Laser Mech FiberCUT HR Operation Manual Download

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PLMNL0252 REV. B Effective Date: 10/16/17

FiberCUT

HR Operation Manual

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 and the companion
control box (PLCSA0062 or
PLCSA0067). See

Figure 17

1. Insert and turn as needed to

tighten the female end of the
control cable into the cutting head.
See

Figure 17

For steps 2 to 6, see

Figure 18

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

EtherNet/IP

6. Use the 10 position terminal block

on the control box to make
discrete I/O connections.

Figure 18

Summary of Contents for FiberCUT HR

Page 1: ...FiberCUT HR Operation Manual ...

Page 2: ...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 PRODU...

Page 3: ...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...

Page 4: ...nstallation and Operation 11 3 1 Connections 11 3 1 1 Main Electrical Box to TRA Electrical Box 11 3 1 2 Main Electrical Box to Collimator Electrical Box 11 3 1 3 Head to Control Box 12 3 1 4 Servo Power Cable and Interlock for Head 13 3 2 Interface Example 14 3 3 Electrical Grounding and Noise 15 3 4 Control Box Mounting 15 3 5 Control Box Interface 16 3 5 1 Terminal Block Connections 16 3 5 2 In...

Page 5: ...w Purge Fault 25 4 4 8 Configuring EtherNet IP Settings If Equipped 26 4 5 FiberCUT Monitor System Identification Information 27 5 Service 28 5 1 Servicing the Gas Jet Tip 28 5 2 Servicing the Cover Glasses 29 5 2 1 Upper Cover Glass 29 5 2 2 Lower Cover Glass 30 5 3 Servicing the Breakaway Insulator 31 5 4 Servicing the Tip Assembly 34 5 5 Removing the Fiber 34 5 6 Removing the Cutting Head 35 5 ...

Page 6: ...ifications 44 12 Appendix E Nozzle Cooling and Air Blast Specifications 44 13 Appendix F Industrial Ethernet Data Mapping and Descriptions 45 13 1 EtherNet I P I O Mapping 45 13 2 PROFINET I O Mapping 46 13 3 Input Output and Other Descriptions 47 14 Appendix G Recommended User Serviceable Parts List 49 15 Appendix H Servicing the Tip Assembly 52 15 1 User Serviceable Parts List 52 15 2 Rebuilding...

Page 7: ...nvenient XY adjustment screws for tip centering Convenient connections for water cooling assist gas purge gas nozzle cooling and air blast Water cooling 150 mm focal length collimating mirror 200 mm focal length focusing mirror Standoff distance of 0 2 8 0 mm Power rating up to 12kW Fully sealed and purged design to prevent contamination Sealed access doors to prevent contamination during cover gl...

Page 8: ...acted 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 ...

Page 9: ... 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 See Appendix E for nozzle cooling and air blast specifications Laser Mechanisms offers a hose management kit PLKIT0318 It includes all necessary hoses fittings and a manifold block used to route and manage stress on the ...

Page 10: ... to Section 5 5 for general guidelines and the fiber manufacturer s information for specific instructions The upper fiber clamp MUST be removed according to Section 2 3 2 to remove or install the fiber 2 3 2 QBH Upper Fiber Clamp The fiber clamp provides added stability to the fiber connection It is necessary to remove the upper fiber clamp to access the fiber See Figure 6 To remove the upper fibe...

Page 11: ... captive M4 SHCS securing the lower fiber clamp 3 Remove the lower fiber clamp and fiber clamp body Figure 7 For steps 4 to 6 see Figure 8 4 Loosen the 4 M4 SHCS in the spacer clamp plate 1 or 2 turns 5 Rotate the fiber input adapter so the fiber input adapter is in the desired position The red alignment dot may or may not be at the front of the head 6 Tighten the 4 M4 SHCS in the spacer clamp pla...

Page 12: ... 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 D...

Page 13: ...ce 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 The image on the screen should be similar to Figure 12 Figure 11 Figure 12 Beam is centered It is sometimes helpful to rotate the camera while...

Page 14: ...r the beam in the gas jet tip see Figure 13 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 13 so the beam is c...

Page 15: ...according to Section 2 4 1 For steps 6 to 12 see Figure 14 6 Slightly loosen the 4 M4 SHCS used to lock the XY fiber position The SHCS must remain snug to assist in holding the fiber in place The purpose of steps 7 to 12 is to make the beam as round as possible The X and Y axes each have 2 opposing 1 4 80 adjustment SHSS located on opposite corners below the spacer clamp plate diagonal from each o...

Page 16: ...m position relative to the tip If the tip is centered on the beam proceed to step 16 If the tip is not centered on the beam re center it according to Section 2 4 1 16 Fully extend the tip move to the bottom of travel 17 Observe the beam position relative to the tip If the beam is centered in the tip the fiber is aligned to the head If the tip is not centered on the beam re center it according to S...

Page 17: ...traight male end of the TRA interface cable PLCAB0631 into the main electrical box The other end of the TRA interface cable arrives already connected to the TRA electrical box 3 1 2 Main Electrical Box to Collimator Electrical Box The FiberCUT HR has one cable that connects the cutting head main electrical box and the collimator electrical box See Figure 16 Figure 16 1 Insert and turn as needed to...

Page 18: ...female end of the control cable into the cutting head See Figure 17 For steps 2 to 6 see Figure 18 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 US...

Page 19: ...d of the Servo Power Interlock Cable PLCAB0595 into the main electrical box 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 located on the head The cabling used at this connection is the female end of PLCAB0595 supplied with the head or ...

Page 20: ...REV B Effective Date 10 16 17 14 FiberCUT HR Operation Manual 3 2 Interface Example The control box interface allows control and feedback of all the FiberCUT HR operations Figure 20 FiberCUT HR Interface Example ...

Page 21: ...r 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 21 Figure 21 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 c...

Page 22: ...tion requires significant processing by the user s machine to determine pierce through and loss of cut values GND Analog Ground Figure 23 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...

Page 23: ...details on device configuration and available data 3 6 Control Box Indicator Lights The control box has 7 indicator lights See Figure 24 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 Th...

Page 24: ...ternal 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 25 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...

Page 25: ...older 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 rema...

Page 26: ...onnected to the head and control box according to Section 3 1 The screen shown in Figure 27 will appear Figure 27 For steps 2 and 3 see Figure 28 2 Click on the Port drop down menu in the upper left corner and choose the appropriate port 3 Click Connect Figure 28 The Main screen appears See Figure 29 for an example 4 Update any settings as necessary according to Section 4 4 4 3 2 System Controls S...

Page 27: ...aterial 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 30 Figure 30 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 h...

Page 28: ... 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 lig...

Page 29: ...der the direction of a Laser Mechanisms technician 4 4 4 Temperature Voltage 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 The acceptable upper voltage limit can be set as desired within the stated range for the Scattere...

Page 30: ...ggested Limits to set all temperature limits to the recommended value of 50 C When enabled the Max Temp Limit Alert will display the message shown in Figure 35 when connecting to a FiberCUT HR or setting a limit if the condition applies Figure 35 4 4 5 Focus Position The Focus Position provides an on screen reference between the position of focus and the end of the nozzle Manually determine the po...

Page 31: ...imilar to Figure 39 will appear Figure 39 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 7 Suppress Low Purge Fault Purge pressure is a measured at the head inlet Working pressure should be a value of 15 20 ...

Page 32: ...2 to 6 see Figure 42 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 42 will appear Figure 42 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...

Page 33: ...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 43 Figure 43 2 Click on the View Hardware Information drop down menu in the pop up box that appears and the image shown in Figure 44 will appear Figure 44 3 Click on the appropriate line to view the identifying information for the desired item 4...

Page 34: ...e tip retainer nut assembly from the tip assembly See Figure 45 2 Unscrew the inner retainer from the outer hex and remove the gas jet tip See Figure 46 Figure 45 Figure 46 To replace the gas jet tip For steps 3 and 4 see Figure 46 3 Insert the gas jet tip into the inner retainer 4 Screw the inner retainer into the outer hex Do not over tighten 5 Screw the tip retainer nut assembly with gas jet ti...

Page 35: ...e the upper cover glass see steps 1 to 5 and Figure 48 1 Loosen the 2 captive M3 SHCS securing the fixed cover glass holder PLFLH0440 and pull it out of the head 2 Cover the opening with tape or insert a spare cover glass holder according to steps 6 to 9 below 3 Push on the side of the cover glass opposite the manifold seal ring to remove the manifold seal ring PLMSR0030 and the cover glass PLLCG0...

Page 36: ... equivalent 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 49 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 49 For steps 4 to 12 see Figure 50 4 Close the s...

Page 37: ...al ring into the drawer to retain the cover glass 10 Open the cover glass door 11 Reinsert the cover glass drawer into the head The orientation grooves MUST match Figure 50 12 Close the cover glass door 5 3 Servicing the Breakaway Insulator The tip assembly contains an internal breakaway insulator PLISR0044 that fractures to protect the head during a crash See Figure 51 The tip assembly nut will r...

Page 38: ...ee Figure 52 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 52 4 Remove the 6 M3 SHCS that secure the broken breakaway insulator to the tip assembly See Figure 53 5 Remove the breakaway insulator with the o rings See Figure 54 Figure 53 ...

Page 39: ...er 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 and the tip assembly nut 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 In...

Page 40: ...ST BE inspected Before opening any part of the head clean off the dust and or process debris using an exterior cleaning towel PLTLS0023 or equivalent 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 upper fiber clamp according to Section 2 3 2 4 Remove the fiber optic cable from the cutting head according to the man...

Page 41: ...t 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 15 Figure 16 Figure 17 and Figure 19 in Section 3 1 6 Remove M6 grounding lug and the ground wire See Section 3 3 ...

Page 42: ...od time to check the water input 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...

Page 43: ...emoved 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 For steps 2 to 8 see Figure 58 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 ...

Page 44: ...to check the water input 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 focusing mirror and either Clean it proceed to step 5 OR Replace it proceed to Section 5 10 Optics are very sensitive to dust and debris It is extremely important to take every possible precaution to ensure the optics remain pristine ...

Page 45: ...tep 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 For steps 2 to 8 see Figure 60 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 ...

Page 46: ...ifice Sizes Assist Gas Pressure up to 25 Bar 375 psi Purge Gas 0 5 to 0 7 Bar 7 0 10 0 psi at inlet Tip Cooling Pressure 2 0 3 5 Bar 30 50 psi Air Blast Pressure 2 0 3 5 Bar 30 50 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 HEIGHT SENSOR Standoff Range 0 2 mm to 8 0 mm Single Point Calibration 12 mm Response Time 1 mse...

Page 47: ...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 wh...

Page 48: ...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 PLO...

Page 49: ...ul 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 practice...

Page 50: ...n 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 Inlet pressure 25 9 Bar 375 psi 11 Appendix D Beam Delivery Purge Specifications The beam delivery system must be purged with clean dry air spe...

Page 51: ...ut 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...

Page 52: ...s 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 BIT 7 BIT 6 BIT 5 BIT 4...

Page 53: ...rn 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 wh...

Page 54: ...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 Reserved For Future Use 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 ...

Page 55: ...Inch NPT Straight Fitting for 1 4 Inch Tubing 9 PLFTG0138 9 16 18 Inch JIC Elbow Fitting for 3 8 Inch Tubing 10 PLFTG0086 G1 8 to 6mm Tubing Straight Female Fitting UPPER FIXED COVER GLASS 11 PLFLH0451 FiberCUT HR Fixed Cover Glass Holder Complete Assembly with Optic 12 PLFLH0440 FiberCUT HR Fixed Cover Glass Holder Complete Assembly No Optic 13 PLLCG0060 Cover Glass 14 PLMSR0030 Manifold Seal Rin...

Page 56: ... 2 5 mm Orifice 27 PLGJT0138 3 0 mm Orifice 28 PLGJT0737 3 5 mm Orifice 29 PLGJT0595 4 0 mm Orifice DOUBLE NOZZLES 30 PLGJT0256 1 0 1 5 mm Orifice 31 PLGJT0257 1 5 1 5 mm Orifice 32 PLGJT0718 1 5 2 0 mm Orifice 33 PLGJT0258 2 0 1 5 mm Orifice 34 PLGJT0721 2 5 1 5 mm Orifice INTERFACE CONTROL BOX Not Shown 35 PLCSA0062 PROFINET Interface Control Box 36 PLCSA0067 EtherNet IP Interface Control Box TO...

Page 57: ...PLMNL0252 REV B Effective Date 10 16 17 51 FiberCUT HR Operation Manual Figure 61 ...

Page 58: ...ined in this manual please contact Laser Mechanisms for further assistance ITEM PART DESCRIPTION NA PLTRA0465 Tip Assembly Complete Assembly 1 PLSCR0109 M3 SHCS 2 PLMOR0030 Small O Ring 3 PLMOR0029 Large O Ring 4 PLISR0044 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 PLISR004...

Page 59: ... 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 o...

Page 60: ...outer body so that the gold post is on your left 20 Thread the 5 mm larger gold post PLSCR0107 into the outer body Torque to 23 inch pounds 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 smaller boss should face down 22 Insert the upper plate so that the 2 alignment ...

Page 61: ...t 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 H...

Page 62: ...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 info lasermech com ...

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