.9-11 Laser power too high

Cut:

Situation: Optimum cut.

Cut:

Situation: Severe chips in the cut. Blue flashes in kerf when cut-ting.

Action: Reduce the gas pressure for cutting (in the figure it is3 bar too high).

Cut:

Situation: Severe chips in the cut. Blue flashes in kerf when cut-ting.

Action: Reduce the laser power for cutting.




Fig. 9.9-12 Focal position too high

Fig. 9.9-13 Focal position too low

Cut:

Situation: Fine cut surface in the upper two thirds of the cut sur-face.

Heavy drag in the lower third of the cutting area.Hard, difficult to remove burr on the underside of thesheet.

Action: Set the focal position, cutting further down (in thefigure it is 2 mm too high).

Cut:

Situation: Clean cut surface. Bead formation on the underside ofthe sheet.

Action: Set the focal position, cutting further up (in the figureit is 2 mm too low).




9.9.3 Piercing with oxygen (O2)

9.9.3.1 Structural steel St 37-2, 6 mm thick

Fig. 9.9-14 Standard piercing in structural steel of thickness 4 mm or greater

Fig. 9.9-15 Uncontrolled piercing at high power

Pulsedpiercing:

Comments: Standard piercing. The piercing hole is only slightlylarger than the cut. Only a small amount of materialis heated and ejected. Both criteria increase processreliability.

CW piercing:

Comments: Uncontrolled piercing at high power creates a largepiercing hole.




9.9.4 Piercing with nitrogen (N2)

9.9.4.1 Rust and acid-resistant steel 1.4301, 2 mm thick

Fig. 9.9-16 Piercing on dry sheet

Fig. 9.9-17 Piercing on oiled sheets

CW piercing:

Comments: The melt blown upwards during piercing is ejectedonto the sheet surface in a star shape. This can ad-here very strongly.

When cutting small holes this can interfere with ca-pacitive sensing. This reduces the quality.

CW piercing:

Comments: Practically no splash on the sheet. The upwardlyejected melt cannot adhere due to the oil film, andruns off.

High process reliability and quality even for smallholes.




9.9.5 Quality of the cut edge

9.9.5.1 Structural steel

9.9.5.2 Rust and acid-resistant steel

Cutting gas Thick-ness[mm]

Cut edge

OxygenO2

1 ... 8 Oxidized surface without burring on the sheet underside. The oxidized surface is not suitable for subsequent surface treatment (painting, varnishing, staining, galvanizing etc.).

The layer of oxide must be removed before subsequent surface treatment.

NitrogenN2

1 ... 3 Oxide-free surface without burring on the sheet underside.

Compressed airAir

1 ... 2 Oxidized surface with possible burring on the sheet underside. The oxidized surface is not suitable for subsequent surface treatment (painting, varnishing, staining, galvanizing etc.).

The layer of oxide must be removed before subsequent surface treatment.


Cut edge

NitrogenN2

1 ... 4 Oxide-free surface without burring on the sheet underside.

NitrogenN2

5 ... 6 Oxide-free surface with possible burring on the sheet underside.

Compressed airAir

1 ... 2 Oxidized surface with possible slight burring on the sheet underside.




9.9.5.3 Aluminum


Cut edge

NitrogenN2

1 ... 2.5 Oxide-free surface without burring on the sheet underside.

NitrogenN2

3 ... 4 Oxide-free surface with possible burring on the sheet underside.

Compressed airAir

1 ... 2 Oxidized surface with possible slight burring on the sheet underside.

The microstructure of the cut edge is affected when com-pressed air is used as the cutting gas.

Advance clarification must be sought as to whether this ispermitted for the part to be made.




9.10 Troubleshooting

Optimum cut quality can only be achieved if the following conditions aremet:

maintenance as per maintenance schedule

operating resources meet specified requirements

workpiece surface is rust and flake-free (etched, pickled or polished),

9.10.1 Cutting head

Nozzle shape must match parameters

Clean lens

Nozzle centered accurately

Focal position

Lens mounted correctly and fixed in place



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