SAMRT6015 User Manual

SMART Series

FIBER LASER
CUTTING MACHINE

OPERATION AND
MAINTENANCE
MANUAL
SAMRT6020 User Manual

Content
1. Security......................................................................................................................................................1
1.1 Introduction...............................................................................................................................................................1
1.2 Laser Resonator ........................................................................................................................................................1
1.3 Laser Radiation.........................................................................................................................................................1
1.4 Visual Impairment ....................................................................................................................................................1
1.4.1 Retina.......................................................................................................................................1
1.4.2 Cornea and crystalline lens ....................................................................................................2
1.5 Skin injury.................................................................................................................................................................2
1.6 Fire risk .....................................................................................................................................................................2
1.7 Mechanical risk .........................................................................................................................................................2
1.8 Electrical risk ............................................................................................................................................................3
1.9 Other risks................................................................................................................................................................. 3
1.10 Safety items for operator .......................................................................................................................................3
1.11 Machine and labels .................................................................................................................................................4
1.12 Dangerous material ................................................................................................................................................4
1.12.1 Introduction ..........................................................................................................................4
1.12.2 Danger ...................................................................................................................................4
1.12.3 Mirror surface material .......................................................................................................5
1.12.4 Zinc coat or plating metal ....................................................................................................5
1.12.5 PTFE......................................................................................................................................5
1.12.6 PC and ABS ..........................................................................................................................5
1.12.7 PVC........................................................................................................................................5
1.12.8 Stainless steel ........................................................................................................................5
1.12.9 Asbestos .................................................................................................................................5
1.12.10 Others ..................................................................................................................................6
1.13 Labeling ...................................................................................................................................................................6
2. Equipment Introduction ..........................................................................................................................7
SMART6020 general layout .................................................................................................................................... 7 2.1
SMART6020 components introduction .................................................................................................................. 7 2.2
2.2.1 Machine tool ............................................................................................................................7
2.2.2 Beam ........................................................................................................................................8
2.2.3 Working table .........................................................................................................................8
2.2.4 Z-Axis box ...............................................................................................................................8
2.2.5 Display .....................................................................................................................................8
2.2.6 Keyboard .................................................................................................................................8
2.2.7 Handheld operation panel .....................................................................................................9
2.2.8 Electrical, gas part ..................................................................................................................9
2.2.9 Laser resonator and water chilling system ...........................................................................9
2.2.10 Drive ......................................................................................................................................9
2.2.11 Hoses and caterpillar ............................................................................................................9
2.2.12 Linear rail..............................................................................................................................9
2.2.13 Lifting device...................................................................................................................... 10
2.3 Cutting head light path ......................................................................................................................................... 10
2.3.1 Collimator ............................................................................................................................ 10
2.3.2 Focus lens ............................................................................................................................. 10
2.3.3 Protection lens...................................................................................................................... 11
2.4 Computer control ...................................................................................................................................................11
2.5 Control introduction .............................................................................................................................................. 11
2.5.1 Height tracking .................................................................................................................... 11
2.5.2 Configure cutting ................................................................................................................. 11
2.5.3 Cancel ................................................................................................................................... 11
2.6 Laser controller ...................................................................................................................................................... 12
2.6.1 Power output ........................................................................................................................ 12
2.6.2 Continuous wavelength（CW） ........................................................................................ 12
2.6.3 Impulse output ..................................................................................................................... 12
2.6.4 Power Ramping ................................................................................................................... 14
2.6.5 Focus length ......................................................................................................................... 15
2.7 Mechanical control ................................................................................................................................................ 15
2.7.1 Manual/Automatic/Zero...................................................................................................... 15
2.7.2 Auxiliary gas and pressure setting ..................................................................................... 15
SAMRT6020 User Manual
3. Operation Regulations .......................................................................................................................... 16
3.1 Steps of turning on the system .............................................................................................................................. 16
3.1.1 Turning off the machine in the long run ........................................................................... 16
Laser Resonator ............................................................................................................................ 16
Chilling system .............................................................................................................................. 16
3.2 Preparations for running the system ................................................................................................................... 16
3.2.1 Load programs onto CNC .................................................................................................. 16
3.2.2 Set laser cutting database ................................................................................................... 16
3.2.3 Adjust focus height .............................................................................................................. 17
3.2.4 Select nozzles ........................................................................................................................ 17
3.2.5 Adjust the nozzle ................................................................................................................. 17
3.3 Cutting quality ....................................................................................................................................................... 17
3.3.1 Cutting speed ....................................................................................................................... 18
3.3.2 Accuracy and cutting quality.............................................................................................. 18
3.3.3 Check the nozzle tip............................................................................................................. 18
3.3.4 Check the optical components ............................................................................................ 19
3.3.5 Beam collimating ................................................................................................................. 19
3.3.6 Material quality ................................................................................................................... 19
3.3.7 Gas quality ........................................................................................................................... 19
3.3.8 Cutting checklist .................................................................................................................. 19
4. Maintenance ........................................................................................................................................... 20
4.1 Operator’s daily maintenance .............................................................................................................................. 20
4.1.1 Brief introduction ................................................................................................................ 20
4.1.2 General principles ............................................................................................................... 20
4.1.3 Machine tool ......................................................................................................................... 20
4.1.4 Laser resonator .................................................................................................................... 20
4.1.5 Chilling system ..................................................................................................................... 20
4.1.6 CNC system .......................................................................................................................... 20
4.1.7 Annually maintenance ......................................................................................................... 21
4.2 Daily maintenance step...........................................................................................................................................21
4.2.1 Chilling system ..................................................................................................................... 21
4.2.2 Machine tool system ............................................................................................................ 21
4.3 Weekly maintenance .............................................................................................................................................. 21
4.4 Monthly maintenance ............................................................................................................................................ 21
4.4.1 Chilling system ..................................................................................................................... 22
4.4.2 Machine tool system ............................................................................................................ 22
4.4.3 Routine ................................................................................................................................. 22
4.5 Clean optical components ..................................................................................................................................... 22
4.5.1 Brief introduction ................................................................................................................ 22
4.5.2 Material ................................................................................................................................ 23
4.5.3 Lens/Protection Lens cleaning procedure ......................................................................... 23
4.6 Recommended maintenance tools ........................................................................................................................ 23
4.7 Lubricating of machine tool...................................................................................................................................24
1. Security

1.1 Introduction

SMART6020 laser cutting machine is a product of HG STAR, could be used for

improperycutting. HG STAR will not bear any responsibility for the damage caused b
operation or operation beyond its using scope.

1.2 Laser Resonator

Laser generated by laser generator is an emission different from natural light in both
beam quality and emission principle. Laser could be continuous or pulse. Laser is a
single wavelength emission, with good accuracy, high power density (high light),
even dozens of times brighter than the sun. There are various types of laser resonator,
and each type has its own typical wavelength. In terms of spectrum, laser wavelength
could be ranged from UV through visible light to far IR. HG STAR adopts IR as its
typical wavelength, wavelength at 1.06μm.

1.3 Laser Radiation

Please refer to EN60825 and ANSI136.1, reference standard explained notes and
attentions item by item of operation for high power laser system. It strictly prohibited
the operator from being exposure within the geometry range, and requires any
operation should not exceed this range, unless under proper protection.
Other than this, in terms of shielding, it has to take steps to block the light path. It’s
recommended to use interlock system to block laser radiation and has to pay attention
to the possibility that laser might be able to penetrate the shield or reflect the other
way around.

1.4 Visual Impairment

1.4.1 Retina

Lasers located in the visible light and near-IR have a great influence on vision. This is
because the eye will cause damage to the retina if the laser beam is focused on the
retina.
This is like the principle that using a magnifying glass to focus the sunlight can burn
holes in the paper. And the laser power density focused on the retina is 100,000 times

1
the laser power density on the cornea. A burn or injury to the retina can cause
permanent damage to vision and even blindness. The exposure time required to cause
damage depends on many factors, but for most lasers, it usually takes one second to
cause damage. For these lasers, there is no time to blink. The laser wavelength of the
HG STAR laser will not be focused by the cornea, but it will cause some damage if
the eyes look directly or are reflected by light radiation. To protect the eyes from
being hurt, it’s necessary for operators and observers to wear Protection Goggle.

1.4.2 Cornea and crystalline lens

High-power infrared laser can also damage the cornea and affect vision. The eye will
absorb infrared radiation and generate heat to cause damage to the cornea and
crystalline lens. This damage has a latent effect. It can cause cataracts in the long term.
Even if the optical power density is very low and can be ignored, the damage is still
there. For example, IR or red continuous lasers, especially fiber lasers, have a
wavelength of 1.06μm. UV radiation is mainly absorbed by the cornea and will cause
ionization to deteriorate the cell nucleus.
Being exposed to the UV will cause the eyelash muscle spasm within 24 hours. The
cornea damage caused by UV will have symptoms within 24 hours, and the crystalline
lens damage caused by IR will immediately manifest and the damage will be visible.

1.5 Skin injury

In normal situation, skin could more bear further laser radiation than bare eyes, but it
depends on the wavelength of radiation. The lights near visible light are the most
harmful to the skin, such as IR light and near-UV light. Infrared radiation can scorch,
burn, and tan the skin. Besides, if the laser power is high enough, it can also damage
the organs under skin.

1.6 Fire risk

Laser cutting is a heat treatment process, so there is a fire hazard. If the auxiliary gas
is oxygen, it is very possible to cause fire, it’s necessary to equip a fire extinguisher
nearby the laser source.

1.7 Mechanical risk

Because the mechanical transmission system is movable. Therefore, the following

serious accidents are likely to occur:
Trapped between the Y-axis bridge and the cutting workbench.
The limbs are entangled by the support feet of the workbench or the cutting material
or the cutting head.
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Hands or fingers are jammed by X-axis cable and electrical cabinet.
When operating the machine, be careful even in a safe position next to the light path,
because you may be injured by the moving Y-axis bracket, even if it is moving at a
reduced speed.
Warning
No one is allowed to step into the laser safety area while the machine running.
When maintain the machine, protective measures must be taken. Except for the laser
radiation, the following situations may be possible:
Hands or fingers are scratched by bearing pulley in X/Y/Z-axis, frame in Z-axis and
bracket in Y-axis.
Entangled by the roller screw.
Warning
When maintain the machine, it’s required the maintenance personnel must keep
the hair and clothes tight, otherwise it has risk to be drawn into the running
machine.

1.8 Electrical risk

There is high voltage on the machine. During maintenance, be very careful when
approaching cables or working in electrical cabinets.
Warning

High power will still be lasting for 4 minutes in the machine

even though the electric is fully shut off.

1.9 Other risks

Potential risk as below:

Volatility materials such as asbestos, carbon dioxide, lead, mercury and other metal
materials that can cause environmental pollution.
Spatters during laser cutting, drilling, and welding.
Laser chemical reaction or explosive reaction of nearby gas.
Plasma radiation.
The human body is directly or indirectly (reflected) damaged by the laser.
High temperature (materials and nozzles) on the surface during cutting.
Fragment caused by prism cracking.

1.10 Safety items for operator

The following precautionary measures coordinates with Australian standard AS2211,

which is also a universal standard.
3
A OD3 protection glasses with 1.06μm wavelength should be equipped with the
operator or maintainer, which could protect the eyes from being hurt by laser as well
as keep the splashes from being entering into the eyes.
The operator should wear working gloves, steel-toe shoes and working uniforms.
Wear earmuff during high-pressure cutting.
Other than above mentioned items, the following tools should be considered:
Heavy lifting equipment, such as cranes or overhead cranes.
Protective glasses, gloves and necessary boots and clothing.
Fume exhausting system.
Enough space should be left around the machine to facilitate operation and
maintenance.
Ensure that the materials are close to the workbench for being available.
Wear a safety belt to prevent following accidents from happening.
Adequate lighting should be provided near the machine and workbench to facilitate
the normal work of operators and maintainer. It is unnecessary to carry out lighting in
the electrical cabinet, because only professional maintenance personnel can carry out
the inspection work in the cabinet.

1.11 Machine and labels

Various labels such as radiation, real-power limit, resonator type, laser light path are
labeled on the HG STAR cutting machine, please refer to 1.14 for more information.
The area warning sign complies with the national safety standards of the place where
the machine is installed, and must be placed in a prominent position at the entrance of
the laser cutting area.

1.12 Dangerous material

1.12.1 Introduction

Laser is generated by light as well as heat, some material might reflect the light, the
others might react with the heat.
Notice
Before cutting a new type of material, it’s necessary to check relative data of the
material to ensure there is no dangerous side product will be generated during
cutting to guarantee the safety of operation.

1.12.2 Danger

The following instruction could be used a reference for checking if toxic gas will be
generated during processing.

4
1.12.3 Mirror surface material

Laser will be reflected no matter what.

1.12.4 Zinc coat or plating metal

Two problems might happen during processing:

Crystal structure of Zinc coat will cause reflecting to any direction.
Zinc oxide will be generated during heat processing, which will cause the metal vapor
to burn.

1.12.5 PTFE

Highly toxic gas will be generated during process, no processing is allowed unless
extremely strict protection measure has been placed. The toxic gas is HF.

Notice
HG STAR recommends not to processing PTFE

1.12.6 PC and ABS

Specialized fume exhausting system has to be deployed before processing such

material, it’s highly recommended to refer to the relative data from the manufacturer
before processing.

1.12.7 PVC

HCI highly toxic gas will be generated during cutting. This gas is dissolved in water
to form hydrochloric acid, which has a damaging effect on metals and tissues.

1.12.8 Stainless steel

When cutting stainless steel, Cr2O3 will be generated, which is irritating and
corrosive to the skin, and it is also likely to cause cancer.

1.12.9 Asbestos

Heavy amount of dust will be generated, HG STAR recommend under no

5
circumstance a direct processing of asbestos is allowed.

1.12.10 Others

To be very careful about the coating, for plastic coating will generate toxic gas, paper
coating will cause fire, the frequent oil coating on iron will also cause toxic gas.

1.13 Labeling

1.13.1 Laser beam label

1.13.2 High voltage label

1.13.3 Laser radiation label

1.13.4 Data plate label

1.13.5 Mechanical warning label

6
2. Equipment Introduction

SMART6020 general layout 2.1

(Graph 1 SMART6020 plan view for reference (actual drawing may different

SMART6020 components introduction 2.2

2.2.1 Machine tool
The machine tool consists of the main body of the machine tool, linear guide rail, rack
and pinion, gearing set and guiding set, fume exhausting system, manual discharging
system, etc.
The main body of the machine tool is the load-bearing part of the entire machine tool,
which is a special-shaped structural part welded by steel plate, square steel and
7
rectangular hollow steel pipe.

2.2.2 Beam

The beam is made of processing cast aluminum, the left and right ends of which are
equipped with sliders and geared motors, and gears are mounted on the output shaft of
the geared motors. The crossbeam is connected with the machine tool through the
linear guides at both ends to form a gantry structure, and is driven bilaterally by the
rack and pinion pairs at both ends (Y-direction movement).
The SMART6015 laser cutting machine adopts a gantry structure, and the beam is
driven bilaterally by a rack and pinion pair at its two ends. Compared with the
cantilever beam, this structure has greater overall rigidity, higher driving efficiency,
and more stable operation. The positioning speed can reach 80 m/min, which is
suitable for high-speed and high-power cutting.

2.2.3 Working table

The working table is welded by a rectangular tube, an angle iron and a steel plate, and
a tooth plate is installed on it. The structure is simple, firm and reliable.

2.2.4 Z-Axis box

The Z-axis box is mainly composed of the following parts: Z-axis box, Z-axis box
back plate, Z-axis sliding table, servo motor and driving device. A pair of linear guide
rails are installed on the bottom plate of the Z-axis box, which cooperate with the 4
sliding blocks on the slide plate to form the guide of the Z-axis movement. The servo
motor drives the screw rod to rotate through the coupling, thereby generating driving
force on the nut fixed on the sliding table. Make the sliding table nut move up and
down relative to the bottom plate of the Z-axis box. The cutting head is installed on
the slide of the Z-axis sliding table to realize the Z-direction movement of the cutting
action, and its stroke is controlled by the proximity switch.

2.2.5 Display

Equipped with a 19" color LCD display, all graphs and status are displayed, including
most of the interface soft button operations.

2.2.6 Keyboard

Wireless keyboard, convenient and efficient.

8
2.2.7 Handheld operation panel

The control function provided is necessary for operation, and the Farley CNC
controller is a complete metal cutting and processing system designed for this
purpose.
It’s easy to grasp all control switches. There are signs above the mechanical switches,
and all the key functions are displayed from its icons.

2.2.8 Electrical, gas part

The solenoid valve system is used to control the pressure of the cutting gas, and the
high-pressure nitrogen is controlled by a high-pressure valve.
In order to match our air compressors, Farley has designed a special laser air device to
meet the requirements of reliable air purification and dehumidification 24 hours per
day.

2.2.9 Laser resonator and water chilling system

The out light path is transmitting through fiber, with good closure; Fiber is rigid,
without any reflecting mirror, simple and maintenance free.

2.2.10 Drive

A very important factor to ensure high cutting quality is the use of high-power servo
drive and motor for both horizontal and vertical axes.

2.2.11 Hoses and caterpillar

All control cables and hoses are concentrated in the caterpillar, it keeps the constant
bearing weight on the cutting head, even though the weight on the cutting head
changed, it doesn’t have any affect against cutting quality.
A similar caterpillar is used on the machine's vertical axis to optimize cutting quality.

2.2.12 Linear rail

To achieve a flat and smooth cutting, the movement of cutting head has to be stable
and flat, and the stable movement of the cutting head is guaranteed by high precision
linear rail on both horizontal axis and vertical axis.

9
2.2.13 Lifting device

The cutting head lifting device is also driven by a servo motor. It eliminates the labor
of operator to switch the height towards various thicknesses of plates. For plates of
different thicknesses, this motorized lifting device can quickly adjust the height of the
cutting head through the keyboard on the control panel.

Machine safety
To inform the potential risks listed in this user manual.
If anyone is in danger, stop running the machine immediately.
If the machine is without guarding, it has to be stopped to avoid any emergency.
It’s not allowed to stand on the rails.
If the machine is running, it’s not allowed to stand on the machine or close to the
machine.
If it’s necessary to stand on the cutting table, check the conditions before step
into.
When the machine is running, never open or cover the control cabinet.
Regular maintenance is necessary.

Security defending system

When the electricity is on, emergency stop can force the machine to stop safely. All
axes are disabled, and the motor is not energized.

2.3 Cutting head light path

2.3.1 Collimator

Collimator (or beam expander) is used for adjusting the diameter of the beam to the
needed size. The maximum diameter allowed is 24mm. Collimator is consists of a
series of mirrors, so the beam waist can be adjusted when the distance is changed. It
also means the best output beam diameter can be achieved by adjusting the cutting
range.

2.3.2 Focus lens

The primary function for the cutting head is to lead the light to the surface of working
piece by using a focus lens and a co-axis auxiliary gas nozzle vertically. At the same
time, by using height-tracing method, the cutting head can automatically select the
best focusing location.

10
2.3.3 Protection lens

Protection lens is located between nozzle and focus lens, the purpose is to protect the
focus lens from being polluted from splashes and gas, and extend the life of focus
lens.

2.4 Computer control

The control system is based on 32 bits Intel microprocessor. The system equips with
regular interfaces for data transfer, USB data transmitting, RJ45 networking, etc.
The operating system is a windowed user interface with a WINDOWS menu, which is
easy to operate.

2.5 Control introduction

The control provides pre-setting and status-adjusting for cutting, please refer to the
instructions in the following chapters.

2.5.1 Height tracking

Height tracking is one of the features of CNC, it keeps a certain distance between the
work piece and nozzle, the distance has to be constant to secure a good cutting quality
once it’s setting up.

2.5.2 Configure cutting

To set up the machine indicates to be prepared for cutting or processing, also

including selecting the auxiliary gas. The corresponding height sensor will be
activated if the surface tracking method is selected. By sending signals to the control
system, the height sensor will propel the nozzle to move until the sensor is right on
the surface of the work piece. Once the cutting parameter is set up, you could start to
process the work piece.

2.5.3 Cancel

To cancel indicates the machine will be turned into preparation status, this function
includes shut down the auxiliary gas and retrieve the nozzle to the previous position
under the selected surface tracing mode. The work piece will not be processed under
this operation.

11
2.6 Laser controller

2.6.1 Power output

The laser resonator is classified based on its output power. The CNC can control the
output power is by the power controlling knob in the front panel. To adjust the output
power of the laser resonator will get the best cutting performance, the steps of pre-set
the output power for different material will be found in the Laser Resonator User
Manual.

2.6.2 Continuous wavelength（CW）

CNC can control different running mode of the resonator. The main work mode is CW;
under this circumstance the output power is constant. CW is the most widely used
mode that adapts to most of materials with various thicknesses. For special
application such as piercing, etching it required other working mode.

2.6.3 Impulse output

CNC can also support impulse mode. Under this mode the resonator “On and Off”
swiftly (refer to Graph 4).
Under impulse mode the parameter can be set up in two ways, by setting “frequency
and duty cycle” or time space between “switch on and switch off”.
To calculate frequency and running by time space between “switch on and switch
off”.
Frequency = 1/ (switch on time + switch off time)
Duty cycle = (switch on time * 100)/ (switch on time + switch off time)
To calculate switch on time and switch off time by frequency and duty cycle.
Switch on time = duty cycle/ (frequency * 100)
Switch off time = (100 - efficiency)/ (frequency * 100)
To summarize, the output power of impulse mode is:
Output power = (efficiency * settled resonator power)/100

12
Graph 4- Introduction of impulse mode

13
Graph 5- Power Ramping or Synchronous Pulsing

2.6.4 Power Ramping

Power ramping is similar to Synchronous pulsing but adapting CW mode rather than
pulse mode, when the cutting head goes through a corner, CW output power will
increase/decrease in accordance with the real-time velocity of the cutting head. Graph
5 indicates the power ramping power level while the cutting head goes through a
corner with deceleration and acceleration.

14
2.6.5 Focus length

The beam can be focused into a very tiny spot by using lens, the distance between the
focal point and lens is called focal length. Usually the nozzle is fixed, so the focal
point locates either above or below the surface of the work piece. The standard focal
length of this system is 125mm.

2.7 Mechanical control

2.7.1 Manual/Automatic/Zero

The system can be running under three methods: Manual, Automatic, Zero. Under
manual method, the operator controls the machine, for example, the shaft can be
manually pushed back and forth slowly； Under automatic method, the machine will
be running with settled program; Zero is the method that needs to be performed after
the machine is turned on, it makes each of the motion parts goes back to the
referenced zero point.

2.7.2 Auxiliary gas and pressure setting

Auxiliary gas is in coaxial with the laser beam with the function of protecting the lens
and eliminating the slag and other cutting derivative. In other words, the auxiliary gas
is to eliminate the melting and evaporating material while decrease the possibility of
burning during cutting process of non-ferrous material. For cutting most ferrous
materials, active gas can be used to accelerate the thermal reaction process. Besides,
we also have to consider the pressure of different type of gas. To avoid slag on the
back surface, the typical gas pressure for high-speed cutting of thin Plate is 15－

20MPa. When the thickness of Plate increases or profiling speed decelerates, the gas
pressure has to be turned down accordingly.

15
3. Operation Regulations

3.1 Steps of turning on the system

3.1.1 Turning off the machine in the long run

Laser Resonator

If the machine will not be using for more than a week, you have to turn off the whole
system completely.

Chilling system

Please refer to the user manual to see if it’s necessary to keep the main power on, even
under the circumstance that the turning off period is more than one week. Please
check your chilling system instruction manual for turning off the machine in the long
run.
Notice: please refer to the recommended measures of how to maintain the laser
resonator and chilling system in both user manuals. Such as: water drainage,
disassembling of gas tank, etc. If you need any support with regard of the issue, please
contact our after-sales service engineer.

3.2 Preparations for running the system

3.2.1 Load programs onto CNC

The programs can be input to the CNC by using below methods:

1. Copy the processing graphics to my documents in desktop via USB port (please
refer to the CypCut software manual for details)

3.2.2 Set laser cutting database

Please refer to the CypCut software manual for details

16
3.2.3 Adjust focus height

3.2.4 Select nozzles

The nozzle that goes with the cutting head is designed to adapt to different cutting
environment, it could guarantee the auxiliary gas in the same axis of the beam. The
system could also well protect the lens from being spoiled by splashes and smug.
Check and clean the nozzle regularly in order to make sure that:
1. The size of the nozzle is appropriate.
2. The nozzle is in round shape, without notch and splashes.
Any irregular nozzle will disturb the flow that results in bad cutting quality. Normal
diameter of nozzle is 1.5mm to 2.0mm.

3.2.5 Adjust the nozzle

After selecting the nozzle, we have to guarantee the beam goes through the right
centre of the nozzle, otherwise the cutting quality will drop. Normally we test with a
plastic tape to see if the beam is in the right centre, and adjust the central position by
fine-tuning the screw on top of the cutting head.

3.3 Cutting quality

It’s necessary to optimize the cutting quality at the beginning of cutting, there are
three main factors to affect the cutting quality, they could be adjusted during the
cutting process, and it’s quite common of frequently setting the parameters.
1. Cutting speed: the best cutting speed is depending on the thickness of the
workpiece (raw material). To most of the materials, the cutting speed can be vary
within a certain range: if the cutting speed is too high, it might not be able to penetrate
the workpiece (the splashes will fly upwards rather than go downwards under the
workpiece); if the cutting speed is too slow, the material will be over-heated with
unacceptable heat affected area nearby the cutting area.
2. Auxiliary gas pressure: the auxiliary gas has to be in sufficient pressure to make
sure the cutting slag being completely cleared, usually the gas pressure should be
slighter when cut with heavier thickness. The slag attach to the workpiece will
jeopardize the cutting edge. On the contrary, over-pressured gas will cause
over-reacted effect (especially with O2) and will cause waste as well. When we cut
with plastic, if the gas pressure is under 25KPA, it could prevent the cutting edge from
being blurred. But it has to be a certain amount of gas to blow away the heat from the
lens in order to prevent the lens from being polluted, and avoid being simply heating
and burning the material rather than cutting.
3. Laser power: Apparently the power will influence cutting quality, at certain extend,

17
it’s depending on the cutting speed and material thickness.

If the cutting quality deteriorated substantially, first to check above parameters, since
other factors that deteriorate the cutting quality is negligible.
1. Clean the protection lens: the pollution on the surface of the protection lens will
partially block the beam, which will cause the power level and focusing quality.
2. Integrity of nozzle: if the nozzle is irregular or partially jammed, it will affect the
auxiliary gas, which will deteriorate the cutting quality.
3. Nozzle/beam adjustment: The beam has to be in coaxial of the nozzle, otherwise
the beam will be partially blocked by the nozzle, which will deteriorate the cutting
quality.

3.3.1 Cutting speed

The cutting speed is a very important feature, if the cutting speed is too high, the
cutting depth is not enough or even won’t be able to penetrate the workpiece at all; on
the contrary, if the cutting speed is too low, the cost will be higher and in certain
conditions the material will be over-heated which will deteriorate the cutting quality.
There are various databases in CNC that provides typical cutting speeds for various
material and power. These databases are for reference only, you could adjust
accordingly based on real circumstance.
Normally, the suitable speed for cutting ferric material could be judged by the
pinniform sparks, HG STAR usually describes erupting slag under the workpiece by
using pinniform sparks.
When the cutting speed is too low, the pinniform sparks goes straight vertically; when
the cutting speed is too high, the pinniform sparks shape an acute angle against the
vertical direction and in an unstable status, the speed will be proper until the angle
becomes obtuse.

3.3.2 Accuracy and cutting quality

To maximize the accuracy and cutting quality of Farley Laserlab machine, you have
to pay attention to the following items.

3.3.3 Check the nozzle tip

Improper usage of the nozzle that caused the pollution or damage of the nozzle tip
will disorder the auxiliary gas; it will also cause the beam to hit the brim of the nozzle
tip. Both cutting width and settled position will affect the cutting quality. As we are
using three-axis cutting, we also have to consider factors such as start program,
maintenance and simple practice to guarantee the cutting accuracy.

18
3.3.4 Check the optical components

Regular checking of the light path in the cutting head is necessary, since some small
particles generated during the cutting process might attach to optical components.
Please clean the optical components only when it’s necessary. Excessive cleaning will
degrade the performance of the optical components.

3.3.5 Beam collimating

To check the collimating status should be a daily procedure. Checking the beam
collimation can ensure that the beam does not hit other non-optical components and
cause energy reduction or spot shape changes. At the same time, the best performance
of the lens is guaranteed. The collimation of the nozzle should also be checked
regularly.

3.3.6 Material quality

We have to choose good quality plates to ensure the cutting quality. Avoid as much of
the curved, rusty, scraped or impurity Plates as possible. Although cold-rolled steel is
much more expensive than hot-rolled steel, the cutting quality is much better.

3.3.7 Gas quality

High quality and purity gas is preferred, for the purpose of both cutting performance
and cost saving.

3.3.8 Cutting checklist

Check below items before cutting:

Check if toxic gas will be generated when cutting.
Make sure there is enough fume exhausting system.
Confirm the processing quality and precision.
Refer to relative samples and notice the cutting quality of the edge.

19
4. Maintenance

4.1 Operator’s daily maintenance

4.1.1 Brief introduction

Regular maintenance is necessary to guarantee the sustainable running of the machine,

to reduce the possible failure, extend lifecycle as well. For detail please refer to the
following chapters with regard of ‘daily’, ‘weekly’ and ‘monthly’ maintenance
arrangement.

4.1.2 General principles

If the general auxiliary work is not well done, the best daily maintenance is very
necessary. In other words, the working area and machine tools should be kept clean
and tidy.

4.1.3 Machine tool

We have a comprehensive set of ‘daily’, ‘weekly’ and ‘monthly’ maintenance

arrangement in following chapters.

4.1.4 Laser resonator

Please refer to the user manual of the Laser Resonator.

4.1.5 Chilling system

Normally this part is highly reliable, and requires minimum level maintenance,
anyway, to operate based on the user manual would increase the lifecycle and
reliability, please refer to the user manual for detail maintenance information.

4.1.6 CNC system

All electronic components and integrated circuit have good reliability and lifecycle,
but have to keep them clean and dustproof.

20
4.1.7 Annually maintenance

We recommend that every 12 months the specialized technician to maintain the

machine based on the user manual.

4.2 Daily maintenance step

When turning on the machine or starting a new shift, please follow the steps below for
check and maintenance:

4.2.1 Chilling system

1. Check the water level in water tank, refill when necessary.

2. Check the temperature of water and adjust to a suitable water temperature if
necessary.
3. Check the water circulation from out light path to the chilling system.
4. Check the cleanness of the dust screen on the side of the chilling system.
Notice: only deionized water (conductivity is less than or equal to 10Micro/Siemens)
is allowed, or the specialized water provided by the manufacturer, for detail
information please refer to the user manual.

4.2.2 Machine tool system

Notice: power off the laser resonator in this process

1. Check the compressed air dehumidifier and drain the water when necessary.
2. Check if the protection lens is clean; clean it according to the procedure when
necessary.
3. Check if the beam is in the right centre of the nozzle.
4. Empty the slag keeper and clean the working table.

4.3 Weekly maintenance

Weekly maintenance should go with the daily maintenance.

4.4 Monthly maintenance

Monthly maintenance should go with both weekly maintenance and daily

maintenance.

21
4.4.1 Chilling system

1. Clean the radiator and screen with compressed air.

2. Check the water level, refill the water when necessary; change the water every 3
months.
3. Check whether the water temperature control is running normal, and if there is
any problem, check it in time and find manufacturer support.

4.4.2 Machine tool system

1、Turn off CNC

2、Check the reliability of electric cable connection, water connection and gas
connection on Z-axis

3、Check all motion system electric cable connection and reinforce.

4、Check emergency stop and emergency shut off operation.

5、Check the function keys on the control panel.

6、Add lubricant to the required lubrication point.

4.4.3 Routine

1. Check if there is any wearing out of the cable tunnel and lay.
2. Check the connectivity of gas, air and water, make sure there is no disconnection,
wearing out and leaking.
3. Clean all the working area.

4.5 Clean optical components

4.5.1 Brief introduction

Properly clean the optical components are a key factor to keep its working efficiency
and extend its lifecycle. In this chapter we will introduce how to clean the optical
components. When checking the lens, check if there is any fissure and concave. If 2%
of the surface is fissure or concave, it needs to be replaced, otherwise it will be
damaged during the operation. Also make sure the lens is fixed. If 5% of the surface is
scratched, burnt or suffered other damage, or the power decreased by 3% or above, we
need to replace the lens. It is preferred the damaged area of surface is under 2%.

22
Notice: The surface of a lens is easily to be damaged, don’t touch with any skin or any
other friction materials to touch the surface unless otherwise under special condition.

4.5.2 Material

Material for cleaning include:

1. Ethyl Alcohol Absolute
2. Lens tissue
3. Degreased cotton bud
4. Rubber air bag
5. Magnifier or microscope

4.5.3 Lens/Protection Lens cleaning procedure

Steps of cleaning Lens/Protection lens:

1. Dip the lens tissue into the Ethyl Alcohol Absolute for 3 to 4 times.
2. Gently rub the surface of lens with lens tissue and don’t touch the surface of lens
with your fingers.
3. Repeat above procedures until there is no trace of dirt or remains on the surface of
lens.
4. Blow with dry air.

Repeat 1-4 at the other side of the lens, if the dirt or remains are still there, follow
below steps:
1. Dip the lens tissue into the isopropyl and gently rub the remains on the surface of
lens.
2. Repeat 1-5 times if necessary, if it still doesn’t work, change the optical
components.

Notice: When using isopropyl, keep the container closed, don’t pour the remaining
isopropyl back to the container. This is to prevent the isopropyl from being polluted
and dampened by the air and used isopropyl.

4.6 Recommended maintenance tools

Below items are the recommended tools for maintenance:

Grease Injector
Lubricant No.46-68
Allen key 1mm – 10mm
Isopropyl
Cotton bud
Lens tissue

23
Magnifier or microscope

4.7 Lubricating of machine tool

We use ZL-2 lithium lubricating grease or CLP HC synthesized engine oil to lubricate
the linear rail pair, ball screw pair and bearings. For the bearings on the bearing
pedestals of the ball screw pair, we inject ZL-2 lithium lubricating grease every 3
months. Be noticed that no solid lubricating grease (such as graphite or MoS2) is
allowed for bearing pedestals of the ball screw pairs; We have to manually inject the
linear rail pair by using a thin oil lubricant pump after 72 hours continuous working of
the machine tool.

4.7.1.1 Lubricant of the linear rail and ball screw pair

Initial lubrication (basic lubrication)
All motion components of machine tool should be lubricated thorough:
1. Manually supply the oil by using a thin oil lubricant pump to every part of the
machine tool.
2. Use a grease injector to inject lithium soap-based grease into the ball screw
sub-bearing.
3. Push the sliding block back and forth for 3 times, the sliding length for each time is
at least 3 times the length of the sliding block.
4. Repeat 1 and 2 twice.
5. Check if a layer of oil film is on the rail.
Under normal situation, the sliding block has already been oiled in the factory. It’s
unnecessary to do first lubrication. Please confirm the sliding block is oiled before
using. It’s strictly not allowed to put the no oiled sliding block into production.

Supplement lubrication of sliding block:

Under the circumstance of pollution, applying cooling lubrication material, vibrating,
impact load, etc., we recommend shorten the supplement period.
If the load is relatively smaller, the lubricating period should be extended.
Dirty stuff could easily attached onto the bare rails, in order to keep the rails and
sliding block in smooth condition, we have to get rid of the dirty stuff regularly.

4.7.1.2 Lubricating material

1. ZL-2 lithium lubricating grease (graphite and MoS2 free)
Lubricating grease needle penetration: 265 – 295 (1/10mm), dropping point≥175℃,
well water-resistant, mechanical-stability, water-proof and oxidation stability. Suitable
temperate range -20 – 120℃.
2. CLP HC synthesized engine oil
ISO viscosity level: 220, viscosity index:96, open cup flash point: 260℃, pour point:
-21℃, extreme pressure standard industrial gear oil, fine antifriction performance.

24
4.7.1.3 Machine tool lubrication system general map
The linear rail pair of X-axis and Y-axis are manually and centrally oiled by thin oil
lubricating pump. Be noticed that the thin oil is highly vaporable, so it’s
recommended to centrally oil the machine tool within 72 hours continuously working.
The manual thin oil pump locates at the end of the Y gantry. When the oil level is too
low, we have to refill it. Please refer to graph 2 and graph 3.

Graph 2 Power-operated lubricate by using thin oil lubricating pump

Graph 3: Central lubrication by using the manual thin oil lubricating pumps

25
 1 2 3 4 5 6 7 8 9 10 11 12
Foundation drawing

A A

Ø25,00
1250 1250 1250 1250 1250 1050

1636
B B

2512
2956

155
140
C C

Foot Margin Module

Leveling Bolts

（100）
D D

7500

power box 700 Drop in Anchors

stabilizer
500 N2
880

2000
1500

700

O2
300

E 1200 The technical requirements: E

Chiller
Laser
Maintenance Area 1. The thickness of the basic cement layer is greater than
800 200mm.
Industrial Control Cabinet
2.Keep the ground flat ,
high and low difference is not greater
than 5mm. And there is no vibration source surrounding.
3. The laser source is recommended to keep in the air con
3000

F ditioning room, F
7500

Operating
Area and the room is made by the customer himself.
4. The hole location of the trench can be adjusted accordi
Part number ng to the actual situation of the customer.
5. The unmarked outer cable is laid by the bridge.
Loan Parts(General
Parts)Registration
1000
2000

Tracing
Storage area for material receiving trolley G

Scan Calibration

General number of
the old base map 6000
Hg Star Technology Co., Ltd.
General number of
the base map 9600
mark number change the sign
partotionfile year month stage mark weight proportion
of places number day
6020
Signature design standardization
1:50
check craft
H
Date supervisor
review
Foundation drawing
design

approve Total 1 Sheet 1 version replace

1 2 3 4 5 6 7 8 9 10 11 12
 0 1 2 3 4 5 6 7 8 9

F26_001

HG STAR TECHNOLOGY CO.Ltd

电话

公司/客户
项目描述 SMART-6020（F6020-6000）
项目编号 HG-STAR-LCM-003
代理
制造商(公司) HG STAR TECHNOLOGY CO.Ltd

路径
项目名称 SMART 6020
版权保护。严令禁止在未获得明确授权的情况下转发和复制本文档，利用及传播其内容。

制作
类型
安装地点
项目负责人
部件特点

创建日期 2024/10/11
编辑日期 2024/11/25 源自(缩写) USER 页数 14

2
项目名称 SMART 6020 项目编号
HG-STAR-LCM-003
HG STAR TECHNOLOGY 首页 = &EAA
SMART-6020（F6020-6000） 图号 CO.Ltd
+ 页 1
修改 日期 姓名 创建者 USER 批准人 日期 2021/3/30 校对 EPL 页数 1 从 14
 0 1 2 3 4 5 6 7 8 9

24V switching power

servo servo servo
driver
servo BCL4568E supply
driver driver driver
X Y1 Y2 Z
850W 1.8KW 1.8KW 400W

intermediate relay
24V 0V
QF1 KM1 KM2 KM3 QF2 QF3
4P PE
1P 1P
63A 38A 65A 38A 10A 10A
XP1 XP2 XP3 XP4 XP5 PE

XP7
socket socket socket

servo servo braking braking

resistor resistor
filter power supply

PC

24V
power
filter power
XP6 filter
A1 A2 A3 A4 A5
POWER IN

air
control

1 3
日期 2024/11/25 HG STAR TECHNOLOGY 施工布局图 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 2
修改 日期 姓名 原始项目 替换 替换人 页 2 / 14
 0 1 2 3 4 5 6 7 8 9

-QF1

BK 2 1
L1 L1 / 5.9
BN 4 3
L2 L2 / 5.9
GY 6 5
L3 L3 / 5.9
BU 8 7
N N / 5.9
63A

380V INPUT x6

L1 N L1 L3 L3 N

L2

1 3 5 1 3 5 1 3 5

-KM1 -KM2 -KM3

/12.3 2 4 6 /12.4 2 4 6 /12.5 2 4 6
38A 95A 38A

1L 1N L11 L21 L31 N

power servo 24V

filter L N power R S T N power L N
E-transformers filter
L N U V W L N

L12 L32 1L 1N

L22

1L 1N L N
servo -T1
filter L1 L2 L3

L1 L2 L3 V+ V-

24V power
supply

1L 1N L13 L33
4.0 4.0 6.0 6.0
XP3 XP5
XP1 XP2 L23 24V 0V
6.0 7.1 7.1

XP4 24V 0V

2 4
日期 2024/11/25 HG STAR TECHNOLOGY 电源稳压滤波 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 3
修改 日期 姓名 原始项目 替换 替换人 页 3 / 14
 0 1 2 3 4 5 6 7 8 9

1L / 3.2 1L / 8.

1N / 3.2 1N / 8.

PE / 4.9 PE / 4.

1L 1N 1L 1N 1L 1N

PE PE PE

1 1
QF3 QF2
2 2

1L
AC

L PE N L PE N L PE N
-X1 -X2 -X3
AC Socket

AC Plug

L PE N

Air Conditioner

3 5
日期 2024/11/25 HG STAR TECHNOLOGY 插座空调 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 4
修改 日期 姓名 原始项目 替换 替换人 页 4 / 14
 0 1 2 3 4 5 6 7 8 9

L1 L1 / 3.9

L2 L2 / 3.9

L3 L3 / 3.9

N N / 3.9

工厂自备电源

1 3 5 1 3 5
-F1 -F2
125A 63A
2 4 6 2 4 6

L1 L2 L3

LAN-laser / 11.3

chiller laser
L1 L2 L3 source L1 L2 L3 LAN

Chiller signal laser signal

Chiller signal laser signal

13.3

4 6
日期 2024/11/25 HG STAR TECHNOLOGY 水冷和激光器 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 5
修改 日期 姓名 原始项目 替换 替换人 页 5 / 14
 0 1 2 3 4 5 6 7 8 9

L13 / 3.4 L13 /

L23 / 3.5 L23 /

L33 / 3.5 L33 /

X servo -Y1 servo -Y2 servo -Z servo

X:R Y1:R Y2:R Z:R
X:S L1 Y1:S L1 Y2:S L1 LAN03 / 6.4 Z:S L1
LAN01 / 11.3 LAN02 / 6.2 LAN1 LAN04 / 6.6
X:T L2 LAN1 Y1:T L2 LAN1 Y2:T L2 LAN04 / 6.9 Z:T L2 LAN1
LAN02 / 6.4 LAN03 / 6.7 LAN2 LAN05 / 7.1
X:L1C L3 LAN2 Y1:L1C L3 LAN2 Y2:L1C L3 Z:L1C L3 LAN2
X:L2C L1C Y1:L2C L1C Y2:L2C L1C Z:L2C L1C
L2C L2C L2C L2C
Y1:B1 Y2:B1
X:B3 P P P Z:B3 P
-R1 -R2
X:B2 RB Y1:B2 RB Y2:B2 RB Z:B2 RB
B B B B
M-X X AXIS M-Y1 Y1 AXIS M-Y2 Y2 AXIS M-Z Z AXIS
X:U Y1:U Y2:U Z:U
U U U U
M X:V M Y1:V M Y2:V M Z:V
3 V 3 V 3 V 3 V
X:W Y1:W Y2:W Z:W
W W W W
X:PE Y1:PE Y2:PE Z:PE
PE PE PE PE

/ X axis encoders CN2

/ Y1 axis encoders CN2
/ Y2 axis encoders CN2
/ Z axis encoders CN2
PE PE PE PE

PE / 6.9 PE / 6.0
The servo sequence follows the direction of the network cable
5 7
日期 2024/11/25 HG STAR TECHNOLOGY 伺服驱动 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 6
修改 日期 姓名 原始项目 替换 替换人 页 6 / 14
 0 1 2 3 4 5 6 7 8 9

6.9 13.5 10.5 10.4 10.3 10.2 10.2 10.1 9.9 9.8 9.7 12.6
LAN05 122 111 110 109 108 107 106 105 103 102 101

IN OUT COM I27 I26 I25 I24 I23 I22 I21 I20 I19 COM I18 I17 I16 I15 I14 I13 I12 I11 I10 COM I09 I08 I07 I06 I05 I04 I03 I02 I01
INPUT3(J08) INPUT3(J07) INPUT3(J06)

EtherCAT_IN(J10) PWE(BLT)(J09)

BCL4568E
POWER(J01) PWM&DA(J02) OUTPUT1(J03) OUTPUT1(J03) OUTPUT1(J03)
24V 0V FG P24 P5 P- DA1 DA2 DA3 DA4 DA- 01 02 03 04 05 06 07 08 COM 09 10 11 12 13 14 15 16 COM 17 18 19 20 21 22 23 24 COM

24V 0V PE P+ P- D1+ D2+ D+ D- 001 002 003 004 005 006 007 008 009 010 011 012 013 远程 F23 F24
3.6 3.7 11.8 13.3 13.3 9.0 9.2 13.3 13.3 8.0 8.1 8.2 8.3 8.4 8.4 8.5 8.5 8.6 8.7 8.1 8.2 8.3 8.6 13.4 13.4

激光头

6 8
日期 2024/11/25 HG STAR TECHNOLOGY 板卡和激光头 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 7
修改 日期 姓名 原始项目 替换 替换人 页 7 / 14
 0 1 2 3 4 5 6 7 8 9

7.3 9.6 9.7 7.4 9.1 7.4 9.2 7.4 9.3 7.4 9.4 7.5 9.7 7.5 9.8 7.6 9.9
001 ZYL ZYN 002 F02 003 F03 004 F04 005 F05 008 F08 009 F09 010 F10

13 8 5 13 8 5 13 8 5 13 8 5 13 8 5 13 8 5 13 8 5 13 8 5
-KA1 -KA2 -KA3 -KA4 -KA5 -KA6 -KA7 -KA8
14 12 9 14 12 9 14 12 9 14 12 9 14 12 9 14 12 9 14 12 9 14 12 9

1L 1N
4.9 4.9

8.0 / 24V 24V / 8.9

8.0 / 0V 0V / 8.9
9.6
7.6 9.1 7.6 9.2 7.6 9.3 7.4 9.4 7.5 F22 9.5 7.6 13.6
011 F11 012 F12 013 F13 006 F06 007 F07 远程 A-A

24V

13 8 5 13 8 5 13 8 5 13 13 13 8 5
-KA9 -KA10 -KA11 KA12 4 8 KA13 4 8 KA14
14 12 9 14 12 9 14 12 9 14 14 14 12 9
12 12

24V

B-B
13.6

8.0 / 24V 24V / 8.9

8.0 / 0V 0V / 8.9

7 9
日期 2024/11/25 HG STAR TECHNOLOGY 中间继电器 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 8
修改 日期 姓名 原始项目 替换 替换人 页 8 / 14
 0 1 2 3 4 5 6 7 8 9

9.0 / 0V 0V / 9.0

x1 x1 x1 x1 x1 x1 x1 x1
Z-axis BK- x1
green yellow 分区 分区 分区
02 valve N2 valve AIR valve red
brake light light 输出1 输出2 输出3
x2 x2 x2 light x2 x2 x2 x2 x2
control BK+ x2

F02 F03 F04 F05 F06 F07 F22 F08 F09 F10
8.2 8.3 8.4 8.4 8.4 8.5 8.5 8.5 8.6 8.7

9.0 / 0V 0V / 10.0

x1 x1 x1
O2 x1 N2 x1 AIR x1
分区 分区 分区 pressure pressure pressure
输出4 x2
输出5 x2
输出6 x2
switch x2 switch x2 switch x2

102 103 105

F11 F12 F13 7.8 7.8 7.8
8.1 8.2 8.3

9.9 / 0V

N2B O2B
proportional proportional
7.2 / D1+
valve 7.2 / D2+
valve grease pump

x2 x1
8.1 / ZYL ZYN / 8.1

N2B O2B
13.5 13.3

10.0 / 24V

8 10
日期 2024/11/25 HG STAR TECHNOLOGY 阀组 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 9
修改 日期 姓名 原始项目 替换 替换人 页 9 / 14
 0 1 2 3 4 5 6 7 8 9

9.0 / 24V 24V / 13.0

9.9 / 0V 0V / 12.6

1 2 1 2 1 2 1 2 1 2 1 2
X+ + -
X- + -
Y1+ + -
Y1- + -
Z+ + -
Z- + -

limit limit limit limit limit limit

3 3 3 3 3 3

106 107 108 109 110 111

7.8 7.7 7.7 7.7 7.6 7.6

9 11
日期 2024/11/25 HG STAR TECHNOLOGY 限位 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 10
修改 日期 姓名 原始项目 替换 替换人 页 10 / 14
 0 1 2 3 4 5 6 7 8 9

IPC
/12.7

ECAT LAN01 / 6.2

Laser
LED-
LED+
USB USB USB USB /
screen
/ power- POWER-
/ power+ POWER+

/ DVI VGA
DVI 1L 1N PE
D

LAN LAN-laser / 5.6 PE / 7.1

1N / 12.2
LAN 1L /

HDMI
USB main Servo 24V Standy IPC E-STOP
power Power
USB USB

USB
/ remote control
receiver

USB-D

10 12
日期 2024/11/25 HG STAR TECHNOLOGY 工控机 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 11
修改 日期 姓名 原始项目 替换 替换人 页 11 / 14
 0 1 2 3 4 5 6 7 8 9

13.0 / L3

1L 1L

13 23
-Q2
M/C 14 24
power

1L 1L 1L 1L

13 23 13 23
-Q3 -Q4
SERVO 14 24 24V 14 24
POWER
7.9
101 SW+(IPC)

K1 K2 1L K3 1L

11 13

12 14
E-STOP IPC
/11.1

A1 A1 x1 A1 x1
KM1 KM2 H1 KM3 H2
A2 A2 press x2 A2 press x2 0V SW-(0V)
light light 10.9

N N 1N N 1N

1 2 1 2 1 2
3 4 3 4 3 4
5 6 /3.2 5 6 /3.4 5 6 /3.6

11.8 / 1N

/N

11 13
日期 2024/11/25 HG STAR TECHNOLOGY 屏幕按钮 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 12
修改 日期 姓名 原始项目 替换 替换人 页 12 / 14
 0 1 2 3 4 5 6 7 8 9

13.0 13.0 13.0 13.1 13.1 13.1 13.0 13.1 13.2 13.2 13.1 13.2 13.2 13.3 13.3 13.3 9.3 13.3 13.3 13.4 13.4 13.1 13.4 13.4 13.5 13.5 13.5 13.5 9.1 13.6 13.5 13.6 13.6 13.6 13.6 13.7 13.7 13.7 13.7 13.7 13.7 13.8 13.8 13.8 13.8
106 107 24V 0V 108 109 24V 0V 110 111 24V 0V F02 0V F03 0V O2B D2+ 0V ZYL ZYN PE 102 0V 103 0V F04 0V N2B D1+ 0V F08 0V F09 0V F10 0V F11 0V F12 0V F13 0V F14 0V F15 0V

106 107 24V 0V 108 109 24V 0V 110 111 24V 0V F02 0V F03 0V O2B D2+ 0V ZYL ZYN PE 102 0V 103 0V F04 0V N2B D1+ 0V F08 0V F09 0V F10 0V F11 0V F12 0V F13 0V 105 0V F05 0V
13.0 13.0 13.1 13.1 13.1 13.1 13.2 13.1 13.2 13.2 13.2 13.2 13.3 13.3 13.3 13.3 13.3 13.4 13.4 13.4 13.4 13.5 13.5 13.5 13.6 13.6 13.6 13.6 13.7 13.6 13.7 13.7 13.7 13.7 13.8 13.7 13.8 13.8 13.8 13.9

13.0 13.0 13.0 13.1

F06 F07 F22 0V

F06 F07 F22 0V

13.0 13.0 13.0 13.1

13.0 13.0 10.9 13.1 13.1 13.1 13.1 13.2 13.1 7.2 7.2 7.3 7.3 7.8 7.9 13.4 13.4 7.3 13.5 8.6 8.6
101 0V 24V 0V K1 K2 K3 L3 1N P+ P- D+ D- F23 F24 0V 0V 122 0V A-A B-B

-A1 -A2 -A3 -A4 -A5

101 0V 24V 0V K1 K2 K3 L3 1N 调制输入+ 使能输入+ H1 H3 外部出光+

13.0 13.0 13.0 13.1 13.1 13.1 13.1 13.2

调制输入- 使能输入- Chiller 外部出光-

signal
1-10V输入+

12.2 13.2 13.4

1-10V输入-
L1 L2 L3 1N PE

laser signal
5.6

POWER IN

12 14
日期 2024/11/25 HG STAR TECHNOLOGY 端子与外部对接 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 13
修改 日期 姓名 原始项目 替换 替换人 页 13 / 14
 0 1 2 3 4 5 6 7 8 9

HC1 HC2
106 1 17 O2B X:U 1 17 F05

107 2 18 D2+ X:V 2 18 0V

24V 3 19 0V X:W 3 19 F08

0V 4 20 ZYL X:PE 4 20 0V

108 5 21 ZYN Y1:U 5 21 F09

109 6 22 104 Y1:V 6 22 0V

24V 7 23 0V Y1:W 7 23 F10

0V 8 24 102 Y1:PE 8 24 0V

110 9 25 0V Y2:U 9 25 F11

111 10 26 103 Y2:V 10 26 0V

24V 11 27 0V Y2:W 11 27 F12

0V 12 28 F04 Y2:PE 12 28 0V

F02 13 29 0V Z:U 13 29 105

0V 14 30 N2B Z:V 14 30 0V

F03 15 31 D1+ Z:W 15 31

0V 16 32 0V Z:PE 16 32

13
日期 2024/11/25 HG STAR TECHNOLOGY 航插 =
校对 USER CO.Ltd +
审核 SMART-6020（F6020-6000） HG-STAR-LCM-003 页数 14
修改 日期 姓名 原始项目 替换 替换人 页 14 / 14
 Installation
FSCUT4000E User Manual
 FSCUT4000E User Manual 2

Table of Contents
Table of Contents ................................................................................................................................ 2
Chapter 1 Overview ............................................................................................................................ 4
1.1 Introduction .......................................................................................................................... 4
1.2 System Diagram .................................................................................................................... 4
1.3 Product Details ......................................................................................................................6
Chapter 2 Wiring Instruction .............................................................................................................. 8
2.1 BMC228X Installation ............................................................................................................8
2.1.1 Dimension Diagram ................................................................................................... 9
2.1.2 Installation Diagram ...................................................................................................9
2.1.3 Ethernet Terminal .................................................................................................... 11
2.1.4 PCIE Socket ...............................................................................................................12
2.2 HPL2720E Wiring ................................................................................................................ 13
2.2.1 Interface Layout ....................................................................................................... 14
2.2.2 J01 EtherCAT Input Terminal ....................................................................................14
2.2.3 J02 EtherCAT Output Terminal .................................................................................14
2.2.4 J03 Power Input Terminal ........................................................................................ 14
2.2.5 J04 PWM Output Terminal ...................................................................................... 15
2.2.6 J05 DAOutput Terminal ............................................................................................16
2.2.7 J06 Common Output Interface ................................................................................ 16
2.2.8 J07 Common Input Interface ................................................................................... 17
2.3 BCL4566E Wiring .................................................................................................................19
2.3.1 Interface Layout ....................................................................................................... 20
2.3.2 J01 Power Supply ..................................................................................................20
2.3.3 J02PWM/DA Terminals .........................................................................................21
2.3.4 J03/J04/J05 Output Terminal ................................................................................22
2.3.5 J06/J07/J08 Input Terminal ...................................................................................22
2.3.6 J09/J10 Network ................................................................................................... 24
2.3.7 J11 Sensor ............................................................................................................. 25
2.3.8 J12DB15 Servo Axis Interface ............................................................................... 25
2.4 Cutter Wiring .......................................................................................................................29
2.4.1 ProCutter Wiring ......................................................................................................29
2.5 Laser Wiring ........................................................................................................................ 30
2.5.1 IPG_ YLS Germany ....................................................................................................30
2.5.2 IPG_ YLS American ...................................................................................................31
2.5.3 Raycus ...................................................................................................................... 32
2.5.4 Trumpf ......................................................................................................................33
Chapter 3 Installation ........................................................................................................................34
3.1 Installation Steps .................................................................................................................34
3.1.1 Step 1. Install BMC228X Control Card ..................................................................... 34
3.1.2 Step 2. Install MC228X Driver ..................................................................................34
 3 FSCUT4000E User Manual

3.1.3 Step 3. Connect slave ...............................................................................................35

3.1.4 Step 4. Scan in Cypfig ...............................................................................................35
1.3.1 Step 5. Use CypCutE .................................................................................................35
Chapter 4 Precautions .......................................................................................................................36
4.1 Wiring Precautions ..............................................................................................................36
4.1.1 Drag Chain Wiring ....................................................................................................36
4.1.2 Machine Tool Wiring ................................................................................................38
4.1.3 Assembly Requirements .......................................................................................... 40
4.2 Troubleshooting .................................................................................................................. 40
4.2.1 Device Manager cannot find PCIe devices .............................................................. 40
4.2.2 Device Manager cannot install driver ......................................................................41
4.2.3 Bus Scan failed ......................................................................................................... 41
4.2.4 Bus network alarm ...................................................................................................42
 FSCUT4000E User Manual 4

Chapter 1 Overview

1.1 Introduction

FSCUT4000E is a cost-effective CNC system dedicated to laser cutting. It is based on EtherCAT

bus technology and capable of motion control, laser control, and cutting gas control. It is common
used in sheet metal, kitchen ware, lamps and such industries. This user manual is only for
installation guidance.

1.2 System Diagram

FSCUT4000E includes the bus BMC228X Control Card, the bus IO board, and the bus height
controller, among which the BMC228X control card integrates the EtherCAT master protocol
stack.

The network cable is led out from the network port of BMC228X and connected to the BLT
cutting head. The wiring diagram is shown in Figure 1.

Figure 1 Wiring diagram of FSCUT4000E - BLT cutter

The wiring diagram of other cutting head is shown in Figure 2.

5 FSCUT4000E User Manual

Figure 1 Wiring diagram of FSCUT4000E - other cutter

 FSCUT4000E User Manual 6

1.3 Product Details

FSCUT4000E bus CNC system includes BMC228X Control Card, BCL4566E terminal board or
BCS210E height controller, HPL2720E, WKB V6 and related cables, etc.

BMC228X Control Card BCS210E Motion Control HPL2720E EtherCAT Terminal Board
(1) (1) (1)

LAN Cables
WKB V6 LAN-20X-PWE Wire LAN-0.5X (4)
(1) (1) LAN-1X (2)
LAN-3X (1)

Table 1-1 FSCUT4000E - BLT cutter details

 7 FSCUT4000E User Manual

BMC228X Control Card WKB V6 BCL4566E Terminal Board

(1) (1) (1)

BNC RF cables Amplifier HC 4-core cable

(2) (1) (1)

LAN Cables
LAN-0.5X (4)
LAN-1X (1)
LAN-3X (1)

Table 1-2 FSCUT4000E - other cutter details

 FSCUT4000E User Manual 8

Chapter 2 Wiring Instruction

2.1 BMC228X Installation

BMC228X Control Card is a motion control card based on the EtherCAT bus. Its 1.0Ghz
main chip provides excellent overall performance and has passed Friendess stringent testing
standards.

BMC228X
EtherCAT Control
Card

Bus Protocol EtherCAT Master Protocol

PCI Express PCI Express2.0 (Gen2)
Power Supply Powered by PCIe motherboard, max 12V/1A, no hot plug
Anti-interference ESD 3 (6kV contact, 8kV air), EFT 4 (4kV power supply, 2kV signal), Surge
Level international 2 (2kV AC line, 1kV DC line)
Dimension and Weight
Dimension (L x W x H) 127.6mm x121.0mm x21.45mm
Weight 80g
Features
Cooling Nature Cooling
Operating 0~+60℃
temperature
Storage temperature -20~+70℃
Humidity 0% to 90% (non-condensation
Certification CE
Environment Requirements
The waterproof and dustproof grade of the Control Card is IP00, unprotected. Please place
the computer in a clean, dust-free environment.
Table 2-1 BMX228X Technical Data
9 FSCUT4000E User Manual

2.1.1 Dimension Diagram

BMC228X Control Card dimension ( mm) is shown in Figure 3.

Figure 3 BMC228X Dimension

2.1.2 Installation Diagram

Install BMC228X in the socket of PCIE X4 and up with even force (refer to ②), and
secure its blank screw (refer to ①). Be aware of the heat dissipation for BMC228X and keep it
away from other cards as far away as possible. Refer to the diagram below.
 FSCUT4000E User Manual 10

Figure 4 BMC228X Control Card Installation

BMC228X installed is shown below.

Figure 5 BMC228X Control Card After Installation

 11 FSCUT4000E User Manual

2.1.3 Ethernet Terminal

The standard socket of BMC228X is RJ45 that can be used to connect EtherCAT slave
devices(servo drives, BCS100E, HPL2720E, etc.)

Label Description LED color Status Description

Ethernet Off 10 Mbps connection
communication
1: Speed Green
connection Solid 100 Mbps connection
speed
Ethernet Off No connection
2: Link communication Yellow Flashes Communicating
link status Solid Connected
Table 2-2 Description of RJ45 connection status
 FSCUT4000E User Manual 12

2.1.4 PCIE Socket

BMC228X PCIE socket is X4 (Figure 6①)and can be used for X4, X8, X16. Its PCI Express
Protocol standard is V2.0 (Gen2) and the motherboard requirements are as shown in Table 2-3.

Figure 6 Gold Fingers

System 64-Bit Win7/10

CPU Intel i3 8100 and up
Memory 4GB and up
PCIE Socket X4 and up
PCI Express PCI Express2.0 (Gen2) and up
Motherboard PCIE power 12V/1A and up
supply
Table 2-3 Motherboard Requirements
13 FSCUT4000E User Manual

2.2 HPL2720E Wiring

HPL2720E is an IO extend board based on the EtherCAT bus, which supports the
peripheral resources required by the FSCUT6000 high-power cutting system, as shown in
Table 2-4.

HPL2720E

Module Qty Description Note

Power / 24V DC/5A

Supply
PWM 1 24V, ±50kHz 0.3% Max 50kHz,3%
DA 4 0-10V, 12bit, ±20mV
Common 20 High level 24V output, ≤ 0.7A per channel External relay
Output The total current output ≤ 2.5A recommended
24V level, active low (<15.6V); IN1~IN3 can be
Common 27
switched to active high (>5.8V)

Input

Temperature: 0~60℃
Working
Humidity: 10%~90% (no condensation)

Environment

Dimension 195×118×45.2mm
Weight 480g
Table 2-4 HPL2720E Hardware Resources
 FSCUT4000E User Manual 14

2.2.1 Interface Layout

The interface layout of the HPL2720E terminals is shown in the figure below.

2.2.2 J01 EtherCAT Input Terminal

EtherCAT network cable input interface, standard RJ45 network cable;

2.2.3 J02 EtherCAT Output Terminal

EtherCAT network cable output interface, standard RJ45 network cable;

2.2.4 J03 Power Input Terminal

Notice
 24V and 0V are respectively connected to the positive and negative poles of the DC
24V switching power supply; FG needs to be reliably connected to the ground, and
the ground wire should be as short and thick as possible.
 All terminals are pluggable only, and disassembly is shown in the right figure above.
There is no need to unplug the terminals for wiring.
 15 FSCUT4000E User Manual

2.2.5 J04 PWM Output Terminal

HPL2720E has a PWM pulse width modulation signal, which can be used to control the laser
power. The PWM signal level is 24V. The duty cycle is continuously adjustable from 0% to 100%,
and the max carrier frequency is 50KHz.
The signal output mode is shown in the figure below.

Note: The P+ and P- signals have enabled solid-state relays inside, and no external
relays are needed for isolation!
 FSCUT4000E User Manual 16

2.2.6 J05 DA Output Terminal

HPL2720E has 4 analog outputs of 0~10V. The four-way DA can be configured as the
control signal of the laser peak power and the gas proportional valve through the "Cypfig"
that comes with the CypCutE software.

Output Signal 0~10V

Maximum Output 50mA
Maximum Error +/-20mV
Resolution 2.7mV
Conversion 400us
Table 2-5 DA Output

2.2.7 J06 Common Output Interface

OUT1~OUT20, total 20 high-level 24V outputs In the "Cypfig" that comes with
CypCutE, the output port can be configured as "height controller", "laser", "cutting head",
"auxiliary gas", "alarm", "pallet changer" and other related controls interface.

Note: Only DC loads can be connected, the output current of each channel must be ≤
0.7A, and the total current of the output port must be ≤ 2.5A, otherwise the short
circuit protection will be triggered.
If you need to connect to an AC load, please connect an external relay;
17 FSCUT4000E User Manual

2.2.8 J07 Common Input Interface

HPL2720E does not set a dedicated input, and each input port can be set as limit/origin
signals
The Normally Open and Normally Closed modes of the limit and origin signals can be set in
the "Cypfig" that comes with CypCutE. When it is set to NO, the input is valid when the
input port is connected to 0V; when it is set to NC, the input is valid when it is disconnected
from 0V.

The typical connection of the photoelectric switch is shown in the figure below, and an NPN
type 24V photoelectric switch must be used;
The typical connection of mechanical contact switch is shown in the figure below;
The typical connection of the magnetic induction switch is shown in the figure below, and the
NPN type 24V magnetic induction switch must be used;

Among them, IN1~IN3 can adjust the polarity of the effective level through hardware
jumpers:
FSCUT4000E User Manual 18
 19 FSCUT4000E User Manual

2.3 BCL4566E Wiring

The BCL4566E bus height controller uses the EtherCAT bus to control the laser cutting
capacitive follower. It is a high-performance capacitive height controller.

BCL4566E
Terminal Board

Module Qty Description

Power Supply / 24V DC /3.5A
DA 2 0-10V, 12bit, ±50mV
PWM 2 5V and24V, ±50KHz 0.3%
24V active high
Common
24 1) The current of single output ≤ 0.7A
Output
2) The current of all outputs ≤ 2.5A
Axis 1 Pulse digital quantity, PUL±/DIR± output, up to 600KHz
Dedicated IN1-IN24, active low, 0~ 15V
27
Input IN25-IN27, active high, 24~ 8V
Capacitance
1 Capacitance frequency 2Mhz~4Mhz
Sensor
Working Temperature: 0℃~60℃
Environm /
Humidity: 10%~90%Rh(no(no condensation)
ent
Dimension / 300mm×123×34mm
Weight / 640g

Table 2-6 BCL4566E Technical Data

 FSCUT4000E User Manual 20

2.3.1 Interface Layout

BCL4566E interface layout of terminals

Figure 2.3.1 BCL4566E interface terminals

2.3.2 J01 Power Supply

Figure 2.3.2 Power Supply Terminal

The machine case is the negative pole of the measured capacitance. In order to ensure the
stable operation of the measurement circuit, the "FG pin" of the power interface must be reliably
connected to the machine case (that is, it is in good conduction with the machine case). The case
of the preamplifier of BCL4566E must also be connected with the machine case well. The
specific index is that the DC impedance is always less than 10 ohms, otherwise the EMC effect
may not be good.
 21 FSCUT4000E User Manual

2.3.3 J02PWM/DA Terminals

Figure 4 PWM/DA Terminals

BCL4566E has 2 channels of PWM pulse width modulation signal, the left channel is
24V level PWM. The right channel is 5V level PWM, and P- is the negative terminal of the
PWM signal. The duty cycle is adjustable from 0% to 100%, and the highest carrier
frequency is 50KHz. The signal output mode is shown in the figure below.

Figure 5 PWM Output Circuit

Note: 1) There are dedicated enabling relays for PWM+ and PWM- signals, and there is no need
for external relay isolation.
2) Wrong connection of 5V/24V PWM signal may cause damage to the laser.

BCL4566E has 2 channels of 0~10V analog output. DA1/DA2 is the positive terminal of analog
quantity, and D- is the negative terminal of analog quantity. DA1/DA2 can be configured as
the control signal of laser peak power and gas proportional valve in the "Cypfig" that comes
with CypcutE software.
Output signal 0V~+10V
Max Output 50mA
Max Error +/-10mV
Resolution 2.7mV
Conversion 400us
 FSCUT4000E User Manual 22

2.3.4 J03/J04/J05 Output Terminal

Take J03 as an example, the interface diagram is as follows.

Figure 6 Output Terminal

J03-J05 has a total of 24 high-level (24V level) outputs. The above figure is the wiring
diagram of J03. O1-O8 are the positive terminals of the output port, and COM is the negative
terminal of the output port. The 24 output ports can be configured as control interfaces ，
e.g."laser", "cutting head", "auxiliary gas", "alarm" and "pallet changer” etc. in the "Cypfig"
that comes with CypcutE software.
Note: 1) The maximum current of one output port is 0.7A, otherwise the short circuit
protection will be triggered.
2) The total current of the output ports cannot exceed 2.5A, otherwise the short
circuit protection will be triggered.

2.3.5 J06/J07/J08 Input Terminal

Take J06 as an example, the interface diagram is as follows.

Figure 7 Input Terminal

J06-J08 has a total of 27 input ports. IN1-IN24: active low (0~15V), high level (19-24V) has no
conduction; IN25-IN27: active high(24~8V conduction), low level (0~4V) has no conduction.
Take J06 as an example, I1-I9 are the positive terminals of the input port signal, and COM is
the negative terminal of the input port.
23 FSCUT4000E User Manual

The typical connection of the photoelectric switch is as shown in the figure below. An NPN 24V
photoelectric switch should be used.

The typical connection of the contact switch is shown in the figure below.

The typical connection of the magnetic induction input switch is shown in the figure
below. An NPN 24V magnetic induction switch should be used.
 FSCUT4000E User Manual 24

2.3.6 J09/J10 Network

J09 is the EtherCAT network output interface, and J10 is the EtherCAT network input interface,
supporting 100Mbps network communication. It is recommended to use standard RJ45
network cables in CAT5E or up for bus communication

Description of RJ45 connection status of network terminal

Label Description LED color Status Description
Off No connection
EtherCAT Bus
Connected, without
Connection and Solid
1: Link Green communication
Communication
Connected, with
Status Flashes
communication
EtherCAT Bus Off/Flashes Not in the OP state
2: Status Yellow
Link Status Solid in the OP state
 25 FSCUT4000E User Manual

2.3.7 J11 Sensor

Figure 8 Sensor interface

The 4-core signal transmission cable of the sensor can be made by yourself with a 3-core
shielded cable and two 4-pin plugs. 1, 2, and 3 cores are connected in pairs, and the 4th core
must be connected with a shielding layer. It is recommended to use the original cable to
ensure stability.

2.3.8 J12DB15 Servo Axis Interface

The control interface of BCL4566E focusing servo driver is double-row female DB15F, and the
pin definition of the corresponding wire is shown in the figure below:

Figure 9 Servo drive interface

Axes are defined in the table below.

Servo Axis Interface Definition
15-pin Female Servo Control Interface
Pin Signal name Pin Signal name
1 yellow PUL+ 9 yellow PUL-
black
2 blue DIR+ 10 blue DIR-
black
3 black A+(encoder) 11 black A-(encoder)
white
4 orange B+(Encoder) 12 orange B-(encoder)
black
5 red Z+(encoder) 13 red Z-(encoder)
black
6 green SON(servo enable) 14 purple ALM(alarm)
 FSCUT4000E User Manual 26

7 green - 15 brown 0V(power ground)

blac black
k
8 brown 24V(power output)
+24V, 0V: 24VDC power for the servo driver.
PUL: digital signal, pulse signal for the driver.
DIR: digital signal, direction signal for the driver.
SON: output servo drive enable signal.
ALM: Receive the alarm signal of the servo drive.
A+, A-, B+, B-, Z+, Z-: three phases of the encoder, input signal.
Please refer to the figure below for the wiring with the Yaskawa servo drive.
Yaskawa Servo Wiring

Figure 10 Yaskawa Servo Wiring Diagram

Pay attention to the following when connecting drives in other brands:

1. Please first confirm the type of SON signal of the servo drive you choose and whether it is
active low (that is, it is ON when it is connected to the GND of the 24V power supply).
2. Make sure the parameter of the servo drive: the pulse signal received is "pulse + direction".
3. Confirm whether there is an external emergency stop signal input in the input terminal of the
servo drive, and its logic.
 27 FSCUT4000E User Manual

4. Before the test run of the driver, 24V power must be supplied to the terminal board first,
because the 24V power required by the servo is transferred through the terminal board.
5. If the drive still cannot run, make sure that the parameter is set to not use "POT/NOT".
 FSCUT4000E User Manual 28

Figure 11 BCL4566E Wiring Diagram

 29 FSCUT4000E User Manual

2.4 Cutter Wiring

2.4.1 ProCutter Wiring

The connection of ProCutter cutting head is shown in the figure below.
 FSCUT4000E User Manual 30

2.5 Laser Wiring

2.5.1 IPG_ YLS Germany

31 FSCUT4000E User Manual

2.5.2 IPG_ YLS American

 FSCUT4000E User Manual 32

2.5.3 Raycus
33 FSCUT4000E User Manual

2.5.4 Trumpf
 FSCUT4000E User Manual 34

Chapter 3 Installation

3.1 Installation Steps

3.1.1 Step 1 Install BMC228X Control Card

1) Power off the host.
2) Open the host case, select a free PCIE slot, and use a screwdriver to remove its slat.
3) Insert BMC228X into the slot. The installation is shown in 2.1.2.
4) Tighten the screws of the BMC228X block with a screwdriver.
5) Cover the case, turn on the power of the host PC, and start the host.

3.1.2 Step 2 Install MC228X Driver

Two ways to install BMC228X driver.
1. Use CypCutE to install the driver, check the driver when installing CypCutE, as shown
in Figure 7. The BMC228X driver will be automatically installed.

Figure 7 Check Driver Program

2. Open the "Device Manager", it will display "Other Devices” as shown in Figure 8, if its
driver is not installed.
 35 FSCUT4000E User Manual

Figure 8 Unknown Device

Right click on "PCI FLASH Memory" and select "Update Driver Software".

Select CypCutE and find the default location of driver files: C:\Program Files
(x86)\Friendess\CypCutE\Drivers, then click Next.

The driver installation is complete, if "BMC228X DMA" is displayed as shown.

3.1.3 Step 3 Connect the slave

Use CAT5E or above standard network cable ( Friendess network cable recommended) to
connect the slave. The wiring diagrams of BLT series cutting head and other cutting heads are
shown in section 1.2.

3.1.4 Step 4 Scan in Cypfig

Open “Cypfig” and click “BUS Scan”-”Start”. The system will scan the connected slave
information.

1.3.1 Step 5. Use CypCutE

After setting the parameters in the "Cypfig", open CypCutE, import the graphics, and set the
process parameters, then it can be processed See the software manual for details.
 FSCUT4000E User Manual 36

Chapter 4 Precautions

4.1 Wiring Precautions

4.1.1 Drag Chain Wiring

1) When releasing the 4-pin cable from the coil, it is necessary to prevent the cable from
twisting (the cable must be released along the tangential direction) and the cable must be laid
straight. This work should be done before laying the cables, to give the cables a period of
stress relief. Because the manufacturing process cannot completely guarantee that the cable is
straight and free of distortion, the printed logo on the surface of the cable rotates in a tiny
spiral.

Correct Wrong

2) Cables are not allowed to be twisted when installed in a closed space, and twisting during
installation may cause damage to the core wire stranding. This effect is gradually
strengthened during the operation of the cable, resulting in back-twisting, which eventually
leads to the breakage of the core wire and failure.

3) The cables must be laid loosely next to each other in the drag chain support. Spacers should
be used to separate the cables as much as possible. The space between the cable and the
spacer, separator and the cable adjacent to it, shall be at least 10% of the diameter.

Correct Wrong
 37 FSCUT4000E User Manual

4) The cables should be installed according to the weight and size of the cables. The larger
diameter and heavier cables should be placed outside; the smaller diameter and lighter cables
should be placed inside. The cables can also be placed from the inside to the outside
descendingly by size. Do not place one cable on top of another without using a spacer.

5) For vertically suspended drag chains, keep more free space for the vertical support, because
the cables will be stretched during operation. After a short run, it is necessary to check that
the cables run along the center area and adjust them if necessary.

6) For self-supporting drag chain, cables are fastened to moving and fixed points. Suitable cable
supports from the supplier are required. Cable ties have very limited applicability when
operating at high accelerations. So you should not bundle multiple cables together. Cables
should not be fixed or tied to any moving parts of the drag chain. The gap between the fixed
point and the bending area should be wide enough.

7) It is recommended to fix the cable on the moving point for sliding drag chains. A small cable
protection zone is required at the fixing point. (Refer to the instructions from the drag chain
supplier)

8) Please ensure that the cable runs along the center area with the desired bending radius. Do
not apply tension to the cable (do not pull it too tightly), otherwise the friction inside the drag
chain will cause the cable sheath to wear; do not let the cable be too loose in the drag chain,
otherwise it will easily cause abrasion of the cable and the inner wall of the drag chain, or
tangled with other cables.

Correct Wrong
 FSCUT4000E User Manual 38

9) If the cable does not run smoothly, check whether it is twisted along the longitudinal axis
during operation. The cable should slowly rotate at a certain fixed point until it runs freely.

10) Given the size of cables and drag chains, their length characteristics vary considerably.
During the first few hours, the cable naturally elongated. For drag chains, it takes more hours
for this to happen. Such a large discrepancy can be remedied by regularly checking the cable
installation locations. It is recommended to do regular inspections, every three months for the
first year and at every maintenance thereafter. This includes checking that the cables are
completely free to move within the intended bending radius and making adjustments if
necessary.

4.1.2 Machine Tool Wiring

1. Power Supply（Power) Wiring
1) Strong Electricity
 Strict separation of strong and weak electricity
Select the appropriate diameter for the power cable according to the power. The table
below is the cable diameter and its corresponding power.
Cable Cross 25℃ Copper Single-phase Three-phase
Spec(mm2) Section(mm2) Wire 220v 380v load
Ampacity load power (W)
(A) power
(W)
1.5 1.38 15 3300 9476.8
2.5 1.78 25 5500 13163.2
4 2.25 32 7040 16848.8
6 2.85 45 9900 23693.6
10 7*1.35 60 13200 31591.2
16 7*1.7 80 17600 42121.6
25 7*2.14 110 24200 57917.6

 Add auxiliary devices such as short-circuit protectors and filters for strong electricity.
2) Weak Electricity (DC24V for example)
 Distinguish the positive and negative wires of the power supply in color, e.g.,the red
wire is connected to the positive pole, and the blue wire is connected to the negative
pole
 Loads with relatively large interference (e.g. servos and solenoid valves) are powered
separately from the controller.

2. Grounding
 The ground wiring adopts the standard two-color, yellow and green, wires.
 It is recommended to use multi-point grounding, for some high-frequency signals (PWM,
pulse, encoder, capacitance, etc.) in the laser cutting machines.
 The machine tool uses galvanized grounding screws and a special grounding wire for
39 FSCUT4000E User Manual

grounding. The resistance between the grounded metal body and the main grounding
point should be ≤ 0.1Ω.

3. Signal (Control)
 Signal wire color, e.g. black.
 Choose the signal wire according to the power.
 DC 24V solenoid valve is recommended. Add absorption circuits at both ends of the
solenoid valve, that is, connect a freewheeling diode in parallel at both ends of the
solenoid valve (pay attention to the direction, withstand current, and withstand voltage),
as shown in the figure below。

 It is recommended that the digital signal (PWM) shielding layer be grounded at both
ends, and the analog signal (DA) shielding layer be grounded at one end. Single-ended
grounding can avoid low-frequency current noise on the shielding layer; double-ended
grounding can effectively eliminate high-frequency interference. If the transmission
cable is very long, it is recommended to ground at multiple points to ensure that the
shielding layer is at the same potential.
 The resistance from the cutting head connected to the amplifier to the shell of the
machine tool is ≤ 1Ω, and the resistance to the grounding point of the electrical cabinet
is ≤ 6Ω.

4. Notes
 Each cable is marked clearly and accurately.
 Cables are in parallel and not crossed, and the harnesses should be straight and leveled.
 If using the cables from Friendess, choose the appropriate cable according to the layout
space, and do not pile up and circle it.
 All wiring must be firm to prevent sparking.
 Wiring should avoid loops and antenna effects. The current loop composed of signal
source---transmission line---load is equivalent to a magnetic field antenna. As shown in
the figure below, the wrong connection is on the left, and the correct connection is on
the right.
 FSCUT4000E User Manual 40

4.1.3 Assembly Requirements

Handle with care. Please wear anti-static gloves or touch a grounded metal
object to prevent static electricity from damaging the motion control card
before touching the control card circuit or inserting/pulling the control
card.
Except for the USB interface, plugging and unplugging with power is
prohibited for other interfaces, which may cause internal components
damaged.

Handle with care. Do not press the card. Pressing might cause the card to bend
and its function damaged.

4.2 Troubleshooting

4.2.1 Device Manager cannot find PCIe devices

If the device manager cannot find any PCIe devices:
1. Check the status of the indicators on BMC228X. The positions of the power indicator and
system status indicator are shown in Figure 14
 41 FSCUT4000E User Manual

Figure 14 BMC228X Indicators

If it is not in the OP state, the power indicator is always on, both the system status indicator 1
and the system status indicator 2 flash at 1 Hz at the same time, and the system status indicator
3 is always on.
If it is in the OP state, the power indicator is always on, the system status indicator 1 and
system status indicator 2 flash alternately at 1 Hz, and the system status indicator 3 is always
on.
If the BMC228X status indicator is abnormal, change the card and try again.
2. If the BMC228X status indicator is normal, change a card slot or host computer to scan again
3. If the PCIe device still cannot be found, contact our customer service.

4.2.2 Device Manager cannot install driver

If PCIE devices are in the device manager, but the BMC228X driver is not recognized:
1) Please manually install the driver again according to section 3.1.2.
2) If the driver is still not installed, change a card slot or install the driver on the host.
3) If the driver is still not installed, contact our customer service.

4.2.3 Bus Scan failed

If the Cypfig failed to scan the slaves:
 FSCUT4000E User Manual 42

1. Check whether the EtherCAT bus servo and slaves are powered on.
2. Check whether the network cable installed securely.
3. Check whether the slave device is supported. If not, contact customer service If yes, change the
slave device and scan again.
4. If still failed, contact customer service

4.2.4 Bus network alarm

Common Bus Network Alarms and Solutions
Alarm Reason Solution
Bus network alarm, the network The slave device is not powered Check the power supply of
cable is not connected on or the network port is the slave device and the
0x9811002D connected incorrectly wiring of the network port
Watchdog timeout alarm Communication between If it is automatically
CypCutPro and BMC228X released, it can be ignored; if
timed out it occurs during processing,
record the operation steps
and give feedback to our
customer service.
Bus network alarm, network The network cable between the 1. Check the wiring of the
mismatch EtherCAT network port of the EtherCAT network port
0x9811001E computer and the slave is loose 2. Sort out the wiring and
or the power supply of the slave check for interference
is disconnected 3. Check the power supply of
the slave
Bus network alarm frame lost EtherCAT network 1. Check the wiring of the
0x98110025 communication data frame loss EtherCAT network port
2. Sort out the wiring and
check for interference
3. Check the power supply of
the slave
Bus network alarm, the slave is The Nth slave is abnormal, the 1. Check the wiring of the
not in OP state network cable between the N-1 EtherCAT network port
slave and the Nth slave is loose 2. Sort out the wiring and
or interfered check for interference
3. Check the power supply of
the slave
Bus network alarm, network EtherCAT network 1. Check the wiring of the
timeout communication data frames are EtherCAT network port
0x98110010 lost continuously 2. Sort out the wiring and
check for interference
3. Check the power supply of
the slave
Table 2-1 Master card bus alarm and solution
Continuous-Wave Fiber Laser
User Guide
RFL-C6000S

Wuhan Raycus Fiber Laser Technologies Co., Ltd

2
 TABLE OF CONTENTS
1 Safety Information ..................................................................................................................... 4

1.1 Symbols Used in this User Guide ..................................................................................... 4

1.2 Laser Classification ........................................................................................................... 4
1.3 Safety Labels ..................................................................................................................... 5
1.4 Optical Safety ....................................................................................................................6
1.5 Electrical Safety ................................................................................................................ 6
1.6 Other Safety Rules ............................................................................................................ 6
2 Product Description ................................................................................................................... 8

2.1 Features ............................................................................................................................. 8

2.2 Package Contents .............................................................................................................. 8
2.3 Unpacking and Inspection .................................................................................................8
2.4 Operation Environment ..................................................................................................... 9
2.5 Precautions for Use ......................................................................................................... 11
2.6 Specifications .................................................................................................................. 11
3 Installation ................................................................................................................................ 14

3.1 Dimensions ......................................................................................................................14

3.2 Output Head and Installation .......................................................................................... 15
3.3 Cooling Requirements .....................................................................................................15
3.4 Installation Procedure ......................................................................................................18
4 Using the Product ..................................................................................................................... 20

4.1 Front Panel ...................................................................................................................... 20

4.2 Rear Panel ....................................................................................................................... 20
4.3 Power Connection ........................................................................................................... 21
4.4 Interface Definitions ........................................................................................................22
4.5 Steps of Installation .........................................................................................................26
4.6 Steps of Starting .............................................................................................................. 27
4.7 Functions of the clientware ............................................................................................. 27
4.8 Control Modes .................................................................................................................34
4.9 Guide laser control .......................................................................................................... 40
4.10 The Programming Mode (Waveform Editing) ..............................................................41
4.11 Laser timing diagram .................................................................... 错误！未定义书签。
4.12 Modulation signal requirements ....................................................................................42
4.13 Steps of shutting down .................................................................................................. 43
5 Alarms and Solutions ............................................................................................................... 51

5.1 Alarms Display ................................................................................................................51

5.2 Alarm solutions ............................................................................................................... 52
6 Warranty, Return and Maintenance ......................................................................................54

6.1 General Warranty ............................................................................................................ 54

6.2 Limitations of Warranty .................................................................................................. 54
6.3 Service and Repair .......................................................................................................... 55

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

1 Safety Information

Thank you for choosing Raycus fiber laser. This User Guide provides important safety,

operation, warranty and other information. Please read it carefully before you use this product. In

order to ensure safe operation and optimal performance of the product, please follow the

warnings, cautions, operating procedures and other instructions accordingly.

1.1 Symbols Used in this User Guide

WARNING: Refers to a potential hazard that may leads to a personal

injury or death.

CAUTION: Refers to potential a hazard that may leads to general

personal injury or product damage.

1.2 Laser Classification

This series of lasers are classified as a high power Class 4 laser instrument according to the

European Community standards EN 60825-1, clause 9. This product emits invisible laser

radiation at or around a wavelength of 1080 nm, and the total power radiated from the laser is

greater than 12000W (depending on model). Direct or indirect exposure of this level of light

intensity may cause damage to the eyes or skin. Despite the radiation being invisible, the beam

may cause irreversible damage to the retina and/or cornea. Appropriate and approved laser safety

eyewear must be worn all the time while the laser is operating.
WARNING: You must use appropriate laser safety eyewear when this
device is operating. Thelaser safety eyewear is selected according to the
range of wavelengths emitted from this product. The end user must
ensure that the laser safety eyewear being used protects against light
emitted by the device over its entire range of wavelengths. Please verify
that the personal protective equipment (e.g. enclosures, viewing
windows or viewports, eyewear, etc.) being utilized is adequate for the
output power and wavelength ranges listed on the product.
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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

1.3 Safety Labels

The position of the safety labels on products varies depending on the model of the

continuous-wave fiber laser, as shown in Figure 1:

Figure 1: Safety Label Locations of RFL-C6000S

These safety labels include warning labels, apertures through which laser radiation is

emitted and labels of certification and identification, etc. Specifications of these labels are as

follows:

Table 1: Specifications of Safety Labels

English label(Take 500W for

English label example) English label

Chinese label English label (Take 500W for Chinese label

example)
3.Class 2M Laser Product
1.Aperture Label 2.Class 4 Laser Product
Label for Guide Laser

6.Laser Radiation Hazard

4. CE Compliance 5. Identification Plate
Label

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

7.Electrical Hazard

1.4 Optical Safety

Any dust on the end of the collimator assembly can burn the lens and damage the laser.

CAUTION: If the output of the device is delivered through a lens with

an anti-reflection coating,make sure that the lens is of good quality and
clean.

1.5 Electrical Safety

a) Make sure your product is grounded through the PE line of the AC power cord. The

grounding must be firm and reliable.

WARNING:Any interruption from the protective earth will electrify

the enclosure, which may result in personal injury.

b) Make sure that the correct voltage of the AC power source is used.

CAUTION: Failure to connect the correct voltage could damage the

product.

1.6 Other Safety Rules

a) Never look directly into the laser output port when power is supplied to the laser.

b) Avoid using the laser in a dim or darkened environment.

c) If this device is used in a manner not specified in this document, the protection provided

by the device may be impaired and the warranty will be voided.

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

d) There are no operator serviceable parts inside, and all maintenance must be performed

in Raycus or by qualified Raycuspersonnel. Do not try to remove covers, or electrical

shock may be caused, and warranty will be void.

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

2 Product Description

2.1 Features

Compared with traditional lasers,Raycus CW fiber laser has higher efficiency

electric-optical conversion, lower power consumption and excellent beam quality. The fiber laser

is compact and ready to use. It can be used as a stand-alone unit or easily inserted into user’s

apparatus.

Main Features:

a) Excellent beam quality

b) High quality fiber output

c) High Power Stability

d) Continuously tunable output power, quick switching response

e) Slow rise and slow fall, Waveform editing

f) Maintenance free operation

g) High wall plugefficiency

Applications:

a) Cutting, Welding

b) 3D Printing

c) Scientific research

2.2 Package Contents

Please refer to the packing list accompanying the shipment to check actual items included.

2.3 Unpacking and Inspection

Raycus CW fiber laser is shipped in a package designed to provide maximumprotection.

Upon delivery, please inspect all packaging for evidence of mishandling or damage. If you find

any evidence of mishandling, please save the damaged material and contact the shipping agent

and Raycus immediately.

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

Remove all the contents from the packing case. Take extra care when removing the unit out

of the packing case to ensure that the fiber optic cable is not twisted, hauled or damaged. A

comprehensive packing list is included with the system documentation. Check all items against

the list and contact Raycus immediately if there is any missing item or evident damage to the

unit. DO NOT attempt to install or operate the laser, if there is any evident or suspected damage

to the unit.

It is recommended to keep the packing materials, as they will be necessary if you ever need

to ship the unit back for service at a later date.

CAUTION:The fiber optic cable and output head is precise optic

instrument, any vibration or impact to the output head, and twist or
excessive bend to the cable will damage the instrument.

2.4 Operation Environment

The basic operation conditions are listed in the table below:

Table 2 Basic Operation Conditions for the Laser

Model RFL-C6000S
Supply Voltage(V) 380±15%Vac，50/60Hz
Supply Capacity(kW) >20
Installation Requirements Install on flat surface, no vibration or impact
Ambient Temperature(℃) 10~40
Relative Humidity(%) 30~70
Warning：

a) Ensure reliable grounded before using the laser.

b) The laser output is connected to the output cable. Please check the laser output carefully

to prevent dust or other contamination. Use special paper when cleaning the laser output

lens.

c) If the laser is used in accordance without the method specified in this manual, the laser

may be in abnormal working state and cause damage.

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

d) It is strictly forbidden to install the laser output when the laser is in operation.

e) Do not look directly into the laser output. Be sure to wear protective glasses when

operating the laser.

 Do not expose this product to high humidity（＞95%）

 Do not let this product work below the ambient dew pointtemperature.(see

Table 3)

Table 3 TheConstant Dew Point Table

AMBIENT DEW POINT
Room Maximum Relative humidity
Temperature(℃) 20% 30% 40% 50% 60% 70% 80% 90% 95%
20 -3.5 2 6 9 12 14.5 16.5 18 19
25 0.5 6 10.5 14 16.5 19 21 23 24
30 4.6 10.5 15 18.5 21.5 24 26 28 29
35 8.5 15 19.5 23 26 28.5 31 33 34
40 13 20 24 27.5 31 33.5 36 38 39
Laser operating temperature range

 Green area: The dew point temperature is 22℃that is lower than the laser

cooling water temperature, which can be used safely；

 Red area: If the dew point temperature is higher than 22℃ and exceeds

the laser cooling water temperature by 22℃, there must bedew

condensation, and measures must be taken.

Measure 1: Connecting clean and dry air from CDA port to reduce relative

humidity, works for 10-15 minutes in standby mode;

Measure 2: Installing cabinet air conditioner to reduce ambient

temperature.

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

2.5 Precautions for Use

a) Before supplying the power to the device, make sure that the correct voltage of the AC

power source is used. Failure to connect power source correctly will damage the

device.

b) Failure to follow the instructions may cause malfunction and damage to the device,

such damage is not covered by warranty.

c) It is very important to ensure the cleanness of the calibrated laser output head, other

wise it will cause irreparable damage to the laser.

d) Please inspect the output head carefully for dust or other contaminations. Use

appropriate lens paper to clean it if necessary. Do not touch the output lens at any time;

as well as remember to cap the output head when it is not in use, and make sure the cap

is clean.

e) Failure to follow the specified instructions may result in the loss of laser power, and

such loss will not be covered by the warranty.

2.6 Specifications

Table 4 Specifications
Minimum Standard Maximum
Number Index Condition Unit
value value value
Fiber technical index
Nominal
1 Operation Mode Output Continuous Wave / Modulated
Power
Water
Nominal Output
2 Temperature 6000 6100 6200 W
Power
22±1℃
Nominal
Emission Power
3 Output 10 100 %
Range
Power
Emission Nominal
4 1075 1080 1085 nm
Wavelength Output
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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

Power
Nominal
3dB Spectral
5 Output 4 6 nm
width
Power
Nominal
Long-term power
6 Output ±1.5 %
stability
Power
Nominal
Modulation
7 Output 1 20k Hz
Frequency
Power
Nominal
8 Duty ratio Range Output 1 100 %
Power
Red Guide Laser
9 / 1 3 mW
Power
QBH Optical index of output optical cable
Fiber Core / 75 μm
10
Diameter / 50 μm
Beam Quality 75μm Fiber
11 2.7 3.1 mm×mrad
(BPP) Core
75μm Fiber
12 Fiber NA 0.2 /
Core
Fiber Delivery 75μm Fiber
13 20 20 m
Cable Length Core
Other technical indicators
Nominal
Operating Three-phase four-wire system
14 Output VAC
Voltage 50/60Hz，380±15%
Power
15 Way to Control / AD/RS-232/Ethernet
Nominal
Power
16 Output 21 22 23 kW
Consumption
Power
Nominal
Water flow
17 Output 60 L/min
requirement
Power
Water Nominal
18 Temperature Output 21 22 23 ℃
requirement Power
19 Dimension W×D×H 455×802×168 mm
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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

20 Weight 70 kg
Operating
21 Ambient / 10~40 ℃
Temperature
Operating
22 Ambient / 30~90 %
Humidity
Storage
23 / -10~60 ℃
Temperature

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

3 Installation

3.1 Dimensions

Figure 2 shows dimensions of RFL-C6000S.

Figure 2a) Frontand Rear panel view(unit: mm)

Figure 2b) Top and Side view(unit: mm)

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

3.2 Output Head and Installation

The laser output head of RFL-C6000S is the standard QBH interface. The specific

appearance and dimensions are shown in Figure 3 above. Compared with other models, the size

of the protective end cap of the fiber delivery cable of this model is lengthened.

Figure 3 Dimensions of the QBH fiber delivery cable (unit:mm)

CAUTIONS:
 Inspect the output lens before installing the output head to the
processing head. Clean the output lens if necessary.
 It is strictly prohibited to disassemble the output head by personnel not
approved by Raycus, or the warranty is void.

3.3 Cooling Requirements

Table 5 Cooling Requirements

Model RFL-C6000S
Cooling Capability(W) >15000
Minimum Flow(L/min) 60
Maximum Pressure(Bar) 7
Pipe Inner Diameter(mm) 25
Water temperature of cooling system(℃) 22±1℃
a) The water temperature setting of cooling system:

22±1℃

b) Cooling system filter access requirements:

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

When the water quality of the laser cooling system is poor (more impurities), the laser water

path is easy to be blocked, causing flow alarm or high temperature alarm, resulting in laser

shutdown. In serious cases, the laser waterway will be scrapped. Therefore, RFL-C6000S

laser is equipped with water inlet filter module, as shown in Figure 4.

Figure 4 The inlet filter module

When the laser is installed and used, firstly connecting the water inlet filter module with the

water outlet of the customer's on-site cooling water system according to the water flow

direction indicated by the arrow in Figure 4, and then connect the water inlet filter module

with the water inlet of the RFL-C6000S laser, as shown in Figure 5.

Figure 5Thewater inlet filtration module is connected to the water cooling system

When the laser is in use, cleaning the Y-type filter of the inlet water filter module

periodically according to the water quality of the cooling water system (openning the nut

cover of the Y-type filter, taking out the filter screen, cleaning it, reinstall it, and tightenning

the nut cover), it is recommended that the cleaning frequency be no less than once a week.

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

c) Cooling water requirements:

1） It is recommended to use purified water.

2） In order to prevent mould growing that may lead to pipe blockage, we recommend to

add alcohol about 10% of the total volume.

3） If the product is used in an environment that ambient temperature is between -10℃

and 0℃, we recommend to use 30% alcohol, and replace it every two months.

4） If the product is used in an environment that ambient temperature is below -10 ℃ ,

please to use dual-system chillers (with heating function) and ensure uninterrupted

operation of the cooling system.

d) Requirements for output cable cooling system:

1） Rate of liquid flow: 1.7-2.0 L/min;

2） Pressure of liquid flow: < 0.6 MPa at the inflow;

3） Type of liquid exchange junction: SMC MS-5H-6:

4） Type of tube: outer diameter6; inner diameter4;

5） Direction of cooling liquid: unidirectional; connect the tube with the water-pipe

strictly according to direction shown on the layer of the tube;

6） Type of liquid: de-ionized water, condensed water, pure water;

7） PH value of liquid: 5.5-9;

8） Filter is needed for the cooling system, and the size of the solid residual practical

should be within 100um;

9） Maximum temperature of liquid: 45℃:

10） Minimum temperature of liquid: greater than the saturated dew-point 5℃;

11） Additive to the liquid: satisfies the requirements of PH value and size of solid

residual practical as above;

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

12） Radius of the bending of the armored pipe: off-work state (i.e. transportation

and reservation): minimum radius of bending ≥ 20 cm; in-work state: minimum

radius of bending ≥ 30 cm;

13） Long-term vibration < 2 G; Impact action < 10 G.

e) Other requirements for chiller:

1） When starting the cooling system for the first time, check the entire water system

and the joint for water leakage. The external water pipe must be installed and

connected according to the inlet (IN) and outlet (OUT) by the laser. Other wise, the

laser may not work properly.

2） If you will not use the laser for a long time, water must be emptied from the product,

and then both the inlet and outlet must be blocked with the nuts we provide. Failure

to do so may lead topermanent equipment damage.

CAUTION: Please set the water temperature in strictly accordance with
the requirements above. Too low temperature may lead to condensation on
the laser module and the output cable. This can cause serious damage to
the equipment.
CAUTION:Please clean the water inlet filter module in time. If the water
inlet filter module is blocked, the laser flow alarm or high temperature
alarm will be triggered.

CAUTION: Make sure that the water temperature reaches the set point
and the cooling system is working well before you start the laser.
〖summer：22±1℃；winter： 22±1℃〗

3.4 Installation Procedure

a) Place the product inan still and stable position.

b) Check if the power supply has the correct voltage (See Table 4 for the laser model and

corresponding input voltage ), and the earth line is connected, make sure it is firm and

reliable.

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

c) Connect the power cable and control cable to the product when power supply is OFF.

d) Insert the water pipes into the inlet and outlet.

e) Check the output head and clean it if necessary. This procedure must be performed by

personnel of Raycus or authorized by Raycus. Make sure the environment is clean, or the

output cable may be contaminated.

f) Prevent the delivery cable from treading, pinching or excessive bending during

installation.

g) During the installation and disassembly process, please take care to handle the laser

output head gently, avoiding any shock.

h) In the installation of laser output cable and output head process, please make sure that the

surrounding environment is clean, other wise it may pollute the output head (do not use

fans, which actually may bring more dust).

i) The minimum bending radius of the output fiber cable of the laser should not be less than

20 cm under the non-working conditions, and the minimum bending radius should not be

less than 30 cm when the laser is working.

CAUTION:
 All the cables can only be connected when power supply is OFF. Hot
plug may damage the laser.

CAUTION:
 The laser output optical cable should be kept as natural as possible and
not be distorted.
 The too small bending radius of the output fiber cable will damage the
laser.

CAUTION:
 Make sure the aperture and the cavity of the processing head is clean.
 Keep the protective cap properly, prevent it from contamination; Or
the aperture will be contaminated when capped.

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

4 Using the Product

Please use the correct the latest PC software and the relevant
manual.

4.1 Front Panel

Figure 6 shows the front panel of RFL-C6000S：

Figure 6 Front Panel of RFL-C6000S

a) POWER:Control system power indicator light, when the red light is on, it means that

the laser is powered on.

b) LASER:The laser is emitting light normally. When the green light is on, it means that

the laser is emitting light.

c) ALARM:Alarm indication, when the yellow light is on, it means that the machine
has an alarm.

4.2 Rear Panel

Figure 7 shows the rear panel of RFL-C6000S:

Figure 7 Rear Panel of RFL-C6000S

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

a) AC INPUT: The socket for supply source input that can only be mated with the plug on

the power cord we provided (See Table 4 product technical parameters for laser model

and corresponding input voltage). Please use only the enclosed power cord provided by

Raycus.

b) CTRL-INTERFACE: Control interface, CTRL-INTERFACE interface (DB-25),

multi-function multiplex interface, users can set control mode, input analog voltage

signal, modulate 24V signal, and it is also an alarm signal output interface.

c) RS232：Provide remote control and fault information storage of the laser.

d) WATER: Pipe connectors, the inlet and outlet for cooling water to flow in and return.

(See Table 5 for the laser model and corresponding water pipe size for cooling system

requirements)

e) ETHERNET: Ethernet interface. It can provide remote control and storage alarm

information for the laser.

f) CDA：Dry air inlet.

4.3 Power Connection

CAUTION: Before connecting the product to AC supply source, you must

check for sure that the AC supply you will apply is in accordance with the
specifications provided in Table 2 or 4.

Table 6 Power Connection Requirements

Model RFL-C6000S
Supply Source 380±15% V AC 50/60Hz

Power Cord

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5 wires, the diameter of single wire is 4mm2,

One End of Power Cord
wires labeled L1，L2，L3and PE
L1，L2，L3-> Phase Line,
Sign Description
PE-> Protective Earth
L1, L2, L3->Phase wire, PE->Protective ground wire (one PE wire
is required to be connected to the ground wire of the circuit breaker,
Note
and the other one is connected to the equipment ground wire to
ensure that the laser is fully grounded)

4.4 Interface Definitions

4.4.1 CTRL-INTERFACE Definitions

The CTRL-INTERFACE(DB-25) is for laser control, the designation and definition is

below：

Figure 8 Diagram of CTRL-INTERFACE

Table 7 Definitions of 24 pin Ctrl Interface

PI
Typical
N Drive
Name LineMark Type Level Respon Description
No Current
se Time
.
1 Interlock1A ITL-1A “EN954-1”
2 Interlock2A ITL-2A or”ISO13849-1
Contact
3 Interlock2B ITL-2B <500m Cat.3PLd”.
Closure 24Vdc <10mA
s Passive contact, not
Input
4 Interlock1B ITL-1B connected to external
voltage or grounding.
5 NC
6 NC
7 NC

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Activates the internal

8 RPA control system power
Contact
Remote Key supply in REM mode.
Closure 24Vdc --- 20s
Switch Passive contact, not
Input
9 RPB connected to external
voltage or grounding.
In REM mode, start
START-
10 Instantaneou the laser main power
A
Remote Start s Contact supply.Passive
24Vdc --- 1s
Button Closure contact, not connected
11 START-B Input to external voltage or
grounding.
Analog Input Analog Input 1-10
1-10
12 to Control 1-10V Analog Input 10 mA 100µs VDC= 10 – 100%
Vdc
Current Setpoint
Analog Output
Analog Output Analog 0-8.0 0-8VDC（Refer to
13 AOUT >5mA 20µs
Power Monitor Output Vdc factory inspection
report for details）
Isolated Return for signals on
14 AGND Return --- --- ---
Analog Com pins 12, 13
<10
15 Modulation+ MOD+ Digital Input 24VdC 20µs 24 VDC Input
mA
Return for signal on pin
16 Modulation- MOD- Return --- --- ---
15
Guided Laser RED-LAS <10 Positive edge activates
17 Digital Input 5-24Vdc 120ms
Control ER mA emission in REM mode
Emission 5-24Vd <10 Positive edge activates
18 LAS-C Digital Input 120ms
Enable C mA emission in REM mode
＞
19 READY READY Digital output 24VdC 120ms High=Laser is ready
10mA
System Return for pin
20 GND2 Return --- --- ---
Common 17/18/19/21/22/23/24
5-24Vd <10 Rising edge reset (the
21 Error RESET RESET Digital Input 120ms
C mA resettable alarm)
＞
22 Laser Alarm S-ERR Digital output 24VdC 120ms High=Alarm status
10mA
23 Power started POWER Digital output 24VdC ＞ 120ms High= The main power

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10mA supply is started

24 Laser emission LASER Digital output 24VdC >10mA 100ms High=Laser is emission

 Caution: Please check the control voltage level and ensure that the level is in
accordance with the requirements. Over voltage and voltage ripple may damage
the product.

The Service Security Interface is pin 1-4 and pin2-3， of CTRL-INTERFACE.If the pin 2-3

and pin 1-4 are disconnected, the laser will immediately stop emitting light, and the laser Ready

signal output will change to low level. Be sure to short-circuit pin 2-3 and pin 1-4 before using

the laser. If it is not short-circuited, the laser will display InterLock alarm after power-on.

 Interlock interface must not be connected to active signal, otherwise it

will cause interface damage and laser alarm.

4.4.2 TCP/IP Interface Configuration

Thedefault IP address of this product is 192.168.0.10, only supporting UDP communication.

The laser listens for connection on port is 8098, and the command must be sent in a single data

string.

Table 8 Thepin definitions of Ethernet interface

PIN FUNCTION DESCRIPTION
1 TX+ TRANSMIT+
2 TX- TRANSMIT-
3 RX+ RECEIVE+
4 N/C NONE
5 N/C NONE
6 RX- RECEIVE-
7 N/C NONE
8 N/C NONE
For better communication stability, recommend to use this interface first.

Table 9 The default IP address of the laser

The default IP address of the laser
IP address 192.168.0.10
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Subnet mask 255.255.255.0

Steps of Ethernet connection:

a) Open “Local Connection” on your computer, and then click “property”;

b) Select "Internet Protocol Version 4 (TCP/IP 4)；

c) Click the “Property”;

d) Check “Use the following IP address:” to manually assign an IP address;

e) Manually assign an IP address is 192.168.0. x（x cannot be 10, because 192.168.0.10 has

been assigned to the laser ） , and assign a subnet mask address. The default is

255.255.255.0;

f) Click the "OK" button to confirm the settings and exit. The IP address is different from

the default gateway, see Figure 9.

Figure 9 Steps of Ethernet Connection

When the IP setting is completed, turn on the host computer, and the connection status in

the corresponding text box on the host computer interface displays: connected, indicating that the

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microcontroller program is running normally and the communication connection is normal. The

display interface is shown in Figure 10 below.

Figure 10 The main interface is displayed when the communication connection is normal

4.5 Steps of Installation

a) Carefully takeout the laser from the box and move it to the installing position and then

lock the casters;

b) Remove the output cable protective cap and check the output lens for dust with strong

light and clean it if necessary, then cover the output cable protective cap;

c) Install the output cable on the processing equipment according to the actual situation

(install the output head cooling water pipe at the same time), pay attention to the output

cable and head,then remove the protective cap andconfirm that the output lens is clean

and install the output head；

d) Connect cooling water pipe;

e) Connect the control line and power according to the control mode.

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4.6 Steps of Starting

It is determined that the air switch is disconnected, and all electrical connections must be

completed before the laser is powered on;

a) Make sure that the pins the 24-pin are closed;

b) Turn on the chiller and check leakage. If there is no water leakage, turn off the chiller

and wait for the laser to turn on;

c) Turn on the air switch ;

4.7 Functions of the clientware

The RFL-C6000S clientware communicates with the main control board through UDP when

it is working. Through the background program running in the software and the human-computer

interaction operation, the laser parameters are read and set and the control functions are realized.

The interface displayed by the software is divided according to functional categories, including

control, alarm, about, language selection, authorization, working mode selection and other pages.

Figure 11 The clientware interface

4.7.1 The control interface

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The control interface is the content displayed on the first page after opening the clientware,

including the user's most commonly used status signal, laser parameter setting and laser control

related functions.

Control abnormal laser reset: Click the reset button to run the abnormal laser reset

command.

Guide laser: the guide laser is turned on or off in the internal control state of guide laser.

After the guide laser is turned on or off, there will be changes in the guide laser state on the

software.

Guide laser external control: turn on the guide laser external control or turn off the guide

laser external control. After turning on and turn off the guide laser external control, there will be

changes of the guide laser external control state in the software.If the current red external control

state, then disable the red control button.

Control laser parameters: Optical output parameters include power, frequency, pulse width,

and duty cycle. The communication between the software and the main control board requires

only power, frequency, and pulsewidth.The duty cycle can be calculated from the pulse width

and frequency, and the pulse width can also be calculated from the duty cycle and frequency.

During the software operation, the frequency and duty cycle will be changed synchronously with

the pulse width, and the duty cycle will also be changed synchronously with the frequency and

duty cycle. The output power can be an integer in the range of [0,100]. The frequency can be set

to a decimal in the range of[0,20000]. The duty cycle can be set to a decimal in the range of

[0,100].

Control light emission mode: light emission related modes include AD mode, external

enable, external modulation mode, and internal modulation mode. You can individually control

the opening and closing of each mode, and display the current status of each mode. After the AD

mode is turned on, the optical power is controlled by an external signal, and the power setting

function of the software should be set to a disabled state. When the external modulation mode is

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turned on, the frequency, pulse width and duty cycle are controlled by the external modulation

signal, and the function of the software to set the frequency, pulse width and duty cycle should

be set to the disabled state.

Control the light: control to turn on or off the laser emission or laser enable. Only when the

laser has a ready signal, can it be controlled normally, otherwise the buttons for turning on and

off the laser are set to the disabled state. When the external control light enable is turned off, and

the external modulation mode or internal modulation mode is turned on, the "laser enable" is

displayed, otherwise, the "laser emission" is displayed.

Status display: Including emergency stop, laser enable, Interlock logic normal, Interlock1

closed, Interlock2 closed, power ramp up and down, program mode, program execution, program

execution completed, program execution abnormal and other most commonly used laser states,

and machine Internal ambient temperature, internal ambient humidity, dew point, external 0-10V,

light output frequency, light output duty cycle, light pulse width, laser water flow, output optical

cable water flow and other data. These status and data refresh time intervals should not exceed

300ms.

Laser usage time display: including today's turn-on time, today's light-emitting time,

cumulative turn-on time, and cumulative light-emitting time.

4.7.2 The alarm interface

All the alarm information of the current laser is displayed on the alarm interface, and the

alarm information is updated in real time.

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Figure 12 The alarm interface

4.7.3 About

The laser time, model, serial number, master control serial number, key version number and

system information are displayed in the interface，when the about interface is opened, the upper

computer software reads them from the master control module once.

Figure 13 The about interface

4.7.4 Language Selection

In the language selection interface, you can set the language used by the software. After
selecting the language and clicking OK, you do not need to restart the software, automatically
convert the content displayed in the software into a language, save the currently selected
language to the configuration file, and display it according to the last set language when starting
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the software next time.

Figure 14 Language selection interface

4.7.5 Authorization

The authorization interface is used to control the limited time lock of the laser, when the
authorization interface is opened, the machine code, laser lock time and lock time are loaded
once, the laser lock time is Raycus's limited time lock for integrators, and the lock time is for the
integrator to end customers. Limited time lock. In the authorization interface, only Raycus’
authorization code can be set, and the function of calculating the authorization code is
implemented in the server and has nothing to do with the host computer software. The
authorization code used by the integrator can be generated in the authorization interface.

Figure 15 Authorization interface

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4.7.6 The Mode Selection function

Select the operating mode of the software, including monitor mode, control mode,

diagnostic mode, and debug mode.

Monitor mode: The monitor mode is selected by default when the software is opened.

The most commonly used and concerned information is displayed on the software interface to

avoid the interference of too much information to the user. The monitor mode can be used

without password.

Control mode: The control mode adds the function of the operable control interface on the

basis of the observation mode, and the password is required to enter the control mode.

Debug mode: On the basis of diagnostic mode, the parameter setting interface is added.

Only Raycus debug engineers can enter the encryption mode.

Diagnostic mode:When a laser fails to diagnose remote after -sales, or the integrated dealer

needs to understand more status information of the laser, you can enter the diagnostic mode.

4.7.7 Main control module

The main control module contains all states, alarms and system parameters of the main

control module. The status and alarm information are automatically refreshed. Only when the

currently selected page is in the main control module, the upper machine software will

automatically read and refresh status and alarm information information information. , Reduce

the frequency of communication and avoid too many resources to occupy the main control

module.

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Figure 16 Main control module status information interface

Figure 17 Alarm information interface of main control module

4.7.8 Slave control module

Power surveillance contains the alarm of the ACDC module and DCDC module. The

monitoring enables the control, the failure level is high, the low level is set, the level is high, low

settings, and the CAN communication enables the settings.

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Figure 18 Slave control module status information interface

4.8 Control Modes

The laser selects AD mode, external control, internal modulation mode and external

modulation mode through the upper machine interface.

4.8.1 Control mode wiring diagram

4.8.2.1 Internal control mode

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Figure19 Internal control wiring diagram mode

Operation method:

a) Short connection of 8, 9 pin on the 24 -pin of 24 stitches (power on the control board);

b) Open the air, the panel "POWER" indicator lights;

c) Open the upper machine software and close all the external mode (turn off the red light

external control, external envelopes, external AD and external modulation);

d) Click the red light button to view the red light;

e) Set out the light parameter;

f) Click “laser ON”.

4.8.2.2 Internal/external modulation modes for power and communication

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Figure 20 Wiring diagram of internal power control and external signal control

Operation method:

a) Shortconnect the 8 and 9 pins on the INTERFACE 24 pins (the control board is

powered on);

b) Open the laser clientware;

c) Click “the guide laser ON” button to view the guide laser;

d) Disabling the AD mode and the external envelopes。

e) Waiting “Ready”;

f) Setting laser power parameters;

g) When the duty cycle of the internal output frequency of the laser is set, set the output

frequency/duty cycle/pulse width; (the output light is determined by the modulation

signal of pin 15.16 and the output frequency and duty cycle set by the upper computer

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software); the internal output frequency of the laser is not required When the duty cycle

is used, the default setting parameters are that the frequency is 100Hz and the duty cycle

is 100%.

h) Modulation signal (15, and 16-pin) provide a high level to turn on the laser.

4.8.2.3 Power communication setting parameters in the external control mode, external

modulation, external envelopes

Figure 21 In the external control mode, the power internal control, out -of -light external control,

and the external enable wiring chart

Operation method:

a) Shortconnect the 8 and 9 pins on the INTERFACE 24 pins (the control board is powered

on);

b) Open the laser clientware;

c) Click “the guide laser ON” button to view the guide laser;

d) Turn off the AD mode, and opening external enable mode 、 external modulation mode;

e) Waiting “Ready”;
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f) Interface 24 stitches on 18 pins input rising edges;

g) Setting laser power parameters;

h) When the internal output frequency occupation ratio of the laser is required, set out the light

frequency/duty cycle/pulse width; (out of the output of the light and the output of the output

of the 15.16 -pin and the output ratio of the upper machine software); no internal output

inside the laser is required When the frequency occupation ratio, the default setting

parameter is 100Hz and the duty cycle is 100%.

i) 15, 16 -foot adjustment signal output high level to turn on laser.

4.8.2.4 In the external control mode, the power simulation amount is set in external

settings, external modulation mode, internal control enable enable

Figure 22 In the external control mode, the power and light are all external control wiring

diagrams

Operation method:

j) Shortconnect the 8 and 9 pins on the INTERFACE 24 pins (the control board is powered

on);
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k) Open the laser clientware;

l) Click “the guide laser ON” button to view the guide laser;

m) Open the AD mode、external modulation mode, turn off the external enable.

n) Waiting “Ready”;

o) When the internal output frequency occupation ratio of the laser, set out the light

frequency/duty cycle/pulse width; (out of the output of the light and the output ratio of the

upper machine software set by the 15.16 -footed signal and the upper machine software); the

internal output frequency of the laser is required for At the time of occupation ratio, the

default setting parameter is 100Hz, and the duty cycle is 100%;

p) Control board card output analog (12, 14 pin) and outlet signals (15, 16 pin).

4.8.2.5 In the external control mode, the power simulation amount is set in external

settings, external modulation mode, external enable

Figure 23 In the external control mode, the power, light, and enable all control wiring diagrams

Operation method:

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q) Shortconnect the 8 and 9 pins on the INTERFACE 24 pins (the control board is powered

on);

r) Open the laser clientware;

s) Click “the guide laser ON” button to view the guide laser;

t) Open the AD mode, the external enable, the external modulation mode;

u) On Click on the main power ON;

v) Waiting “Ready”;

w) Interface 24 stitches on 18 pin input rising edges;

x) When the internal output frequency occupation ratio of the laser is required, set out the light
frequency/duty cycle/pulse width; (out of the output of the light and the output of the output

of the 15.16 -pin and the output ratio of the upper machine software); no internal output

inside the laser is required When the frequency occupation ratio, the default setting

parameter is 100Hz and the duty cycle is 100%.

y) Control board card output analog (12, 14 pin) and outlet signals (15, 16 pin).
4.8.2.6 Modification mode and Gate mode

Modification mode: When the duty cycle of the internal frequency of the laser is set to

100%, the laser works in the external modulation mode.

Gate mode: When the duty occupation ratio of the internal frequency of the laser is less than

100%, the laser works in the internal modulation mode. Stop the internal pulse occurring;

4.9 Guide laser control

Table10 Guide laser control

Guide laser control
ON 17 pin of INTERFACE
Rising edge -- turns on guide laser;
Fallingedge -- turns on guide laser.
OFF The clientware：
Red ON -- turns ON guide laser;
Red OFF -- Turns OFF guide laser.
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4.10 The Programming Mode (Waveform Editing)

Figure24 Single -machine mode -continuous control time sequence diagram

Figure25 Single -machine mode -pulse control time sequence diagram

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Figure 26 Modify mode control time preface diagram

Figure 27 Gate mode control time sequential chart

4.11 Modulation signal requirements

The modulation frequency range of the RFL-C6000S laser is 1-20000Hz, and the minimum

pulse width of the laser must be greater than or equal to 160μs, reference value of laser

frequency and duty cycle setting is shown in Table 11.

Table11 Reference value of the frequency and duty occupation ratio of laser
Frequency
Vein 95% 90% 80% 70% 65% 60% 55% 50% 45% 40% 35% 30% 25% 20% 15% 10%
Duty ratio

5000Hz 190μs 180μs 160μs

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4500Hz 200μs 177μs

4000Hz 200μs 175μs 162μs

3500Hz 200μs 185μs 170μs

3000Hz 200μs 183μs 166μs

2500Hz 200μs 180μs 160μs

2000Hz 200μs 175μs

1500Hz 200μs 166μs

1000Hz 200μs

500Hz 300μs 200μs

4.12 Steps of shutting down

Please turn off the laser in the order below:

a) Turn off the emission;

b) Disconnect the air switch;

c) Turn off the cold water machine;

d) Cover the output head protection cap;

4.13 Bluetooth app operation description

4.13.1 Log in

After opening the single -mode laser app, there is an account password login page, as

shown in Figure 28:

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Figure28 login interface

4.13.2 Connect

After entering the login interface, enter the mobile phone number and password, and then

click the login. After the login is successful, enter the APP connection page, as shown in Figure

29:

Figure29 Verification code login interface

Open the Bluetooth switch of the single -mode laser app. If there is a Bluetooth device

nearby, ensure that the switch of the Bluetooth device is turned on and click the "Search" button

on the connection page.

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Figure 30 connect

Click the "Connection" on the right side of the searched Bluetooth device to enter the

connection state, as shown in Figure 31:

Figure 31 connecting

4.13.3 Equipment

After the connection is successful, enter the laser device-status interface, as shown in

Figure 32:

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Figure32 device status

The device status page mainly includes the main power supply, equipment, alarm, and light

state display, as well as the state of light percentage, light power, laser temperature status, and

the state of emergency stop, REM, laser enablement, red light display, and laser device, and laser

The specific state and some parameter values are displayed.

There is also a device-alarm page, as shown in Figure 33:

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Figure33Equipment-alarm
If the device alarm page is connected to the laser, the laser is not alarm, and the interface

will display "No alarm, check the historical records!", If there is a alarm state, the specific title of

the alarm will be displayed.

The state display of the laser also has the setting function that supports some parameters. It

can be visible in the device-settings interface, as shown in Figure 34:

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Figure34 Equipment-Settings
In the device-lock interface, the laser can be locked or unlocked to the laser through the

device authorization code. The specific form of the page is shown in Figure 35:

Figure35 Equipment-Lock

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4.13.4 My page

Entering my page, you can see function introduction, version update, and about machines,

as shown in Figure 36.

Figure36 page
The function introduction interface is a specific introduction to the laser. As shown in

Figure 37:

Figure37 Features

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The version update interface is the content of the current version of the laser and the

content of the upgraded version. As shown in Figure 38:

Figure38 new version update

Mine-about the machine page shows the relevant information of the laser, such as laser

time, laser model, laser serial number, main control serial number, key version number, system

information. As shown in Figure 39:

Figure39 Mine-About the machine

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In my-about machine-system information page, and laser detailed information. As shown

in Figure 40:

Figure 40 Mine-About Machine-System Information

4.13.5 Software introduction

The single -mode laser app is a mobile software that can be connected to the laser through

Bluetooth to facilitate the after -sales, maintenance, and commissioning engineers, etc., without

portable notebooks, you can use the single -mode laser app installed on Android phones to and

the laser. Connect, read the state of the laser or set some parameters, which is conducive to the

rapid, effective and convenient solution to some problems in the use of laser use.

5 Alarms and Solutions

5.1 Alarms Display

Connect the computer and open the host computer software, after the laser and the client

software establish normal communication. All alarm states of the laser can be displayed on the

host computer software interface, as shown in Figure 41. When the internal temperature of the

laser is abnormal, the power is abnormal, the scattered light is abnormal, the power supply is

abnormal, the condensation is abnormal, the flow rate is abnormal, etc., the laser will alarm.

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Figure41 The homepage of the clientware

If any alarm occurs (except for Interlock alarm)when the laser is running, the clientware will

display the alarm that occurs, and the ALARM light (yellow) on the front panel of the laser will

light up, the laser will stop emitting and lock.

When the Interlock is abnormal, the output of Ready signal is low, and the Interlock state is

abnormal in the clientware, but the laser is not locked, and the ALARM light (yellow) is not lit.

Theoutput of Ready signal is on high level when the Interlock is normal.

5.2 Alarm solutions

The instructions and solutionsof alarms are as follows:

Table 12 Instructions and solutionsfor alarms of laser

Alarm name Alarm instructions and solutions

Instruction:
Low temperature/high temperature alarm of the laser. The sensor in the laser
detects an abnormal temperature inside the laser. A high-temperature /
low-temperature error occurs when the temperature at the monitoring point
exceeds the set upper / lower limit.
T1/T2 Alarm
Solution:
High temperature alarm,please check if the water-cooling system is normally
working, the water temperature is set correctly, and the water connection is
correct. When the water cooling system works normally and the water
temperature drops below 30°C, restart the laser.
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Low temperature alarm, please check if the actual water temperature of the
water is too low. In addition, a low ambient temperature may also cause a low
temperature alarm when the laser is cold. Please wait until the water
temperature of the water rises above 10°C.
Instruction:
The water flow rate of the laser alarms. The current water flow rate detected
inside the laser is lower than the required value, and there is a safety risk.
Solution:
Stop using the laser immediately.Please check the output model and working
Laser Water flow
status of the laser water cooler and clean the laser water filter module
according to the laser operation requirements in the section 3.3 cooling
System Installation and Requirements.It is recommended to clean the water
cooler and the water inlet filter assembly regularly, and replace the cooling
water.
Instruction:
Scattering light alarm, when the intensity of ambient light inside the laser
exceeds the set value, the scattering light alarm will be generated, and the laser
emission function will be locked (cannot be unlocked).The scattered light
Scattered Light
alarm only occurs when the laser emission.
Alarm
Solution:
Please restart the laser, check the guide laser state of the laser, and through the
clientware "from the control module" reading the scattered light monitoring
voltage value, and contact Raycus.
Instruction:
The alarm is generated when the emission of the laser cannot reach the set
value. Power error occurs only when the laser is emitting.
Laser Power Alarm
Solution:
Please restart the laser, check the red light state of the laser,and contact
Raycus.
Instruction:
AC DC Error, failure ofthe laser power supply or sudden power failure of the
power supply system may cause an alarm.
AC DC Alarm
Solution:
Check if the input AC voltage is normal. Restart the laser, if this error
continues to occur, please contact Raycus.
Instruction:
Current Driver Current Driver Alarm,this error occurs when the constant current driver board
Alarm inside the laser is abnormal.
Solution:
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User Guide of RFL-C6000S

Restart the laser, If this error continues to occur, please contact Raycus
In addition to the above, if there are any questions or errors inusing of the laser, you can

contact Raycus to get help.

6 Warranty, Return and Maintenance

6.1 General Warranty

Raycus warrants that all Raycus fiber laser products are conformed to applicable product
specifications under normal use and are free from defects in materials and workmanship. The
warranties start on the date of shipment from Raycus for a period of time as set forth in the
applicable purchase contracts or product specifications. Raycus has the right to choose to repair
or replace any product that proves to be defective in materials and workmanship selectively
during the warranty period. Only products with particular defects are under warranty. Raycus
reserves the right to issue a credit note for any defective products produced in normal conditions.

6.2 Limitations of Warranty

The warranty does not cover the maintenance or reimbursement of our productof which the
problem results from tampering, disassembling, misuse, accident, modification, unsuitable
physical or operating environment, improper maintenance, damages caused by those who are not
from Raycus due to excessive use or not following the instructions.Customer has the
responsibility to understand and follow this instruction to use the device. Any damage caused by
fault operating is not warranted. Accessories and fiber connectors are excluded from this
warranty.
According to the warranty, client should write to us within 31 days after the defect is
discovered. This warranty does not involve any other party, including specified buyer, end-user
or customer and any parts, equipment or other products produced by other companies.

 It is the customer’s responsibility to understand and follow operating

instructions in this User Guide and specifications prior to
operation-failure to do so may void this warranty.Accessories and
fiber connectors are not covered by this warranty.

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 Wuhan Raycus Fiber Laser Technologies Co., Ltd.
User Guide of RFL-C6000S

6.3 Service and Repair

a) Do not open the device. There are no user serviceable parts, equipment orassemblies
for user in this product. All service and maintenance shall be performedby qualified
Raycus personnel.
b) Please contact Raycus as soon as possible when problems under warranty about
maintenance happened to the product.
c) The product returned with permission should be placed in a suitable container.
d) If any damage happened to the product, please notify the carrier in document
immediately.
We reserve the right to make changes in design or constructions of any of our
products at anytime without incurring any obligation to make changes or install the same
on units previously purchased.

All the items about warranty and service above provided by Raycus are for user’s

reference; formal contents about warranty and service are subject to the contract.

© 2023 Wuhan Raycus Fiber Laser technologies Co. Ltd, All Rights Reserved.

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BLT421 Product Manual

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Excellent Optical Cutting Instrument

 BLT421 Product Manual

Document History

Number Date Version

01 2022/08/19 V1.1

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Notice:
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Thank you for choosing the BLT intelligent cutting head. This manual provides you with
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important information such as product parameters, installation, and maintenance, so

please read this manual carefully before using the product. At the same time, in order to

ensure the safety of operation and the operation of the product in the best condition,

please strictly follow the precautions in the manual.

BOCI is constantly updating/upgrading products, so our company reserves the right to

modify the product models and descriptions in this manual without prior declaration.

Unauthorized disassembly of the product is strictly prohibited without the

authorization of BOCI Technology, otherwise the warranty will be invalid!
 BLT421 Product Manual

Table of contents
BLT421 Product Manual ..............................................................................................1

1. Product Description ................................................................................................ 1

1.1 Product View .................................................................................................................................................... 1

1.2 Technical parameters ...................................................................................................................................... 2

1.3 Meaning of LED indicator ................................................................................................................................ 3

2. Gas port ..................................................................................................................4

3. Water cooling interface .......................................................................................... 5

4. Electrical interface .................................................................................................. 6

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4.1 Bus system ....................................................................................................................................................... 7

4.2 Non-bus systems ............................................................................................................................................. 8

5. Cutting head installation ........................................................................................ 9

5.1 Preparation before operation ......................................................................................................................... 9

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5.2 Specific operation process ............................................................................................................................ 10

5.2.1 Preparation of clean bench ................................................................................................................. 10

5.2.2 The cutting head is placed in the clean workbench ........................................................................... 10

5.2.3 Clean and wipe the fiber interface of the cutting head ......................................................................11

5.2.4 Check the laser fiber end face ............................................................................................................. 11

5.2.5 Tear off the protective film/remove the protective cap ..................................................................... 11

5.2.6 Insert the laser fiber interface into the cutting head .......................................................................... 12

5.2.7 Winding seal ........................................................................................................................................ 12

5.2.8 Mount the cutting head on the backplane ..........................................................................................13

5.2.9 Installing the ceramic body and nozzle .............................................................................................. 14

 BLT421 Product Manual

5.2.10 Beam centering ..................................................................................................................................15

Appendix A - Care/Maintenance .............................................................................. 17

1.1 Schematic diagram of product structure ...................................................................................................... 17

1.2 Replace the upper protective lens ................................................................................................................ 18

1.3 Replace the lower protective lens ................................................................................................................. 19

Appendix B - Mechanical Dimensions ...................................................................... 20

1.1 Cutting head installation size ........................................................................................................................20

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 BLT421 Product Manual

1. Product Description

1.1 Product View

1
11

10
4
12

9
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5

8 13
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14

15

16

Product View (Structure and Interface Description)

1. Optical fiber interface; 9. Nozzle cooling air interface;

st
2. 1 Upper protective lens; 10. Cutting gas interface;
nd
3. 2 Upper protective lens; 11. Cooling water outlet;
4. Collimation unit; 12. Cooling water inlet;
5. Focusing unit; 13. Anti-collision screw;
nd
6. 2 Lower protective lens; 14. Ceramic body lock ring;
st
7. 1 Lower protective lens; 15. Ceramic body;
8. Working indicator; 16. Nozzle;

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 BLT421 Product Manual

1.2 Technical parameters

Cutting head BLT421

Laser wavelength: 1030-1090nm

Laser power: ≤8kW

Fiber interface: QBH, EOC

Spot magnification: M=1.5/2.0 (100:150/100:200)

Focus adjustment range: ±50mm (optical ratio 1:2 100:200)

NA: Max.0.13 at Fc100

Centering adjustment range: ±1.5mm

Focus acceleration:

Cutting gas interface:

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Nozzle cooling gas connection:

Water cooling interface:

7.5m/s²

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ø10, maximum 25bar (2.5Mpa)

ø6, maximum 5bar (0.5Mpa)

ø8, maximum 5bar (0.5Mpa), minimum flow 2.0l/min

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Operating temperature: 5～55℃

storage temperature: -25～+55 ℃

size: 404x122

weight: About 5.5kg

Notice:

To avoid damage to the cutting head during storage and transportation, pay attention to
the following:
 The cutting head should be stored within the allowable temperature and humidity
range.
 Avoid storage in and near magnetic fields such as permanent magnets or strong
alternating fields.
 Avoid collision of the cutting head.

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 BLT421 Product Manual

1.3 Meaning of LED indicator

icon state meaning

green Power is normal.

red Under-voltage alarm: insufficient electrical power.

not No power supply: There is no power supply, the connection cable is broken, and the

bright interface is loose.

icon state meaning

green The system is operating normally.

Abnormal motor: The current consumption of the motor is too large, and the
red

icon
C not

bright

state
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mechanical components cannot run smoothly.

The cable is broken, and the interface is loose.

meaning
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green System communication is normal.

red System communication is abnormal.

not
The cable is broken, and the interface is loose.
bright

icon state meaning

green The readings of each sensor are normal.

red There is an abnormal sensor reading.

not
The cable is broken, and the interface is loose.
bright

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 BLT421 Product Manual

2. Gas interface

Cutting gas
interface

Nozzle cooling gas

C I connection
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Installation connection: cutting gas 1, nozzle cooling gas 2

Notice:

 The maximum pressure of cutting gas is 25bar (2.5Mpa).

 The cutting gas quality shall meet the requirements of gas quality in accordance with ISO

8573-1:2010: solid particles - class 2, water - class 4, oil - class 3. The purer the cutting gas,

the longer the life of the protective lens.

 The cutting gas pipe diameter (outer diameter) is 10mm, and the nozzle cooling gas pipe

diameter (outer diameter) is 6mm.

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 BLT421 Product Manual

3. Water cooling interface

Water cooling water

outlet

Water cooling water

Notice:



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recommended.
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Installation connection: water-cooled water inlet port 2A, water-cooled water outlet port 1A

Deionized/distilled water (conductivity < 10 μ S/cm) specified by the laser manufacturer is

Recommended cooling water setting value: cooling water pressure ≤5bar (0.5Mpa), water flow rate ≥
2.0l/min.
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 Please refer to the dew point table to set the cooling water temperature to prevent condensation on
the optical components.
Dew point temperature at different temperature and humidity

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 BLT421 Product Manual

4. Electrical Interface

PWE and aviation plug interface waterproof precautions:

1. PWE interface and air plug interface are equipped with dust plugs from the
factory. If the dust plug does not fall off, the protection level of IP64 can be
achieved; at the same time, when the PWE cable and the air plug cable are
well connected, IP64 can also be achieved;
2. After the dust plug is removed, the protection level of IP64 cannot be achieved.
If it encounters spraying or flushing at this time, it will cause water to enter the
product and affect the function;
3. Ensure that the water circuit is connected well, and the water pipe interface is
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4.
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tightened before removing the dust plug to prevent the water pipe from
accidentally loosening and water rushing to the interface, causing the product
to enter the water;
When adjusting the wiring, remove the dust plug for wiring. It is recommended
to keep the removed dust plug of the PWE interface. Install the dust-proof plug
as soon as possible after the stitches are removed to prevent accidental water
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ingress in the transfer, water connection and other links.

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 BLT421 Product Manual

4.1 Bus system

BCS210EE

Power
supply 220V
AC
CBLT421 cutting head installation
wiring diagram
I Hypcut
Slave Station
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IPC
HyPanel
master
station

Notice:
 The above wiring operations should only be performed by
trained and professional personnel.
 When the cutting head is connected to the BCS210E, the
BCS210E must be powered off.

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 BLT421 Product Manual

4.2 Non-bus systems

C I BCL4500A
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BLT421 cutting head installation
Power
wiring diagram
24VDC

Cypcut
IPC Slaves

master Station

station

Notice:
 The above wiring operations should only be performed by trained and professional
personnel.
 When the cutting head is connected to the BCL4500A, the BCL4500A must be powered
off.
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 BLT421 Product Manual

5. Cutting head installation

During the installation of the cutting head, dust or dirt may accidentally enter the cutting head, contaminate the
optical lens, and affect its normal functions. To prevent dust or dirt from entering the cutting head, please refer
to the following methods for the installation of the cutting head:

5.1 Preparation before operation

The following objects are required before operation:

 Cutting head;
 Clean workbench (clean workbench type: vertical purification; cleanliness level: ISO 5, 100; average wind
speed ≥ 0.4m/s);
 Cleaning kit: strong light flashlight, absolute ethanol (or IPA), dust-free purification cotton swab, dust-free
cloth, compressed air dust removal tank (or air blower).

C I clean workbench
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Cutting head

Purification
Flashlight Ethanol Dust-free cotton swab
Kit

dust-free cloth Compressed air dust removal tank

Notice:
 The above operations can only be carried out by personnel who have received
appropriate training and have professional knowledge.
 In order to ensure the normal operation of the laser device and the safety of
operators, please be sure to follow the relevant operating instructions.

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 BLT421 Product Manual

5.2 Specific operation process

5.2.1 Preparation of clean bench

Prepare the clean bench, start it up and ensure its functionality:

Clean table type: vertical

purification; cleanliness class:
ISO 5, 100; average wind speed
≥ 0.4m/s

1. Check that the equipment is clean and qualified (checks the cleanliness of the dust particle counter ),
and confirm that the FFU purification unit is within the validity period (measure the average wind speed in the
working area, when the wind speed cannot reach 0.3m/s, the FFU purification unit must be replaced);
2.
3.
flow is not disturbed;
4.
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Check whether each switch is running normally, and check whether the fan is running normally;
It is strictly forbidden to install unnecessary items in the clean working area to ensure that the clean air

For clean workbenches that are newly installed or have not been used for a long time, please use a
clean cloth and anhydrous ethanol to wipe them clean before use;

During operation:
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1. Turn on the power, and pull the glass sliding door of the clean workbench to the lowest position
(leaving a gap of about 10cm);
2. Start the fan, it is recommended to purify the clean table for about 30 minutes in advance;
3. Turn on the light source of the clean workbench.

5.2.2 The cutting head is placed in the clean workbench

Put the cutting head horizontally inside the clean workbench.

Notice:
 To prevent dust from contaminating the core area of
the cutting head, please ensure the integrity of the
special protective film/cap for the optical fiber
interface before plugging and unplugging the
optical fiber.

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 BLT421 Product Manual

5.2.3 Clean and wipe the fiber interface of the cutting head

Wipe the fiber interface of the cutting head with a clean cloth and anhydrous ethanol.

5.2.4 Check the laser fiber end face

Remove the protective cap of the laser fiber, and irradiate the end face of the fiber with a strong flashlight to
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observe whether there is any pollution; if it is clean, you can directly insert the fiber;

Check the fiber interface end face before insert

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Compatible interfaces: Trumpf LLK-Q, IPG HLC-8/LC-8

5.2.5 Tear off the protective film/remove the protective cap

Remove the special protective cap/protective plug for the optical fiber interface on the cutting head.

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 BLT421 Product Manual

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5.2.6 Insert the laser fiber interface into the cutting head

Align the fiber optic plug with the red dot, insert it into the unlocked fiber optic port, and ensure that it is
inserted as far as it will go. Rotate the lock cap until it tightly locked.

5.2.7 Wrap and seal

After inserting the optical fiber, wrap and seal the interface between the optical fiber and the cutting head
with tape.

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 BLT421 Product Manual

Tape wrap seal

Notice:
 To achieve affective sealing, it is recommended to wrap the
tape at least three times for sealing.

5.2.8 Mount the cutting head on the backplane

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The cutting head can be installed on the Z-axis backplane of the machine tool through four screws A, B, C,

and D. When fixing the cutting head on the machine, it must be ensured that the cutting head is locked and there
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is no obvious movement.

A B

C D

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 BLT421 Product Manual

5.2.9 Installing the ceramic body and nozzle

Install the ceramic body and secure with the locking ring, then install the nozzle.

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Tighten the nozzle on the ceramic

body by hand,
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Use a wrench to tighten the ceramic

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 BLT421 Product Manual

5.2.10 Beam centering

Adjust the XY centering knob to make the focal point in the center of the nozzle by low-power dotting.

The conditioned laser

X/Y
beam must be in the
center of the nozzle.
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adjustment

screw
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Relative position of laser beam

Tape

pass Fail

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 BLT421 Product Manual

Manual alignment operation:

1. Make sure the laser beam is turned off.

2. Place scotch tape under the nozzle.

3. Click to trigger a low-power laser pulse and assess the position of the laser beam relative

to the nozzle through the penetration of the tape.

4. Adjust the X/Y centering screws to center the laser beam on the nozzle.

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 BLT421 Product Manual

Appendix A - Care/Maintenance

1.1 Schematic diagram of product structure

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Notice:
 During the maintenance of cutting head accessories, dust or dirt may accidentally enter the cutting head and damage the
product. Please pay attention to keep it clean during maintenance and replacement of accessories;
 The maintainable parts of different products will have different specifications. If you need to replace them, please contact
your after-sales service personnel for specific models;
 Optical products have high quality requirements for maintainable accessories. Please ensure that the replacement and
maintenance accessories are original accessories. Otherwise, there may be potential safety hazards.

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 BLT421 Product Manual

1.2 Replace the upper protective lens

st
1 Upper protective lens
protective door

st
1 Upper protective
lens base

st
1. Open the protective door of the 1 upper protective lens;
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3.
4.
5.
6.
7.
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Pull out the upper protective mirror drawer;
Close the protective mirror drawer door to prevent dust from entering;
Remove the pressure ring on the protective lens;
Replace the protective lens;
Open the upper protective mirror drawer protective door;
Insert the upper protective mirror drawer with lens into the cutting head.
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Pressing ring

No
upper protective pressing!
lens

Upper protective
mirror base

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 BLT421 Product Manual

1.3 Replace the lower protective lens

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1.
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Press the buckle to open the protective door of the lower protective
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mirror drawer;
2. Pull out the lower protective mirror drawer;
3. Close the protective door of the lower protective mirror drawer to
prevent dust from entering;
4. Remove the pressure ring on the protective lens;
5. Replace the lower protective lens;
6. Open the protective door of the lower protective mirror drawer;
7. Insert the lower protective mirror drawer with lens into the inside of
the cutting head.

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 BLT421 Product Manual

Appendix B - Mechanical Dimensions

1.1 Cutting head installation size

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