FiberCUT HR - Laser Mechanisms, Inc. · PDF fileThe FiberCUT® HR laser processing head was...

FiberCUT ®

HR Operation Manual

PLMNL0252 REV. A Effective Date: 05/11/17 i FiberCUT® HR Operation Manual

WARNING

WORKING AROUND HIGH-POWERED LASERS CAN BE DANGEROUS

Laser Mechanisms, Inc.’s cutting heads must be operated with the cutting head interlock switch connected. The switch must be CLOSED when the head is properly attached. In the event of a crash and the cutting head becoming dislodged from its normal operating position, the switch must be OPEN. This interlock switch must be connected in a circuit in such a way that it will immediately turn off the laser and stop all machine motion. Check the wiring diagrams for your system.

Serious personal injury and/or equipment damage can occur if the head becomes dislodged and:

The head interlock is not connected properly.

Any interlock in the Laser Mechanisms’ product or laser system is defeated.

Laser Mechanisms, Inc. assumes no responsibility or liability for interlock switches or circuits and all interlocks are the sole responsibility of the purchaser of this head.

It is the responsibility of the integrator or end user to install, connect and activate all interlocks in compliance with the applicable ANSI, CEN, DIN, etc. standard.

All wiring should be done by personnel knowledgeable in electrical wiring and in accordance with the national and local electrical codes.

DISCLAIMER

The information in this manual is subject to change without notice.

Laser Mechanisms, Inc. makes no warranty of any kind with regard to the material in this manual, including but not limited to, the warranties or merchantability and fitness for a particular purpose.

Laser Mechanisms, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in connection with furnishing, performance or use of this product.

Laser Mech® is a registered trademark of Laser Mechanisms, Inc.

Corporate names and trademarks stated herein are the property of their respective companies.

COPYRIGHT

©2017 Laser Mechanisms, Inc. All rights reserved. No part of this publication may be reproduced in any form, or by any means without the prior written permission of Laser Mechanisms, Inc.

PRODUCT WARRANTY

Laser Mechanisms, Inc. warrants this product against defects in material and workmanship for a period of one year from the date of shipment from Laser Mechanisms Inc. or an authorized distributor. During the warranty period, Laser Mechanisms, Inc. will at its option, repair or replace products that prove to be defective.

For all products returned to Laser Mechanisms, Inc. for warranty service the customer must:

Call Laser Mechanisms, Inc. for a Return Material Authorization (RMA) number.

Properly pack the product with the RMA number on the outside of the package. Include in the package, all cables, and all accessories shipped with the product along with a description of the problem.

Prepay shipping charges to Laser Mechanisms, Inc.

Insure the shipment in case of loss or damage. Laser Mechanisms, Inc. will not accept any liability in case of damage or loss.

Laser Mechanisms, Inc. will pay the shipping charges, duties and taxes for the products returned to Laser Mechanisms, Inc. from outside the United States.

The foregoing warranty will not apply if damage is incurred resulting from improper or inadequate maintenance by the customer, unauthorized modifications or misuse, operation of the product outside its specifications, interlocks not connected properly, improper site preparation, parts or assemblies not supplied by Laser Mechanisms, Inc. or unauthorized repair by non-Laser Mechanisms, Inc. authorized personnel.

For complete warranty information visit our web site at www.lasermech.com.

PLMNL0252 REV. A Effective Date: 05/11/17 ii FiberCUT® HR Operation Manual

INITIAL INSPECTION

Inspect all shipping containers for damage as soon as the device arrives. It is your responsibility, the recipient, to notify the freight company of any damage. The freight company will require you to provide the container that any goods were shipped in, all shipping documentation and a list of all damages. Photographs of the damage are helpful in settling a freight claim.

Do not return damaged goods to the factory without a Return Material Authorization Number (RMA number).

Although it is Laser Mechanisms, Inc.’s intent to insure you are up and running as soon as possible, damage incurred during shipment must be settled with the freight company before arranging for repairs or replacement. No return shipments will be accepted without an RMA number clearly printed on the outside of all shipping containers. Failure to follow this procedure could void any warranty coverage on your head. Call your sales engineer at Laser Mechanisms, Inc. for a RMA number.

Carefully remove the device from its shipping container and all packing material to avoid damage. Save all packaging material, including the sealed, padded pelican case, in the event the head requires shipping or storage.

Check all items received against the packing list to verify that all the items were received.

Please note the product you receive may differ slightly from the illustrations in this manual. While the drawings may differ, the basic procedures described within remain the same.

TERMS USED IN THIS MANUAL

WARNING: The user could be injured if the warning is not followed.

CAUTION: The device or system could be damaged if the CAUTION is not followed.

NOTE: Clarification of a step or steps.

SAFETY

WARNINGS: Follow all warnings in this manual.

SAFETY GLASSES: Everyone in the area where the laser is being used must wear laser safety glasses designed for the laser being used.

SECONDARY REFLECTIONS: Secondary reflections are dangerous; never expose any part of your body to a reflected laser beam.

INTERLOCKS: Interlocks are safety devices and should never be defeated.

ADJUSTMENTS: Always turn off or put the laser in standby before making any adjustments to beam delivery components.

BEAM DUCT: Never open any component of the beam duct while the laser is operating. Always turn the laser off before servicing any beam duct components.

MANUALS: Always read the instruction manuals before attempting to install or make adjustments to any beam delivery component.

PLMNL0252 REV. A Effective Date: 05/11/17 iii FiberCUT® HR Operation Manual

TABLE OF CONTENTS

1 Introduction ........................................................................................................................................................1

2 Mechanical Installation and Operation ............................................................................................................3 2.1 Machine Mount ................................................................................................................................... 3

2.2 Plumbing – Water Cooling / Purge Gas / Assist Gas / Nozzle Cooling / Air Blast ............................. 3

2.3 Fiber Input ........................................................................................................................................... 4

2.3.1 QBH Fiber Clamp .............................................................................................................4

2.3.2 Fiber Orientation Adjustment ...........................................................................................5

2.4 Beam Centering .................................................................................................................................. 6

2.4.1 Beam Centering Camera .................................................................................................6

2.4.2 Manual ..............................................................................................................................8

3 Electrical Installation and Operation ................................................................................................................9 3.1 Connections ........................................................................................................................................ 9

3.1.1 Main Electrical Box to TRA Electrical Box........................................................................9

3.1.2 Main Electrical Box to Collimator Electrical Box ..............................................................9

3.1.3 Head to Control Box ...................................................................................................... 10

3.1.4 Servo Power Cable and Interlock for Head ................................................................... 11

3.2 Interface Example ............................................................................................................................. 12

3.3 Electrical Grounding and Noise ........................................................................................................ 13

3.4 Control Box Mounting ....................................................................................................................... 13

3.5 Control Box Interface ........................................................................................................................ 14

3.5.1 Terminal Block Connections ......................................................................................... 14

3.5.2 Industrial Ethernet Connection ...................................................................................... 15

3.6 Control Box Indicator Lights .............................................................................................................. 15

3.7 Collimator Electrical Box Indicator Lights ......................................................................................... 16

4 FiberCUT® Monitor .......................................................................................................................................... 17 4.1 Installation ......................................................................................................................................... 17

4.1.1 Downloading FiberCUT® Monitor Software ................................................................... 17

4.1.2 Installing FiberCUT® Monitor Driver .............................................................................. 17

4.2 System Requirements ...................................................................................................................... 18

4.3 Using FiberCUT® Monitor ................................................................................................................. 18

4.3.1 Start Up ......................................................................................................................... 18

4.3.2 System Controls ............................................................................................................ 18

4.3.3 Faults and Status Indicator ........................................................................................... 20

PLMNL0252 REV. A Effective Date: 05/11/17 iv FiberCUT® HR Operation Manual

4.4 FiberCUT® Monitor Settings ............................................................................................................. 20

4.4.1 Unlock Settings ............................................................................................................. 20

4.4.2 HSU Curve .................................................................................................................... 21

4.4.3 Temperature Limits ....................................................................................................... 21

4.4.4 Focus Position ............................................................................................................... 22

4.4.5 Process Monitor Gain .................................................................................................... 22

4.4.6 Suppress Low Purge Fault ............................................................................................ 23

4.4.7 Configuring EtherNet/IP Settings (If Equipped) ............................................................ 24

4.5 FiberCUT® Monitor System Identification Information ...................................................................... 25

5 Service.............................................................................................................................................................. 26 5.1 Servicing the Gas Jet Tip .................................................................................................................. 26

5.2 Servicing the Cover Glasses ............................................................................................................ 27

5.2.1 Upper Cover Glass ........................................................................................................ 27

5.2.2 Lower Cover Glass ........................................................................................................ 28

5.3 Servicing the Breakaway Insulator ................................................................................................... 29

5.4 Servicing the Tip Assembly .............................................................................................................. 32

5.5 Removing the Fiber........................................................................................................................... 32

5.6 Removing the Cutting Head .............................................................................................................. 33

5.7 Cleaning the Collimating Mirror ........................................................................................................ 34

5.8 Replacing the Collimating Mirror ....................................................................................................... 35

5.9 Cleaning the Focusing Mirror ............................................................................................................ 36

5.10 Replacing the Focusing Mirror .......................................................................................................... 37

6 Specifications .................................................................................................................................................. 38

7 Troubleshooting .............................................................................................................................................. 39

PLMNL0252 REV. A Effective Date: 05/11/17 v FiberCUT® HR Operation Manual

8 Appendix A – Cleaning Non-Metal Optics .................................................................................................... 40

9 Appendix B – Coolant Specifications ........................................................................................................... 42

10 Appendix C – Assist Gas Specifications ...................................................................................................... 42

11 Appendix D – Beam Delivery Purging ........................................................................................................... 42

12 Appendix E – Industrial Ethernet Data Mapping and Descriptions ........................................................... 43 12.1 EtherNet I/P I/O Mapping .................................................................................................................. 43

12.2 PROFINET I/O Mapping ................................................................................................................... 44

12.3 Input, Output, and Other Descriptions .............................................................................................. 45

13 Appendix F – Recommended User-Serviceable Parts List ......................................................................... 47

14 Appendix G – Servicing the Tip Assembly ................................................................................................... 50 14.1 User Serviceable Parts List .............................................................................................................. 50

14.2 Rebuilding the Tip Assembly ............................................................................................................ 51

15 Glossary ........................................................................................................................................................... 53

PLMNL0252 REV. A Effective Date: 05/11/17 1 FiberCUT® HR Operation Manual

1 Introduction

The FiberCUT® HR laser processing head was developed to provide cutting-edge performance for flatbed systems. The following features are included in the FiberCUT® HR (see Figure 1):

Mounting plate with grounding lug

Automatic programmable focus with 25 mm of moving nozzle assembly travel. See Figure 2.

(2) cover glasses

o (1) above the collimating mirror

o (1) between the focusing mirror and the tip

Convenient XY adjustment screws for tip centering

Convenient connections for purge, assist gas, nozzle cooling, and air blast

Water cooling

200 mm focus length

Multiple collimating length options: 100 mm or 150 mm

Standoff distances from 0.2 – 8.0 mm

Power rating up to 12kW

Fully sealed and purged design to prevent contamination

Sealed access doors prevent contamination during cover glass service

Pierce detection and loss of cut process monitoring

Internal sensors to determine the condition of ALL optics

Standard nozzle cooling and air blast

Breakaway tip assembly protects the head during a crash

Laser Mechanisms patented height sensing technology

Figure 1


The FiberCUT® HR has 25 mm of programmable travel for the moving nozzle assembly. See Figure 2.

The moving nozzle assembly:

Includes all of the components indicated in Figure 2.

The fully retracted position locates the nozzle 12.5 mm above the fixed focus point.

The center of travel position locates the nozzle at the fixed focus point.

The fully extended position locates the nozzle 12.5 mm below the fixed focus point.

Figure 2

The fixed focus point does not move relative to the FiberCUT® HR mounting plate.

The moving nozzle assembly moves relative to the fixed focus point.


2 Mechanical Installation and Operation

2.1 Machine Mount

The mount plate attaches directly to your 3-axis machine according to Figure 3.

Figure 3

2.2 Plumbing – Water Cooling / Purge Gas / Assist Gas / Nozzle Cooling / Air Blast

See Figure 4 and Figure 5 for line locations.

See Appendix B for laser head cooling specifications.

See the manufacturer’s information for specifications on cooling the fiber.

See Appendix C for assist gas specifications.

See Appendix D for purge gas specifications.

Figure 4


Figure 5

2.3 Fiber Input

The fiber input adapter is where the fiber optic cable plugs into the cutting head. See Figure 6. There are several standard types of industrial fiber (QBH/HLC-8, QD/LLK-D/LCA, Q5/LLK-B, and PIPA). Each of these fibers requires a unique fiber input adapter. Refer to the fiber manufacturer’s information for specific instructions.

EVERY TIME the fiber is removed and/or installed the upper cover glass MUST BE:

Inspected and/or cleaned according to Appendix A.

OR

Replaced according to Section 5.5.

2.3.1 QBH Fiber Clamp

The QBH fiber clamp provides added stability to the fiber connection (see Figure 6).

1. Loosen the (2) captive M4 SHCS and remove the fiber clamp.

2. Install the fiber into the fiber input adapter according to the fiber manufacturer’s instructions.

If the water cooling fittings on the fiber interfere with the QBH fiber clamp, rotate the QBH fiber interface according to Section 2.3.2.

3. Replace the fiber clamp.

Verify the (2) alignment pins are in-line with the alignment holes.

Tighten the (2) captive M4 SHCS.

Figure 6


2.3.2 Fiber Orientation Adjustment

If the water cooling fittings on the fiber interfere with the QBH fiber clamp, it is necessary to rotate the QBH fiber interface adapter.

The QBH fiber interface adapter has a red alignment dot.

To reorient the fiber connection (see Figure 7):

1. Remove the (4) M4 SHCS securing the QBH fiber clamp.

2. Remove the QBH fiber clamp.

3. Loosen, but do not remove, the (4) M4 SHCS in the QBH fiber interface adapter lock down plate.

4. Rotate the QBH fiber interface adapter so the red alignment dot is in the desired position.

Figure 7

5. Tighten the (4) M4 SHCS in the QBH fiber interface adapter lock down plate.

6. Slide the QBH fiber clamp back on so the clearance holes for the M4 SHCS are in line with the M4 tapped holes in the QBH fiber interface adapter lock down plate.

7. Insert and tighten the (4) M4 SHCS removed in step 1.

8. Install the fiber according to Section 2.3.

9. Install the fiber clamp according to Section 2.3.1.


2.4 Beam Centering

2.4.1 Beam Centering Camera

The beam must be centered in the tip.

Move the tip to the center of Z-axis travel for the best possible results.

Check the beam alignment during initial installation or whenever the fiber or collimator optics are replaced.

Laser Mechanisms’ beam centering camera (PLFXT0218) is used for tip centering and aligning the beam through the head.

It shows the position of the red aiming beam in the orifice of the gas jet tip.

The beam centering camera requires a Windows computer with a USB port and Digital Microscope Suite software or equivalent.

1. Download and install the latest version of Digital Microscope Suite software to the computer that will be used. See

http://www.lasermech.com/productupdates

A PDF copy of the Celestron® Handheld Digital Microscope Instruction Manual, with more details on the features and use of the microscope, is also available on the website above.

2. Thread on a gas jet tip with a 2 mm or larger orifice.

3. Turn on the red aiming beam from the fiber laser.

4. Connect the beam centering camera (PLFXT0218) to the computer using a USB cable.

5. Open the Digital Microscope Suite software.

6. Install the beam centering camera onto the tip assembly. See Figure 8.

Rotate the camera until it is fully seated against the tip assembly nut.

O-rings in the beam centering camera help keep it in place.

Figure 8

http://www.lasermech.com/productupdates


7. Adjust the camera focus knob (see Figure 8) until the end of the gas jet tip becomes in focus with a clear image. See Figure 9.

You should be able to see tooling marks on the end of the tip.

Figure 9

8. Adjust the opposing XY adjustment screws (see Figure 10) so the beam is centered in the nozzle orifice.

Loosen the adjustment screw in the desired direction then tighten the opposing screw (180° away, on the opposite side of the head).

One set of screws adjusts the X direction. The other set of screws adjusts the Y direction.

Some trial and error may be necessary.

Verify all screws are tight after adjustment is complete.

Figure 10

The image on the screen should be similar to Figure 11.

Figure 11 Beam is centered

It is sometimes helpful to rotate the camera while it is seated against the tip assembly nut to confirm the beam centering.


2.4.2 Manual

Do not look directly into the red beam.

Visually locating the beam inside the tip orifice can be difficult. Adequate lighting and a magnifying glass are highly recommended.

If necessary, Laser Mechanisms offers an alternative solution. See Section 2.4.1, Beam Centering Camera.

To manually center the beam in the gas jet tip (see Figure 12):

1. Verify that the high power beam is disabled.

2. Put a piece of translucent tape on the end of the gas jet tip.

3. Turn on the red aiming beam from the fiber laser and observe the position of the beam on the tape. If the beam is not centered in the gas jet tip orifice, proceed to step 4.

4. Adjust the opposing XY adjustment screws (see Figure 12) so the beam is centered in the nozzle orifice.

Loosen the adjustment screw in the desired direction then tighten the opposing screw (180° away, on the opposite side of the head).

One set of screws adjusts the X direction. The other set of screws adjusts the Y direction.

Some trial and error may be necessary.

Verify all screws are tight after adjustment is complete.

Figure 12


3 Electrical Installation and Operation

3.1 Connections

For clarity, the subsections of Section 3.1 each show only one cable and connection.

3.1.1 Main Electrical Box to TRA Electrical Box

The FiberCUT® HR has one cable that connects the cutting head main electrical box (PLEBX0082) and TRA electrical box (PLEBX0080). See Figure 13.

Figure 13

1. Insert and turn as needed to tighten the straight male end of the TRA interface cable (PLCAB0631) into the main electrical box (PLEBX0082).

The other end of the TRA interface cable arrives already connected to the TRA electrical box (PLEBX0080).

3.1.2 Main Electrical Box to Collimator Electrical Box

The FiberCUT® HR has one cable that connects the cutting head main electrical box (PLEBX0082) and Collimator electrical box (PLEBX0081). See Figure 14.

Figure 14

1. Insert and turn as needed to tighten the straight male end of the collimator interface cable (PLCAB0630) into the main electrical box (PLEBX0082).

2. Insert and turn as needed to tighten the right angle female end of the collimator interface cable (PLCAB0630) into the collimator electrical box (PLEBX0081).


3.1.3 Head to Control Box

The FiberCUT® HR has a companion control box which acts as the interface between the FiberCUT® HR, the power, the motion system and a personal computer.

There is one control cable that connects the cutting head main electrical box (PLEBX0082) and the control box. See Figure 15.

Figure 15

1. Insert and turn as needed to tighten the female end of the control cable into the cutting head. See Figure 15.

For steps 2 to 6, see Figure 16.

2. Insert the male end of the control cable into the 14-pin connection on the control box.

3. Connect the user-supplied, 24V DC, 0.5A power source to the three position terminal block on the control box labeled POWER.

4. If necessary, insert the mini USB cable into the connector on the control box labeled USB. The other end is connected to the user supplied computer.

5. Insert the RJ-45 connector into the connection that is labeled PROFINET or EtherNet/IP.

6. Use the 10 position terminal block on the control box to make discrete I/O connections.

Figure 16


3.1.4 Servo Power Cable and Interlock for

Head

The FiberCUT® HR has one cable to supply servo power to the cutting head main electrical box (PLEBX0082).

The cable also provides an interlock output. See Figure 17.

Figure 17

1. Insert the straight female end of the Servo Power/Interlock Cable (PLCAB0595) into the main electrical box (PLEBX0082).

2. Connect the wires as necessary according to the following:

The head side machine interface connection:

Power: 24VDC, 2.5 A

It has an M12 thread, 4 pins, and a female connection on the top of the main electrical box (PLEBX0082) located on the head.

The cabling used at this connection is the female end of PLCAB0595 (supplied with the head), or equivalent.

M12 Pin Wire Color Description

1 BRN +24V

2 WHT Interlock

3 BLU Ground

4 BLK Interlock

28VDC, 0.1 A Max


3.2 Interface Example

The control box interface allows control and feedback of all the FiberCUT® HR operations.

Figure 18

FiberCUT® HR Interface Example


3.3 Electrical Grounding and Noise

The capacitive height sensing circuitry contained in the FiberCUT® HR cutting head measures small changes in electrical capacitance between the tip and earth-ground to determine tip-to-part standoff distance. In order for this circuit to function properly the part and the cutting head need to be connected to a good earth ground.

Ideally the ground should be established from a ground rod, approximately 2 meters in length driven into the ground located near the base of the machine.

A large gauge (1.6mm diameter or larger) ground wire should be run from the ground rod to the part.

Run a separate wire from the ground rod to the FiberCUT® HR grounding lug. See Figure 19.

Figure 19

Electrical noise can create height sensing issues. Large electric motors, arc welders and other devices may be a source of significant electrical noise. In order to eliminate this noise, it may be necessary to connect a ground wire to the chassis of any such device near the process.

3.4 Control Box Mounting

The control box mounting pattern is illustrated in Figure 20. Important things to consider when mounting the control box:

Standard cable length is 8 meters (25 feet).

Easy access for maintenance.

Mounting so debris from the process is not directed at the control box.

Mounting in an area where there are no water leaks or oils from hydraulic lines.

Figure 20


0

1

2

3

4

5

6

7

8

9

10

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Vo

lts

Tip Standoff Distance (mm)

HSU Output

HSU out (Linear)

HSU out (Optimized)

3.5 Control Box Interface

3.5.1 Terminal Block Connections

There are 3 analog outputs (HSU, Position and Process) available through the terminal block connection.

Each analog output signal is referenced to Ground.

ANALOG OUTPUTS

OUTPUT DESCRIPTION

HSU Out See

Figure 21

The HSU output signal (0-10V) indicates the standoff distance of the tip and the part. In general two types of output curves are available; linear and optimized. Additional curves may be added according to customer requirements.

GND Analog Ground

Pos Out*

The Position Output signal (0-10V) is set using FiberCUT® 2D Monitor or the IE interface. ~ It is scaled linearly from 0 to 30mm, 500mbar, or 100°C depending on the assigned function.

GND Analog Ground

Proc Out

The Process Monitor output signal (0-10V) indicates the status of the laser cutting process. ~ Interpretation requires significant processing by the user’s machine to determine pierce through and loss of cut values.

GND Analog Ground

Figure 21

There is one analog input (Pos In)

available through the terminal block connection.

ANALOG INPUT

INPUT DESCRIPTION

Pos In The Pos In signal (0-10V) is used to set the position of the focus relative to the moving nozzle assembly.

There are 4 digital outputs (Ready, Touch, In Pos and SVON) available through the terminal block connection.

Each output is a solid-state relay connected to Out Com when active.

DIGITAL OUTPUTS

OUTPUT DESCRIPTION

Ready

The Ready output indicates the head is communicating, the moving nozzle assembly is in position and the HSU is operating with no fault conditions.

Touch The Touch output indicates that the tip has contacted the part or another conductive surface.

In Pos

The In Position output indicates that the moving nozzle assembly has reached the commanded position.

NOTE: This output is NOT an indication of the tip standoff distance.

SVON The servo on output indicates that the servo holding the tip is active.

Out Com

The Output Common allows users to configure the outputs for either sourcing or sinking. ~ Connect Out Com to 24 V DC for “sourcing.” ~ Connect Out Com to 0 V DC for “sinking.”


There are 4 digital inputs (Cal, Reset, Move and Enable) available through the terminal block connection.

DIGITAL INPUTS

INPUT DESCRIPTION

Cal In

The Cal In input recalibrates the height sensor. Clear any HSU faults by activating this input for 20 – 200 µsec.

Reset In The Reset In input clears any position faults and moves the focus to the Home position.

Move In When the Move input is active, the focus position will follow the Pos In analog input.

Enable In The Enable input will activate the servo in order to adjust the focus position.

3.5.2 Industrial Ethernet Connection

The Industrial Ethernet (IE) interface provides extensive control and monitoring of the FiberCUT® HR. Depending on the control box model, either EtherNet/IP or PROFINET communications protocol is used.

See Appendix E for details on device configuration and available data.

3.6 Control Box Indicator Lights

The control box has 7 indicator lights. See Figure 22.

The indicator light labeled POWER is green and illuminated when power is supplied to the control box.

The indicator light labeled READY is illuminated in green when the READY output is active. The light illuminates in red when a fault is detected within the head.

The indicator light labeled TOUCH is green and illuminated when the tip is in contact with the part or another conductive surface.

The indicator lights labeled A, B, C, and D may be red or green. They work together to indicate the network status of the IE connection and other diagnostic information. See the charts below.

At power up or reset, the four indicators will cycle in the order A>B>D>C first in red and then in green. This pattern confirms the IE module is installed and functioning properly.

Figure 22 During normal operation the indicator lights respond as follows:

LED A

STATE STATUS

Green Module connected to a network

Green and Flashing

RX / TX Activity


LED B

STATE STATUS

Green EtherNet/IP: 100 Mbps operation

Green and Flashing

PROFINET: Identification

Red No communications with head

Red and Flashing

PROFINET: Diagnostic event(s) available

LED C

STATE STATUS

Green EtherNet/IP: Device has a connection PROFINET: Normal operation

Green and Flashing

EtherNet/IP: Device has no connection PROFINET: Network settings error

Red EtherNet/IP: Major fault (unrecoverable) PROFINET: Internal error

Red and Flashing

EtherNet/IP: Minor fault (recoverable) PROFINET: Configuration error

LED D

STATE STATUS

Green EtherNet/IP: connection(s) established PROFINET: Online, PLC in RUN

Green and Flashing

EtherNet/IP: No connection established PROFINET: Online, PLC in STOP/CLEAR

Red EtherNet/IP: Duplicate IP address detected PROFINET: Internal error

Red and Flashing

EtherNet/IP: One (or multiple) connections has timed out

3.7 Collimator Electrical Box Indicator Lights

The collimator electrical box has 4 indicator lights. See Figure 23. They will only illuminate (red or green) when:

The head is powered.

The collimator electrical box is properly connected to the main electrical box using the collimator interface cable. See Section 3.1.

During normal operation the indicator lights respond as follows:

POWER LED

STATE STATUS

Green Head is powered ON and all modules are initialized

Red Communications fault with one or more modules

Off Module is not connected Invalidates other LEDs

SERVO LED

STATE STATUS

Green Servo is energized

Red Servo is enabled, but failed to energize

Off Servo is disabled

POSITION LED

STATE STATUS

Green Nozzle assembly is in position

Red Position fault has occurred Requires reset

Off Out of position

READY LED

STATE STATUS

Green HSU is ready

Red The cover glass and/or focusing parabola are not properly inserted

Off HSU fault

Figure 23


4 FiberCUT® Monitor

FiberCUT® Monitor is a very useful tool for use with your FiberCUT® HR head. FiberCUT® Monitor runs on a standard PC and connects to the control box with a USB cable. It provides real time monitoring of the tip standoff, moving nozzle assembly position, and head temperatures of your FiberCUT® HR on a single, easy-to-read screen. See Figure 24.

Figure 24

4.1 Installation

4.1.1 Downloading FiberCUT® Monitor Software

Download the latest copy of FiberCUT® Monitor 2D from the FiberCUT® Updates web page:

http://www.lasermech.com/fibercut2dupdates

Once the compressed folder is downloaded from the web site it only needs to be decompressed.

1. Right-click on the compressed folder and select Extract All....

2. Follow the on-screen instructions to complete the decompression (extraction) of the compressed files.

The resulting folder will have a single FiberCUTMonitor2D.exe file, a driver folder, and a folder named FiberCUTMonitor2D Libs.

It is important that the Libs folder remain at the same location as FiberCUT® Monitor.

The parent folder for these files can be moved and copied as needed. No license key is needed.

4.1.2 Installing FiberCUT® Monitor Driver

Before operating the FiberCUT® Monitor, it must be connected to a customer supplied Windows based computer.

If the system is connected and is not recognized, install the FDTI CDM drivers using the installer in the Driver/FiberCUT HR directory of the FiberCUT® Monitor folder.



4.2 System Requirements

Windows 7 or later

Minimum Screen Resolution: 1024 x 768

USB 2.0 Port

4.3 Using FiberCUT® Monitor

4.3.1 Start Up

1. Verify that all cables are connected to the head and control box according to Section 3.1.

The screen shown in Figure 25 will appear.

Figure 25

For steps 2 and 3, see Figure 26.

2. Click on the Port drop down menu in the upper left corner and choose the appropriate port.

3. Click Connect.

Figure 26

The Main screen appears. See Figure 27 for an example.

4. Update any settings, as necessary, according to Section 4.4.

4.3.2 System Controls

See Figure 27 (the Main screen).

Figure 27


1. Click the following, as necessary:

Under proper operating conditions, click the Servo Enable button to command the servo to turn on and maintain the set position.

o Click the button while the servo is active to disable.

ENABLE IN must be active on the Control Box before you can set Servo Enable.

Click the Reset button to allow the servo to be enabled and clear a Position Fault.

To modify the Set Position

o Use the slider bar on the right to update the Set Position value.

o Click the Go button to apply the new value.

Click the Calibrate button to recalibrate the HSU.

Perform calibration at 12 mm above the material surface.

o Use the Calibrate button to clear a Tip or Cable Break fault.

o An alternate method to recalibrate the FiberCUT® Monitor is to click the Settings menu in the upper left corner of the Main screen and select Calibrate. See Figure 28.

Figure 28

Click the Disconnect button (top center of the Main Screen) or the red X (upper right corner of the Main screen) to disconnect the control box and head.

o Either of these actions will end the session.

2. Note the following displays:

The status of the head is displayed in the upper right corner of the Main Screen.

If the tip contacts another surface, the indicator light next to TIP TOUCH (lower right of the Main screen) will be illuminated green.

The Main screen displays the current value of:

o Standoff Height

o Focus Position

o Temperature for electronics, both cover glasses, process monitor, and both parabolas

o Purge gas pressure


4.3.3 Faults and Status Indicator

See Figure 27 (the Main screen).

When a fault occurs, the Ready output turns off and the corresponding light on the control box turns red. A description of the fault is also displayed in red in the upper right corner of the Main screen and the module responsible for the fault will be highlighted on the diagram of the head.

Faults occur when:

The HSU fails to calibrate.

A cable break occurs within the head. For instance, if the tip assembly is removed or one of the external modules is not connected.

Communication between the controller and head is lost.

A temperature goes above the upper limit.

The cover glass door is open or drawer is removed.

The purge pressure goes below the lower limit (unless suppressed) or above the upper limit.

The nozzle assembly moves unexpectedly or encounters difficulty moving to the commanded position.

The status indicator may also show that the head is Not Ready if the head is operating normally but is not ready for laser processing, such as when the HSU is calibrating.

The on-screen Ready indicator may not change during some operations due to the software refresh interval. See the READY output or light on the control box for real-time status.

4.4 FiberCUT® Monitor Settings

The FiberCUT® Monitor software and driver are available for download. See Section 4.1 for details.

This section lists the settings that must be specified before operating FiberCUT® Monitor.

Before adjusting any settings:

The software must be installed on your PC. See Section 4.1 for more details.

The head and control box must be connected properly. See Section 3.1 for more details.

4.4.1 Unlock Settings

1. Click the Settings menu in the upper left corner of the Main screen and select Unlock Settings. See Figure 29.

In the pop up that appears, enter the password: cutsetup.

Figure 29


4.4.2 HSU Curve

See Figure 30.

1. Click the Settings menu in the upper left corner of the Main screen and hover over HSU Curve.

2. Click Linear, Optimized, or Other as desired.

Figure 30

Load Curve is an advanced function that should only be performed under direction of Laser Mechanisms support.

4.4.3 Temperature Limits

The acceptable upper temperature limit can be set as desired within the stated range for the following components:

Upper Cover Glass

Collimating Parabola

Process Monitor

Focusing Parabola

Lower Cover Glass

Height Sensor

Temperature readings outside the acceptable range will result in a fault condition.

To modify the desired upper temperature limit:

1. Click the Settings menu in the upper left corner of the Main screen and hover over Temperature Limits. Click on the desired temperature range to set. See Figure 31 .

Figure 31

A screen similar to Figure 32 will appear.

Figure 32

2. Enter a desired upper limit that is within stated range using the provided value field.

3. Click OK to apply the settings.

The current upper temperature limit is displayed. The temperature upper limit must be within the stated range. Click Use Defaults to set all temperature limits to their maximum possible values.


4.4.4 Focus Position

The Focus Position provides an on-screen reference between the position of focus and the end of the nozzle.

Manually determine the position that places focus at the end of the tip.

Use that value for the Focus Position setting.

1. Click the Settings menu in the

upper left corner of the Main screen and select Focus Position. See Figure 33.

Figure 33

A screen similar to Figure 34 will appear.

Figure 34

2. Enter the desired value within the

stated range in the provided field.

3. Click OK to apply the settings. The current Focus Position value is displayed.

The Focus Position voltage must be within the stated range.

4.4.5 Process Monitor Gain

The process monitor output can be adjusted to compensate for signal differences in the cutting process by using the gain setting.


upper left corner of the Main screen and select Process Monitor Gain. See Figure 35.

Figure 35


A screen similar to Figure 36 will

appear.

Figure 36

2. Enter the desired value within the stated range in the provided field.

3. Click OK to apply the settings. The current Process Gain Monitor value is displayed.

Typical Process Monitor Gain values are in the lower half of the allowed range.

4.4.6 Suppress Low Purge Fault

Faults generated by a purge pressure reading below the lower limit can be temporarily disabled by clicking Suppress Low Purge Fault or setting the corresponding IE bit. See Figure 37.

Figure 37

A checkmark appears if a fault is currently suppressed.

Clicking the checkmark will restore the fault.

The fault is automatically restored following a power cycle of the controller.


4.4.7 Configuring EtherNet/IP Settings (If

Equipped)

FiberCUT® HR control boxes are set by default to use DHCP for EtherNet/IP communications. A static IP address can be set using FiberCUT® 2D Monitor.


upper left corner of the Main screen and select EtherNet/IP… See Figure 38.

Figure 38

For steps 2 to 6, see Figure 39. 2. Click the Settings menu in the

upper left corner of the Main screen and select EtherNet/IP…

The EtherNet/IP Settings screen, shown in Figure 39, will appear.

Figure 39

3. Configure the DHCP, IP Address, Subnet Mask, and Gateway settings as desired.

When using EtherNet/IP, Swap Byte Order should be checked.

4. Click OK to apply the settings.

5. If desired, click the Store button to save the changes to the control box.

6. If desired, click the Reset button to reset the control box and implement the new configuration.

Otherwise, power must be cycled in order for new settings to take effect.


4.5 FiberCUT® Monitor System Identification Information

The hardware, controller, interface, and HSU are all specific to your system. So, version and serial numbers are critical in order for Laser Mechanisms to provide support.

To display system information:

1. Click the Display menu in the upper left corner of the Main screen and select About FiberCUT®… See Figure 40.

Figure 40

2. Click on the View Hardware Information drop down menu in the pop up box that appears and the image shown in Figure 41 will appear.

Figure 41

3. Click on the appropriate line to view the identifying information for the desired item.

4. Repeat steps 2 and 3 as needed.

5. Click OK to exit the About FiberCUT® screen.


5 Service

Routine maintenance and service is required for the FiberCUT® HR Head. The operating environment has a critical impact on the frequency of maintenance procedures. Consult your Laser Mechanisms representative for guidance.

5.1 Servicing the Gas Jet Tip

To remove the gas jet tip:

1. Unscrew the tip retainer nut assembly from the tip assembly. See Figure 42.

2. Unscrew the inner retainer from the outer hex and remove the gas jet tip. See Figure 43.

Figure 42

Figure 43

To replace the gas jet nozzle tip:


3. Insert the gas jet tip into the inner retainer.

4. Screw the inner retainer into the outer hex. Do not over tighten.

Hand tighten the tip retainer nut assembly. Do not use a wrench.

5. Screw the tip retainer nut assembly with gas jet tip into the tip assembly. Do not over tighten. See Figure 42.

Hand tighten the tip retainer nut assembly. Do not use a wrench.

6. Verify beam centering according to Section 2.4.


5.2 Servicing the Cover Glasses

The FiberCUT® HR has an upper and a lower cover glass. Each cover glass is sealed to protect the optics. See Figure 44.

The upper cover glass is located in a fixed holder just above the collimating mirror.

The lower cover glass is located in a drawer just below the focusing optic.

Figure 44

5.2.1 Upper Cover Glass

Before opening any part of the head, clean off the dust and/or process debris using an exterior cleaning towel (PLTLS0023) or equivalent.

Always wear powder free gloves or finger cots when handling optics and optic holders.

To remove the upper cover glass, see steps 1 to 4 and Figure 45.

1. Loosen the (2) captive M3 SHCS securing the fixed cover glass holder (PLFLH0440) and pull it out of the head.

2. Remove the manifold seal ring (PLMSR0030) and the cover glass (PLLCG0060) from the fixed cover glass holder.

3. Inspect the cover glass and:

Clean it according to Appendix A.

OR

Replace it (proceed to step 4).

4. Inspect the manifold seal ring and:

Replace it if it is damaged.

Save it if it is in good condition.

Figure 45

To install the upper cover glass, see steps 5 to 8 and Figure 45.

5. Place the cover glass in the fixed cover glass holder.

6. Press the manifold seal ring into the fixed cover glass holder to retain the cover glass.


7. Align the fixed cover glass holder so:

The (2) captive M3 SHCS are in line with the (2) M3 tapped holes in the head.

The alignment notch is in line with the alignment pin in the head.

The fixed cover glass holder is inserted fully into the head.

The orientation slots MUST match Figure 45.

8. Tighten the (2) captive M3 SHCS.

5.2.2 Lower Cover Glass


Always wear powder free gloves or finger cots when handling optics and optic holders.

To remove the lower cover glass:

For steps 1 to 3, see Figure 46 .

1. Release the cover glass door by pushing the door latch.

2. Swing the cover glass door open.

3. Grasp the handle on the cover glass drawer and pull straight out to remove it from the head.

Figure 46


4. Close the sealed cover glass door during service to keep contaminants out.

5. Remove the manifold seal ring (PLMSR0030) and the cover glass (PLLCG0060) from the cover glass drawer.

6. Inspect the cover glass and:

Clean it according to Appendix A.

OR

Replace it (proceed to step 7).


7. Inspect the manifold seal ring and:

Replace it if it is damaged.

Save it if it is in good condition.

Figure 47

To install the lower cover glass:


8. Place the cover glass into the drawer.

9. Press the seal ring into the drawer to retain the cover glass.

10. Open the cover glass door.

11. Reinsert the cover glass drawer into the head.

12. Close the cover glass door.

The orientation slots MUST match Figure 47.

5.3 Servicing the Breakaway Insulator

The tip assembly contains an internal breakaway insulator (PLISR0041) that fractures to protect the head during a crash. See Figure 48.

The tip assembly nut will remain threaded on the head.

The remaining parts of the tip assembly tip may fall from the head.

Figure 48


1. Gather the tip assembly if it was fractured from the head.


2. Unscrew the tip assembly nut from the head.

3. If it was fractured, remove the broken (top) portion of the breakaway insulator from inside the tip assembly nut.

Figure 49

4. Remove the (6) M3 SHCS that secure the broken breakaway insulator to the tip assembly. See Figure 50.

5. Remove the breakaway insulator with the o-rings. See Figure 51.

Figure 50


To install a breakaway insulator:


6. Verify that all (4) o-rings are present and installed correctly:

In both the breakaway insert and the tip assembly:

o (1) smaller o-ring near the edge

o (1) larger o-ring at the center

7. Install a new breakaway insulator into the tip assembly nut so the counterbores are facing up.

8. Orient the alignment pin in the tip assembly so it is in-line with the alignment hole in the breakaway insulator.

9. Fasten the breakaway insulator to the tip assembly using the (6) M3 SHCS removed in step 4.

10. If necessary, replace the gas jet tip according to Section 5.1.

11. Install the tip assembly according to Section 5.4.

12. IMPORTANT!

Verify beam centering according to Section 2.4.

Figure 51


5.4 Servicing the Tip Assembly

See Figure 52.

To remove:

1. Unthread the tip assembly nut and remove the tip assembly from the head.

Figure 52

To install:

2. Verify that the alignment flat on the tip assembly faces the front of the head.

3. Push the tip retainer assembly up until it is centered on and flush against the head.

4. Rotate the tip retainer assembly slightly until the alignment pin seats in the alignment hole in the head.

5. Thread the retainer nut into the head.

Do not allow the aligned components to rotate.

5.5 Removing the Fiber

EVERY TIME the fiber is removed and/or installed the upper cover glass MUST BE inspected.


1. Wipe the head clean of any foreign matter prior to removing the head.

2. Verify that the upper cover glass is in place.

3. Remove the fiber clamp according to Section 2.3.1.

4. Remove the fiber optic cable from the cutting head according to the manufacturer’s instructions.

5. Cover the fiber end with an appropriate cap from the fiber manufacturer.

Special attention must be given to the fiber optic cable.

Care must be taken to insure dirt and debris do not contaminate the glass block at the end of the fiber.

Plug or tape off the fiber input to prevent contamination.

Damage will occur if:

The output is not covered with manufacturer’s cap.

The fiber input adapter is not protected by the provided dust cover.

6. Cover the fiber input adapter with an appropriate cap or tape.


5.6 Removing the Cutting Head


1. Remove the fiber according to Section 5.5.

2. The open area of the QBH receiver MUST be covered.

Use the manufacturer supplied dust cap.

OR

Use blue painter’s tape or equivalent.

For steps 3 and 4, see Figure 4 and Figure 5 in Section 2.2.

3. Turn off the water supply and disconnect the water fittings.

4. Remove the purge air, assist gas, air blast and nozzle cooling lines.

5. Disconnect ALL communication cables. See Figure 13, Figure 14, Figure 15 and Figure 17 in Section 3.1.

6. Unbolt the head from the machine using a 6mm hex wrench as shown in Figure 53.

Figure 53

7. Separate the head from the machine.

8. Take the cutting head to a clean area.


5.7 Cleaning the Collimating Mirror

Perform the instructions in this section ONLY if there is a problem with the mirror.


1. Remove the FiberCUT® HR head according to Section 5.6 and move it to a clean area.


2. Loosen, but do not remove the (4) captive M4 SHCS securing the collimating mirror spacer cap to the collimating mirror spacer block.

3. CAREFULLY, pull the collimating mirror spacer cap straight out to remove it.

Take care not to damage the sides of the collimating mirror by contacting the collimating mirror spacer block.

Figure 54

Now is also a good time to check the water input or output fittings (PLFTG0104).

If necessary, unthread the old fitting(s) and thread in a new one.

Verify the new fitting(s) do not leak.

4. Inspect the collimating mirror and either:

Clean it (proceed to step 5).

OR

Replace it (proceed to Section 5.8).

Optics are very sensitive to dust and debris. It is extremely important to take every possible precaution to ensure the optics remain pristine.

Clean optics in a dust free air-conditioned room.

ALWAYS handle optics by their edges, never touch the optical surfaces.

ALWAYS wear powder free gloves or finger cots when handling optics and optic holders.

Inspect the optics with high power illumination, such as Laser Mechanisms pen light (PLTLS0021) under 2X magnification.

5. Hold the optic by its edges and blow any dust or lint particles off with low-pressure dry nitrogen (2 to 5 psi) or air from a blow bulb.

NEVER USE SHOP AIR BECAUSE IT CAN CONTAIN OIL AND WATER.

If this does not remove all the contamination, continue to step 8.


6. Lay a piece of clean lens tissue on the surface of the optic. With an eyedropper squeeze a few drops of reagent grade acetone on the lens tissue wetting the complete area of the optic.

7. Without lifting the dampened lens tissue, drag the tissue across the optic just fast enough so the acetone evaporates behind the tissue.

If it is done correctly there will be no streaks left on the optic.

It may be necessary to repeat steps 6 and 7 multiple times.

If steps 7 to 9 do not remove all contamination, proceed to Section 5.8 to replace the collimating mirror.

5.8 Replacing the Collimating Mirror



If the head is not removed and relocated to a clean area already, see step 1.

If the head is removed and relocated to a clean area, proceed to step 2.

1. Remove the collimating mirror spacer cap and collimating mirror according to Section 5.7.


2. Remove the M6 SHCS and serrated washer securing the collimating mirror spacer cap to the collimating mirror.

3. Remove the collimating mirror, but keep the M6 SHCS and serrated washer.

4. Align a new collimating mirror so:

The M6 threaded hole in the center is in line with the M6 hole in the collimating mirror spacer cap.

The (2) alignment holes are in line properly with the (2) keyed alignment pins in the collimating mirror spacer cap.

5. Insert and tighten the M6 SHCS and M6 serrated washer.

6. Align the collimating mirror spacer cap and collimating mirror so the (4) captive M4 SHCS are in line with the (4) M4 threaded holes in the collimating mirror spacer block.

7. CAREFULLY insert the collimating mirror spacer cap and collimating mirror straight into the collimating mirror spacer block.

Take care not to damage the sides of the collimating mirror by contacting the collimating mirror spacer block.


Figure 55


5.9 Cleaning the Focusing Mirror



1. Remove the fiber according to Section 2.3.

2. Unplug all cables and cooling lines from the head.

3. Remove the FiberCUT® HR head according to Section 5.6 and move it to a clean area.


4. Loosen, but do not remove the (4) captive M4 SHCS securing the focusing mirror spacer cap to the focusing mirror spacer block.

5. CAREFULLY pull the focusing mirror spacer cap straight out to remove it.

Take care not to damage the sides of the focusing mirror by contacting the focusing mirror spacer block.

Figure 56

Now is also a good time to check the water input or output fittings (PLFTG0104).

If necessary, unthread the old fitting(s) and thread in a new one.

Verify the new fitting(s) do not leak.

6. Inspect the focusing mirror and either:

Clean it (proceed to step 7).

OR

Replace it (proceed to Section 5.10).






7. Hold the optic by its edges and blow any dust or lint particles off with low-pressure dry nitrogen (2 to 5 psi) or air from a blow bulb.

NEVER USE SHOP AIR BECAUSE IT CAN CONTAIN OIL AND WATER.

If this does not remove all the contamination, continue to step 8.


8. Lay a piece of clean lens tissue on the surface of the optic. With an eyedropper squeeze a few drops of reagent grade acetone on the lens tissue wetting the complete area of the optic.

9. Without lifting the dampened lens tissue, drag the tissue across the optic just fast enough so the acetone evaporates behind the tissue.

If it is done correctly there will be no streaks left on the optic.

It may be necessary to repeat steps 8 and 9 multiple times.

If steps 7 to 9 do not remove all contamination, proceed to Section 5.10 to replace the focusing mirror.

5.10 Replacing the Focusing Mirror



If the head is not removed and relocated to a clean area already, see step 1.

If the head is removed and relocated to a clean area, proceed to step 2.

1. Remove the focusing mirror spacer cap and focusing mirror according to Section 5.9.


2. Remove the M6 SHCS and serrated washer securing the focusing mirror spacer cap to the focusing mirror.

3. Remove the focusing mirror, but keep the M6 SHCS and serrated washer.

4. Align a new focusing mirror so:

The M6 threaded hole in the center is in line with the M6 hole in the focusing mirror spacer cap.

The (2) alignment holes are in line properly with the (2) keyed alignment pins in the focusing mirror spacer cap.

5. Insert and tighten the M6 SHCS and M6 serrated washer.

6. Align the focusing mirror spacer cap and focusing mirror so the (4) captive M4 SHCS are in line with the (4) M4 threaded holes in the focusing mirror spacer block.

7. CAREFULLY insert the focusing mirror spacer cap and focusing mirror straight into the focusing mirror spacer block.

Take care not to damage the sides of the focusing mirror by contacting the focusing mirror spacer block.


Figure 57


6 Specifications

CUTTING HEAD

Power Rating ............................................................................................................................ up to 12 kW

Focusing Optic (Nominal Focal Length) ........................................................................................... 200 mm

Clear Aperture ................................................................................................................................... 35 mm

Nozzle Tip .............................................................................................. Various Shapes and Orifice Sizes

Assist Gas Pressure .................................................................................................. up to 25 Bar (375 psi)

Purge Gas ........................................................................................................ 0.2 – 0.3 Bar (3.0 – 5.0 psi)

Water ................................................................................................................ 5.0 Bar Max (72.5 psi max)

Weight ................................................................................................................................ 6.6 kg (14.5 lbs)

Focal Point to Nozzle Adjustment ................................................... Approximately -12.5 mm to +12.5 mm

COLLIMATOR

Nominal Focal Length ................................................................................................ 100 mm and 150 mm

Fiber Input Adapter (Others Available On Request) .............................................................. QBH (HLC-8)

HEIGHT SENSOR

Standoff Range ............................................................................................................... 0.2 mm to 8.0 mm

Single Point Calibration ..................................................................................................................... 12 mm

Response Time .............................................................................................................................. <1 msec

Temperature Stability ......................................................................... ±5% of Standoff Setting, 0° to 45° C

Output ..................................................................................................................................... 0-10 V Analog

Specifications are subject to change without notice.


7 Troubleshooting

SYMPTOM CAUSE REMEDY

HSU Fault: 1: Tip Open

There is no connection between the HSU and tip assembly during calibration.

Verify the tip assembly and internal sense cables are properly installed and then recalibrate.

HSU Fault: 2: Tip Shorted

The tip is not fully insulated from ground and the body of the cutting head during calibration.

Remove any debris that may be causing a short and then recalibrate.

HSU Fault: 3: Cable Break

The connection between the HSU and tip has been broken.

Verify the tip assembly and tip are properly installed and then recalibrate.

HSU Fault: 5: Curve Data Error

There is no curve data in the selected location or the data failed to load correctly.

Load the curve data again or select a different curve number.

HSU Fault: 6: Invalid curve number

The value in the Set HSU Curve IE register is outside the allowed range (1-31).

Enter a valid number or 0 to idle the input.

HSU Fault: 7: Failed to set curve

The HSU did not respond successfully to a value change in the Set HSU Curve IE register.

Attempt to set the curve again by setting the value to 0 and then to the new curve number.

Verify the head and HSU are properly connected.

Position Fault

The nozzle assembly was out of the commanded position for an excessive amount of time or encountered unusual resistance while attempting to move.

Activate the Reset bit or button to re-enable the servo.

Purge Fault The purge pressure is too low or too high.

Verify the purge gas is turned on and properly regulated.

Expand the allowable range by lowering or raising limits.

Temperature Fault

The temperature of one or more sensors has exceeded the limit.

Allow the component to cool. Consider raising the temperature limit if it is safe.

A temperature sensor is disconnected. Check the internal cable connections.

Optics Fault

The focusing parabola has been removed.

Verify the parabola is properly mounted and installed in the head. Adjust the Presence Threshold if the error persists.

The lower cover glass drawer has been removed.

Verify the drawer is fully inserted and the door is latched securely.


8 Appendix A – Cleaning Non-Metal Optics







If installing a new optic, inspection and cleaning are still recommended.

Laser Mechanisms Inc. cannot be held responsible for any damage to optics resulting from improper cleaning or handling.

1. Wash hands with soap to remove all oils, and then put on powder free gloves or finger cots.

2. If necessary, remove the optic(s) according to the appropriate section of this document.

3. Hold the optic by the edge and inspect it.

If you see any scratches or pits, replace the optic.

4. Hold the optic by its edges and blow any dust off each side with low-pressure dry nitrogen (2 to 5 PSI) or air from a blow bulb.

DO NOT USE AN AIR COMPRESSOR.

5. Secure the optic by its edge with the curved side facing up.

A fixture may be helpful. Consult your Laser Mechanisms Sales Engineer for assistance.

6. Fold a clean lens tissue (PLOCK0014 – Texwipe Absorband Wipes – or equivalent) so there are several layers and soak it with a non-sterile solution of 70% isopropyl alcohol/30% USP purified water pre-filtered through a 0.2 micron filter (Texwipe TX167 or equivalent).

7. With the soaked lens tissue gently scrub the optic with a circular motion, then slowly wipe in one direction.

8. Turn the optic over (flat side facing up).

9. Using a new lens tissue, repeat steps 6 and 7.

10. Inspect the optic.

If you see any scratches, replace the optic and return to step 3.

If you see any debris, streaks, or cloudiness, proceed to step 11.

If the optic is completely clean, proceed to step 18.

11. Secure the optic by its edge with the curved side facing up.

12. Fold a clean lens tissue so there are several layers and soak it with isopropanol.

Isopropanol is also known as 2-Propanol or UN1219.

Chemical Abstract Service Registry Number (CASRN) – 67-63-0

Chemical formula – [(CH3)2CHOH]


13. With the soaked lens tissue gently scrub the optic with a circular motion, then slowly wipe in one direction.

14. Turn the optic over (flat side facing up).

15. Using a clean lens tissue, repeat steps 12 and 13.

16. Hold the optic by its edges and blow any dust off each side with low-pressure dry nitrogen (2 to 5 PSI) or air from a blow bulb.

17. Inspect the optic(s).

If you see any scratches, replace the optic and return to step 3.

If you see any debris, streaks, or cloudiness repeat steps 11 to 17 using acetone.

o Acetone is also known as UN1090.

Chemical Abstract Service Registry Number (CASRN) – 67-64-1

Chemical formula – (CH3COCH3)

o Acetone is especially helpful with eliminating haze on cover glasses.

o If using acetone, proceed slowly enough so that the liquid has time to evaporate.

o Lint free cotton swabs (PLOCK0005 – Texwipe 6 inch swabs, or equivalent) may be helpful to remove concentrated contaminants.

If the optic is completely clean, proceed to step 18.

18. Reassemble the optic according to the appropriate section of this document.

Recommended best practices include:

o Blow any dust, lint, debris, etc. off the seals and rings using low-pressure dry nitrogen (2 to 5 PSI) or air from a blow bulb.

o Gently shake the assembled optic near your ear to verify no components are loose.

o Tighten any components as necessary.

o Before reinstalling, inspect the assembled optic again to verify it is clean and unscratched.

o If the optic is not going to be reinstalled immediately, cover it with painter’s tape or equivalent to keep out contaminants.

Take care no adhesive gets on the optic surface.


9 Appendix B – Coolant Specifications

The cooling manifolds are designed to be operated on either a closed-loop cooling system or facility tap water. For either type of system, the requirements in the table below must be met.

Minimum Flow Rate 1.5 liter/minute @ 2 BAR minimum

Inlet Pressure 5.0 Bar (72.5 psi) Max

Inlet Temperature ≥room temperature / >dew point

Hardness (Equivalent to CaCO3) <250mg/liter

pH 6 to 8

Particulate Size <200 microns in diameter

See the manufacturer’s specifications for information on cooling the fiber

10 Appendix C – Assist Gas Specifications

Impurities in the assist gas such as hydrocarbons (THC) and moisture (H2O) can damage optics, cause power fluctuations and result in inconsistent cuts. See the table below for recommended assist gas specifications.

Impurities can also be picked up in the supply lines. Non-metallic materials can allow oxygen and moisture to permeate the system and can be a source of dust and hydrocarbons. Stainless steel lines and fittings are recommended. Use filters that remove particles down to .01 microns and purifiers that guard against oil or water from getting into the optical system.

Regulators with a stainless steel diaphragm are recommended. Industrial regulators can aspirate air and the neoprene diaphragm can be a source of hydrocarbons.

11 Appendix D – Beam Delivery Purging

The beam delivery system must be purged with clean, dry air {specification to meet or exceed ISO 8573.1:2001 Class 1.5.2}; Solids <100 particles per cubic meter of 0.1-0.5 µm size, and <1 particle per cubic meter of 0.5-0.1 µm; Water dew point <+7º C; Oil <0.1 mg per cubic meter. Purge flow rate is 1400 liters/hr (50 SCFH) @ 20 kPa. A self-regenerating desiccant air dryer filter unit (PLKIT0188) is available as an option from Laser Mechanisms.

GAS PURITY MAX H2O ppm MAX THC ppm

Oxygen 99.8% <5 ppm <1 ppm

Nitrogen 99.998% <5 ppm <1 ppm

Argon 99.998% <5 ppm <1 ppm

Helium 99.998% <5 ppm <1 ppm


12 Appendix E – Industrial Ethernet Data Mapping and Descriptions

12.1 EtherNet I/P I/O Mapping

The EDS file is available for download at http://www.lasermech.com/fibercut2dupdates

WORD TYPE NAME

0 Input Data Digital Outputs

1 Input Data HSU Voltage

2 Input Data Process Monitor

3 Input Data Purge Pressure

4 Input Data Current Position

5 Input Data Process Monitor Temp

6 Input Data HSU Temp

7 Input Data Upper CG Temp

8 Input Data Collimating Parabola Temp

9 Input Data Focusing Parabola Temp

10 Input Data Lower CG Temp

11 Input Data Scattered Light

12 Input Data HSU Curve

13 Input Data Reserved For Future Use

14 Input Data Focus Position

15 Input Data Maximum Position

16 Input Data Process Monitor Gain

0 Output Data Digital Inputs

1 Output Data Set Target Position

2 Output Data Set HSU Curve

3 Output Data Set Focus Position

4 Output Data Reserved For Future Use

5 Output Data Set Process Monitor Gain

Digital Outputs

BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8

No Comm. Optics Fault Temperature

Fault Purge Fault

Position Fault

HSU Fault


Reserved For Future Use

Move Input Active

Cal Ack. Servo

Enabled In Position

Servo Is On

TOUCH READY

Digital Inputs


Reserved For Future Use Enable Servo

Suppress Low Purge Fault


Reserved For Future Use Zero

Pressure Move

Nozzle Reset CAL

ITEM DESCRIPTION

Device Anybus-IC EIP

Name Exclusive Owner

Input 17 INT, Connection Point 100

Output 6 INT, Connection Point 150



12.2 PROFINET I/O Mapping

The GSDML file is available for download at http://www.lasermech.com/fibercut2dupdates

SLOT MODULE NAME

1 Input 001 byte Fault Digital Outs

2 Input 001 byte Status Digital Outs

3 Input 002 bytes HSU Voltage

4 Input 002 bytes Process Monitor

5 Input 002 bytes Purge Pressure

6 Input 002 bytes Current Position

7 Input 002 bytes Process Monitor Temp

8 Input 002 bytes HSU Temp

9 Input 002 bytes Upper CG Temp

10 Input 002 bytes Collimating Parabola Temp

11 Input 002 bytes Focusing Parabola Temp

12 Input 002 bytes Lower CG Temp

13 Input 002 bytes Scattered Light

14 Input 002 bytes HSU Curve

15 Input 002 bytes Reserved For Future Use

16 Input 002 bytes Focus Position

17 Input 002 bytes Maximum Position

18 Input 002 bytes Process Monitor Gain

19 Output 001 byte Config Bits

20 Output 001 byte Command Bits

21 Output 002 bytes Set Target Position

22 Output 002 bytes Set HSU Curve

23 Output 002 bytes Set Focus Position

24 Output 002 bytes Reserved For Future Use

25 Output 002 bytes Set Process Monitor Gain

Fault Digital Outs


No Comm. Optics Fault Temperature

Fault Purge Fault

Position Fault

HSU Fault

Status Digital Outs



Move Input Active

Cal Ack. Servo

Enabled In

Position Servo Is On

TOUCH READY

Config Bits


Reserved For Future Use Enable Servo

Suppress Low Purge Fault

Command Bits


Reserved For Future Use Zero

Pressure Move

Nozzle Reset CAL

ITEM DESCRIPTION

Device Name ABIC-PRT



12.3 Input, Output, and Other Descriptions

Digital Output Descriptions

OUTPUT DESCRIPTION

No Comm. The head is not communicating with the controller. Check connections or cycle power.

Optics Fault The lower cover glass or focusing parabola is not present, or the Scattered Light reading is above the upper limit.

Temperature Fault One or more temperatures are above the upper limit.

Purge Fault The Purge Pressure is below the lower limit or above the upper limit.

Position Fault The nozzle assembly moved unexpectedly or encountered difficulty moving to the commanded position. Perform a Reset.

HSU Fault

Indicates the fault code of the HSU or an error with the curve setting. 1 (001) = Tip Open 2 (010) = Tip Shorted 3 (011) = Cable Break 5 (101) = Curve Data Error 6 (110) = Invalid Curve Number (Set HSU Curve register) 7 (111) = Failed to set curve (Set HSU Curve register)

Servo Enabled Under proper operating conditions , the controller is commanding the servo to turn on.

Cal Ack. The HSU has received and completed a calibration command.

Servo Is On The servo motor is energized and maintaining the commanded position.

In Position The nozzle assembly is in the commanded position.

TOUCH The tip is making contact with a surface.

READY The HSU is calibrated and all sensors are within the appropriate ranges.

Digital Input Descriptions The config bit states are updated whenever the byte value is changed. Note that USB commands such as those generated using FiberCUT® 2D Monitor can also change these states.

INPUT DESCRIPTION

Enable Servo Energize the servo motor to maintain the moving nozzle assembly position.

Suppress Low Purge Fault When set to 1, Purge Pressure readings below the lower limit will not generate a Purge Fault.

Each command bit below triggers ONLY ONCE on a state change (from 0 to 1).

INPUT DESCRIPTION

Zero Pressure Sets the zero point of the Purge Pressure reading to the current ambient pressure. The purge gas must be turned off for this setting to function.

Move Position Move the nozzle assembly to the Set Position specified in tenths of millimeters.

Reset Clears a Position Fault and allows the servo to be re-enabled.

CAL Send a Calibrate command to the HSU.


Other Descriptions

DATA DESCRIPTION

HSU Voltage The 12 bit ADC voltage output of the HSU.

Process Monitor The 12 bit ADC voltage output of the process monitor.

Purge Pressure The pressure (in millibars) within the purge path relative to the programmed ambient pressure.

Current Position The commanded position of the moving nozzle assembly in tenths of millimeters above the zero position.

Process Monitor Temp

The temperature of the process monitor electronics from 100-850 = 10.0-85.0 degrees Celsius.

Electronics Temp The temperature of the height sensing electronics from 10.0-70.0 degrees Celsius.

Upper CG Temp The temperature of the upper cover glass from 100-700 = 10.0-70.0 degrees Celsius. Reports 999 if the drawer not present.

Collimator Temp The temperature of the collimator from 100-700 = 10.0-70.0 degrees Celsius.

Focusing Optic Temp

The temperature of the focusing optic from 100-700 = 10.0-70.0 degrees Celsius.

Lower CG Temp The temperature of the lower cover glass 100-700 = 10.0-70.0 degrees Celsius. Reports 999 if the drawer is not present.

Scattered Light The voltage level indicating the amount of scattered light within the upper cover glass.

HSU Curve The active HSU curve number from 1-31.


Maximum Position The highest allowable Position value that can be commanded.

Process Monitor Gain

The current level of gain on the process monitor output from 1-255. A value of 0 indicates an error reading the current gain value.

Target Set Position The moving nozzle assembly position in tenths of millimeters above the zero position. Movement will not occur until the moving nozzle assembly bit is activated.

Set HSU Curve Changes the active curve of the HSU to the selected curve number and recalibrates. Valid values are 1-31 as long as a curve is loaded in that location. 0 is considered an idle state and will retain the most recent setting.

Set Focus Position

Establishes the moving nozzle assembly position in tenths of millimeters where focus is at the end of the tip. Valid values are 1 to Maximum Position. 0 is considered an idle state and will retain the most recent setting in memory.


Set Process Monitor Gain

The desired level of gain on the process monitor output from 1-255. Values outside this range are ignored.


13 Appendix F – Recommended User-Serviceable Parts List

For recommended user-serviceable spare parts, please call Laser Mechanisms at (248) 474-9480. If your head requires service beyond the instructions outlined in this manual, please contact Laser Mechanisms for further assistance.

ITEM PART # DESCRIPTION

FIBER INTERFACE ASSEMBLY

1 PLFIA0001 Fiber Interface Assembly (for QBH Fiber – Contact Laser Mechanisms)

CABLES

2 PLCAB0630 Collimator Interface Cable

3 PLCAB0608 Control Box Interface Cable

4 PLCAB0631 TRA Interface Cable

5 PLCAB0595 Machine Interface Cable

FITTINGS

6 PLFTG0104 G1/8 to 6mm Tubing Male Banjo Fitting

7 PLFTG0022 1/8 Inch NPT Elbow Fitting for 1/4 Inch Tubing

8 PLFTG0033 1/8 Inch NPT Straight Fitting for 1/4 Inch Tubing

9 PLFTG0138 G1/4 to 3/8 JIC Elbow Fitting

UPPER FIXED COVER GLASS

10 PLFLH0451 FiberCUT® HR Fixed Cover Glass Holder (Complete Assembly with Optic)

11 PLFLH0440 FiberCUT® HR Fixed Cover Glass Holder (Complete Assembly – No Optic)

12 PLLCG0060 Cover Glass

13 PLMSR0030 Manifold Seal Ring

REFLECTIVE COPPER COLLIMATING OPTIC

14 PLFPC0061 Reflective Copper Collimating Optic – 100 mm

15 PLFPC0048 Reflective Copper Collimating Optic – 150 mm

REFLECTIVE COPPER FOCUSING OPTIC

16 PLFPC0051 Reflective Copper Focusing Optic – 200 mm

LOWER COVER GLASS

17 PLFLH0448 FiberCUT® HR Lower Cover Glass Drawer (Complete Assembly)

12 PLLCG0060 Cover Glass

13 PLMSR0030 Manifold Seal Ring

AIR BLAST

18 PLTUC0006 Air Blast Assembly

TIP RETAINER ASSEMBLY

19 PLTRA0447 Height Sensing Tip Retainer Assembly (Complete Assembly)

20 PLTRN0005 Outer Hex

21 PLTRN0004 Inner Retainer



STANDARD NOZZLES (Call Laser Mechanisms for more options)

GAS JET TIPS

22 PLGJT0058 1.0 mm Orifice







DOUBLE NOZZLES

29 PLGJT0256 1.0 – 1.5 mm Orifice





INTERFACE CONTROL BOX (Not Shown)

34 PLCSA0062 PROFINET Interface Control Box

35 PLCSA0067 EtherNet/IP Interface Control Box

TOOLS (Not Shown)

36 PLFXT0218 USB Camera Alignment Tool (Optional)


Figure 58


14 Appendix G – Servicing the Tip Assembly

14.1 User Serviceable Parts List

For recommended user-serviceable spare parts, please call Laser Mechanisms at (248) 474-9480. If your head requires service beyond the instructions outlined in this manual, please contact Laser Mechanisms for further assistance.


PLTRA0447 Tip Assembly (Complete Assembly)

1 PLSCR0109 M3 SHCS

2 PLMOR0030 Small O-Ring

3 PLMOR0029 Large O-Ring

4 PLISR0041 Breakaway Insulator

5 PLSCR0042 M3 SHCS

6 PLADR0604 Upper Aluminum Plate

7 PLISR0042 Upper Insulator

8 PLSCR0112 Threaded Stud, 2.5 mm Diameter

9 PLTRE0350 Inner Cone

10 PLISR0043 Lower Tip Insulator

11 PLSCR0107 Threaded Stud, 5 mm Diameter

12 PLSDR0003 Outer Body

Figure 59


14.2 Rebuilding the Tip Assembly

To disassemble the tip assembly:

1. Remove the tip assembly from the head according to Section 5.4.


2. Unthread the tip retainer nut assembly and gas jet tip from the outer body.

3. Remove the (6) M3 SHCS (PLSCR0109) that secure the breakaway insulator (PLISR0041) to the top plate.

4. Remove the tip retainer nut and the breakaway insulator with the o-rings from the top plate.

5. Inspect the large o-ring (PLMOR0029) and the small o-ring (PLMOR0030) in the breakaway insulator.

Replace any worn or damaged o-rings.

6. Inspect the large o-ring (PLMOR0029) and the small o-ring (PLMOR0030) in the top plate.

Replace any worn or damaged o-rings.

7. Remove the (3) M3 SHCS (PLSCR0042) that secure the top plate to the outer body.

8. Remove the top plate and upper insulator (PLISR0042).

The upper insulator may:

o Remain on top of the inner cone (PLTRE0350).

o Remain on or fall off of the bottom of the top plate.

9. Inspect the small o-ring (PLMOR0030) in the outer body.

Replace it if it is worn or damaged.

10. Unthread the 5 mm (larger) gold post (PLSCR0107) from the outer body.

11. Unthread the 2.5 mm (smaller) gold post (PLSCR0112) from the inner cone.

12. Remove the inner cone (PLTRE0350) and lower tip insulator (PLISR0043) from the outer body.

13. Inspect the large o-ring (PLMOR0029) in the inner cone.

Replace it if it is worn or damaged.

14. If desired, remove and/or replace the gas jet tip according to Section 5.1.

Figure 60


To reassemble the tip assembly:

Worn or damaged o-rings were replaced during the disassembly procedure.

Replace any other worn or damaged components during the reassembly procedure.


15. If necessary, replace the gas jet tip and/or tip retainer nut assembly according to Section 5.1.

16. Thread the 2.5 mm (smaller) gold post (PLSCR0112) into the inner cone.

17. Push the lower tip insulator (PLISR0043) onto the inner cone (PLTRE0350) so that the inner cone alignment tab seats in the lower tip insulator alignment notch.

18. Orient the outer body so the alignment flat (with the Laser Mechanisms logo) faces you.

19. Insert the lower tip insulator and inner cone with threaded stud into the outer body so that the gold post is on your left.

20. Thread the 5 mm (larger) gold post (PLSCR0107) into the outer body.

21. Insert the upper insulator (PLISR0042) so that the smaller gold post is aligned with the upper insulator hole.

The notch should approximately face the back of the tip assembly.

The counterbore should face down.

22. Insert the upper plate so that the (2) alignment holes are aligned with the (2) gold posts.

23. Replace the (3) M3 SHCS (PLSCR0042) that secure the top plate to the outer body.

You will see (3) counterbores.

24. Insert the breakaway insulator (PLISR0041) into the retainer nut.

25. Align the breakaway insulator and retainer nut so that the breakaway insulator alignment holes are in line with the gold posts.

You will see (6) counterbores.

26. Replace the (6) M3 SHCS (PLSCR0109) that secure the breakaway insulator to the top plate.

27. Replace the tip assembly on the head according to Section 5.4.

28. Thread the tip retainer nut assembly and gas jet tip onto the outer body.


15 Glossary

Aiming Beam

A low power, visible red beam used to indicate the position of the high-powered laser beam.

Assist Gas

Coaxial gas that flows through the nozzle (gas jet tip) orifice to aid the cutting process and evacuate molten material from the kerf.

Air Blast

A stream of air to keep debris out of the cutting area while piercing.

CFN

Cold Formed Nozzle

Collimator

An assembly with optics that converts diverging light into collimated (parallel) light within the head.

Cover Glass

A consumable optic used to protect more expensive optics in the head.

Double Nozzle

A nozzle or gas jet tip that includes an insert to enhance the cutting performance.

Fiber Input Adapter

An assembly that connects a specific type of fiber to the head.

FL

Focal Length

Focal Point

The point at which the light rays refracted by a lens or reflected by a mirror, intersects and produces the highest concentration of energy.

GJT

Gas Jet Tip

HSU

Height Sensing Unit

IC

Integrated Circuit

IE

Industrial Ethernet

I/O

Inputs(s) and Output(s)

LHCS

Low head Cap Screw

PCB

Printed Control Board

PSI

Pounds per Square Inch

Purge Gas

Gas used to positively pressurize the inside of the head to keep debris from entering.

SHCS

Socket Head Cap Screw

TRA

Tip Retainer Assembly

TRN

Tip Retainer Nut

Laser Mechanisms, Inc.

25325 Regency Drive • Novi, Michigan 48375 USA

Phone: (248) 474-9480 • Fax: (248) 474-9277

In Europe: Phone: +32(0)92 18 70 70 • Fax: +32(0)92 18 70 79

Web: www.lasermech.com • E-Mail: [email protected]

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