By Vent Ion 2200 en

ByVention
Operating Instructions
Issued on: 10.2007
Operating Instructions © Bystronic Laser AG, 2006 0-1

ByVention_2200_BA_V04_en.fm
ByVention
0-2 © Bystronic Laser AG, 2006 Operating Instructions

ByVention
Product identification
These operating instructions apply to the product:
ByVention with 2 200 W laser module
Document identification
Operating Instructions: ByVention_2200_BA_V04_en.fm
Please specify the document identification and issue date when reorder-
ing.
Purpose of the operating instructions

These operating instructions form part of the overall documentation. They
provide information on the safe and proper use of the product.
Other documents
The complete set of documentation contains the following documents:
Operating Instructions
Installation Guide
Spare parts catalog
Diagrams
Supplier documentation
Machine documentation
Machine logbook

ByVention
Target group
These operating instructions are intended for the owner and operator of
the machine and for maintenance and repair personnel.
Storage
The operating instructions must always be freely accessible to the speci-
fied target group.
Copyright
Dissemination or duplication of this document, or exploitation or commu-
nication of its content without the express permission of the author is pro-
hibited. Contravention will result in damages. All rights reserved.

ByVention
Argentina Australia
BEHRENDT MAQUINARIAS S.A. LMC LASER SERVICE PTY. LTD
Lima 355 - Piso 8 Factory 2
AR-1073 Buenos Aires 1 Frias Road, Moorabbin
Tel.: +54 11 5031 5312 AU-3198 Victoria
Fax: +54 11 5031 5301 Tel.: +61 3 9555 5525
Email: info@bmaq.com.ar Fax: +61 3 9555 2970
Email: sales@lmclaser.com.au
Austria Brazil
BYSTRONIC AUSTRIA GmbH BYSTRONIC DO BRASIL Ltda.
Wienerstrasse 131 Rua Arapongas, 285
AT-4020 Linz BR-83040 200 São Cristóvão
Tel.: +43 732 341 377 0 São José dos Pinhais - Paraná
Fax: +43 732 341 377 11 Tel.: +55 41 3398 2000
Email: office@bystronic.at Fax: +55 41 3398 1789
Email: bystronic@bystronic.com.br
China China
BYSTRONIC CO., LTD BYSTRONIC MACHINERY CO. LTD.
Rijing Road 88, Level 1 Part A Economic Development Zone
Waigaoqiao FTZ Pudong Ninghe County
CN-200131 Shanghai CN-301500 Tianjin, PRC
Tel.: +86 21 5868 0480 Tel.: +86 22 6958 9988
Fax: +86 21 5868 0481 Fax: +86 22 6958 8168
Email: byadmin@sh163.net Email: sales@afmtianjin.com
Czech Republic England

Bystronic Czech Republic s.r.o. BYSTRONIC UK LIMITED
Slatina, Tuřanka 115/1222 Maple Park
PSČ 627 00, Brno Lowfields Avenue
Česká republika GB-Leeds LS12 6HH
Tel.: +420 532 123 314 Tel.: +44 113 222 8112
Fax: +420 532 123 315 Fax: +44 113 271 9862
Email: info.cz@bystronic.com Email: service.cutting.uk@bystronic.com
France Germany
BYSTRONIC FRANCE SA BYSTRONIC DEUTSCHLAND GmbH
Parc Technipolis Mollenbachstrasse 33-35
3 avenue du canada D-71229 Leonberg
F-91940 Les Ulis Tel.: +49 (0)7152 6090 0
Tel.: +33 1 6941 9984 Fax: +49 (0)7152 6090 11
Fax: +33 1 6941 9951 Email: info@bystronic.de
Email: info@bystronic.fr
Greece Hungary
ADECA SA AUTOREL Kft.
Technical and Commercial Company Attila ut 131 / III. 12.
Ave. Alexandras 56 HU-1012 Budapest
GR-11473 Athens Tel.: +36 1 212 7270
Tel.: +302 10 822 8503 Fax: +36 1 212 7271
Fax: +302 10 821 6746 Email: sales@autorel.hu
Email: adeca@otenet.gr

ByVention
Israel Italy
ALON Laser Services Ltd. BYSTRONIC ITALIA SRL
23 Robinzon St. Via del Lavoro 30
IL-49560 Petach-Tikva I-20030 Bovisio Masciago / MI
Tel.: +972 3 931 0127 Tel.: +39 0362 59931
Fax: +972 3 931 0128 Fax: +39 0362 5941 35
Email: alon_ch@zahav.net.il Email: services.it@bystronic.com
Netherlands North America

BYSTRONIC BENELUX BV BYSTRONIC INC.
Stek 8 Bystronic North American Headquarters
NL-3371 Hardinxveld-Giessendam 185 Commerce Drive
Tel.: +31 (184) 611 020 Hauppauge, NY 11788
Fax: +31 (184) 617 774 Tel.: +1 631 231 1212
Email: info@bystronic.nl Fax: +1 631 231 1040
Email: info@bystronicusa.com
Mexico Poland
Bystronic Mexico S.A. de C.V. BYSTRONIC POLSKA Sp. z o.o.
Lago Onega No. 424, Col. Granada Al. Krakowska 38
MX-11520 Mexiko, D.F. Janki
Tel: + 52 (0)5 525 815 147 PL-05090 Raszyn
Fax: +52 (0)5 525 815 156 Tel.: + 48 22 331 37 70
Email: info@bystronicusa.com Fax: + 48 22 331 37 71
Russia / Ukraine and Rest CIS Singapore

Bystronic Russia Sales Office BYSTRONIC PTE. LTD.
c/o United Machinery AG 2 Leng Kee Road #03-05
2. Hutorskaja Street, 38 A Thye Hong Centre
RU-127287 Moscow SG-159086 Singapore
Tel.: +7 (495) 961 21 67 Tel.: +65 6472 6300
Fax: +7 (495) 961 21 68 Fax: +65 6472 2418
Email: sales.ru@bystronic.com Email: bystronicasia@bystronic.com.sg
Slowakei South Africa

Bystronic Czech Republic s.r.o. FOREST ENGINEERING
Slatina, Tuřanka 115/1222 P.O.Box 169
PSČ 627 00, Brno ZA-1600 Isando
Česká republika Tel.: +27 11 397 4050
Tel.: +420 532 123 314 Fax: +27 11 397 4210
Fax: +420 532 123 315 Email: forest@fhmt.co.za
Email: info.cz@bystronic.com
South Korea Spain / Portugal

BYSTRONIC KOREA, LTD BYSTRONIC IBERICA, S.A.
6Fl, Teleron B/D Avenida Tenerife No. 2
KR-1459-2 Gwanyang-dong, Dongan-gu Edifigo 1 3A Planta Oficina D
Anyang-si E-28700 San Sebastian de los Reyes
Geonggi-do Tel.: +34 91 654 4496
Tel.: +82 314 25 5729 Fax: +34 91 652 4983
Fax: +82 314 25 0057 Email: info@bystronic.es

ByVention
Sweden Switzerland
BYSTRONIC SCANDINAVIA AB BYSTRONIC SALES AG
Östra Bangatan 18 Industriestrasse 21
SE-19560 Arlandastad CH-3362 Niederönz
Tel.: +46 (0)8 5944 1550 Tel.: +41 (0)62 956 37 83
Fax: +46 (0)8 5944 1555 Fax: +41 (0)62 956 33 81
Email: info@bystronic.se Email: info.sales@bystronic.com
Taiwan Rest of the World

CHASER C.D. ENTERPRISE CO. LTD BYSTRONIC LASER AG
22F, No. 639, Chung Cheng Rd. Industriestrasse 21
TW-238 Shuh Lin City - Taipei Hsien CH-3362 Niederönz
Tel.: +886 22 689 7988 Tel.: +41 (0)62 956 3333
Fax: +886 22 689 7986 Fax: +41 (0)62 956 3386
Email: chaser@tpts5.seed.net.tw info.laser@bystronic.com

ByVention

ByVention
Table of contents
1 Product description
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

1.1.1 Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1.1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1.1.4 Working positions . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
1.1.4.1 Standard installation . . . . . . . . . . . . . . . . . . . . . . 1–6
1.1.4.2 Special installation . . . . . . . . . . . . . . . . . . . . . . . 1–7
1.1.5 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.2 Product data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 12
1.2.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 12
1.2.2 Material formats and thicknesses that can be cut . . . . 1 – 13
1.2.2.1 Standard sheet . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 13
1.2.2.2 Partly cut standard sheet . . . . . . . . . . . . . . . . . . . 1 – 14
1.2.2.3 Sheet segment . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 14
1.2.2.4 Residual sheet . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 15
1.2.2.5 Cutting area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 16
1.2.2.6 Cuttable thicknesses . . . . . . . . . . . . . . . . . . . . . . 1 – 17
1.2.3 Combined cooling and filtration unit . . . . . . . . . . . . . 1 – 19
1.3 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 20

ByVention_2200_BA_V04_enTOC.fm
ByVention
Table of contents
2 Safety regulations
2.1 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . 2–3

2.2 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.2.1 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.2.2 Safety-conscious working . . . . . . . . . . . . . . . . . . . . 2–6
2.3 Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.3.1 Warning and information labels . . . . . . . . . . . . . . . . 2–8
2.4 Requirements for personnel . . . . . . . . . . . . . . . . . . 2 – 13
2.4.1 Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 13
2.4.2 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 14
2.4.3 Responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 14
2.4.4 Personal protection equipment . . . . . . . . . . . . . . . . . 2 – 14
2.5 Product-specific hazards. . . . . . . . . . . . . . . . . . . . . 2 – 15
2.5.1 Laser radiation hazards . . . . . . . . . . . . . . . . . . . . . . 2 – 15
2.5.1.1 Normal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 15
2.5.1.2 Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 16
2.5.1.3 Direct laser beam . . . . . . . . . . . . . . . . . . . . . . . . 2 – 17
2.5.1.4 Reflected and stray radiation . . . . . . . . . . . . . . . . 2 – 18
2.5.2 High-voltage hazard . . . . . . . . . . . . . . . . . . . . . . . . 2 – 19
2.5.3 Electrical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 20
2.5.4 Hazards arising from the pneumatic system . . . . . . . 2 – 21
2.5.5 Hazards arising from gas, dust, vapors, smoke . . . . . 2 – 22
2.5.5.1 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 22
2.5.5.2 Handling LASERMIX 312. . . . . . . . . . . . . . . . . . . . 2 – 24
2.5.5.3 Handling nitrogen (N2). . . . . . . . . . . . . . . . . . . . . 2 – 26
2.5.5.4 Handling oxygen (O2) . . . . . . . . . . . . . . . . . . . . . 2 – 27
2.5.5.5 Dust extraction unit. . . . . . . . . . . . . . . . . . . . . . . 2 – 28
2.5.5.6 Toxic fumes emitted when cutting plastics . . . . . . . 2 – 29
2.5.6 Hazards associated with handling the optical system . 2 – 30
2.5.6.1 General information. . . . . . . . . . . . . . . . . . . . . . . 2 – 30
2.5.6.2 Warnings in case of fire or accident . . . . . . . . . . . . 2 – 30
2.5.6.3 Notes on health protection . . . . . . . . . . . . . . . . . . 2 – 30
2.5.7 Lubricants, coolants and cleaning agents. . . . . . . . . . 2 – 31
2.6 Additional hazards . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 32
2.7 Emergency information. . . . . . . . . . . . . . . . . . . . . . 2 – 33
0 - 10 © Bystronic Laser AG, 2006 Operating Instructions

ByVention
Table of contents
3 Design and operation
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

3.1.1 Beam path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.1.2 Flying optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.1.3 Deflecting mirror . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.2 Layout of the laser cutting machine . . . . . . . . . . . . 3–7
3.2.1 Operating side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
3.2.2 Loading side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.3 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
3.3.1 Positions of safety devices . . . . . . . . . . . . . . . . . . . . 3 – 10
3.3.2 Main power switch . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 12
3.3.3 EMERGENCY STOP circuit . . . . . . . . . . . . . . . . . . . . 3 – 13
3.3.4 Shutter lock (key-operated switch) . . . . . . . . . . . . . . 3 – 14
3.3.5 Safety door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 15
3.3.5.1 Safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 15
3.3.5.2 Emergency release . . . . . . . . . . . . . . . . . . . . . . . 3 – 16
3.3.6 Safety cover for cutting area . . . . . . . . . . . . . . . . . . 3 – 17
3.3.6.1 Safety door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 17
3.3.6.2 Service opening . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 18
3.3.6.3 Protective flap on unloader opening. . . . . . . . . . . . 3 – 19
3.3.7 Safety cover on the unloader . . . . . . . . . . . . . . . . . . 3 – 20
3.3.8 Safety covers on laser module . . . . . . . . . . . . . . . . . 3 – 21
3.3.8.1 Covers and folding doors . . . . . . . . . . . . . . . . . . . 3 – 21
3.3.8.2 High voltage covers . . . . . . . . . . . . . . . . . . . . . . . 3 – 22
3.3.9 Radiation protection . . . . . . . . . . . . . . . . . . . . . . . . 3 – 23
3.4 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 24
3.5 Operator console. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 25
3.6 Machine stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 26
3.6.1 Clean air supply unit . . . . . . . . . . . . . . . . . . . . . . . . 3 – 27
3.6.2 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 28
3.6.2.1 Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 29
3.6.2.2 Cutting gases . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 30
3.7 Travel unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 31
3.7.1 Cutting bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 31
3.7.2 Cutting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 32
3.7.3 Severance-cut monitoring . . . . . . . . . . . . . . . . . . . . 3 – 33
3.7.4 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 34
3.7.5 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 36
3.7.5.1 Range of nozzles available . . . . . . . . . . . . . . . . . . 3 – 37
3.7.5.2 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 38
Operating Instructions © Bystronic Laser AG, 2006 0 - 11

ByVention
Table of contents
3.8 Cutting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 39

3.8.1 Lifting unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 40
3.8.2 Cutting grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 41
3.8.3 Zero point / Sheet stop . . . . . . . . . . . . . . . . . . . . . . 3 – 42
3.8.4 Nozzle cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 43
3.8.5 Calibration plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 44
3.8.6 Dust extraction system . . . . . . . . . . . . . . . . . . . . . . 3 – 45
3.8.7 Waste trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 46
3.9 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 47
3.9.1 Loading table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 47
3.9.2 Sheet stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 48
3.9.3 Sheet feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 49
3.10 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 51
3.10.1 Unloading table . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 52
3.10.2 Waste tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 53
3.11 Laser module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 54
3.11.1 Upper section of laser module . . . . . . . . . . . . . . . . . 3 – 56
3.11.2 Lower section of laser module . . . . . . . . . . . . . . . . . 3 – 58
3.12 Combined cooling and filtration unit . . . . . . . . . . . 3 – 60
3.13 Remote diagnostics (option) . . . . . . . . . . . . . . . . . 3 – 61
3.14 Cutting gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 64
3.14.1 Cutting gas quality . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 64
3.14.2 Compressed air quality . . . . . . . . . . . . . . . . . . . . . . 3 – 65
3.14.3 Cutting gas consumption . . . . . . . . . . . . . . . . . . . . . 3 – 66

ByVention
Table of contents
4 Control elements
4.1 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

4.1.1 Indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.1.2 Loading status . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.1.3 System, status and error messages . . . . . . . . . . . . . 4–5
4.1.3.1 Color coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
4.1.3.2 Priorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
4.2 Controls and indicators . . . . . . . . . . . . . . . . . . . . . . 4–6
4.2.1 Control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.2.2 Laser module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4.2.3 Operator console . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
4.2.3.1 Membrane keypad . . . . . . . . . . . . . . . . . . . . . . . . 4–9
4.2.3.2 Function buttons . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 10
4.2.3.3 Traverse buttons . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 11
4.2.4 Sheet-clamping foot switch . . . . . . . . . . . . . . . . . . . 4 – 12
4.3 Operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 13
4.3.1 Normal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 13
4.3.2 Manual operating mode. . . . . . . . . . . . . . . . . . . . . . 4 – 13
4.3.3 Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 13

ByVention
Table of contents
5 Operation
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

5.1.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.1.2 Requirements of the operating personnel . . . . . . . . . 5–3
5.2 Operating the laser cutting machine . . . . . . . . . . . 5–4
5.2.1 Pre start-up check . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.2.2 Switching on in normal operating mode . . . . . . . . . . 5–5
5.2.3 Switching off in an emergency . . . . . . . . . . . . . . . . . 5–8
5.2.4 Switching on again after an EMERGENCY STOP . . . . . 5–8
5.2.5 Switching off in normal mode. . . . . . . . . . . . . . . . . . 5–9
5.3 Layout of the user interface . . . . . . . . . . . . . . . . . . 5 – 11
5.3.1 Standard functions . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 11
5.3.2 Advanced functions . . . . . . . . . . . . . . . . . . . . . . . . 5 – 12
5.4 Material flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 13
5.4.1 Cutting standard sheets . . . . . . . . . . . . . . . . . . . . . 5 – 13
5.4.2 Cutting residual sheets . . . . . . . . . . . . . . . . . . . . . . 5 – 17
5.5 Setting up and adjustment tasks . . . . . . . . . . . . . . 5 – 18
5.5.1 Initiating a function . . . . . . . . . . . . . . . . . . . . . . . . 5 – 18
5.5.2 Removing or inserting the cutting head . . . . . . . . . . . 5 – 19
5.5.3 Adjusting the focal position . . . . . . . . . . . . . . . . . . . 5 – 21
5.5.4 Changing the nozzle . . . . . . . . . . . . . . . . . . . . . . . . 5 – 23
5.5.5 Centering the nozzle . . . . . . . . . . . . . . . . . . . . . . . . 5 – 25
5.6 Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 28
5.6.1 Loading a job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 28
5.6.1.1 Importing a job from USB memory stick . . . . . . . . 5 – 28
5.6.1.2 Load job automatically from the network . . . . . . . . 5 – 30
5.6.2 Job selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 32
5.6.2.1 Order of processing . . . . . . . . . . . . . . . . . . . . . . . 5 – 32
5.6.3 Standard sheet production . . . . . . . . . . . . . . . . . . . 5 – 33
5.6.3.1 Loading standard sheets or partly cut
standard sheets . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 33
5.6.3.2 Starting the cutting process . . . . . . . . . . . . . . . . . 5 – 39
5.6.3.3 Removing the cut parts and skeleton . . . . . . . . . . . 5 – 41
5.6.4 Residual sheet production . . . . . . . . . . . . . . . . . . . . 5 – 42
5.6.4.1 Loading a residual sheet . . . . . . . . . . . . . . . . . . . 5 – 42
5.6.4.2 Starting the cutting process . . . . . . . . . . . . . . . . . 5 – 48
5.6.4.3 Removing the cut parts and skeleton . . . . . . . . . . . 5 – 52

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5.6.5 Start and Stop functions . . . . . . . . . . . . . . . . . . . . . 5 – 53

5.6.5.1 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 53
5.6.5.2 Start part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 53
5.6.5.3 Start job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 53
5.6.5.4 Stop part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 53
5.6.5.5 Cancel job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 54
5.6.6 Changing cutting parameters . . . . . . . . . . . . . . . . . . 5 – 55
5.6.7 Saving cutting parameters. . . . . . . . . . . . . . . . . . . . 5 – 57
5.6.8 Resetting cutting parameters . . . . . . . . . . . . . . . . . . 5 – 57
5.6.9 Repeating the cutting process (Restart) . . . . . . . . . . 5 – 58
5.6.9.1 Repeat sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 59
5.6.9.2 Next part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 59
5.6.9.3 Contour lock-on . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 59
5.6.9.4 From stop point. . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 60
5.7 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 61
5.7.1 Switching to manual mode . . . . . . . . . . . . . . . . . . . 5 – 61
5.7.2 Laser mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 65
5.7.3 Tool mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 65
5.7.4 Cutting parameters for manual operation . . . . . . . . . 5 – 66
5.7.4.1 Laser mode: Burn . . . . . . . . . . . . . . . . . . . . . . . . 5 – 66
5.7.4.2 Laser mode: Pulsed . . . . . . . . . . . . . . . . . . . . . . . 5 – 67
5.7.4.3 Distance Z-reference - cleaning height. . . . . . . . . . 5 – 68
5.7.5 Moving the axes manually . . . . . . . . . . . . . . . . . . . . 5 – 69
5.7.6 Moving the axes to the service position . . . . . . . . . . . 5 – 71
5.7.7 Manual severance cuts . . . . . . . . . . . . . . . . . . . . . . 5 – 72
5.7.8 Moving the cutting table manually . . . . . . . . . . . . . . 5 – 74
5.7.9 Moving the unloading table manually . . . . . . . . . . . . 5 – 76
5.7.10 Unloading sheets manually . . . . . . . . . . . . . . . . . . . 5 – 78
5.8 Maintenance functions . . . . . . . . . . . . . . . . . . . . . . 5 – 80
5.8.1 CNC Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 80
5.8.2 Laser module maintenance . . . . . . . . . . . . . . . . . . . 5 – 82
5.8.2.1 Calibrating the optical power . . . . . . . . . . . . . . . . 5 – 83
5.8.2.2 Operating status of laser components . . . . . . . . . . 5 – 83
5.8.2.3 Leak test for gas circuit . . . . . . . . . . . . . . . . . . . . 5 – 84
5.9 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 85
5.9.1 Changing the dialog language . . . . . . . . . . . . . . . . . 5 – 85
5.9.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 87
5.9.2.1 Selecting the dimensional units. . . . . . . . . . . . . . . 5 – 88
5.9.2.2 Defining the PIN code . . . . . . . . . . . . . . . . . . . . . 5 – 89

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5.9.3 Operating-hours counter . . . . . . . . . . . . . . . . . . . . . 5 – 90

5.9.4 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 92
5.9.5 Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 93
5.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 94
5.10.1 System, status and error messages . . . . . . . . . . . . . 5 – 94
5.10.2 Message list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 95
5.10.3 Using the Help facility . . . . . . . . . . . . . . . . . . . . . . . 5 – 96
5.10.4 Resetting errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 98
5.11 Using the remote diagnostics facility (option) . . . . 5 – 99
5.11.1 Connect / Disconnect (Administration) . . . . . . . . . . . 5 – 100
5.11.2 Connection status. . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 101
5.11.3 Viewing diagnostic data. . . . . . . . . . . . . . . . . . . . . . 5 – 102
5.11.3.1 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 103
5.11.3.2 Detailed diagnostic data . . . . . . . . . . . . . . . . . . . . 5 – 104

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6 Maintenance
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

6.1.1.1 Work on live (hot) components . . . . . . . . . . . . . . . 6–3
6.1.1.2 Work on gear units . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.1.1.3 Remaining in the danger zone. . . . . . . . . . . . . . . . 6–4
6.1.1.4 Operating materials . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.1.1.5 External modules . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.1.1.6 Tools, test equipment and spare parts . . . . . . . . . . 6–4
6.1.2 Requirements to be met by personnel performing
the work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.2 Customer service information. . . . . . . . . . . . . . . . . 6–6
6.3 Operating materials . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.4 Operating hours display . . . . . . . . . . . . . . . . . . . . . 6–9
6.5 Maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . 6 – 10
6.6 Maintenance record . . . . . . . . . . . . . . . . . . . . . . . . 6 – 21

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7 Repair
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

7.1.1.1 Work on live (hot) components . . . . . . . . . . . . . . . 7–3
7.1.1.2 Work on gear units . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.1.1.3 Remaining in the danger zone . . . . . . . . . . . . . . . 7–4
7.1.1.4 Operating materials . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.1.1.5 External modules . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.1.1.6 Tools, test equipment and spare parts . . . . . . . . . . 7–4
the work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.3 Safety inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
7.3.1 EMERGENCY STOP buttons . . . . . . . . . . . . . . . . . . . 7–8
7.3.2 Limit-of-travel monitoring . . . . . . . . . . . . . . . . . . . . 7–9
7.3.2.1 Limit switches on X-axis and Y-axis . . . . . . . . . . . . 7–9
7.3.2.2 Limit switch on Z-axis . . . . . . . . . . . . . . . . . . . . . 7 – 10
7.4 Lubrication, service and cleaning work . . . . . . . . . 7 – 11
7.4.1 Operator console . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 11
7.4.2 Safety door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 12
7.4.3 Travel unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 13
7.4.3.1 X-axis linear guides . . . . . . . . . . . . . . . . . . . . . . . 7 – 13
7.4.3.2 Y-axis spindle bearings . . . . . . . . . . . . . . . . . . . . 7 – 14
7.4.3.3 X-axis motor bearings . . . . . . . . . . . . . . . . . . . . . 7 – 15
7.4.3.4 X-axis rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 16
7.4.3.5 Y-axis linear guides . . . . . . . . . . . . . . . . . . . . . . . 7 – 17
7.4.3.6 Y-axis recirculating ball drive . . . . . . . . . . . . . . . . 7 – 18
7.4.3.7 Z-axis linear guides . . . . . . . . . . . . . . . . . . . . . . . 7 – 19
7.4.3.8 Cutting-head mount . . . . . . . . . . . . . . . . . . . . . . 7 – 20
7.4.3.9 Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 21
7.4.3.10 Severance-cut monitoring . . . . . . . . . . . . . . . . . . 7 – 23
7.4.4 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 24
7.4.4.1 Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 24
7.4.4.2 Water couplings . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 25
7.4.4.3 Nozzle and copper plate . . . . . . . . . . . . . . . . . . . . 7 – 26
7.4.5 Cutting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 27
7.4.5.1 Extraction system . . . . . . . . . . . . . . . . . . . . . . . . 7 – 27
7.4.5.2 Extraction duct . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 28

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7.4.5.3 Linear guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 29

7.4.5.4 Precision screw jack. . . . . . . . . . . . . . . . . . . . . . . 7 – 30
7.4.5.5 Waste trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 31
7.4.6 Sheet feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 32
7.4.6.1 Telescopic rails . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 32
7.4.6.2 Suction-frame linear guides . . . . . . . . . . . . . . . . . 7 – 33
7.4.7 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 34
7.4.7.1 Fork-system linear guides . . . . . . . . . . . . . . . . . . 7 – 34
7.4.7.2 Fork-system gears. . . . . . . . . . . . . . . . . . . . . . . . 7 – 35
7.4.8 Clean air supply unit . . . . . . . . . . . . . . . . . . . . . . . . 7 – 36
7.4.8.1 Air drier (adsorption drier) . . . . . . . . . . . . . . . . . . 7 – 36
7.4.8.2 Reset switches . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 37
7.4.8.3 Cleaning the muffler . . . . . . . . . . . . . . . . . . . . . . 7 – 38
7.4.9 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 40
7.5 Cleaning or replacing the lens . . . . . . . . . . . . . . . . 7 – 41
7.5.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 43
7.5.2 Construction of cutting head . . . . . . . . . . . . . . . . . . 7 – 44
7.5.3 Removing the lens holder . . . . . . . . . . . . . . . . . . . . 7 – 46
7.5.4 Removing the lens . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 48
7.5.5 Lens cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 53
7.5.5.1 Cleaning in the case of light soiling . . . . . . . . . . . . 7 – 55
7.5.5.2 Cleaning in the case of moderate soiling . . . . . . . . 7 – 56
7.5.5.3 Cleaning in the case of heavy soiling . . . . . . . . . . . 7 – 59
7.5.5.4 Cleaning in the case of stubborn dirt . . . . . . . . . . . 7 – 60
7.5.6 Fitting the lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 62
7.5.7 Fitting the lens holder . . . . . . . . . . . . . . . . . . . . . . . 7 – 66
7.5.8 Measuring the focus reference setting . . . . . . . . . . . . 7 – 68
7.6 Laser module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 71
7.6.1 Check the vacuum-pump oil level. . . . . . . . . . . . . . . 7 – 71
7.6.2 Top up oil in the vacuum pump . . . . . . . . . . . . . . . . 7 – 72
7.7 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 74
7.7.1 Cutting gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 75
7.7.1.1 Cylinder pressure reducer . . . . . . . . . . . . . . . . . . 7 – 75
7.7.1.2 Changing gas cylinders during operation . . . . . . . . 7 – 76
7.7.2 Laser gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 77
7.7.2.1 Cylinder pressure reducer . . . . . . . . . . . . . . . . . . 7 – 78
7.7.2.2 Changing gas bottles during operation . . . . . . . . . . 7 – 79
7.7.2.3 Removing an empty gas cylinder. . . . . . . . . . . . . . 7 – 80
7.7.2.4 Connecting a full gas cyclinder . . . . . . . . . . . . . . . 7 – 82
7.8 Circuit diagrams, drawings . . . . . . . . . . . . . . . . . . . 7 – 84
7.9 Customer service information. . . . . . . . . . . . . . . . . 7 – 85

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8 Disposal
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

the work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
8.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
8.2.1 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
8.2.2 Operating resources . . . . . . . . . . . . . . . . . . . . . . . . 8–4
8.3 Components suitable for disposal . . . . . . . . . . . . . . 8–5
8.3.1 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
8.4 Disposal centers, authorities . . . . . . . . . . . . . . . . . 8–6
8.4.1 Return to manufacturer. . . . . . . . . . . . . . . . . . . . . . 8–6
8.4.2 Notification of government agencies and
manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6

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9 Cutting technology
9.1 General information . . . . . . . . . . . . . . . . . . . . . . . . 9–3

9.2 Design guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
9.2.1 Sheet formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
9.2.2 Kerf width for laser cutting . . . . . . . . . . . . . . . . . . . 9–4
9.2.3 Orthogonality of the cut surface . . . . . . . . . . . . . . . . 9–5
9.2.4 Roughness of the cut surface . . . . . . . . . . . . . . . . . . 9–6
9.2.5 Contour radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
9.2.6 Sheet thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
9.2.7 Common cut edges . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
9.2.8 Hole as a paint coating aid. . . . . . . . . . . . . . . . . . . . 9 – 10
9.2.9 Edge deformations . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 10
9.2.10 Cut-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 11
9.2.11 Tongues (bent parts only) . . . . . . . . . . . . . . . . . . . . 9 – 12
9.2.12 Strain relief cuts. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 12
9.2.13 Discontinuous limb . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 13
9.2.14 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 14
9.2.15 Labeling similar parts . . . . . . . . . . . . . . . . . . . . . . . 9 – 15
9.3 Definitions and ranges . . . . . . . . . . . . . . . . . . . . . . 9 – 16
9.3.1 Minimum distance from sheet edge. . . . . . . . . . . . . . 9 – 16
9.3.2 Minimum distance of parts from severance cut. . . . . . 9 – 17
9.3.3 Minimum parts separation . . . . . . . . . . . . . . . . . . . . 9 – 18
9.3.4 Minimum hole diameters . . . . . . . . . . . . . . . . . . . . . 9 – 19
9.3.5 Minimum web width . . . . . . . . . . . . . . . . . . . . . . . . 9 – 20
9.4 Laser cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 22
9.4.1 Laser fusion cutting . . . . . . . . . . . . . . . . . . . . . . . . 9 – 23
9.4.2 Laser gas cutting . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 24
9.4.3 Laser sublimation cutting . . . . . . . . . . . . . . . . . . . . 9 – 25
9.4.4 Cutting process . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 26
9.4.5 Gas parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 27
9.5 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 28
9.5.1 Technology wizard . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 28
9.5.2 Technology table in Bysoft. . . . . . . . . . . . . . . . . . . . 9 – 30
9.5.3 Piercing and lead-ins. . . . . . . . . . . . . . . . . . . . . . . . 9 – 32
9.5.3.1 Outer contour . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 33
9.5.3.2 Inside contour (cut-outs) . . . . . . . . . . . . . . . . . . . 9 – 34
9.5.4 Programming process macros . . . . . . . . . . . . . . . . . 9 – 35

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9.5.5 Machining strategies . . . . . . . . . . . . . . . . . . . . . . . . 9 – 36

9.5.5.1 Strategy A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 36
9.5.5.2 Strategy B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 36
9.5.6 Cutting-time calculation . . . . . . . . . . . . . . . . . . . . . 9 – 38
9.6 Cutting parameters . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 39
9.6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . 9 – 39
9.6.2 Adjusting cutting parameters . . . . . . . . . . . . . . . . . . 9 – 41
9.6.2.1 Reasons for adjusting parameters . . . . . . . . . . . . . 9 – 42
9.6.2.2 Conditions to be met before adjusting parameters . 9 – 42
9.6.3 Procedure for optimizing the cutting parameters . . . . 9 – 43
9.6.4 Cutting parameters on the laser cutting machine . . . . 9 – 44
9.6.4.1 Focal position, cutting . . . . . . . . . . . . . . . . . . . . . 9 – 45
9.6.4.2 Feed rate, cutting . . . . . . . . . . . . . . . . . . . . . . . . 9 – 47
9.6.4.3 Laser power, cutting . . . . . . . . . . . . . . . . . . . . . . 9 – 48
9.6.4.4 Gas pressure, cutting. . . . . . . . . . . . . . . . . . . . . . 9 – 49
9.6.4.5 Width of microjoints . . . . . . . . . . . . . . . . . . . . . . 9 – 51
9.6.4.6 Tool radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 52
9.6.4.7 Pulse width, piercing . . . . . . . . . . . . . . . . . . . . . . 9 – 53
9.6.4.8 Laser power, engraving . . . . . . . . . . . . . . . . . . . . 9 – 54
9.6.4.9 Protective film vaporization . . . . . . . . . . . . . . . . . 9 – 56
9.6.5 Cutting parameters for different dimensional units . . . 9 – 57
9.6.6 Structure of saved default parameters . . . . . . . . . . . 9 – 58
9.7 Cutting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 60
9.7.1 Summary of the various technologies . . . . . . . . . . . . 9 – 60
9.7.2 Cutting structural steel with oxygen (O2) . . . . . . . . . 9 – 61
9.7.3 Oxide-free cutting of structural steel with
nitrogen (N2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 62
9.7.4 Cutting structural steel with normal pulse . . . . . . . . . 9 – 63
9.7.4.1 Pulsed cutting (application examples) . . . . . . . . . . 9 – 63
9.7.4.2 Pulsed piercing (application examples). . . . . . . . . . 9 – 63
9.7.4.3 Programming for pulsed contours . . . . . . . . . . . . . 9 – 65
9.7.5 Oxide-free cutting of rust and acid-resistant steel . . . 9 – 67
9.7.5.1 Technology table for rust and acid-resistant steel . . 9 – 67
9.7.5.2 Rust and acid-resistant steel with protective film . . 9 – 68
9.7.5.3 Protective film vaporization . . . . . . . . . . . . . . . . . 9 – 71
9.7.5.4 Recommended protective films . . . . . . . . . . . . . . . 9 – 71
9.7.6 Oxide-free cutting of aluminum alloys. . . . . . . . . . . . 9 – 72
9.7.7 Laser cutting using compressed air. . . . . . . . . . . . . . 9 – 73
9.7.7.1 Providing the compressed air . . . . . . . . . . . . . . . . 9 – 73

ByVention
Table of contents
9.7.8 Engraving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 75
9.7.8.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 75
9.7.8.2 Assessment of engraving quality . . . . . . . . . . . . . . 9 – 75
9.7.9 Machining with process macros . . . . . . . . . . . . . . . . 9 – 76
9.7.9.1 Process macro 1 . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 76
9.7.9.2 Example with process macro . . . . . . . . . . . . . . . . 9 – 77
9.7.10 Microjoints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 78
9.8 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 81
9.8.1 Material properties . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 81
9.8.2 Alloy components . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 81
9.8.3 Microstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 82
9.8.4 Sheet surface finish . . . . . . . . . . . . . . . . . . . . . . . . 9 – 82
9.8.4.1 Unwanted surface finishes . . . . . . . . . . . . . . . . . . 9 – 82
9.8.4.2 Preferred surface finishes . . . . . . . . . . . . . . . . . . . 9 – 82
9.8.5 Surface treatment . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 83
9.8.5.1 Oiled surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 83
9.8.6 Beam reflection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 84
9.8.7 Thermal conductivity . . . . . . . . . . . . . . . . . . . . . . . 9 – 84
9.8.8 Heat affected zone . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 85
9.9 Cut evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 86
9.9.1 Cutting with oxygen (O2). . . . . . . . . . . . . . . . . . . . . 9 – 86
9.9.1.1 Structural steel St 37-2, 4 mm thick . . . . . . . . . . . 9 – 86
9.9.2 Cutting with nitrogen (N2) . . . . . . . . . . . . . . . . . . . . 9 – 88
9.9.2.1 Structural steel, hot galvanized, 2 mm thick . . . . . . 9 – 88
9.9.2.2 Rust and acid-resistant steel 1.4301, 6 mm thick . . 9 – 89
9.9.2.3 Aluminum AlMg3, 3 mm thick . . . . . . . . . . . . . . . . 9 – 90
9.9.3 Piercing with oxygen (O2) . . . . . . . . . . . . . . . . . . . . 9 – 92
9.9.3.1 Structural steel St 37-2, 6 mm thick . . . . . . . . . . . 9 – 92
9.9.4 Piercing with nitrogen (N2) . . . . . . . . . . . . . . . . . . . 9 – 93
9.9.4.1 Rust and acid-resistant steel 1.4301, 2 mm thick . . 9 – 93
9.9.5 Quality of the cut edge . . . . . . . . . . . . . . . . . . . . . . 9 – 94
9.9.5.1 Structural steel . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 94
9.9.5.2 Rust and acid-resistant steel. . . . . . . . . . . . . . . . . 9 – 94
9.9.5.3 Aluminum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 95
9.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 96
9.10.1 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 96

ByVention

ByVention
Chapter 1
1 Product description
This chapter contains general information, product data and notes on fit-
ted equipment. Further details are given in the order confirmation.

ByVention_2200_Kap01.fm
Product description ByVention

ByVention Product description
1.1 Introduction
1.1.1 Overall view
Fig. 1.1-1 Overall view of the laser cutting machine
A
B C
A Control cabinet
B Loading table
C Combined cooling and filtration unit
D Laser module
E Unloader
F Machining area

1.1.2 Intended use
The laser cutting machine is used for the industrial cutting and engraving
of sheets of the materials listed below. Operation is manned.
Tab. 1.1-1 Permitted materials and surface treatments
Material Surface treatment
protective film
single-sided
galvanized
none
oiled
Structural steel St 37-2 ⎯
Thickness 1 to 8 mm Stw 22
a)
Rust and acid-resistant X5CrNi18 -10 ⎯ ⎯

steel
Thickness 1 to 6 mm b)
Aluminum AlMg3 ⎯ ⎯ ⎯
Thickness 1 to 4 mm
a) Structural steel, galvanized, thickness 1 to 3 mm

b) Rust and acid-resistant steel with single-sided protective film, thickness 1 to 3 mm
The information given in these operating instructions and the

cutting parameters apply to the permitted materials specified in
Tab. 1.1-1.
Other materials or material with a different specification may
produce a poorer cutting result or reduce process stability.

1.1.3 Safety precautions
Only those materials approved for the laser cutting machine may be ma-
chined.
Any use in addition to that specified without written approval

by the manufacturer is at your own risk.

1.1.4 Working positions
1.1.4.1 Standard installation
Fig. 1.1-2 Working positions at the laser cutting machine (safety door opened)
F
D
B E
A Control cabinet
B Machining area
C Operator console
D Loading table
E Unloader
F Combined cooling and filtration unit

1.1.4.2 Special installation
Fig. 1.1-3 Working positions at the laser cutting machine (safety door opened)
F
D
B E
A Control cabinet
B Machining area
C Operator console
D Loading table
E Unloader
F Combined cooling and filtration unit

1.1.5 Labeling
Fig. 1.1-4 Position of type plates
A Machine type plate (see Fig. 1.1-5)

B Control box type plate (see Fig. 1.1-6)
C Laser module type plate (see Fig. 1.1-7)

Fig. 1.1-5 Type plate on the machine
A D
B E
F
C
G H
A Machine name
B Job number
C Total weight of machine in [kg]
D Year of manufacture
E Machine number
F Equipment number (technical ID number of the complete laser cut-
ting machine)
G Maximum weight of a sheet in [kg/m2]
H CE conformity mark

Fig. 1.1-6 Type plate in the control cabinet
A
B C
E
F
A Equipment number of controller

B Wiring diagram number
C Year of manufacture
D Electrical power supply. Supply ratings as specified in the Installa-
tion Guide, chapter 4 ›Power supply‹
E Degree of protection provided by electrical equipment enclosure
(contact, foreign bodies, water)
F Standard on which it is based
G CE conformity mark

Fig. 1.1-7 Type plate on the laser module
A D
B E
C F
G
H J
I K
A Machine name
B Job number
C Total weight of laser module in [kg]
D Year of manufacture
E Laser module number
F Equipment number (technical ID number of the complete laser cut-
ting machine)
G Laser medium
H Emitted wavelength in [NM]
I Beam diameter [mm]
J Maximum output power in [W]
K Beam divergence in [mrad]
L CE conformity mark

1.2 Product data
1.2.1 Specification
Positioning accuracy Paa) ±0,10 mm ±0,004 inches
Repeatability Psa) ±0,05 mm ±0,002 inches
Positioning speed in X-direction 100 m/min 3940 in/min
Positioning speed in Y-direction 100 m/min 3940 in/min
Simultaneous positioning speed 140 m/min 5510 in/min
Max. axis acceleration 8 m/s2 315 in/s2
Max. cutting speed 20 m/min 788 in/min
Max. laser power 2 200 W 2 200 W
a) as per VDI/VDQ 3441. Measurement length 1 m (3.28 ft). The precision of the finished
part depends on the given material, its thickness and quality.
X-axis 1 562 mm 61.50 inches

Maximum cutting area
Y-axis 772 mm 30,40 inches
Vertical range of cutting Z-axis 100 mm 4 inches

head
Max. load-bearing capacity of loading table 300 kg 660 lbs
Max. load-bearing capacity of cutting table 80 kg 176 lbs

1.2.2 Material formats and thicknesses that can be cut
1.2.2.1 Standard sheet
Standard sheets have the following commercial sheet sizes:
Fig. 1.2-1 Standard sheet dimensions
B
Y+
X+
Length L Width B
[mm] [inches] [mm] [inches]

+20 +20
Standard sheet 1 3 000 0 ⎯ 1 500 0 ⎯
+1.5 +1.5
Standard sheet 2 ⎯ 120 0 ⎯ 60 0
+20 +20
Standard sheet 3 2 500 0 ⎯ 1 250 0 ⎯
+1.5 +1.5
+20 +20
Standard sheet 5 2 000 0 ⎯ 1 000 0 ⎯
+1.5 +1.5

1.2.2.2 Partly cut standard sheet
A partly cut standard sheet is a sheet with a standard width and a length
of at least 1 200 mm.
1.2.2.3 Sheet segment
A sheet segment is a piece cut off a standard sheet. A segment can be cut
by the machine without moving the standard sheet.
Fig. 1.2-2 Sheet segment dimensions

Y+
1) Recommended edge distance (default

setting)
10 mm1) B2 10 mm1)
10 mm1)
L2
L1
10 mm1)
X+
B1
Length Width
L1 L2 B1 B2
[mm] [mm] [mm] [mm]
Sheet segment min. 250 ⎯ max. 1 562 ⎯

max. 772
Parts size ⎯ max. 752 ⎯ max. 1 542

1.2.2.4 Residual sheet
A residual sheet is a small-size sheet that is placed on the cutting table

and removed from it from the front.
Fig. 1.2-3 Residual sheet dimensions
L
Y+
X+
Length L Width B
Residual sheet max. 772 max. 30.40 max. 1 562 max. 61.50
See section 9.3 ›Definitions and ranges‹ for minimum distances

from sheet edge.

1.2.2.5 Cutting area
Fig. 1.2-4 Cutting area dimensions

Y+
X+
X range Y range
Cutting area max. 1 562 max. 61.50 max. 772 max. 30.40
Cutting plans that lie outside this area cannot be processed.

1.2.2.6 Cuttable thicknesses
The following conditions must be met in order to be able to cut the maxi-
mum thicknesses.
Laser cutting machine must be in optimum condition with optimum set-
tings and adjustments
Materials must meet the quality standards specified by the machine
manufacturer (laser materials)
Tab. 1.2-1 Material: Structural steel
Thickness Cutting gas
[mm] [inches] [Gauge No] Oxygen Nitrogen Com-

O2 N2 pressed air
Air
1.0 0,040 19
1.5 0,060 16
2.0 0,074 14
2.5 0,104 12 ⎯
3.0 0,125 11 ⎯
4.0 0,160 8 ⎯ ⎯
5.0 0,187 7 ⎯ ⎯
6.0 0,250 ⎯ ⎯ ⎯
8.0 0,312 ⎯ ⎯ ⎯
Structural steel, galvanized, thickness 1 to 3 mm can be cut (hot-galva-

nized or electro-galvanized). Cutting gas: Nitrogen N2

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

O2 N2 pressed air
Air
1.0 0,040 19 ⎯
1.5 0,060 16 ⎯
2.0 0,074 14 ⎯
2.5 0,104 12 ⎯ ⎯
3.0 0,125 11 ⎯ ⎯
4.0 0,160 8 ⎯ ⎯
5.0 0,187 7 ⎯ ⎯
6.0 0,250 ⎯ ⎯ ⎯
Rust and acid-resistant steel, thickness 1 to 3 mm, with well-bonded pro-

tective film, can be cut. Cutting gas: Nitrogen N2
See section 9.7.5.2 ›Rust and acid-resistant steel with protective film‹
Tab. 1.2-3 Material: Aluminum

O2 N2 pressed air
Air
1.0 0,040 19 ⎯
1.5 0,060 16 ⎯
2.0 0,074 14 ⎯
2.5 0,104 12 ⎯ ⎯
3.0 0,125 11 ⎯ ⎯
4.0 0,160 8 ⎯ ⎯

1.2.3 Combined cooling and filtration unit
Please refer to the manufacturer's operating instructions for information

on the combined cooling and filtration unit.

1.3 Equipment
Freestanding laser cutting machine with integral laser module. Manual

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

ByVention
Chapter 2
2 Safety regulations
This chapter describes the safety precautions for the protection of person-
nel and machine.
It also explains the symbols and warnings used in these operating instruc-
tions.

Safety regulations ByVention

ByVention Safety regulations
2.1 Warnings and symbols
DANGER
Immediate risk of severe injuries or death
WARNING
Potentially dangerous situation leading to severe injuries
or death
CAUTION
Potentially dangerous situation leading to minor injuries
or damage to property

Indicates technical features of the machine or control unit

that the operating and maintenance staff must be aware of.
Indicates useful tips on specific topics.
1. Explains a handling sequence or the steps involved in an activity.
2.
3.

2.2 Product safety
Those persons whose job requires them to work within the danger zone of
the laser cutting machine are, despite all safety measures, exposed to an
acceptable level of risk.
Read the operating instructions before starting up the laser cutting ma-
chine.
Safe working is only guaranteed if:

directions in the operating instructions are observed
operating, maintenance and repair personnel have been trained on the
machine
where several persons are involved in the operation, responsibilities are
clearly established and complied with
unauthorized persons are kept clear of the work area
any working practices that compromise safety are avoided
faults that impair safety are rectified immediately
maintenance intervals are observed
2.2.1 Safety devices
The safety devices must never be removed, bridged or bypassed.

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

2.2.2 Safety-conscious working
Work on mechanical, electrical and gas-system equipment must be carried

out solely by skilled staff1) or under their supervision.
Improper use and operation can be dangerous and may damage the ma-
chine.
For this reason it is forbidden to:
process materials that are not approved
remain inside the danger zone. It is the operator's responsibility to en-
sure that no unauthorized persons remain within the danger zone.
1) Skilled staff: a skilled member of staff means someone who, on the basis of his/her
technical education, knowledge and experience, plus knowledge of the relevant
regulations, can assess the work given to him/her and recognize the potential hazards.

2.3 Danger zones
DANGER
Remaining within a danger zone
While the laser cutting machine is operating it is forbid-
den to stay within the machining area.
Keep unauthorized persons away from the work area.
Do not obstruct access to the EMERGENCY STOP buttons on the operator

console and the laser module.
It is particularly dangerous when loading or unloading the laser cutting

machine.
CAUTION
Risk of pinch/crushing injury when loading or un-
loading the laser cutting machine
Wear protective gloves and steel-capped boots
The laser cutting machine must be arranged so that there is space around
it to allow unrestricted access to the loading and unloading tables for
bringing in and taking away material.

2.3.1 Warning and information labels
Signs must be permanently affixed and easily legible. Signs must be re-
placed if they are very worn or no longer legible.
Do not change the original position of the signs when replacing them.
Fig. 2.3-1 Warning and information labels on the laser cutting machine
D
B
A Label for key-operated switch

B Electrical voltage warning
C Label for main power switch
D Label for EMERGENCY STOP enable button

Fig. 2.3-2 Warning and information labels on the laser cutting machine
A Electrical voltage warning

B Warning of external voltage supply (power supply for dehumidifier)
C Electrical voltage warning
Please refer to the manufacturer's operating instructions for de-

tails on the position and meaning of the Warning and informa-
tion labels on the combined cooling and filtration unit.

Fig. 2.3-3 Warning and information labels on the laser module
A
C
A High voltage warning

B Warning of external voltage supply (power supply for dehumidifier)
C High voltage warning
Warning and information labels inside the laser module must

only be replaced by the manufacturer's service personnel.

Fig. 2.3-4 Warning and information labels on the laser module
A E
C D
A Invisible laser radiation warning

B Laser radiation warning
C Warning of external voltage supply (power supply for dehumidifier)
D Warning that the capacitors carry dangerous voltages
E High voltage warning
Warning and information labels inside the laser module must

only be replaced by the manufacturer's service personnel.

Fig. 2.3-5 Warning and information labels on the cutting head
A Focus reference setting

B Laser radiation warning
C Focal length of cutting head in inches

2.4 Requirements for personnel
Training of operators takes place after the system has been commissioned
by the manufacturer's service staff. Please see the order confirmation for
further details.
It is the responsibility of the owner of the machine to ensure that operat-
ing staff are properly trained.
A selection of optional training courses are offered for the machines. Fur-
ther information is available from the Customer Training Center.
2.4.1 Users
All persons who work with or at the machine are designated as a user in
these operating instructions.
The demands placed on users vary according to the activity they must
perform.
Users are classified as follows:
Owner
The term owner is used to describe the signatory to the agreement with
the manufacturer, or their representative. The owner is authorized as
legally-binding signatory to agreements.
He/she procures the laser cutting machine and ensures that it is used
correctly and in accordance with regulations.
Operator
The term operator refers to a person trained to operate the machine.
The operator operates and looks after the machine in normal operation.
Relevant training of the operator includes participation in a training
course by the manufacturer.
Works engineer
Works engineer refers to a skilled person with training in mechanical or
electrical engineering. The works engineer maintains the machine, ser-
vices it and carries out minor repairs as necessary.
Training of the work's engineer includes participation in a course held by
the manufacturer.

2.4.2 Qualifications
Only persons instructed and trained by the owner may work on the ma-
chine. Personnel are responsible for third persons in the work area.
Personnel still requiring training, instruction or teaching are only allowed
to operate the machine under constant supervision by an experienced per-
son.
2.4.3 Responsibility
Responsibilities for the various activities performed on the machine (oper-

ation, setup, maintenance, repair) must be clearly specified and observed.
Undefined responsibilities are a safety risk.
The owner must provide operating and maintenance personnel with ac-
cess to the operating instructions and ensure that they have read and un-
derstood them.
2.4.4 Personal protection equipment
Where technical or organizational measures are unable to rule out health

risks in full or in part, the owner must provide the operating and mainte-
nance staff with the required personal protection equipment.
Steel-capped boots
Protective gloves
Laser protective eyewear
Breathing mask
Personal protection equipment is not included in the deliver-

ables of the laser cutting machine.

2.5 Product-specific hazards
2.5.1 Laser radiation hazards
Laser devices are classified according to the potential danger of the laser
radiation. The applicable laser class depends on the operating mode of the
laser cutting machine (see section 4.3 ›Operating modes‹).
2.5.1.1 Normal mode
In normal operating mode the laser cutting machine corresponds to a

Class 1 laser (i.e. fully screened laser radiation). All safety covers must be
in place.
Laser radiation does not pose a risk to eyes or skin if the laser cutting ma-
chine is used correctly.
The safety door protects against reflected and stray radiation. There is no
need to wear safety goggles to provide protection from reflected and stray
radiation.
It is recommended, however, that people wear goggles with

an antidazzle filter when exposed to the cutting beam for a
prolonged period.

2.5.1.2 Service mode
The laser cutting machine is in Service mode when Normal operating

mode has been interrupted. It makes no difference whether the interrup-
tion is for adjustment and inspection tasks, or for cleaning and mainte-
nance work.
The machine enters Service mode at the moment when the safety door is
opened or permanent safety devices are dismantled.
Normal mode is restored when the laser cutting machine is made ready
for use, the safety devices are reset and the process is started up again.
WARNING
In Service mode the laser cutting machine corre-
sponds to a Class 4 laser (i.e. not fully screened la-
ser radiation).
The direct laser beam and reflected and stray radiation
are very dangerous for eyes and skin.
Fence off laser area
Cover or remove reflective objects.
Remove combustible objects.
Avoid producing explosive solvent fumes
Wear laser safety eyewear

2.5.1.3 Direct laser beam
WARNING
Direct laser beam
In service mode the laser cutting machine corresponds
to a Class 4 laser.
The direct laser beam can cause life-threatening injuries
to the whole body.
The following points must be observed when working with the laser cut-
ting machine:
Never expose yourself to direct laser radiation.
Never modify the fastenings used on optical components.
Follow all instructions in the operating instructions.

2.5.1.4 Reflected and stray radiation
Avoid exposing eyes or skin to reflected or stray radiation.

Laser protective eyewear must be worn during Service mode. These laser
safety glasses offer sufficient protection against reflected and stray radia-
tion.
Use laser protective eyewear of protection grade L5A (for viewing dif-
fuse laser light only OD 5 + at 10 600 nm) as per standard EN 207 (DIN
58215).
Fig. 2.5-1 Laser protective eyewear providing L5 protection (as per EN 207)
Standard design Version for spectacle wearers
Laser protective eyewear is not included in the deliverables of

the laser cutting machine.
Reflected and stray radiation is also possible if the waste trays happen to
be pulled forwards during a cutting process.
Before every cutting process, make sure that the waste trays are inserted
correctly.
WARNING
Risk of injury from reflected and stray radiation
The laser cutting machine must only be used when the
waste trays are inserted.

2.5.2 High-voltage hazard
A high voltage of 25 000 volts is generated in the laser module. In addi-

tion, electrical storage devices such as capacitors store large amounts of
energy, These can deliver dangerous electric shocks if touched.
WARNING
High voltage 25 000 VDC
Voltages greater than 50 V and currents greater than
20 mA are dangerous and can cause death.
Work on high-voltage components must be performed
solely by the manufacturer’s service personnel.

2.5.3 Electrical hazards
WARNING
Dangerous electrical voltage
Improper or negligent handling of electrical installations
or equipment can result in severe injuries or death.
Work on electrical installations or equipment must be
performed solely by skilled staff or under their supervi-
sion.
The following points must be observed when working with electrical instal-
lations or equipment:
Only use original fuses with the specified amperage.
Switch the machine off immediately in the event of a fault in the electri-
cal supply.
Electrical components on which maintenance work is being performed
must be disconnected from the electrical supply unless otherwise speci-
fied.
First check that isolated parts are de-energized, then earth and short-
circuit them and also insulate adjacent live parts.
Inspect electrical equipment regularly. Rectify faults such as loose con-
nections or singed cables immediately.
When working on live (hot) parts, a second person must be present
who can operate the EMERGENCY STOP button or power switch in an
emergency. Fence off the work area with a red-and-white safety chain
and a warning sign.
Always use insulated tools.

2.5.4 Hazards arising from the pneumatic system
Inspect loads, valves and hoses regularly for leaks.
WARNING
Risk of injury from flying parts and escaping air
Do not perform any assembly or disassembly work, or
unscrew or tighten any screw connections, while the
system is under pressure.
Depressurize all subsystems which require opening, be-
fore commencing maintenance and repair work.

2.5.5 Hazards arising from gas, dust, vapors, smoke
2.5.5.1 Gas supply
If there are leaks in the gas supply, escaping oxygen can combine with a
naked flame to cause deflagrations. Check the lines on the gas supply are
connected correctly.
DANGER
Danger to life and limb of the operator or third
party
Impaired respiration and cardiac functions if containers
or lines are leaking.
Check connections and lines for leaks.
WARNING
Risk of explosion
Do not oil or grease gas-bottle connections.
This could lead to an explosion from a chemical reaction.
Further information on the gas supply and its hazards is given in the in-
stallation instructions.

Where air is recirculated, ventilate rooms well with fresh air after every
shift. Prevent gas collecting in enclosed accessible areas (e.g. shafts
and ducts).
Select fire extinguishers to suit the flammable materials present in the
room. Signpost the location of extinguishers and escape routes.
Perform leak tests regularly. Leave the room immediately if there is a
major leak or equipment failure, and do not re-enter unless using self-
contained breathing apparatus. At least two people must be present in
this case.
Keep gas bottles away from naked flames and heat sources (>50°C).
Protect bottles from direct sunlight if stored outside.
Always transport bottles with safety cap fitted. Secure bottles against
falling over.
Look out for leaks from bottles during storage and when in use. Store in
a well-ventilated location away from combustible materials. Do not
store in escape routes or work areas, or in their immediate vicinity. Do
not fill bottles in storerooms.
Only use original parts. Close bottle valves before handling. When
changing the bottles, check the valves on full and empty bottles for
leaks. Never adjust safety valves. Do not release gases in enclosed
spaces.
Repairs must be performed by specialists.
Wear protective clothing and gloves made of leather or thick material. If
the gas escapes into enclosed spaces, self-contained breathing appara-
tus must be worn.
Observe additional national directives, for example vehicle labeling dur-
ing transport, regular staff training etc.
Observe national directives on bottle licensing and test periods.

2.5.5.2 Handling LASERMIX 312
LASERMIX 312 is composed of the gases helium (He), nitrogen (N2) and
carbon dioxide (CO2). The main constituent is helium at > 60%. Carbon
dioxide forms the smallest component at < 5%.
Note on its chemical and physical behavior and usage
Helium Helium is a noble gas that does not form chemical

He bonds. It is also used as an inert gas in arc welding of
steel, aluminum, magnesium and titanium, as it pre-
vents oxidation and nitride formation by displacing the
air. It has low solubility in water and organic solvents.
Nitrogen Nitrogen reacts with only a very few substances at room

N2 temperature, for example lithium and calcium to form
nitrides. Even at high temperatures nitrogen does not
react easily. This is why it is used as an inert gas in tech-
nical processes, and for conveying and storing flamma-
ble fluids.
Carbon dioxide Carbon dioxide can react strongly with various substanc-
CO2 es, particularly at higher temperatures, and is therefore
not suitable for universal extinguishing purposes. Dan-
gerous reactions may occur when mixed with ammoniac,
ethylamine, methylamine, dimethylamine and trimethy-
lamine. When liquid carbon dioxide expands rapidly to
atmospheric pressure, it freezes to dry ice as it cools to -
79 °C, then quickly vaporizes without passing through
the fusion stage.
Warnings in case of fire or accident

LASERMIX 312 itself (and its constituent gases) is not flammable. Fire
leads to an increase in pressure and can cause the bottle to burst /
explode. Select fire-extinguishing measures to suit the surroundings.
From a safe position, cool down nearby containers and bottles thoroughly
with plenty of water. Risk of suffocation, particularly in enclosed and low-
lying areas. Keep on the up-wind side.
Wear self-contained breathing apparatus, and full protective clothing.
LASERMIX 312 itself (and its constituent gases) is not a water contami-
nant.

Notes on health protection

The nature of effect of LASERMIX 312 and its toxicity depends on the na-
ture of effect and toxicity of each of the constituent gases. As helium
forms the largest part by volume, its properties are dominant, while the
properties of carbon dioxide as the smallest component are least promi-
nent.
Helium Nature of effect and toxicity: insufficient oxygen, de-

He pending on length of inhalation, may cause drowsiness,
indisposition, increased blood pressure, breathlessness.
The speed of sound in helium is different from that in air,
so that inhalation of helium in low, breathable concen-
trations can be detected by the breathing noise or al-
tered voice frequency. A pure helium atmosphere will
cause immediate loss of consciousness and suffocation
without obvious symptoms. Owing to its low solubility in
blood, forced inhalation of helium is less hazardous than
nitrogen.
Nitrogen Nature of effect and toxicity: nitrogen has no physiologi-

N2 cal effect; in concentrations of more than 88%, however,
it prevents vital respiration and thus leads to suffoca-
tion. It does not cause irritation and has no warning
symptoms.
Carbon dioxide Nature of effect and toxicity: carbon dioxide paralyzes

CO2 the respiratory center in high concentrations. At low con-
centrations, an adequate supply of oxygen or the lack of
it determines the severity of injury or the extent of car-
bon dioxide poisoning.
Depending on the length of inhalation, insufficient oxy-
gen supply at about 8 to 10 % by vol. causes headache,
buzzing in the ears, dizziness, raised blood pressure, ac-
celerated heart rate, accelerated breathing or breath-
lessness, blue skin tinge, excited state, nausea,
sickness.
Above 10 % by vol. problems occur with proper func-
tioning and coordination of muscle movements, includ-
ing convulsions similar to an epileptic fit, loss of
consciousness, drop in blood pressure.
Rapid recovery if supplied with fresh air in good time,
otherwise suffocation. Above 18 to 20 % by vol. stroke.
First aid
if carbon dioxide has been inhaled, remove the victim from the hazard ar-
ea. Provide sufficient fresh air. In enclosed spaces, first-aid personnel
must wear self-contained breathing apparatus. Victims need rest, warmth
and possibly artificial respiration. Keep air passages clear, monitor blood
circulation, perform cardiac massage if necessary. If patient loses con-
sciousness, place and transport him in a stable lateral position. Consult
doctor.

2.5.5.3 Handling nitrogen (N2)

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

Nitrogen is not flammable. Fire leads to an increase in pressure and can
cause the bottle to burst / explode. In case of fire use water spray, or gas
or powder-type extinguishers. If gas escapes do not spray the bottle with
water. Cool down nearby containers and bottles thoroughly with plenty of
water. Large amounts of escaping gas mixed with moist air form a cold fog
that is heavier than air.
Wear self-contained breathing apparatus, and full protective clothing.
Nitrogen is not a water contaminant.

Nature of effect and toxicity: nitrogen has no physiological effect; in con-
centrations of more than 88%, however, it prevents vital respiration and
thus leads to suffocation. It does not cause irritation and has no warning
symptoms.
First aid
if carbon dioxide has been inhaled, remove the victim from the hazard ar-
ea. Provide sufficient fresh air. In enclosed spaces, first-aid personnel
must wear self-contained breathing apparatus. Victims need rest, warmth
and possibly artificial respiration. Keep air passages clear, monitor blood
circulation, perform cardiac massage if necessary. If patient loses con-
sciousness, place and transport him in a stable lateral position. Consult
doctor.

2.5.5.4 Handling oxygen (O2)

Oxygen is not flammable, but does assist combustion. Although it is 11%
heavier than air at ambient temperatures, the air does not separate out
and hence the oxygen concentration near the ground does not increase.
Liquid oxygen has a very low temperature (minus 183°C at atmospheric
pressure). At this temperature, skin that comes into contact with oxygen
will suffer "cold burns" extremely rapidly. These low temperatures can also
make some materials brittle.

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

Oxygen is naturally present in air in the proportion 21 % by volume.
Hence if oxygen escapes into the atmosphere, it does not have a polluting
effect. Inhaling pure oxygen or air with a raised oxygen content normally
produces no detrimental effects on the human body.
Any clothes worn in an atmosphere that may have a raised oxygen con-
centration must be aired very carefully. Oxygen adheres very strongly to
clothing. An ignition source such as a cigarette could cause clothes to
catch fire.
If cryogenic liquid oxygen is accidentally spilt, the soil will not be contami-
nated because cryogenic liquid oxygen vaporizes and hence does not pen-
etrate the soil, or only to a small degree. The temporary local frost formed
on the ground leaves no permanent damage to the soil.

2.5.5.5 Dust extraction unit
The dust and fumes produced during cutting are extracted from the cut-
ting area by a dust extraction unit. The dust is filtered out.
Check that the dust extraction unit is running and operating at the correct
extraction rate if any smells are noticed during cutting.
WARNING
Risk of fire
If extraction levels are inadequate, there is a risk of gas-
es and cutting residues remaining in the extraction ducts
and catching fire there.
The extraction rate of the extraction unit must always
equal that given in the specification.
Observe maintenance intervals as per maintenance
schedule
Do not let stubbed cigarettes or objects that are still
alight get into the extraction chambers or piping of
the dust extraction system.
When changing from steel to aluminum or vice versa,
the dust must be kept strictly separate. A separate
dust hopper must be used for each material.
For flammable, potentially explosive and self-igniting
dusts, empty the hopper frequently to minimize the
amount of dust held in it.
Ensure that there is sufficient ventilation when working in confined spac-

es.
If the extracted air is released outdoors, local regulations

must be observed.

2.5.5.6 Toxic fumes emitted when cutting plastics
The fumes given off on combustion are highly toxic. They cannot be com-
pletely removed by the extraction system.
Plastics must not be cut on the laser cutting machine.

2.5.6 Hazards associated with handling the optical system
2.5.6.1 General information
The output coupler of the laser module and the lens in the cutting head
are made of zinc selenide. When intact, these components pose no dan-
ger.
However, toxic fumes are generated if thermal decomposition of a lens oc-
curs. In addition, damage to the coating allows the escape of thorium flu-
oride, which is slightly radioactive.
2.5.6.2 Warnings in case of fire or accident
Zinc selenide is not flammable. Thermal decomposition sets in at temper-

atures above 400°C, releasing toxic fumes and dust particles.
Wait until dust has settled before starting cleaning work. Do not stir up
dust.
CAUTION
Toxic fumes and dust particles
Wear a breathing mask and protective gloves during
cleaning work.
Defective lenses must be returned to the manufacturer
of the laser cutting machine in a sealed container.
Always ventilate the working environment thoroughly
after any damage.
2.5.6.3 Notes on health protection
For further details on first aid measures refer to the safety data sheets
on zinc selenide and thorium contained in the supplier documentation
folder.

2.5.7 Lubricants, coolants and cleaning agents
When handling working materials, in particular oils, grease and other

chemical substances, observe the product's safety regulations from the
manufacturer. The supplier documentation folder contains the relevant
information.
Avoid prolonged, intensive skin contact with these materials
Wear protective gloves, safety glasses and an apron if required
Apply a suitable protective skin cream before starting work
Change any oil-soaked clothing immediately
Do not carry oily cloths about your person.
CAUTION
Poisoning
Inhaling oil vapors or oil fumes can lead to nausea and
sickness.
Avoid contact with oil vapors and oil fumes. Ensure ade-
quate ventilation.
WARNING
Risk of explosion
Do not allow sprays or spray cans to come into contact
with hot objects, machine parts, gases or vapors.
Place working materials on suitable surfaces (e.g. tool
trolley).
The owner of the machine is responsible for the proper dis-

posal of lubricants, coolants and cleaning agents and of mate-
rials contaminated with these products.

2.6 Additional hazards
Unauthorized modifications or additions to the machine are prohibited for

safety reasons.
It is not permitted to make changes to programmable controllers.
The machine must not be integrated with existing systems without the ap-
proval of the manufacturer.

2.7 Emergency information
In the event of personal injury

take first-aid measures
notify a doctor
inform immediate supervisor
observe national and company regulations


ByVention
Chapter 3
3 Design and operation
This chapter provides information on the position and functions of the var-
ious hardware units. The safety and monitoring devices fitted on the prod-
uct are also described in greater detail.

Design and operation ByVention

ByVention Design and operation
3.1 Introduction
For laser cutting, a focused laser beam is directed at the sheet metal to be
cut on the cutting table.
The laser beam is directed from the laser module via a number of deflect-
ing mirrors to the focusing lens in the cutting head.
Fig. 3.1-1 Beam guidance system (shown without safety covers)
C
B
A
F G
A Laser module
B Laser beam
C Cutting-bridge deflecting mirror
D Cutting-carriage deflecting mirror
E Cutting head
F Focused laser beam
G Cut part

3.1.1 Beam path
The route taken by the laser beam from the output of the laser module to
the cutting head is called the beam path.
WARNING
Risk of fire and explosion
The laser beam can cause flammable and explosive flu-
ids and vapors to ignite. Foreign bodies, fluids and gases
can also have an adverse effect on the beam quality.
Cleaning agents and solvents and their vapors should
therefore be kept away from the beam path.
3.1.2 Flying optics
The cutting bridge and carriage move during operating, together with the
deflecting mirrors mounted on them. This changes the length of the beam
path.
This principle of laser-beam guidance is called Flying optics.

3.1.3 Deflecting mirror
Deflecting mirrors are used along the machine axes to deflect the laser
beam. These mirrors are flat.
The beam quality (the parallelism, for example) is maintained with flat
mirrors.
Fig. 3.1-2 Deflecting mirror
A Deflecting mirror
B Laser beam

The angle of incidence and the angle of reflection are measured with re-
spect to the normal line. The angles of incidence and reflection are equal.
If the deflecting mirror is rotated through a certain angle then the direc-
tion of the reflected beam alters by twice that angle.
Fig. 3.1-3 Angle of reflection of a deflecting mirror
A B
A Angle of incidence α
B Angle of reflection β
C Laser beam
D Coating
E Base material
F Normal line

3.2 Layout of the laser cutting machine
3.2.1 Operating side
Fig. 3.2-1 Laser cutting machine, safety door open
I B
G
C
F
E
D
A Control cabinet
B Machine stand
C Laser module
D Unloader
E Operator console
F Travel unit
G Cutting table
H Sheet feed
I Safety door

3.2.2 Loading side
Fig. 3.2-2 Laser cutting machine, loading table empty
C
A
A Safety covers
B Loading table
C Combined cooling and filtration unit

3.3 Safety devices
Protective measures have been put in place at danger spots according to

the safety regulations that apply to laser cutting machines.
It is the operator’s responsibility to install the appropriate barriers and to
check them regularly for proper functioning.
It is only permitted to remove, modify or take out of service protective
and safety devices if this is necessary for transport and repair. Before
work commences, appropriate measures must be taken to protect per-
sons, and to prevent damage to machine parts.
Before putting the system into operation, it must be ensured that all pro-
tective devices are in place and that all danger zones are protected ac-
cording to local safety regulations.

3.3.1 Positions of safety devices
Fig. 3.3-1 Safety devices on the laser cutting machine viewed from the operating side
C
F
E
D
A Safety cover for cutting area

B Safety door
C EMERGENCY STOP button on the operator console
D Safety cover on unloader
E Shutter lock (key-operated switch)
F EMERGENCY STOP button on the laser module

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

H EMERGENCY STOP button on the control cabinet
I Main power switch
The laser cutting machine must only be used when safety de-
vices are operating correctly.

3.3.2 Main power switch
After the power is switched on (ON position), all the units and controllers
required for operating the laser cutting machine are started automatically.
The combined cooling and filtration unit is fitted with a separate

power switch.
tailed information.
The main switch can be secured in the OFF position with a padlock to pre-
vent unauthorized switch-on.
Fig. 3.3-3 Main power switch

3.3.3 EMERGENCY STOP circuit
Pressing an EMERGENCY STOP button triggers an EMERGENCY STOP

situation.
There are three EMERGENCY STOP buttons on the laser cutting machine,
which can be used to shut down the laser cutting machine and its compo-
nents in an emergency.
Control cabinet
Operator console
Laser module
Fig. 3.3-4 EMERGENCY STOP button
Pressing an EMERGENCY STOP button disconnects all electrical loads

from the supply apart from the controller and the combined cooling and
filtration unit.
Operation of the machine can only be resumed once the emergency situa-
tion has been cleared and all defects and damage have been rectified (see
section 5.2.4 ›Switching on again after an EMERGENCY STOP‹).

3.3.4 Shutter lock (key-operated switch)
The shutter lock is used to protect service personnel working on the beam
path against accidental opening of the shutter.
In normal operating mode, the shutter switch is always in the UNLOCK
position.
Fig. 3.3-5 Shutter switch in UNLOCK position
Service work on the beam path and the associated locking of

the shutter must only be performed by the manufacturer's
service staff.

3.3.5 Safety door
3.3.5.1 Safety switch
When the safety door is open, the emission of laser power, movement of
machine parts and a machine restart are prevented.
The laser cutting machine can only be put into operation with the safety
door shut.
Fig. 3.3-6 Safety switch
A Safety position switch

B Safety interlock
In the event of damage or wear, the complete switch or com-

plete interlock must be replaced.

3.3.5.2 Emergency release
When no power is supplied, the safety interlock is engaged, locking the

safety door. In a fault or emergency situation, the safety interlock can be
released manually.
Fig. 3.3-7 Releasing the safety interlock manually
Detail X
C D
A Safety interlock
B Switch
C Switch in home position
D Safety interlock released manually

3.3.6 Safety cover for cutting area
The whole machining area is enclosed by covers and a safety door, which
protect the machining area during the work process. The safety door posi-
tion is monitored by safety switches.
DANGER
Standing within a danger zone
Moving parts such as the cutting bridge, cutting carriage
or Z-axis pose a risk of crushing, which can be fatal.
No-one is permitted within the machining area when the
safety door is closed.
Fig. 3.3-8 Safety covers with safety door
3.3.6.1 Safety door
The closed safety door blocks access to the cutting area. It protects
against:
reflected laser radiation
sparks
injury from moving parts
The safety door must be closed and locked before a work process can be
started on the laser cutting machine.

3.3.6.2 Service opening
The service opening gives access for maintenance work (e.g. access to
clean air filter). In normal operating mode, the service opening is closed.
DANGER
Standing within a danger zone
Moving parts such as the cutting bridge, cutting carriage
or Z-axis pose a risk of crushing, which can be fatal.
Before removing the cover, shut down the machine, turn
off the main power switch and secure it in this position
with a padlock.
Fig. 3.3-9 Service opening
A Safety cover for cutting area

B Service opening

3.3.6.3 Protective flap on unloader opening
A protective flap is fitted on the unloader opening, which opens automati-

cally when the cut sheet segments are moved out.
When moving the unloading table into the machining area, the protective
flap checks whether the cut sheet segment has been completely removed.
The skeleton or parts left on the table press against the shutter plate, ac-
tuating a limit switch. Movement of the unloading table is interrupted and
the safety cover opens.
Fig. 3.3-10 Unloader
C
B
A Pneumatic cylinder
B Telescopic rail
C Diaphragm

3.3.7 Safety cover on the unloader
The unloader is enclosed by covers and a safety cover. The safety cover
opens automatically as soon as a cut sheet segment is ready to be re-
moved.
The safety cover can also be released manually by pressing the relevant
button on the operator console (see section 4.2.3.2 ›Function buttons‹).
Closing the safety cover confirms that the unloading table is empty.
Fig. 3.3-11 Unloader, safety cover closed
Fig. 3.3-12 Unloader, safety cover open

3.3.8 Safety covers on laser module
3.3.8.1 Covers and folding doors
The covers and folding doors on the laser module are mechanically locked.
The main power switch must always be in the OFF position before remov-
ing covers or opening the folding doors.
Use a padlock to secure the main power switch against unauthorized
switch-on.
CAUTION
External supply
Turning off the main power switch does not cut off the
supply to the dehumidifier.
To turn off the dehumidifier, pull out the mains plug.
Fig. 3.3-13 Safety covers on the laser module
A A
B B B
A Folding doors
B Covers
To prevent dirt entering the laser module, ensure that the

covers and folding doors are always properly closed and
locked.

3.3.8.2 High voltage covers
The covers prevent accidental contact with high-voltage parts. The covers
are screwed on and fitted with a safety switch.
When a cover is removed, the high voltage is immediately switched off.
DANGER
High voltage -25 000 VDC
Touching live (hot) high-voltage parts may result in
death.
The covers must only be removed by the manufacturer’s
service personnel.
Fig. 3.3-14 High voltage covers on the laser module
B
B
A Folding doors
B High voltage covers

3.3.9 Radiation protection
The beam path is totally sealed by structural parts, bellows and protective
covers.
Bellows and safety covers protect people from stray radiation and from di-
rect contact with the laser beam. They also double as protection for the
optical system from outside influences.
DANGER
Invisible laser radiation
The beam path protective covers must never be re-
moved or modified.
The beam shielding tube between the laser module and
the machine must not be subjected to mechanical loads.
Bending of the beam shielding tube can allow the laser
beam to escape unprotected or damage the tube.

3.4 Control cabinet
The control cabinet contains electrical components such as power-supply,

CNC controller and fuses / circuit-breakers etc.
The temperature in the control cabinet is maintained at an optimum level
by an air conditioning unit.
Fig. 3.4-1 Control cabinet
A Control cabinet
B Air conditioning unit
C Doors
D Controls (see section 4.2.1 ›Control cabinet‹.)

3.5 Operator console
The operator console is inserted in the holder on the safety cover. For op-
eration, this can be removed from the holder and carried around by the
user.
Fig. 3.5-1 Operator console
The controls on the operator console are described in section

4.2.3 ›Operator console‹.
If the touch screen is not operated using the finger, the use of a
suitable touch stylus is recommended.

3.6 Machine stand
The machine stand provides the support for the laser cutting machine. As-
semblies, including travel unit, cutting table and unloader are built onto
the machine stand.
The clean air supply and power supply are housed in the machine stand.
Fig. 3.6-1 Machine stand (shown without safety covers)
A F
A Bridge
B Clean air supply unit (behind cover)
C Cutting table
D Travel unit
E Unloader
F Supply unit (behind cover). See section 3.6.2 ›Supply unit‹
G Supply connections (see installation instructions)

3.6.1 Clean air supply unit
The air drier (adsorption drier) supplies the laser cutting machine with
clean air for ventilation of the beam path.
The air drier contains two adsorber units. These work reciprocally, i.e. the
air is filtered and dried in one element whilst the other regenerates itself.
Fig. 3.6-2 Air supply system
A Air filter for filtered air

B Muffler
C Operation indicator
D Replace drying agent cartridge
E Replace post-filter
F Replace pre-filter

3.6.2 Supply unit
The pressure regulators and the compressed-air and cutting-gas pressure

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

3.6.2.1 Compressed air
See the installation instructions for details of the quality and pressure
of the compressed air supply.
Fig. 3.6-4 Pressure regulator and compressed-air pressure gage
A C
B F
E
D
A Beam-path ventilation pressure reducer

B Beam-path ventilation pressure gage
C Inlet pressure to the pressure reducer
D Tap
E Water trap / prefilter
F Inlet pressure gage
G Fine filter

3.6.2.2 Cutting gases
See the installation instructions for details of the quality and pressure
of the cutting gas supply.
Fig. 3.6-5 Pressure regulators and cutting-gas pressure gages
D
E
C F
N2
O2
r )
Ai 1
1) only when option fitted
A Pressure reducer, Nitrogen N2

B Pressure reducer, Oxygen O2
C Pressure gage, Nitrogen N2
D Pressure gage, Oxygen O2
E Pressure reducer, compressed air (Air)1)
E Pressure gage, compressed air (Air)1)

3.7 Travel unit
The travel unit hangs from linear guides in the X direction.
3.7.1 Cutting bridge
The cutting bridge moves along the X-axis. It carries the cutting carriage,
which moves along the Y-axis.
The laser beam is deflected from the X-axis onto the Y-axis by the deflect-
ing mirror mounted on its rear side (see Fig. 3.1-1).
Fig. 3.7-1 Travel unit (shown without safety covers)
A Bridge
B Cutting bridge
C Cutting carriage
D Laser beam

3.7.2 Cutting carriage
The cutting carriage moves along the Y axis. It carries the Z-axis on which
the cutting head is mounted.
On the Z-axis, the cutting head moves in a vertical direction. It raises the
cutting head when traversing between different figures on the work piece,
and ensures that the nozzle clearance height remains constant even when
the work piece is uneven.
In the cutting carriage, the laser beam is deflected from the Y-axis onto
the Z-axis.
Fig. 3.7-2 Cutting carriage (shown without safety covers)
B
C
A Cutting carriage
B Cutting head
C Laser beam
D Severance-cut monitoring

3.7.3 Severance-cut monitoring
The light sensor scans the severance cut before removing a cut sheet seg-
ment. It detects if a severance cut is not made properly.
If the severance cut is OK, the cut sheet segment is transferred to the
unloading area.
If the severance cut is not OK, an error message is issued and produc-
tion halted.
Fig. 3.7-3 Severance-cut monitoring (shown without safety covers)
A
B
A Reflection light sensor

B Window
C Laser diode
D Compressed-air nozzle (aimed at laser diode)
E Cutting carriage

3.7.4 Cutting head
The cutting head is the final element of the beam guidance system. The
laser beam is focused in the cutting head to achieve the power density re-
quired for cutting.
The cutting gas is fed through the cutting head. During the cutting process
this drives molten material out of the cut gap and prevents the focusing
lens from being damaged by splashes of slag.
The stream of cutting gas is shaped by the nozzle so that the greatest
possible percentage of the gas flows through the kerf.
The two centering screws center the laser beam in the nozzle (see section
5.5.5 ›Centering the nozzle‹).
Fig. 3.7-4 Cutting head (dismantled)
X
F
B
G
H
D
E E

Detail X
A Focal-position scale (6 mm divisions)

B Measured focus reference setting
C Locking screw (for locking the focal-position adjusting ring)
D Focal length in inches
E Centering screws for nozzle centering
F Focal-position adjusting ring
G Adjusting-ring scale (0.2 mm divisions)
H Clamping device pin (for Z-axis attachment)
I Anti-rotation element
J Nozzle
See section 5.5.2 ›Removing or inserting the cutting head‹ for

how to change the cutting head.

3.7.5 Nozzles
During the cutting process, there is a controlled supply of cutting gas

through the nozzle. The shape and diameter of the nozzle depend on:
Focal position
Gas pressure
volume flow rate
gas-jet shape
range of uses
Fig. 3.7-5 Nozzle mounting on cutting head
A Cutting head
B Nozzle
The nozzle to be used can be found in the selected job (param-

eter set). Sections 5.5.4 ›Changing the nozzle‹ and
5.5.5 ›Centering the nozzle‹ describe how to change and center
the nozzle.

3.7.5.1 Range of nozzles available
Tab. 3.7-1 Nozzle shape and area of use
Nozzle Area of use Labeling

shape
Normal pressure K10

All applications for gas cutting (O2) K12
Structural steel, 0.5…8 mm thick
K15
K17
High pressure HK10

Universal nozzles for all applications HK12
Structural steel to 8 mm (O2 and N2)
HK15
Rust and acid-resistant steel up to
6 mm (N2) HK17
Aluminum up to 4 mm (N2) HK20

Various materials (O2 and N2) HK25
Rust and acid-resistant steel up to
HK30
2 mm (Air)

3.7.5.2 Labeling
H High pressure (up to 20 bar)

K Capacitive detection
10 Nozzle diameter 1.0 mm

Normal pressure (capacitive detection)
Capacitive detection
K 10 Nozzle diameter 1.0 mm
High pressure (capacitive detection)
High pressure
H K 17 Nozzle diameter 1.7 mm
Capacitive detection

3.8 Cutting table
The cutting table is equipped with plug-in cutting grates on which the
sheet to be cut is laid.
CAUTION
loading material
Fig. 3.8-1 Cutting table (shown without safety covers)
A
B
H
C
G
F E D
F
A Cutting grate E Scrap hoppers

B Dust extraction system F Scrap trolley
C Nozzle cleaning G Sheet stop
D Calibration plate H Sheet stop

3.8.1 Lifting unit
During the unloading procedure, the unloading table moves under the cut
sheet segment. The lifting unit lowers the cutting table until the cut sheet
segment comes to rest on the unloading table.
Fig. 3.8-2 Lifting unit (shown without safety covers)
A Guide
B Lifting unit

3.8.2 Cutting grate
The cutting grate supports the sheet to be cut. The slats are made of
steel.
Steel slats impair the cutting process less than other materials. The dura-
bility of these slats depends on the laser power used for cutting.
Fig. 3.8-3 Cutting grate
A Sheet
B Cutting grate

3.8.3 Zero point / Sheet stop
Two sheet stops are provided for positioning leftover sheets at the zero
point. One of the sheet stops can be moved in the X-direction to fit the
size of the sheet.
The sheet stops are set up initially by the manufacturer’s service person-
nel.
Before cutting a standard sheet (Standard sheet produc-

tion), both sheet stops must be removed.
Fig. 3.8-4 Sheet stops
A Fixed sheet stop

B Movable sheet stop
C Leftover sheet
D Zero point

3.8.4 Nozzle cleaning
During the cleaning procedure, the nozzle head passes several times
across the brass brush on the cutting table, removing any dirt, deposits
and metal splashes.
Fig. 3.8-5 Nozzle cleaning
The nozzle cleaning procedure is carried out at the end of a cutting plan or
after a certain number of piercing cuts.
This function cannot be controlled by the machine operator. See

section 5.7.4.3 ›Distance Z-reference - cleaning height‹ for how
to adjust the cleaning height.

3.8.5 Calibration plate
During calibration, the nozzle is lowered to the calibration plate until con-
tact is made. Then the Z-axis moves upwards checking various nozzle
clearance heights in the process.
Fig. 3.8-6 Calibration position
The calibration procedure is carried out at the beginning of a cutting plan

or after nozzle cleaning.
This function cannot be controlled by the machine operator.

3.8.6 Dust extraction system
The cutting area is divided into two extraction sectors. The appropriate ex-
traction flaps are opened depending on the position of the cutting head.
The extracted air is cleaned by the air filtration unit.
Fig. 3.8-7 Cutting table (shown without cutting grate and safety covers)
A
C
A Air extraction sector 1

B Air extraction sector 2
C Extracted air
WARNING
Risk of fire
Production of flammable or explosive mixtures.
The extraction chambers, waste trays and swarf in the
cutting area must be cleared completely when changing
material from steel to aluminum or vice versa.

3.8.7 Waste trays
Small parts or cutting waste fall through the support grate and are collect-
ed in waste trays. The waste trays can be moved out to the front for emp-
tying.
There are two waste trays under the cutting table and one under the un-
loader.
Fig. 3.8-8 Waste trays under the cutting table
Before every cutting process, make sure that the waste trays are inserted
correctly.
WARNING
Risk of injury from reflected and stray radiation
The laser cutting machine must only be used when the
waste trays are inserted.

3.9 Unloader
3.9.1 Loading table
The loading table is fitted with roller balls on which the standard sheet or
partly cut standard sheet can be pushed up to the stops (see section
5.4.1 ›Cutting standard sheets‹).
Fig. 3.9-1 Loading table

3.9.2 Sheet stop
The stops are located between the loading table and the cutting area.
The correct position of the standard sheet or partly cut standard sheet is
monitored by inductive proximity switches in the stops. The loading status
is shown by an indicator lamp (see section 4.1.2 ›Loading status‹).
The sheet can only be clamped and pulled in if it is correctly positioned.
Fig. 3.9-2 Standard sheet or partly cut standard sheet against sheet stop.
A B C
A Longitudinal stop
B Transverse stop
C Sheet clamping
D Standard sheet or partly cut standard sheet

3.9.3 Sheet feed
For the subsequent cutting process, the standard sheet or partly cut stan-
dard sheet is pulled into the cutting area by the sheet feed.
The sheet is held by the suction unit by a vacuum. To pull the sheet in, the
cutting carriage couples to the suction unit and pulls the sheet in the Y di-
rection onto the cutting table.
Once the sheet has been pulled in, the feed unit is returned to its home
position by the cutting carriage.
Fig. 3.9-3 Sheet feed
A Coupling
B Suction unit
C Telescopic rail
D Standard sheet or partly cut standard sheet

The rows of suction cups must be switched on or off manually using vacu-
um switches depending on the size of the sheet placed on the table. When
using standard sheets 1 and 2, both vacuum switches must be in the ON
position.
View X
E Vacuum switch 1 (switch suction-cup row 5 on/off manually)

F Vacuum switch 2 (switch suction-cup row 4 on/off manually)
Tab. 3.9-1 Switch settings based on standard sheet
Standard sheet Switch position
Vacuum switch1 Vacuum switch2
1 3 000 mm × 1 500 mm ON ON
2 120 inches × 60 inches ON ON
3 2 500 mm × 1 250 mm OFF ON
4 96 inches × 48 inches OFF ON
5 2 000 mm × 1 000 mm OFF OFF
6 72 inches × 40 inches OFF OFF

3.10 Unloader
The unloader enables the cut sheet segment to be removed while the next
sheet segment is being cut.
The cut sheet segment is automatically transported to the unloading table.
Fig. 3.10-1 Unloader
If a cut sheet segment is ready for removal, the safety cover opens auto-
matically. If the safety cover is closed by the operator, this is treated as
confirmation that the cut sheet segment has been removed.

3.10.1 Unloading table
The cut sheet segment is transported from the cutting area on the unload-
ing table.
Fig. 3.10-2 Unloader (shown without safety covers)
A Protective flap
B Unloading table
C Linear guides
D Synchronous belt

3.10.2 Waste tray
During removal of the cut parts, small parts and cutting waste fall into the
waste tray. The waste trays can be moved out to the front for emptying.
Fig. 3.10-3 Waste tray under the unloading table

3.11 Laser module
The laser module is where the laser beam is generated. The operating
state of the laser module is shown by an indicator lamp (see section
4.1.1 ›Indicator lamp‹).
The safety covers and folding doors must only be removed and/or opened
for servicing purposes, with the main power switch in the OFF position.
CAUTION
External supply
Turning off the main power switch does not cut off the
supply to the dehumidifier.
To turn off the dehumidifier, pull out the mains plug.
To prevent dirt entering the laser module, ensure that the covers and fold-
ing doors are always properly closed and locked.

Fig. 3.11-1 Laser module (viewed from operating side)
A Beam outlet
B Lower section of laser module with safety covers
C Upper section of laser module with folding doors
D Indicator lamp

3.11.1 Upper section of laser module
The upper section of the laser module houses the optical system. These
are protected from accidental contact by the high-voltage covers.
The high-voltage covers must only be removed by the manu-

facturer’s service personnel.
Fig. 3.11-2 Laser module viewed from operating side (folding doors open)

The optical components are important and sensitive components of the la-
ser module. They require special handling and care.
Work on the optical components must only be performed by

the manufacturer’s service personnel.
Fig. 3.11-3 Schematic diagram of the optical system
B B
B
C
B
A
H C
G
D
J E
F
I
A End mirror
B Horizontal beam-folding mirror
C Vertical beam-folding mirror
D Output coupler
E Shutter
F 90o deflecting mirror
G 45o deflecting mirror
H Convex telescopic mirror
I Concave telescopic mirror
J Polarizing mirror

3.11.2 Lower section of laser module
The lower section of the laser module houses the excitation modules and
the laser controller.
Fig. 3.11-4 Laser module viewed from operating side (shown without safety covers)
B C
A Frequency converter
B Dehumidifier
C Vacuum pump
D Central gas cooler
E Gasmix unit

Fig. 3.11-5 Laser module viewed from loading side (shown without safety covers)
F
G
F Laser controller
G High-voltage excitation
H Turboblower

3.12 Combined cooling and filtration unit
The purpose of the combined cooling and filtration unit is to cool water
and filter out metal cutting dusts, and is used in conjunction with a laser
cutting machine.
The combined cooling and filtration unit is ready for connection, and con-
sists chiefly of the housing, the components for the cooling-agent, cool-air
and water circuits, the air filtration unit, the control cabinet and all the
control and monitoring units required for automatic operation.
Fig. 3.12-1 Combined cooling and filtration unit

tailed information on the combined cooling and filtration unit.

3.13 Remote diagnostics (option)
The remote diagnostics facility can be used by the manufacturer's Cus-

tomer Services and by the owner to access individual machine compo-
nents such as the CNC, MachineService, laser module and SysInfo.
TCP/IP and HTTP are used as the communications protocols. The system is
operated via a web browser.
For further information please see the Installation guide and

section 5.11 ›Using the remote diagnostics facility (option)‹.

Fig. 3.13-1 System layout with machine network
C K
D
L
E
F
G H
J
M
A Internet environment
B Secure communication (SSH)
C Owner environment
D Firewall
E Router
F Owner's network
G Machine network
H Netbox / Router
I Machines
J Remote Diagnostics Box (RD box)
K Manufacturer environment
L Firewall
M Remote Diagnostics Server (RD server)

Fig. 3.13-2 System layout without machine network
C I
D
J
E
F
H
K
A Internet environment
B Secure communication (SSH)
C Owner environment
D Firewall
E Router
F Owner's network
G Machines
H Remote Diagnostics Box (RD box)
I Manufacturer environment
J Firewall
K Remote Diagnostics Server (RD server)

3.14 Cutting gases
Nitrogen (N2), oxygen (O2) and optionally compressed air (Air) are used
for laser cutting. See section 9 ›Cutting technology‹
3.14.1 Cutting gas quality
The gas quality has a crucial impact on the cut quality. Nitrogen affects
the quality of the cut surface. The following tables show the relationship
between quality grade and oxide formation on the cut surface.
Tab. 3.14-1 Quality level and oxide formation
Proportion of water
nitrogen + argon
Proportion of
N2 + Ar / [ppm]
Cut surface
H2O / [ppm]
Gas type
Quality
[Vol. %]
Purity
Oxygen 3.5a) ≥ 99.95 ≤ 500 ≤5 Oxide formation

O2
Nitrogen 2.8 ≥ 99.8 ≤ 500 ≤ 20 oxide-free, slightly yel-

N2 lowish
3.5a) ≥ 99.95 ≤ 100 ≤ 10 oxide free, not guaran-

teed bright
4.5 ≥ 99.995 ≤ 10 ≤5 oxide-free, guaranteed

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

guaranteed shiny
a) Recommendation

3.14.2 Compressed air quality
A suitable solution for the low-cost production of compressed air is an as-

sembly with compressor and filter units capable of producing the required
volume and quality of compressed air.
Tab. 3.14-2 Compressed-air quality to ISO 8573-1
Maximum particle diameter 0.01 μm

(Class 1 or better)
Maximum particle density 0.01 mg/m3

(Class 1 or better)
Maximum residual oil content 0.003 mg/m3

(Class 1 or better)
Compressed-air dew point -40 °C (-40 °F)

(Class 2r)

3.14.3 Cutting gas consumption
The cutting gas consumption depends on the pressure and the nozzle
used. The following diagrams show recommended values for cutting in the
low-pressure and high-pressure region.
Fig. 3.14-1 Low pressure up to 6 bar (nozzle diameter 0.8 ... 3.0 mm)
Fig. 3.14-2 High pressure up to 20 bar (nozzle diameter 0.8 ... 3.0 mm)
A Cutting gas consumption

B Gas pressure
C Nozzle diameter used

ByVention
Chapter 4
4 Control elements
This chapter provides information on warning signals output by the laser

cutting machine. It also describes the controls and indicators and the indi-
vidual operating modes.

Control elements ByVention

ByVention Control elements
4.1 Warning signs
4.1.1 Indicator lamp
The indicator lamp is mounted on the laser module. The various colors in-
dicate the operating status of the laser module.
Fig. 4.1-1 Indicator lamp on the laser module
A Red indicator lamp

Provides information on the laser module status.
Lamp not illuminated: shutter is closed
Lamp illuminated: shutter is open, the laser beam is being emitted
from the laser module.
Lamp flashing: laser module is in Service mode (class 4 laser), the
safety door is open. Service mode tasks are described in section
4.3.3 ›Service mode‹.
B Orange indicator lamp

Provides information on the high-voltage status.
Lamp illuminated: high voltage switched on
C White indicator lamp

Provides information on the laser gas supply.
Lamp flashing: gas pressure <2 bar, replace laser gas bottle
Lamp illuminated: gas pressure <1 bar, laser module high-voltage
switches off, cutting process is halted.

4.1.2 Loading status
The loading status is indicated by an indicator lamp.
Fig. 4.1-2 Position of indicator lamp
Lamp flashing No standard sheet against sheet stop

Lamp illuminated Standard sheet against sheet stop
Lamp not illuminated Standard sheet clamped
or
No sheet clamped and sheet stop re-
tracted

4.1.3 System, status and error messages
All system, status and error messages are shown in the user interface
(see section 5.10 ›Troubleshooting‹).
4.1.3.1 Color coding
The individual messages are divided into classes and color-coded.
Tab. 4.1-1 Message colors
paint Priority / Class Description
1 Operator prompt The message requires operator in-

tervention (e.g. press the CONT or
yellow STOP button).
2 Fault Processes already started are inter-

rupted (e.g. stop caused by EMER-
red GENCY STOP).
The cause must be fully cleared be-
fore operation is resumed.
3 Warning A safety-related element has

tripped (e.g. safety door open).
orange
4 Information Information on the active process

(e.g. cutting plan import).
light
blue
4.1.3.2 Priorities
All messages are listed in the message list with the highest priority mes-
sage always at the top. See section 5.10.2 ›Message list‹

4.2 Controls and indicators
4.2.1 Control cabinet
Fig. 4.2-1 Controls on the control cabinet
A Main power switch (see section 3.3.2 ›Main power switch‹).

B EMERGENCY STOP button (see section 3.3.3 ›EMERGENCY STOP
circuit‹)
C Reset button (safety circuit enable)
D Key-operated switch Operation / Adjustment laser beam
In normal operating mode, the key-operated switch is always in the Oper-

ation position.
Remove the key when in the Operation position and give to the
owner for safekeeping.
The key must only be issued to the manufacturer's Service

personnel.

4.2.2 Laser module
Fig. 4.2-2 Operating and display elements on the laser module
C B
A Indicator lamp (see section 4.1.1 ›Indicator lamp‹)

B EMERGENCY STOP button
C Shutter lock (key-operated switch)
The shutter lock is used to protect service personnel working on the beam
path against accidental opening of the shutter.
In normal operating mode, the shutter switch is always in the UNLOCK
position.
Service work on the beam path and the associated locking of

the shutter must only be performed by the manufacturer's
service staff.

4.2.3 Operator console
The laser cutting machine is operated from the operator console. The op-
erator console is designed as a touch screen. This means that the user in-
terface can be operated by touching the relevant on-screen buttons or
keys.
Fig. 4.2-3 Controls on the operator console
B
C A
E
E
A EMERGENCY STOP button

B Rotary knob
C CONT button
D USB port
E Dead-man button (back of console)
F Screen (touch screen)
G Membrane keypad

4.2.3.1 Membrane keypad
Fig. 4.2-4 Membrane keypad on operator console
C
B D
A Status indicator of operator console

B Shutter status. When the LED is on, the shutter is open.
C Function keys
D X-, Y-, Z-axis traverse buttonsa)
a) Function is only available if Deadman button is held pressed at the same time.

4.2.3.2 Function buttons
Tab. 4.2-1 Function buttons on the membrane keypad
Button Description
Toggles between standard and advanced functions. Access to the

advanced functions can be protected by a PIN code. See section
5.9.2.2 ›Defining the PIN code‹
Changes the user interface language See section

5.9.1 ›Changing the dialog language‹
Dual function, depending on the laser mode defined. See section

5.7.2 ›Laser mode‹
Pulsed laser mode: emit one laser pulse each time the but-
ton is pressed (deadman button must also be pressed)
Burn laser mode: open shutter while button is pressed
(deadman button must also be pressed)
Stops any functions that have been started
Release safety door
Releases safety cover on unloader

4.2.3.3 Traverse buttons
Tab. 4.2-2 Traverse buttons on the membrane keypad
Button Description
Moves X-axis in plus or minus direction in manual mode,

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

Moves Z-axis in plus or minus direction in manual mode,

No function

4.2.4 Sheet-clamping foot switch
Once the standard sheet is lying correctly against the sheet stop (loading
status indicator lamp lit), it can be clamped or released by pressing the
foot switch.
Fig. 4.2-5 Foot switch
At the start of a job, the sheet stop can be retracted/extended by pressing

the foot switch.

4.3 Operating modes
4.3.1 Normal mode
The laser cutting machine is in Normal mode when:

all components have been fitted and set up as specified
all covers correctly fitted
the laser cutting machine is switched on
all safety devices have been initialized
cutting plans and parameters have been imported
the cutting process has been started
4.3.2 Manual operating mode
Manual operation is only available from the advanced functions. While cut-
ting is in progress, manual operation is blocked.
In manual operation, axes can be moved manually and the laser beam can
be switched on for a single pulse or continuously to make a manual sever-
ance cut. Only with the safety door closed and deadman button
held pressed.
4.3.3 Service mode
The laser cutting machine is in Service mode when Normal operating

mode has been interrupted. It makes no difference whether the interrup-
tion is for adjustment and inspection tasks, or for cleaning and mainte-
nance work.
The machine enters Service mode at the moment when the safety door is
opened or permanent safety devices are dismantled.
Normal mode is restored when the laser cutting machine is made ready
for use, the safety devices are reset and the process is started up again.


ByVention
Chapter 5
5 Operation
This chapter provides information on how to operate the product safely,

how to set up and adjust it, and also gives details of its various functions.

Operation ByVention

ByVention Operation
5.1 Introduction
5.1.1 Safety regulations
In order to prevent injuries and damage to property during work on the

laser cutting machine, it is essential to observe the safety regulations. In
particular, all persons working with the machine must have read and un-
derstood Chapter 2 ›Safety regulations‹ .
The machine danger zones that are out of bounds during operation are
listed in section 2.3 ›Danger zones‹.
The machine must only be used as intended, as described in section
1.1.2 ›Intended use‹.
5.1.2 Requirements of the operating personnel
Operators must understand the operating software and have a technical

understanding. Operating staff must be able to perform the following
tasks:
Switch the laser cutting machine on and off
Operate the machine control system
Use the control software
Import a cutting job and start the cutting process
Perform dimensional corrections
Convert the machine for a change in production
Clean the laser cutting machine
Perform maintenance work required during normal operation

Operation ByVention
5.2 Operating the laser cutting machine
The laser cutting machine is operated from the operator console, and at
the loading and unloading table.
5.2.1 Pre start-up check
The following points must be checked before switching on the machine:

All safety equipment, EMERGENCY STOP devices and sound insulation
present and in working order.
The safety door must be closed.
All EMERGENCY STOP buttons must be enabled.
The ByVention machine and its components show no external signs of
damage or defects.
Compressed air is connected with pressure and quality in accordance
with the requirements in the installation instructions. The shut-off valve
is open.
The laser gas bottle is connected and the reducing valve open with
pressure and quality in accordance with the requirements in the instal-
lation instructions.
The high voltage remains off during start-up if no laser gas is available
at the gas controller.
Cutting gas bottles are connected and the pressure reducing valves
open. The shutter remains locked while there is no cutting gas available
at the gas controller.

ByVention Operation
5.2.2 Switching on in normal operating mode
Follow the procedure below to start up the laser cutting machine in normal
operating mode.
1. Switch on at the main power switch (ON position).
2. Press the reset button on the control cabinet. This enables the safety
circuit.
3. Switch on the main power switch on the combined cooling and filtra-
tion unit (ON position).
4. The display on the operator console shows the required start-up

steps in the order they are to be performed.
Fig. 5.2-1 Manual start-up steps
Color-coding:
red Start-up step not carried out

green Start-up step carried out
The remaining start-up procedure remains blocked until

all start-up steps are carried out.

Operation ByVention
5. Press the Unlock safety door button on the operator console. Open
and re-close the safety door.
If the safety door is already open then it must be closed.
6. Move the axes to the reference positions. The operator console dis-
plays the relevant operating prompt.
Fig. 5.2-2 Operating prompt: Move to reference
CONT
7. Press CONT on the hand-held controller. The axes move to the refer-
ence position.
8. Wait until the Ready message for the laser appears in the status bar
in the user interface.
The orange indicator lamp on the laser module also lights up to show
that the laser is ready.

ByVention Operation
The machine is operational. The display shows the main view with the
standard functions.
Fig. 5.2-3 Main view showing standard functions

Operation ByVention
5.2.3 Switching off in an emergency
The laser cutting machine can be switched off in an emergency by press-

ing an EMERGENCY STOP button.
Error message: Stop - external emergency stop
All movements and processes are stopped immediately. Section
3.3.3 ›EMERGENCY STOP circuit‹ contains further details.
Take appropriate action should anyone be injured during an emergency
(observe operating regulations).
If the machine is damaged then the manager and the manufacturer
must be informed.
5.2.4 Switching on again after an EMERGENCY STOP
Operation of the machine can only be resumed once the emergency situa-
tion has been cleared and all defects and damage have been rectified.
1. Enable the actuated EMERGENCY STOP button by pulling it or turn-

ing it clockwise (cw).
2. Press the reset button on the control cabinet. This enables the safety
circuit.
3. Reset error (see section 5.10.4 ›Resetting errors‹).
4. Wait until the laser module is ready (orange indicator lamp on the la-
ser module comes on). You can then continue cutting.

ByVention Operation
5.2.5 Switching off in normal mode
Before the laser cutting machine can be switched off, the active cutting
processes must be completed.
1. Press button (A) in the main view showing standard or advanced

functions.
2. Confirm prompt with yes.
Fig. 5.2-5 Confirmation prompt
Yes No
Yes Continue shutdown procedure

No Cancel shutdown procedure

Operation ByVention
3. The display on the operator console shows the required switch-off

steps in the order in which they are performed.
Once started, the shutdown procedure cannot be inter-

rupted.
Fig. 5.2-6 Manual shutdown functions
4. Wait until the laser module is flooded. As soon as the laser module is
flooded, all applications are automatically closed and the controller is
shut down.
5. Close shut-off valves for cutting gas, laser gas and compressed air.
6. Switch off the main power switch on the machine (OFF position).
7. Switch off the main power switch on the combined cooling and filtra-
tion unit (OFF position).
Do not switch off the combined cooling and filtration

unit if there is a risk of frost.

ByVention Operation
5.3 Layout of the user interface
5.3.1 Standard functions
After starting up the laser cutting machine, the display shows the main
view with the standard functions.
A System, status and error messages. See section

5.10 ›Troubleshooting‹
B Start standard sheet production. See section 5.6.3 ›Standard
sheet production‹
C Import job. See section 5.6.1.1 ›Importing a job from
USB memory stick‹
D Start shutdown procedure. See section 5.2.5 ›Switching off in nor-
mal mode‹

Operation ByVention
5.3.2 Advanced functions
The user can switch to the advanced functions at any time (function key
on operator console).
Access to the advanced functions can be protected by a PIN

code (see section 5.9.2.2 ›Defining the PIN code‹).
Fig. 5.3-2 Main view with advanced functions
A Start residual sheet production. See section 5.6.4 ›Residual sheet

production‹
B Select hand-held controller. See section 5.7 ›Manual operation‹
C Make settings. See section 5.9 ›Settings‹
D Select maintenance functions for the CNC or laser module. See
section 5.8 ›Maintenance functions‹
E Symbol indicating advanced functions
No symbol: standard functions active
Symbol displayed: advanced functions active

ByVention Operation
5.4 Material flow
The material flow differs depending on whether it is a standard sheet

(Standard sheet production) or a residual sheet (Residual sheet pro-
duction) that is being cut.
5.4.1 Cutting standard sheets
Whole or partly cut standard sheets (length greater than 1 200 mm) are
always loaded or removed at the loading table.
The operator is responsible for loading sheets of the correct material.
1. Loading a standard sheet onto the loading table.
Fig. 5.4-1 Standard sheet on loading table

Operation ByVention
2. Push a standard sheet against the sheet stops by hand and clamp.
Fig. 5.4-2 Standard sheet against sheet stop
3. The standard sheet will be pulled into the cutting area by the sheet
feed and travel unit.
Fig. 5.4-3 Standard sheet pulled into place

ByVention Operation
4. Make severance cut and cut first sheet segment.
Fig. 5.4-4 Cut sheet segment
5. The sheet segment is transported from the cutting area to the un-
loading area. Manually remove the cut parts and skeleton.
Fig. 5.4-5 Cut sheet segment on the unloading table

Operation ByVention
6. To cut the next segment, the standard sheet is again pulled into the
cutting area.
Fig. 5.4-6 Standard sheet pulled into place
The following points must be observed:

If the current job requires further standard sheets, the operator console
will display an operating prompt.
To remove a partly cut standard sheet (length less than 1 200 mm), it
must be cut into smaller pieces using severance cuts and shifted out to
the unloading table in several repeat operations.

ByVention Operation
5.4.2 Cutting residual sheets
Residual sheets are loaded and removed through the open safety door (for
maximum dimensions see section 1.2.2.4 ›Residual sheet‹).
The operator is responsible for loading the correct material. He/she must
ensure that the cutting plan fits the loaded residual sheet.

Operation ByVention
5.5 Setting up and adjustment tasks
5.5.1 Initiating a function
Usually each selected function (e.g. Service position, Laser pulse etc.)
is initiated by pressing the CONT button on the operator console. The
safety door must be closed.
A started function can be stopped or aborted at any time using the STOP
button on the operator console.
1. Select the desired function on the user interface (e.g. Service posi-
tion).
2. Look at operating prompt on the user interface (e.g. to press the

CONT or STOP button).
3. Press CONT on the operator console. The selected function is con-

firmed and executed.

ByVention Operation
5.5.2 Removing or inserting the cutting head
When changing the cutting head, the best access is obtained when the
head is in the service position.
Fig. 5.5-1 Mounting the cutting head on the Z-axis.
A Clamping lever
B Mounting plate
C Cutting head
1. Release and open the safety door.
2. Hold the cutting head with one hand while releasing the two clamp-
ing levers with the other.
3. Carefully pull the cutting head down out of the holder.

Operation ByVention
4. With one hand hold the new cutting head against the mount with
even pressure while tightening the two clamping levers with the oth-
er hand to fix the head in place.
5. Close the safety door.
After removing or fitting the cutting head, check that the laser
beam is centered in the nozzle. If necessary, center the noz-
zle.

ByVention Operation
5.5.3 Adjusting the focal position
The focal position for the material to be cut and the cutting gas used must
be set manually on the cutting head to the value shown.
Fig. 5.5-2 Step 2 of 4: Tool preparation
D C
A Focal position to be set

B Focal-position scale (6 mm divisions)
C Scale on adjusting ring (0.2 mm divisions)
D Locking screw (for locking the focal-position adjusting ring)

Operation ByVention
1. Read off value shown on user interface (e.g. 0 - 55).
2. Undo locking screw.
3. Adjust the focal position at the adjusting ring. One revolution of the
adjusting ring moves the foal position by 60/10 mm (6 mm).
Fig. 5.5-3 Changing the focal position
Turning counterclockwise moves Turning clockwise moves the

the focal point downwards. focal point upwards.
4. Check the focal position setting (focal-position scale and adjusting-

ring scale)
5. Lock the adjusting ring with the locking screw.
Every cutting head has its own focus reference setting which is
used by the controller as a basis for calculation.
After cleaning or fitting a new lens, the focus reference setting
must be re-measured and saved in the parameters (see section
7.5.8 ›Measuring the focus reference setting‹).

ByVention Operation
5.5.4 Changing the nozzle
The nozzle must be changed under the following circumstances:

if a different nozzle is required for processing a job (message displayed
on user interface during tool preparation)
if the machining quality deteriorates and you find, on inspection, that
the nozzle is damaged
Fig. 5.5-4 Cutting head with fitted nozzle
A Nozzle
B Unscrewing the nozzle
C Screw in nozzle

Operation ByVention
1. Clean the nozzle externally.
2. Unscrew the nozzle by hand. If it is stuck fast, use a ring wrench with
suitable care.
3. Screw in the new nozzle fully by hand.
Whenever the nozzle is changed, check that the laser beam is

centered in the nozzle. If necessary, center the nozzle.

ByVention Operation
5.5.5 Centering the nozzle
Optimum cut quality is largely dependent on a properly centered nozzle.

If the nozzle is not centered properly, the laser beam can touch the nozzle
and be distorted. So precision is essential when centering the nozzle.
Fig. 5.5-5 Nozzle not centered
A B
Fig. 5.5-6 Nozzle centered correctly
A B
A Nozzle aperture
B Laser burn mark on the adhesive tape
C Adhesive tape

Operation ByVention
1. Affix a strip of transparent adhesive tape onto the nozzle in the cut-
ting head.
3. Press button (D) to select laser pulse.
4. Press CONT to trigger laser pulse.
6. Using a mirror, check whether the hole burnt into the adhesive tape
is positioned exactly in the center of the nozzle aperture (see
Fig. 5.5-6).
7. If necessary, use the centering screws on the cutting head (E) and
(F) to correct the laser beam in the appropriate direction.
z Turning clockwise (cw) moves the nozzle towards the centering
screw (see Fig. 5.5-8).
z Turning counterclockwise (ccw) moves the nozzle away from the
centering screw (see Fig. 5.5-9).

ByVention Operation
Fig. 5.5-8 Turning centering screws clockwise (cw)
E F
Fig. 5.5-9 Turning centering screws counterclockwise (ccw)
E F
8. Repeat step 1 to step 7 until the laser beam is fired exactly through
the center of the nozzle (see Fig. 5.5-6).

Operation ByVention
5.6 Production
5.6.1 Loading a job
The system recognizes whether the loaded job needs to be cut from a
standard sheet or a residual sheet. The job is automatically added to the
end of the appropriate job list (Standard sheet production or Residual
sheet production).
5.6.1.1 Importing a job from USB memory stick
Plus the memory stick into the USB port of the operator console (see sec-
tion 4.2.3 ›Operator console‹).
This function appears both in the standard functions and the advanced
functions.
Fig. 5.6-1 Importing a job
B C
The list can be scrolled up or down line by line (rotary knob on operator
console).

ByVention Operation
A Open selected directory / import selected job

B Back to the previous view
C Cancel import function

Operation ByVention
5.6.1.2 Load job automatically from the network
The created jobs can be copied automatically from the source directory to
the destination directory of the laser cutting machine.
The source directory can be defined on the local hard disk or on a server in
the network. The NcpMachineDistributor software module must be in-
stalled for this function.
Fig. 5.6-2 Copying jobs from the source directory to the laser cutting machine
A A
D
C

ByVention Operation
A Programmer workstation
B Local hard disk
C Server in the network
D Installed NcpMachineDistributor software module
E Jobs created in Bysoft
F Laser cutting machine
The NcpMachineDistributor software module has the role of a job allo-

cator. It looks for new jobs in the defined source directory at regular inter-
vals. Any new jobs present are copied to the destination directory of the
laser cutting machine. Back up files of the copied jobs are created in the
source directory and then deleted afterwards.

Operation ByVention
5.6.2 Job selection
In the Select job window, all available jobs are listed. The list can be
scrolled up or down line by line (rotary knob on operator console).
The job at the top of the list can be processed. If another job is to be pro-
cessed, it must first be moved to the top of the list.
Fig. 5.6-3 Job selection
A C
A Job list
B Prioritize job
C Defer (Move down) job
5.6.2.1 Order of processing
The order of processing can be changed using the Prioritize and Move
down functions.
Pressing button (B) moves the selected job to the top position in the
job list.
Pressing button (C) moves the job down one position in the list.

ByVention Operation
5.6.3 Standard sheet production
The formats specified in section 1.2.2.1 ›Standard sheet‹ and section

1.2.2.2 ›Partly cut standard sheet‹ are permitted for Standard sheet
production. Processing can be carried out with both standard and ad-
vanced functions.
5.6.3.1 Loading standard sheets or partly cut standard sheets
CAUTION
loading sheets
1. Select the Standard sheet production function on the user inter-

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

Operation ByVention
2. Select job. If the correct job is not at the top of the list, it must first
be moved there (see section 5.6.2 ›Job selection‹).
3. Enter number of Remaining runs if required. The number of Re-

maining runs defines how often the cutting plan is worked through.
Fig. 5.6-5 Changing the number of runs
4. Press button (A) to confirm the entry.

ByVention Operation
5. Start the job that appears at the top of the list.
6. Move axes to service position. The safety door must be closed to do

this. Select the function by pressing button (B) and use the CONT
button to start the process.
7. Release the safety door and carry out adjustment work.

z Check nozzle and change if necessary (see section
5.5.4 ›Changing the nozzle‹).
z Set the focal point on the cutting head (see section
5.5.3 ›Adjusting the focal position‹).
z Center the nozzle (see section 5.5.5 ›Centering the nozzle‹).

Operation ByVention
8. Provide sheet according to the required specification (C). For several

repeat runs of the cutting plan, provide the correct number of stan-
dard sheets.
Fig. 5.6-7 Step 3 of 4: Place on material
Ensure that the sheets provided meet the required spec-

ification (C).

ByVention Operation
9. Place a standard sheet on the loading table and push it against the
sheet stop (see section 5.4.1 ›Cutting standard sheets‹).
Fig. 5.6-8 Loading the sheet and pushing it against the stop
The loading status is indicated by the indicator lamp (D).
Lamp flashing No standard sheet against sheet stop

Lamp illuminated Standard sheet against sheet stop
Lamp not illuminated Standard sheet clamped
or
No sheet clamped and sheet stop re-
tracted

Operation ByVention
10. Once the standard sheet is correctly against the sheet stop, clamp it
by pressing the foot switch.
Fig. 5.6-9 Foot switch
11. Press button (E) to confirm that sheet is loaded. The machine is
ready for cutting.
Fig. 5.6-10 Step 4 of 4: Cut plan
12. Start cutting process (see section 5.6.3.2 ›Starting the cutting pro-
cess‹).

ByVention Operation
5.6.3.2 Starting the cutting process
If the machine has been set up correctly and the correct material with the
correct dimensions has been loaded, the cutting process can be started.
A Start and Stop functions (see section 5.6.5 ›Start and Stop func-
tions‹)
Cancel job
Start part
Start job
Stop part
B Manual operating Switch to manual mode. While cutting is in
mode progress, manual operation is blocked.
See section 5.7 ›Manual operation‹
C <Param Switch between the individual cutting pa-
Param> rameter views
See section 5.6.6 ›Changing cutting param-
eters‹
D Restart Run through cutting plan again
See section 5.6.9 ›Repeating the cutting
process (Restart)‹

Operation ByVention
E Cutting plan Show current cutting plan. The cutting plan

view can be scrolled up or down (rotary
knob on operator console).
1. Press the Start job or Start part button. See section 5.6.5 ›Start
and Stop functions‹ for how to start or stop processing.
2. Press CONT on the hand-held controller. The following functions are

carried out automatically:
z pulling in the sheet (first sheet segment in cutting area)
z calibration of Z-axis
z Starting the cutting process
3. Make a severance cut and then cut the parts on the sheet segment.
4. The cut sheet segment is transported to the unloading area.
5. The sheet feed pulls the next sheet segment into the cutting area.
The machine continues to work through the cutting plan.
6. If a job includes several Remaining runs, the operator console dis-

plays an operating prompt when another standard sheet needs to be
loaded.
The nozzle is cleaned after every run through a cutting plan.
7. If the complete job has been worked through, it is deleted from the
job list. The following functions are carried out automatically:
z Clean nozzle
z Move to reference

ByVention Operation
5.6.3.3 Removing the cut parts and skeleton
CAUTION
Risk of burns
There is a risk of burns when removing the cut sheet
segment.
Wear protective gloves.
After transport of the cut sheet segment to the unloading position, the
safety cover on the unloader opens automatically allowing removal of cut
parts and skeleton.
Fig. 5.6-12 Removing material in the case of mass production
Closing the safety cover confirms that the unloading table is empty.
Before the next cut sheet segment can be transported to the

unloading table, a check is made to ensure that it is empty. If
this is not the case then the unloading table moves back to the
unloading position. The safety cover opens automatically.

Operation ByVention
5.6.4 Residual sheet production
The formats specified in section 1.2.2.4 ›Residual sheet‹ are permitted for
residual sheet production. Processing is possible only with the advanced
functions.
5.6.4.1 Loading a residual sheet
CAUTION
loading sheets
1. Switch to advanced functions (button on operator console).
2. Select the Residual sheet production function on the user inter-

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

ByVention Operation
3. Select job. If the correct job is not at the top of the list, it must first
be moved there (see section 5.6.2 ›Job selection‹).
4. Enter number of Remaining runs if required. The number of Re-

maining runs defines how often the cutting plan is worked through.
Fig. 5.6-14 Changing the number of runs
5. Press button (A) to confirm the entry.

Operation ByVention
6. Start the job that appears at the top of the list.
7. Move axes to service position. The safety door must be closed to do

this. Select the function by pressing button (B) and use the CONT
button to start the process.
8. Release the safety door and carry out adjustment work.

z Check nozzle and change if necessary (see section
5.5.4 ›Changing the nozzle‹).
z Set the focal point on the cutting head (see section
5.5.3 ›Adjusting the focal position‹).
z Center the nozzle (see section 5.5.5 ›Centering the nozzle‹).

ByVention Operation
9. Provide sheet according to the required specification (C). For several

repeat runs of the cutting plan, provide the correct number of residu-
al sheets.
Fig. 5.6-16 Step 3 of 4: Place on material
Ensure that the sheets provided meet the required spec-

ification (C).

Operation ByVention
10. Load the cutting table with a residual sheet and position it roughly at
the machine zero point (see section 5.4.2 ›Cutting residual sheets‹).
Fig. 5.6-17 Loading the material
Fig. 5.6-18 Residual sheet positioned at the zero point
Residual sheets are loaded and removed through the open

safety door.

ByVention Operation
11. Press button (D) to confirm that sheet is loaded. The machine is
ready for cutting.
12. Start cutting process (see section 5.6.4.2 ›Starting the cutting pro-
cess‹).

Operation ByVention
5.6.4.2 Starting the cutting process
If the machine has been set up correctly and the correct material with the
correct dimensions has been loaded, the cutting process can be started.
E
D
C
B
A Start and Stop functions (see section 5.6.5 ›Start and Stop func-
tions‹)
Cancel job
Start part
Start job
Stop part
B Manual operating Switch to manual mode
mode See section 5.7 ›Manual operation‹
C Save Save modified cutting parameters
parameters See section 5.6.7 ›Saving cutting parame-
ters‹
D Load Resets cutting parameters to default values
default See section 5.6.8 ›Resetting cutting param-
eters‹

ByVention Operation
E <Param Switch between the individual cutting pa-

Param> rameter views
See section 5.6.6 ›Changing cutting param-
eters‹
F Restart Run through cutting plan again
See section 5.6.9 ›Repeating the cutting
process (Restart)‹
G Cutting plan Show current cutting plan. The cutting plan
view can be scrolled up or down (rotary
knob on operator console).
H Confirm selected start position
1. Press the Start job or Start part button. See section 5.6.5 ›Start
and Stop functions‹ for how to start or stop processing.
2. Press CONT on the hand-held controller. The following functions are

carried out automatically:
z calibration of Z-axis
z move to reference
3. Use the X+, X-, Y+ and Y- buttons while pressing the dead-man but-
ton to move the axes manually to the start position. Note direction of
travel (see Fig. 5.6-21).
step 3 is not needed if the residual sheet has been posi-

tioned correctly at the zero point using the end stops. Con-
tinue with step 4

Operation ByVention
Fig. 5.6-21 Directions of travel
4. Press button (H) to confirm the start position.
Fig. 5.6-22 Shifting the zero point

ByVention Operation
5. Press CONT on the hand-held controller. The zero-point offset is cal-

culated, and machining of the residual sheet starts.
6. If a job includes several Remaining runs, the operator console dis-

plays an operating prompt when another residual sheet needs to be
loaded.
The nozzle is cleaned after every run through a cutting plan.
7. If the complete job has been processed, it is deleted from the job list.
The following functions are carried out automatically:
z Clean nozzle
z move to reference

Operation ByVention
5.6.4.3 Removing the cut parts and skeleton
CAUTION
Risk of burns
There is a risk of burns when removing the cut residual
sheet.
Wear protective gloves.
After the cutting process, manually remove cut parts and skeleton from
the cutting table.
Fig. 5.6-23 Removing material in the case of residual sheet production

ByVention Operation
5.6.5 Start and Stop functions
5.6.5.1 Stop
A started function can be stopped at any time using the STOP button on
the operator console.
Fig. 5.6-24 Button on the operator console
5.6.5.2 Start part

Cut first part in the cutting plan. On pressing the Start part button again,
the next part in the processing sequence is cut. Processing stops after
each cut part.
5.6.5.3 Start job
Process whole job. If a job includes several Remaining runs, the opera-
tor console displays an operating prompt when another standard or resid-
ual sheet needs to be loaded.
5.6.5.4 Stop part

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

Operation ByVention
5.6.5.5 Cancel job
Before a job that has been started can be canceled it must be stopped
(Stop part or STOP button).
Canceled jobs remain in the job list and are marked with a symbol (A).
On restarting a canceled job, processing continues after the last complete-
ly cut standard sheet. Incompletely cut standard sheets are repeated.
Fig. 5.6-25 Canceled job

ByVention Operation
5.6.6 Changing cutting parameters
The cutting parameters are not optimized for maximum process reliability.
This means that adjustments can be needed for an optimum cutting result
(see section 9 ›Cutting technology‹).
The values of the individual cutting parameters are changed as percentag-
es of the default value. The default value is always 100%.
A Next cutting-parameters view

B Previous cutting-parameters view
Cutting parameters can only be changed once processing of the cutting

plan has started.

Operation ByVention
1. Select cutting-parameter views by pressing button (A) or (B).
2. Select cutting parameter to be changed.
Fig. 5.6-27 Selected cutting parameter
3. Increase or decrease parameter value by turning rotary knob.
Fig. 5.6-28 Rotary knob on the operator console
The parameter is highlighted as it is changed.
Fig. 5.6-29 Parameter value when being changed
4. Wait for a few seconds. The modified parameter is automatically

transferred to the controller and takes immediate effect.
Fig. 5.6-30 Modified parameter value
Changes in parameter values remain active until a new job is

started.

ByVention Operation
5.6.7 Saving cutting parameters
Modified cutting parameters can be saved. The modified parameters then

take effect for all jobs that use the same material.
A modified cutting parameter set can be given a new file name.
The function is only available from the advanced functions (see section
5.3.2 ›Advanced functions‹).
A Save modified cutting parameters

B Resets cutting parameters to default values
5.6.8 Resetting cutting parameters
It is possible to reset the cutting parameters to the default values defined

by the manufacturer.
Resetting is only possible when the loaded job is being processed (when at
least one cut has been made). Confirm prompt with Yes or No.
The function is only available from the advanced functions (see section
5.3.2 ›Advanced functions‹).

Operation ByVention
5.6.9 Repeating the cutting process (Restart)
If the cutting process has to be aborted (e.g. following a fault or collision),

repeat functions are available for restarting the cutting process.
A Repeat sheet Repeat entire standard or residual sheet

B Next part Skip current part
C Contour lock-on Manually shift starting point for continued
processing of the cutting plan
D From stop point Continue processing from the position
where cutting was stopped

ByVention Operation
5.6.9.1 Repeat sheet
Repeat entire standard or residual sheet. Individual sheet segments or

parts of a residual sheet cannot be repeated.
This function requires that the standard or residual sheet on which cutting
has been started is removed and another standard or residual sheet is
loaded. Confirm prompt with Yes or No.
5.6.9.2 Next part
The part in processing when the cutting process was interrupted by press-
ing the STOP or Stop part button is skipped.
On resuming the cutting process with Start part or Start job, the axes
move to the zero point of the next part in the cutting sequence.
This function is only possible within the same sheet segment or

the same residual sheet.
5.6.9.3 Contour lock-on
After the cutting process is interrupted with the STOP or Stop part but-
ton, the starting point for further processing of the cutting plan can be
shifted manually (see Fig. 5.6-22 and Fig. 5.6-21).
On resuming the cutting process with Start part or Start job, the axes
move to the part nearest to the starting point. The cutting sequence con-
tinues from this part.
Moving the starting point may lead to parts being skipped.

These will not be cut.

Operation ByVention
5.6.9.4 From stop point
The machine continues to work through the cutting plan from the position
at which cutting stopped.

ByVention Operation
5.7 Manual operation
Manual operation is only available from the advanced functions. While cut-
ting is in progress, manual operation is blocked.
5.7.1 Switching to manual mode
Manual operation can be selected only when a cutting parameter file has
been selected. This is required for a manual severance cut, for example.
The cutting parameter file depends on the material of the loaded sheet.
1. Select the Manual operation function on the user interface.
Fig. 5.7-1 Selecting the cutting parameter file

Operation ByVention
2. Select cutting parameter. The list can be scrolled up or down line by

line (rotary knob on operator console).
The names of the cutting parameter sets are structured according to
the following coding scheme.
Fig. 5.7-2 Structure of parameter set names.
1.0161 1.5 5 N2 GALVANIZED
A B C D E
A Material number using DIN convention

B Sheet thickness in [mm]
C Focal length of cutting head in inches
D Cutting gas
E Additional information
Material number using DIN convention

1.0161 St 37-2 Structural steel
1.0332 Stw 22 Sheet steel
1.4301 X5CrNi18 -10 Rust and acid-resistant steel
3.3535 AlMg3 Peraluman 300
Sheet thickness
1 1.0 mm 4 4.0 mm
1.5 1.5 mm 5 5.0 mm
2 2.0 mm 6 6.0 mm
2.5 2.5 mm 8 8.0 mm
3 3.0 mm

ByVention Operation
Focal length of cutting head

5 Focal length 5 inches
Cutting gas
N2 Nitrogen
O2 Oxygen
Air Compressed air
Additional information
HOT DIP GALVANIZED hot galvanized
GALVANIZED electro-galvanized
PLASTIC FOIL film-coated

Operation ByVention
3. Select manual operation by pressing button (F).
Fig. 5.7-3 Selecting manual operation
F G
F Selecting manual operation

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

ByVention Operation
5.7.2 Laser mode
The laser mode defines which function is actuated when the Laser button
(on the operator console) is pressed. Only with safety door closed and
deadman button held pressed.
Tab. 5.7-1 Laser mode
Laser mode Description
Burn Pressing the Laser button opens the shutter. The laser
beam is emitted continuously, in accordance with the se-
lected cutting parameter set. The shutter stays open for
as long as this button is pressed.
This function is used for a making a manual severance
cut.
Pulsed Pressing the Laser button emits a laser pulse, in accor-

dance with the selected cutting parameters.
This function is used for centering the nozzle.
5.7.3 Tool mode
Tool mode can be used to switch capacitive detection on/off in order to

raise and lower the Z-axis.
Tab. 5.7-2 Tool mode
Tool mode Description
On Capacitive detection is enabled (default)
Off Capacitive detection is disabled
CAUTION
Collision risk
The nozzle may be damaged when detection is disabled.
Only switch off detection for maintenance work.

Operation ByVention
5.7.4 Cutting parameters for manual operation
The cutting parameters only apply during manual operation. See section
5.6.6 ›Changing cutting parameters‹ and section 9.6 ›Cutting parame-
ters‹ for how to change parameters.
5.7.4.1 Laser mode: Burn
On the user interface, three different parameters can be changed for CW

cutting.
In addition, the focal position for each material type and

sheet thickness must be set manually on the cutting head.
Fig. 5.7-4 Cutting parameters in manual operation, Laser mode: Burn
A Cutting parameters in manual operation, Laser mode: Burn

B Cleaning height for nozzle cleaning This is used as a setup value
for nozzle cleaning.
See section 5.7.4.3 ›Distance Z-reference - cleaning height‹

ByVention Operation
5.7.4.2 Laser mode: Pulsed
On the user interface, two different parameters can be changed for the
single pulse mode.
Fig. 5.7-5 Cutting parameters in manual operation, Laser mode: Pulsed
A Cutting parameters in manual operation, Laser mode: Pulsed

B Cleaning height for nozzle cleaning This is used as a setup value
for nozzle cleaning.
See section 5.7.4.3 ›Distance Z-reference - cleaning height‹

Operation ByVention
5.7.4.3 Distance Z-reference - cleaning height
The cleaning height (Z) defines how far the cutting head is lowered from
the Z-axis reference position in order to clean the nozzle.
max. adjustment range 90 ... 105 mm
Adjustment step 1 mm
The value (Z) may need to be increased as the cleaning brush wears
down. The optimum depth for the nozzle tip to extend into the brush
equals 2 ... 3mm.
Fig. 5.7-6 Cleaning height

ByVention Operation
5.7.5 Moving the axes manually
When moving the axes manually, care must be taken to ensure that there
are no obstructions within the range of travel.
This function is available only with safety door closed and deadman button
held pressed.
Fig. 5.7-7 Directions of movement and buttons
X- X+
Y- Y+
Z- Z+

Operation ByVention
Information on the individual axes is shown on the user interface.
Fig. 5.7-8 Manual operation, axis positions
A B C D
A Current axis positions (X, Y and Z axes)

B Ref. (reference position of the X, Y and Z axes)
Axis in reference position
Axis not in reference position
C End.+ (End of travel in positive direction of X, Y and Z axes)
Axis at limit of travel
Axis not at limit of travel
D End.- (End of travel in negative direction of X, Y and Z axes)
Axis at limit of travel
Axis not at limit of travel

ByVention Operation
5.7.6 Moving the axes to the service position
The cutting head is moved to a defined position that is readily accessible

for the operator. The following work is carried out in the service position:
changing the cutting head
adjusting the focal position
changing the nozzle
Center nozzle
2. Press button (A) to select the function.
Fig. 5.7-9 Manual operating mode
3. Press CONT on the hand-held controller. The axes travel to the ser-
vice position.

Operation ByVention
5.7.7 Manual severance cuts
Manual severance cuts are used to cut off waste or cut up residual sheets
into smaller pieces. This function is available only with safety door closed
and deadman button held pressed.
CAUTION
Making separating cuts
The cutting head must always be lowered during cutting
to prevent severe reflections or stray radiation.
Move the cutting head immediately after pressing the
Laser button. Otherwise, the laser beam can damage
the trays under the cutting table or the support grate.
Always make severance cuts using the parameters assigned

to the material of the loaded residual sheet.
1. Place residual sheet on the cutting table.
2. Select manual operation (see section 5.7.1 ›Switching to manual

mode‹).
3. Set Laser mode to Burn.
4. Switch Tool mode to On.
5. Move the cutting head manually to the desired starting position (see
section 5.7.5 ›Moving the axes manually‹). The severance cut is
started from this position.
6. Press the Z- button on the operator console and hold until the cutting
head has been lowered to the appropriate nozzle clearance height.
Then release the button.
When the cutting head is lowered, traversing is performed at a slow-
er speed enabling more precise positioning in the starting position.

ByVention Operation
Fig. 5.7-10 Starting position for severance cut
7. Move the cutting head about 1 mm beyond the edge of the sheet.
8. Open the shutter by pressing the Laser button. The shutter stays
open for as long as this button is pressed.
Use the buttons for the X and Y-axes to move immediately in the de-
sired direction for cutting the sheet.
9. Release the Laser button immediately once the severance cut is

made. This closes the shutter.
10. Press Z+ on the operator console The cutting head moves upwards.

Operation ByVention
5.7.8 Moving the cutting table manually
The cutting table can be moved into defined positions (top, center or bot-
tom). The current position is displayed.
2. Press button (B) or (C) to select the function.
A Current position of cutting table

B Move cutting table up
C Move cutting table down

ByVention Operation
3. Press CONT on the hand-held controller. The cutting table moves in

the selected direction to the next position. The position with respect
to the unloading table is monitored.

Operation ByVention
5.7.9 Moving the unloading table manually
The unloading table can be moved into the limits of travel (cutting area or
unloading area). The current position is displayed.
2. Press button (B) or (C) to select the function.
A C
A Current position of unloading table

B Move unloading table into the cutting area
C Move unloading table into the unloading area

ByVention Operation
3. Press CONT on the hand-held controller. The unloading table moves

in the selected direction to the limit of travel. The position with re-
spect to the cutting table is monitored.
4. If the unloading table is in the unloading position, the safety cover on

the unloader opens automatically.

Operation ByVention
5.7.10 Unloading sheets manually
The sheet is transported from the cutting table to the unloading area. The
machine does not make a severance cut in this case. The following points
must be observed:
Check that the length of a sheet segment or residual sheet does not ex-
ceed the maximum length (see section 1.2.2 ›Material formats and
thicknesses that can be cut‹). If necessary, use manual severance cuts
to reduce the sheet size.
Unloading is only possible when the unloading table is empty
This function is executed whether or not the cutting table contains ma-
terial
2. Press button (A) to select the function.

ByVention Operation
3. Press CONT on the hand-held controller. The sheet on the cutting ta-
ble is transported to the unloading area.
4. If the unloading table is in the unloading position, the safety cover on

the unloader opens automatically.

Operation ByVention
5.8 Maintenance functions
The maintenance functions can only be selected when the cutting process
is not running.
5.8.1 CNC Maintenance
Fig. 5.8-1 Maintenance functions, CNC controller
A D
B C
A Execute RamDump. Save log files in a defined directory on the

operator console. The log files are used solely for fault analysis by
the manufacturer.
B Copy RamDump. Copy log files from the source directory on the
operator console to the destination directory on the USB memory
stick. The files in the source directory are deleted after copying.
C Reset Terminal. Shut down and restart the operating system on
the operator console.
D Reset CNC. Shut down and restart the CNC controller.

ByVention Operation
E Edit saved focus reference setting (see section 7.5.8 ›Measuring

the focus reference setting‹)
F Saved value for the focus reference setting

Operation ByVention
5.8.2 Laser module maintenance
Fig. 5.8-2 Maintenance functions, Laser module
A B
G G
D E
A Start calibration process

B Abort calibration process
C Time remaining for calibration process
D Start leak test
E Stop leak test
F Results of leak test
G Operating status of laser components

ByVention Operation
5.8.2.1 Calibrating the optical power
The optical power of the laser module is monitored (comparison of actual

and setpoint values). Wear and soiling of individual components can lead
to a difference between the two values.
Warning message when difference exceeds 5 % of the setpoint value.
Error message and shut down of laser module when difference exceeds
10 % of the setpoint value
If the warning message is displayed, run the calibration. This takes about
12 minutes. After calibration, the actual value returns to within the per-
mitted tolerance of the setpoint value.
Only run the calibration after the laser module has warmed up
(after about 2 h).
If the calibration establishes that too much current is required

for the specified power, then another error message is dis-
played. Contact the manufacturer’s Customer Services depart-
ment.
5.8.2.2 Operating status of laser components

The operating status of each laser component is displayed on the user in-
terface.
Operating status paint Meaning
Turbine running red Turboblower off
green Turboblower on
Excitation active red Excitation modules off
green Excitation modules on
Vacuum pump red Vacuum pump off
green Vacuum pump on
Laser module flooding red Laser module not flooded
green Laser module flooding

Operation ByVention
5.8.2.3 Leak test for gas circuit
If the laser module is not supplying the required power, or there are prob-
lems with generating the vacuum, the cause may be a leak in the gas cir-
cuit.
The leak test will identify a leak in the gas circuit. A leak rate is displayed
as the result. This must not exceed 1 hPa/h.
min. length of leak test 75 minutes

max. length of leak test 720 minutes
The leak rate is only displayed once the evacuation process has finished
(approx. 10 ... 15 minutes after starting). Watch the operating status of
the laser components.
The started leak test can be stopped at any time.
If the leak test produces a leak rate >1 hPa/h, there is a leak in
the gas circuit. Contact the manufacturer’s Customer Services
department.

ByVention Operation
5.9 Settings
5.9.1 Changing the dialog language
The interface language can be changed without having to restart the laser
cutting machine.
1. Select the Settings function on the user interface or press the Lan-
guage select button on the operator console.
Fig. 5.9-1 Settings ⎯ Default language
A Current interface language

B Available interface languages
C Close view

Operation ByVention
2. Change the interface language by selecting the appropriate button

(B). Changes are effective immediately.
The list can be scrolled up or down line by line (rotary knob on oper-
ator console).
3. Press button (C) to close the language-setting window.
The new interface language will be the default language when

the the laser cutting machine is next started.

ByVention Operation
5.9.2 Configuration
Fig. 5.9-2 Settings ⎯ Machine settings
C B
A Length units ([mm] or [inches])

B Define PIN code
C Close view

Operation ByVention
5.9.2.1 Selecting the dimensional units
The setting for the dimensional units applies to the display of the material
dimensions (length, width, thickness) and to the display of the axis posi-
tions (X, Y and Z axes).
Tab. 5.9-1 Dimensional units
Units Description
Millimeters Display material dimensions and axis positions in

metric units
Inches Display material dimensions and axis positions in im-

perial units

ByVention Operation
5.9.2.2 Defining the PIN code
Access to the advanced functions can be protected by a PIN code (8 digits

maximum). The default setting is no PIN code.
Fig. 5.9-3 Settings ⎯ Change PIN
A
B
C
E
D
A Enter old PIN code

B Enter new PIN code
C Enter new PIN code again to confirm
D Confirm entry
E Delete entry
F Cancel change
Tab. 5.9-2 Set, change or de-activate PIN code
PIN code Input field
A B C
Set PIN code for the first time
Change existing PIN code
De-activate PIN code
No entry
Required entry

Operation ByVention
5.9.3 Operating-hours counter
Maintenance is carried out on the basis of operating hours.

The operating hours listed below are displayed on the user interface.
Fig. 5.9-4 Settings ⎯ Operating-hours counter
A
B
C
D
A Operating-hours counter: Power switch on

B Operating-hours counter: Machine ready for cutting
C Operating-hours counter: Production time
D Operating-hours counter: Turboblower on
Figure used to assess when to carry out maintenance
E Close view

ByVention Operation
Tab. 5.9-3 Operating-hours counter
Hours counter Description
Power switch on Total duration, in hours, for which the main switch has
been on.
Machine ready for Total duration, in hours, for which the laser cutting
cutting machine has been started up and referenced.
Production time Total duration, in hours, for which jobs have been
processed.
Turboblower on Total duration, in hours, for which the turboblower in

the laser module has been running.

Operation ByVention
5.9.4 Versions
Display of installed software versions, protocols used and product infor-

mation.
Fig. 5.9-5 Settings ⎯ Versions
A
B
C F
D G
E H
A Installed software versions (user interface, machine service and

CNC)
B Protocols for internal communication
C Machine type
D Machine version
E Rated power of laser module in [W]
F Installed version of the CNC operating system
G Software-image version on operating terminal
H Software version installed in laser module
I Close view

ByVention Operation
5.9.5 Administration
The manufacturer’s service personnel make machine-specific settings in

the Administration area. The functions are protected by a PIN code.
Fig. 5.9-6 Settings ⎯ Administration
A B
A Close (Exit) application

B Start Administrator
C Close view

Operation ByVention
5.10 Troubleshooting
5.10.1 System, status and error messages
All system, status and error messages are displayed in the status bar (A).
Fig. 5.10-1 Error message
The individual messages are divided into classes and color-coded.
Tab. 5.10-1 Message colors
paint Priority / Class Description
1 Operator prompt The message requires operator in-

tervention (e.g. press the CONT or
yellow STOP button).
2 Fault Processes already started are inter-

rupted (e.g. stop caused by EMER-
red GENCY STOP).
The cause must be fully cleared be-
fore operation is resumed.
3 Warning A safety-related element has

tripped (e.g. safety door open).
orange
4 Information Information on the active process

(e.g. cutting plan import).
light
blue

ByVention Operation
5.10.2 Message list
Touch the status bar to open the message list. All active messages are list-
ed in the message list, with the highest priority message always at the
top.
If a number of messages are active simultaneously, the list can be scrolled
up or down line by line (rotary knob on operator console).
Fig. 5.10-2 Message list
A List of active messages

B Reset error (see section 5.10.4 ›Resetting errors‹)
C Close dialog

Operation ByVention
5.10.3 Using the Help facility
Press button (A) to display details of the selected message.
Fig. 5.10-3 Details
A
B
A Display details
B Detailed information on the selected system message, status mes-
sage or error message
C Close dialog

ByVention Operation
Press button (D) to open the Online Help for the selected message. The
Online Help contains a description of the cause of the error and its correc-
tion.
Fig. 5.10-4 Online Help
D Open the Online Help

E Online Help for the selected system message, status message or
error message
F Close dialog

Operation ByVention
5.10.4 Resetting errors
Most messages are automatically reset once normal conditions are re-
stored.
There are, however, certain fault conditions for which the message must
be reset by the operator after clearance of the fault.
Messages can be reset only after the causes have been com-
pletely cleared.
Fig. 5.10-5 Message list
Press button (A) to reset the message. Press button (B) to close the mes-
sage list.

ByVention Operation
5.11 Using the remote diagnostics facility (option)
The remote diagnostics facility is operated via a web browser (Internet Ex-
plorer, Firefox, Opera etc.).
Open the home page by entering the IP address of the RD box.
Fig. 5.11-1 Entering the IP address in the address bar
http://192.168.100.250 (default IP address)
Fig. 5.11-2 Remote diagnostics home page
A Viewing diagnostic data

B Administration area (Connect / Disconnect)

Operation ByVention
5.11.1 Connect / Disconnect (Administration)
The owner can connect the RD-box to the RD server and disconnect it.
When connected, the manufacturer's Customer Services department can
view diagnostic data for individual machine modules.
Fig. 5.11-3 Administration – Connection view
C D
B
E
A Select the Connection view

B Administrative functions for the manufacturer’s Customer Services
department
C Connection status
D Connect/Disconnect
E Back to home page
Only the owner can re-connect after a disconnection (see

Tab. 5.11-1).

ByVention Operation
5.11.2 Connection status
The connection status to the RD server is displayed after every refresh.

The following table lists the possible connection statuses.
Tab. 5.11-1 Connection status
Connection status Description
Connected Connected to server.

Use disconnect to end connection.
Disconnected Connection to server lost.

Use connect to re-connect.
try connecting Connection terminated because the network con-

nection has been lost. The system is trying to re-
connect.
The connection is established as soon as the server
can be reached again.
Use stop trying to stop trying to connect.

Operation ByVention
5.11.3 Viewing diagnostic data
The status of every machine module can be viewed in the Diagnostics ar-
ea.
Fig. 5.11-4 Diagnostic data view
B
A C
A Navigation by tree structure

B Diagnostic data
C Back to home page

ByVention Operation
5.11.3.1 Navigation
Every time the system is interrogated, each connected module transmits

its current status, which is color coded in the Navigation view. Table
Tab. 5.11-2 shows what the colors mean.
The configuration of the machinery is also transmitted at the same time.
This is shown in the form of a tree structure in the Navigation view.
If a module in the subordinate branch has a problem, then the higher-lev-

el node is also displayed in red.
Tab. 5.11-2 Status of system modules
paint Description
The module responds to the query and has no errors.
green
The module does not respond to the query. Also flagged Offline.
red
The module responds to the query but returns an error status.
red

Operation ByVention
5.11.3.2 Detailed diagnostic data
Selecting a module in the Navigation view displays detailed diagnostic

data for the module.
These operating instructions do not describe the detailed diag-

nostic data.

ByVention
Chapter 6
6 Maintenance
This chapter contains the maintenance schedule and instructions on how

to carry out lubrication, care and cleaning tasks and forms for the mainte-
nance record. Materials required for maintenance work are also listed.

Maintenance ByVention

ByVention Maintenance
6.1 Introduction
Maintenance staff must be familiar with the technical details of the laser
cutting machine. They must have read and understood all operating in-
structions and safety-related directions in these operating instructions.
Always disconnect the machine from the supply when performing mainte-
nance and repair work. Protect the main power switch with a padlock and
store the key in a place inaccessible to a third party.
6.1.1.1 Work on live (hot) components
WARNING
Electric shock
When working on live (hot) components there is a dan-
ger of electric shock.
Electrical components on which maintenance work is be-
ing performed must be disconnected from the electrical
supply unless otherwise specified.
Check that disconnected components are de-ener-
gized.
Insulate any adjacent live (hot) parts.
6.1.1.2 Work on gear units
CAUTION
Risk of burns
Risk of burns if maintenance and repair work is per-
formed on the gears when they are still at working tem-
perature.
Allow gear units to cool down.

6.1.1.3 Remaining in the danger zone
During maintenance and repair work, no unauthorized persons are permit-

ted to remain in the danger zone of the laser cutting machine. Block off
danger zone.
6.1.1.4 Operating materials
Always observe the manufacturer’s safety instructions when handling

working materials, in particular gear oil, solvents and grease.
6.1.1.5 External modules
Always refer to the supplier documentation for all installed third-party

assemblies (e.g. combined cooling and filtration unit).
6.1.1.6 Tools, test equipment and spare parts
Use only the tools and test equipment listed.

Use only original spare parts from the manufacturer (see Spare parts
catalog).

6.1.2 Requirements to be met by personnel performing the work
Maintenance personnel must be capable of performing the following tasks:

Operation of the machine control system
repair work on pneumatic systems,
Replacement, repair and adjustment of mechanical parts
Making mechanical and electrical adjustments to the machine

6.2 Customer service information
The manufacturer's Customer Services department is available in the

event of problems. Please have the following information ready before
calling the department, so that problems and queries can be dealt with as
quickly as possible:
Company / Address
Contact person
Order and equipment number (see type plate)
The contact address appears in the front of these operating instructions.

6.3 Operating materials
Section 7 ›Repair‹ specifies the use of resources, lubricants and cleaning

materials.
Tab. 6.3-1 Resources and cleaning materials
Description Usage Order code
Lubrication set (in tool 4-10845

box)
"Ultrapac" set of spares Air drier (adsorption drier) 10006011

Section 7.4.8
Resin Amberlite MB-5 Combined cooling and filtra- 1991000

tion unit
Kerosene Section 7.4.3.7 / 7.4.6.1
Tab. 6.3-2 Lubricants
Description Usage Order code
Motorex 190 EP univer- Section 7.4.3.1 / 7.4.3.3 / 1971661

sal grease 7.4.3.5 / 7.4.3.6 / 7.4.5.3 /
7.4.5.4 / 7.4.6.2 / 7.4.7.1
Syntheso Proba 270 Chapter 7.5.7 1971659
Motorex Gearsynt Chapter 7.4.3.4 10010453

ISO 460
Chain oil Section 7.4.3.7 / 7.4.6.1 1972790

Chainlube 622
Pump-action spray bot- 1972791

tle
Compressor oil G32 Chapter 7.6.2 1973601

Tab. 6.3-3 Lens cleaning kit
Qty Description Order code
Lens cleaning kit 10006021

Section 7.5.5 / 7.5.5.1 / 7.5.5.2 / 7.5.5.3 /
7.5.5.4
1 Air bulb 10003299
1 Bottle of acetone (100 ml) with separate pipette 500615
4 50 sheet pack of lens cleaning paper 7 × 12 cm 500822
1 100 sheet pack of lens cleaning paper 10003298

15.2 × 22.8 cm
1 Pack of 170 Q-Tips cotton buds 10006017
1 Pack of makeup-remover cotton-wool pads 10003300
1 Bottle of lens polish (60 ml) 10006018
1 Bottle of de-ionized water (100 ml) 10006016
1 Bottle of (6%) acetic acid (100 ml) with separate 10006015

pipette
1 Mount for optical elements 90000623
5 Pair of disposable latex gloves, size M 10000925
1 Cleaning instructions

6.4 Operating hours display
The reading from the Turboblower on operating-hours counter is used to

assess when to carry out maintenance work (see Section
5.9.3 ›Operating-hours counter‹).
Fig. 6.4-1

6.5 Maintenance schedule
The following maintenance schedule serves as a reference guide for plan-

ning and implementing maintenance work on the laser cutting machine.
Maintenance of other modules (e.g. combined cooling and filtra-

tion unit) is described in the operating instructions for that mod-
ule.

Maintenance work Interval
Object Notes/In- Action Operating re-
As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Laser cutting ⎯ Check for external damage X
machine
⎯ Complete cleaning X
Safety devic- Chapter 7.3 Check EMERGENCY STOP buttons and X

es end position monitoring for correct func-
tioning and effectiveness.
Operator con- Chapter 7.4.1 Clean operator console X

sole
Safety door Chapter 7.4.2 Clean and lubricate guides Universal grease X
Motorex 190 EP
Gas supply Chapter 7.7.1 Cutting gas supply, change gas cylinder X
Chapter 7.7.2 Laser gas supply, change gas cylinder X
⎯ Check supply lines for leaks X

As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Travel unit Chapter 7.4.3.9 Check bellows for damage. X
Chapter 7.4.3.1 Grease X-axis linear guides Universal grease X

Motorex 190 EP
Chapter 7.4.3.2 Grease Y-axis spindle bearings Universal grease X

Motorex 190 EP
Chapter 7.4.3.3 Grease X-axis motor bearings Universal grease X

Motorex 190 EP
Chapter 7.4.3.4 Grease X-axis rack Motorex X

Gearsynt ISO 460
Chapter 7.4.3.5 Grease Y-axis linear guides Universal grease X

Motorex 190 EP
Chapter 7.4.3.6 Grease Y-axis recirculating ball drive Universal grease X

Motorex 190 EP

As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Travel unit Chapter 7.4.3.7 Clean and lubricate Z-axis linear guides Chain oil X
Chainlube 622
Chapter 7.4.3.8 Check for leakage at the cutting head X

mount. Replace missing or damaged O-
rings.
Severance- Chapter 7.4.3.10 Check laser diode and window for soiling. X X
cut monitor- Clean if necessary.
ing

As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Cutting table Chapter 7.4.5.1 Clear extraction chambersa) X X
Chapter 7.4.5.1 Check functioning of exhaust air sector X

flaps.
Chapter 7.4.5.3 Lubricate linear guides Universal grease X

Motorex 190 EP
Chapter 7.4.5.4 Precision screw jack, grease spindle nut Universal grease X
Motorex 190 EP
Manufacturer's Precision screw jack, change the gear oil. Motorex X

Customer Ser- Check spindle for soiling. Clean and lubri- Gearsynt ISO 460
vice cate if necessary.
Chapter 7.4.5.5 Empty waste trays X
Chapter 7.4.5.5 Clean waste tray wheels X
a) The extraction chambers must be cleared completely when changing material from steel to aluminum or vice versa.

As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Sheet feed Chapter 7.4.6.1 Clean and lubricate telescopic rails Chain oil X
Chainlube 622
Chapter 7.4.6.2 Grease suction frame linear guides Universal grease X

Motorex 190 EP
Unloader Chapter 7.4.5.5 Empty waste tray X
Chapter 7.4.7.1 Grease fork system linear guides Universal grease X

Motorex 190 EP
Chapter 7.4.7.2 Check gears for oil loss X
Cutting head Chapter 7.4.4.1 Check lens for dirt, metal splashes or Lens cleaning kit X X
scratched surface. Clean or replace if nec-
essary.
Chapter 7.4.4.2 Check water couplings for leaks. Replace X

leaky couplings.
Chapter 7.4.4.3 Check nozzle and copper plate for damage X X

or splashes of metal. Clean or replace if
necessary.

As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Clean air sup- Chapter 7.4.8.1 Check LED display on air drier X
ply unit
Chapter 7.4.8.1 Air direr; replace drying agent cartridge. Spares kit X X
Indicated by LED display Ultrapac
Chapter 7.4.8.1 Air drier; replace inlet and outlet filters. X X

Indicated by LED display
Chapter 7.4.8.3 Cleaning the muffler X
Supply unit Chapter 7.4.9 Replace coarse filter X
Chapter 7.4.9 Replace fine filter X
Manufacturer's Filter on cutting-gas pressure reducer, X

Customer Ser- clean or replace if necessary.
vice

As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Laser module Chapter 7.6.1 Check the vacuum pump oil level. Top up Compressor oil G32 X X
Chapter 7.6.2 with oil if necessary.
Visual inspection for soiling, corrosion and X

water leaks
Check contact pin on the Shutter circuit- X

breaker
Customer Service
Manufacturer's
Adhesive safety labels. All labels and safe- X

ty notices are fitted and legible Clean or
replace if necessary.
Check mirrors in beam-expansion unit for X

soiling. Clean or replace if necessary.
Inspect pneumatic elements (loads, valves X

and hoses) for leaks. Clean or replace if
necessary.

As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Laser module Vacuum pump, change oil X
Customer Service
Manufacturer's
Vacuum pump, replace the air oil-filter el- X

ement (oil-mist filter) and seals
Turboblower, replace bearing cartridges X
Replace turboblower X

As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Combined Empty dust hopper when 75% fulla) X
cooling and
see operating instructions
Check cleaning of filter unit X

Combined cooling and
filtration unit
Check spark trap. Clean if necessary. X
filtration unit
Clean air filter mats. Replace defective or X

very heavily soiled filter mats.
Clean condensers X
Check water level in tank. Top up if neces- Demineralized wa- X X

sary. ter < 20 μS/cm2
Replace resin X
a) When changing material from steel to aluminum or vice versa, empty dust separator hopper. When cutting aluminum, the dust hopper must be emptied when 25%
full.

As necessary
structions source
resources
16 000 h
32 000 h
1 000 h
3 000 h
8 000 h
150 h
500 h
daily
50 h
Combined Check oil / water trap X
cooling and
filtration unit Inspect seals on doors visually. Replace if X
necessary.
see operating instructions
Combined cooling and
Check connecting pipes for leaks. Repair if X

necessary.
filtration unit
Dust extraction system, check that there X

is no caking at the entrance to the spiral
hose. Clean if necessary.
Dust extraction system, check for leaks in X

the spiral hose. Replace if necessary.
Check combined cooling and filtration unit X

for damage or corrosion and ensure it is
fitted securely. Repair or replace if neces-
sary.
Extraction Chapter 7.4.5.2 Check for deposits. Clean if necessary. X

duct

6.6 Maintenance record
The forms below may be copied and used as maintenance records for
proof of maintenance work carried out. This record must be kept in the
machine logbook.
Maintenance and repair work must be recorded with the date and signa-
ture of the person carrying out the maintenance tasks.
The maintenance record forms the basis for any warranty claims.
Warranty is only valid in its entirety if a correctly maintained

logbook is produced.

Maintenance record according to operating hours
Operating Maintenance at Date Signed Comments

hours interval
50 50
100 50
150 50 / 150
200 50
250 50
300 50 / 150
350 50
400 50
450 50 / 150
500 50 / 500
550 50
600 50 / 150
650 50
700 50
750 50 / 150
800 50


hours interval
850 50
900 50 / 150
950 50
1 000 50 / 500 / 1 000
1 050 50 / 150
1 100 50
1 150 50
1 200 50 / 150
1 250 50
1 300 50
1 350 50 / 150
1 400 50
1 450 50
1 500 50 / 150 / 500
1 550 50
1 600 50
1 650 50 / 150


hours interval
1 700 50
1 750 50
1 800 50 / 150
1 850 50
1 900 50
1 950 50 / 150
2 000 50 / 500 / 1 000
2 050 50
2 100 50 / 150
2 150 50
2 200 50
2 250 50 / 150
2 300 50
2 350 50
2 400 50 / 150
2 450 50
2 500 50 / 500


hours interval
2 550 50 / 150
2 600 50
2 650 50
2 700 50 / 150
2 750 50
2 800 50
2 850 50 / 150
2 900 50
2 950 50
3 000 50 / 150 / 500 / 1 000 / 3 000
3 050 50
3 100 50
3 150 50 / 150
3 200 50
3 250 50
3 300 50 / 150
3 350 50


hours interval
3 400 50
3 450 50 / 150
3 500 50 / 500
3 550 50
3 600 50 / 150
3 650 50
3 700 50
3 750 50 / 150
3 800 50
3 850 50
3'900 50 / 150
3 950 50
4 000 50 / 500 / 1 000
4 050 50 / 150
4 100 50
4 150 50
4 200 50 / 150


hours interval
4 250 50
4 300 50
4 350 50 / 150
4 400 50
4 450 50
4 500 50 / 150 / 500
4 550 50
4 600 50
4 650 50 / 150
4 700 50
4 750 50
4 800 50 / 150
4 850 50
4 900 50
4 950 50 / 150
5 000 50 / 500 / 1 000
5 050 50


hours interval
5 100 50 / 150
5 150 50
5 200 50
5 250 50 / 150
5 300 50
5 350 50
5 400 50 / 150
5 450 50
5 500 50 / 500
5 550 50 / 150
5 600 50
5 650 50
5 700 50 / 150
5 750 50
5 800 50
5 850 50 / 150
5 900 50


hours interval
5 950 50
6 000 50 / 150 / 500 / 1 000 / 3 000
6 050 50
6 100 50
6 150 50 / 150
6 200 50
6 250 50
6 300 50 / 150
6 350 50
6 400 50
6 450 50 / 150
6 500 50 / 500
6 550 50
6 600 50 / 150
6 650 50
6 700 50
6 750 50 / 150


hours interval
6 800 50
6 850 50
6 900 50 / 150
6 950 50
7 000 50
7 050 50 / 150
7 100 50
7 150 50
7 200 50 / 150
7 250 50
7 300 50
7 350 50 / 150
7 400 50
7 450 50
7 500 50 / 150 / 500
7 550 50
7 600 50


hours interval
7 650 50 / 150
7 700 50
7 750 50
7 800 50 / 150
7 850 50
7'900 50
7 950 50 / 150
8 000 50 / 500 / 1 000 / 8 000


ByVention
Chapter 7
7 Repair
This chapter provides support in locating and rectifying faults. It also con-
tains instructions for carrying out maintenance and making adjustments.

Repair ByVention

ByVention Repair
7.1 Introduction
Maintenance staff must be familiar with the technical details of the laser
cutting machine. They must have read and understood all operating in-
structions and safety-related directions in these operating instructions.
Always disconnect the machine from the supply when performing mainte-
nance and repair work. Protect the main power switch with a padlock and
store the key in a place inaccessible to a third party.
7.1.1.1 Work on live (hot) components
WARNING
Electric shock
When working on live (hot) components there is a dan-
ger of electric shock.
Electrical components on which maintenance work is be-
ing performed must be disconnected from the electrical
supply unless otherwise specified.
Check that disconnected components are de-ener-
gized.
Insulate any adjacent live (hot) parts.
7.1.1.2 Work on gear units
CAUTION
Risk of burns
Risk of burns if maintenance and repair work is per-
formed on the gears when they are still at working tem-
perature.
Allow gear units to cool down.

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7.1.1.3 Remaining in the danger zone
During maintenance and repair work, no unauthorized persons are permit-

ted to remain in the danger zone of the laser cutting machine. Block off
danger zone.
7.1.1.4 Operating materials
Always observe the manufacturer’s safety instructions when handling

working materials, in particular gear oil, solvents and grease.
7.1.1.5 External modules
Always refer to the supplier documentation for all installed third-party

assemblies (e.g. combined cooling and filtration unit).
7.1.1.6 Tools, test equipment and spare parts
Use only the tools and test equipment listed.

Use only original spare parts from the manufacturer (see Spare parts
catalog).

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Maintenance personnel must be capable of performing the following tasks:

Operation of the machine control system
repair work on pneumatic systems,
Replacement, repair and adjustment of mechanical parts
Making mechanical and electrical adjustments to the machine

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7.2 Troubleshooting
The following section show the step-by-step procedure for determining the
sources of problems.
1. Refer to messages issued by the machine.

Error messages and remedial actions are described in the Online
help.
2. Localizing faults
z Is the fault mechanical or electrical?
z Is it a hardware or software fault?
3. Finding source of problem

One fault often leads to other faults.
4. Frequency of fault
Does the fault always occur or do certain events trigger it?
5. Checking the laser cutting machine

z Obstruction due to soiling, foreign objects, damage?
z Supply connections OK ? (power supply, compressed air)
z Ambient conditions, climatic influences (e.g. heat, storm, etc.)?
6. Interference from other equipment and loads (voltage spikes)?
7. Check sensors and switches

z Buttons on operator console and release of EMERGENCY STOP
buttons
z Sensors, limit switches, safety limit switches
z LEDs on the input and output modules
8. Wiring and terminals

check installation for loose connections and broken conductors.

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9. Switches and settings

have components been changed but not correctly set?
10. Initialization
Shut down the entire system and re-start.
11. Supplier documentation

Other operating instructions may contain information on the fault
and troubleshooting.
12. Telephone
Call the manufacturer's Customer Services department (see section
7.9 ›Customer service information‹).

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7.3 Safety inspection
Check safety and monitoring devices such as EMERGENCY STOP buttons

and limit switches at the specified maintenance intervals to ensure that
they are operating correctly and effectively.
Information on the safety components is given in section 3.3 ›Safety de-
vices‹.
7.3.1 EMERGENCY STOP buttons
Functional test of all EMERGENCY STOP buttons on the laser cutting ma-
chine during an active cutting process.
1. Set up the machine and start the cutting process.
2. Press EMERGENCY STOP button. The EMERGENCY STOP circuit is

working correctly if all electrical loads are disconnected from the
power supply. The power supply to the controller is not switched off.
EMERGENCY STOP buttons are fitted:
z on the operator console
z on the control cabinet
z on the laser module
3. Reset the actuated EMERGENCY STOP button and re-start the laser
cutting machine.
See section 5.2.4 ›Switching on again after an EMERGENCY STOP‹

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7.3.2 Limit-of-travel monitoring
7.3.2.1 Limit switches on X-axis and Y-axis
Follow the procedure below to perform the functional test on the limit
switches on the X-axis and Y-axis.
Fig. 7.3-1 Position of the limit switches
Y+
A
X+
C
A Cutting table
B Limit switch, position X-
C Limit switch, position Y-
1. Select manual operation (see section 5.7 ›Manual operation‹).
3. Move the axes manually to the end position in question until the limit
switch is actuated (see section 5.7.5 ›Moving the axes manually‹).
4. The actuated limit switch is shown in the Axis positions view.

If it not possible to actuate the X-axis limit switch and/or Y-axis limit
switch, the limit switch concerned must be must be replaced by the
manufacturer's Customer Service department.
5. Once the limits switches have been tested successfully with no faults,
reference the machine.

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7.3.2.2 Limit switch on Z-axis
Follow the procedure below to perform the functional test on the Z-axis
limit switches.
1. Select manual operation (see section 5.7 ›Manual operation‹).
3. Lower the cutting table as far as possible (see section 5.7.8 ›Moving
the cutting table manually‹).
4. Switch Tool mode to Off to turn off the capacitive sensing. See
Chapter 5.7.3 ›Tool mode‹.
5. Move the manually, roughly to the middle of the cutting area.
6. Move the Z-axis manually to the Z+ limit of travel until the limit
switch is actuated (see section 5.7.5 ›Moving the axes manually‹).
7. The actuated limit switch is shown in the Axis positions view.

If it is not possible to actuate the limit switch, it must be replaced by
the manufacturer's Customer Service department.
8. Move Z-axis in Z- direction. As soon as the Z-axis reaches the Z- lim-

it of travel, the Z-axis automatically moves upwards again.
Error message: Stop - limit switch Z- tripped
9. Once both limits of travel have been tested successfully with no

faults,
z move the cutting table up to its topmost position.
z Switch Tool mode to On to turn on the capacitive sensing.

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7.4 Lubrication, service and cleaning work
7.4.1 Operator console
Before cleaning the operator console, shut down the laser cutting machine
and switch off at the main switch.
Fig. 7.4-1 Operator console
Never use a solvent-based cleaning agent for cleaning. Solvents or strong

cleaning agents can damage the screen surface and the membrane key-
board.
If necessary, use a soft cloth lightly moistened with soapy water to clean
the keyboard.

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7.4.2 Safety door
Clean and grease the guides every 500 operating hours.
Lubricant: Motorex 190 EP universal grease
Fig. 7.4-2 Guides, safety door
A B
A Safety door
B Guides

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7.4.3 Travel unit
7.4.3.1 X-axis linear guides
Every 500 operating hours, grease the X-axis linear guides. Lubrication
nipples 1 to 6

Quantity: 1,7 cm3 (2 shots with the grease gun)
per lubricating nipple
Fig. 7.4-3 Grease nipples on X-axis linear guides
6
4
2

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7.4.3.2 Y-axis spindle bearings
Every 3 000 operating hours, grease the Y-axis spindle bearings. Grease
nipple No. 7

Fig. 7.4-4 Grease nipples on Y-axis spindle bearings

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7.4.3.3 X-axis motor bearings
Every 3 000 operating hours, grease the X-axis motor bearings. Grease
nipple No. 8

Fig. 7.4-5 X-axis motor bearings lubrication nipple

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7.4.3.4 X-axis rack
Every 1 000 operating hours, grease the X-axis rack. Grease nipple No. 9
Lubricant: Motorex Gearsynt ISO 460

Fig. 7.4-6 X-axis rack lubrication nipple

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7.4.3.5 Y-axis linear guides
Every 500 operating hours, grease the Y-axis linear guides. Lubrication
nipples 1 to 4

Quantity: 0,6 cm3 (1 shot with the grease gun)
Fig. 7.4-7 Lubrication nipples on Y-axis linear guides
4
3
2
1

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7.4.3.6 Y-axis recirculating ball drive
Every 150 operating hours, grease the Y-axis recirculating ball drive (spin-
dles and bearings). Grease nipple No. 5

Quantity: 5 cm3 (4 shots with the grease gun)
Fig. 7.4-8 Lubrication nipples on Y-axis linear guides

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7.4.3.7 Z-axis linear guides
Every 500 operating hours, clean the Z-axis linear guides with kerosene
soaked cloths. Lubricate with chain oil.
Lubricant: Chain oil Chainlube 622 (in pump-action spray bottle)
Fig. 7.4-9 Linear guides, Z-axis

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7.4.3.8 Cutting-head mount
Check condition of seals daily. Replace missing or damaged O-rings.
Fig. 7.4-10 Seals on the cutting head mounting
A Cutting-head mount
B Seals (O-rings)

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7.4.3.9 Bellows
Check all bellows for damage every 500 operating hours. Replace defec-
tive bellows.
Fig. 7.4-11 Bellows on the laser cutting machine

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The laser bellows have a multi-layer construction. So any external damage

in the corners does not necessarily mean the bellows are not sealed. The
flexible inner material remains intact considerably longer than the tough
outer cover.
A thin probe (e.g. pen refill or wire) can be used to investigate any exter-
nal corner damage to see whether the inner material is also damaged
(e.g. contains holes). If damage is clearly present, the bellows must be
replaced.

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7.4.3.10 Severance-cut monitoring
Check laser diode and window for soiling daily (visual inspection). Clean
with a dry, clean cloth as necessary.
Fig. 7.4-12 Reflection light sensor, severance-cut monitoring
A Window
B Laser diode

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7.4.4 Cutting head
7.4.4.1 Lens
Check lens for dirt, metal splashes or scratched surface daily (visual in-
spection).
Clean or replace lens if necessary (see section 7.5 ›Cleaning or replacing
the lens‹).
Fig. 7.4-13 Visual inspection of the lens in the cutting head

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7.4.4.2 Water couplings
Check water couplings on cutting head daily for leaks.
Fig. 7.4-14 Water coupling
A Cutting head
B Water coupling

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7.4.4.3 Nozzle and copper plate
Check nozzle and copper plate daily for damage and splashes of metal.
Clean or replace if necessary. See section 5.5.4 ›Changing the nozzle‹ for
how to replace nozzle.
Fig. 7.4-15 Nozzle and copper plate on cutting head
A Copper plate
B Jet

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7.4.5 Cutting table
7.4.5.1 Extraction system
Every 50 operating hours, remove the cutting residues from the extrac-
tion chambers.
The extraction chambers must be cleared completely when

changing material from steel to aluminum or vice versa.
Every 150 operating hours, check that the flaps on the extraction sec-
tors are working. If the cutting head is located over sector (A) or (B),
the corresponding air extraction sector flap must be open.
Fig. 7.4-16 Extraction sector flaps
A Air extraction sector 1

B Air extraction sector 2

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7.4.5.2 Extraction duct
Check the extraction duct for deposits every 1 000 operating hours. Clean
if necessary.
Fig. 7.4-17 Extraction duct between machine and the combined cooling and filtration unit (cover re-
moved)
Remove extraction duct and clean internally. Check sealing tape for dam-
age. Replace if necessary.

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7.4.5.3 Linear guides
Every 500 operating hours, grease the cutting table linear guides.

Fig. 7.4-18 Cutting table linear guides

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7.4.5.4 Precision screw jack
Every 500 operating hours, grease the spindle nuts.

Grease nipple No. 5

Fig. 7.4-19 Precision screw jack, cutting table

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7.4.5.5 Waste trays
Empty the waste trays daily

Every 150 operating hours, clean the wheels.
Fig. 7.4-20 Waste trays on cutting table and unloading table
A Waste trays under the cutting table

B Waste tray under the unloader

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7.4.6 Sheet feed
7.4.6.1 Telescopic rails
Every 500 operating hours, clean the sheet-feed telescopic rails with kero-
sene soaked cloths. Lubricate with chain oil.
Lubricant: Chain oil Chainlube 622 (in pump-action spray bottle)
Clean and lubricate telescopic rails when fully extended.
Fig. 7.4-21 Sheet-feed telescopic rails

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7.4.6.2 Suction-frame linear guides
Every 500 operating hours, grease the suction-frame linear guides. Lubri-
cation nipples no. 1 and 2

Fig. 7.4-22 Lubrication nipples on suction-frame linear guide
Detail X

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7.4.7 Unloader
7.4.7.1 Fork-system linear guides
Every 500 operating hours, grease the fork-system linear guides.

Fig. 7.4-23 Lubrication nipples on fork-system linear guide

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7.4.7.2 Fork-system gears
Check the gears for oil loss every 1 000 operating hours. If they are losing
oil, contact the manufacturer’s Customer Services department.
Fig. 7.4-24 Fork-system worm-gear

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7.4.8 Clean air supply unit
7.4.8.1 Air drier (adsorption drier)
Every 8 000 operating hours or if there is a relevant error message,

change the filter or cartridge.
The air drier displays an error message when a filter or cartridge needs
changing. The error message stops the cutting process.
Error message on the operator console: Beam path air pressure is
missing
Fig. 7.4-25 LED indicator on the air drier
A Operation indicator
B Replace drying agent cartridge
C Replace post-filter
D Replace pre-filter
Check the LED display to make sure that the air drier really was the source
of the error message.
The LEDs (B, C and D) indicate whether the pre-filter, post-filter or drying-
agent cartridge needs replacing.
The precise procedure is given in the manufacturer's operating manual, in
the supplier documentation folder. The filter replacement pack can be
obtained from the manufacturer of the laser cutting machine.

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7.4.8.2 Reset switches
After replacing the drying agent cartridge, you must flip the Reset switch
with the machine switched off (resets the last-change counter).
The Reset switch is located behind the LED display cover.
Fig. 7.4-26 Reset switch on the control board
Only operate the Reset switch once after each cartridge

change.
Resetting the last-change counter only works with the ma-
chine switched off.

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7.4.8.3 Cleaning the muffler
Every 150 operating hours, check the muffleers for deposits (visual in-
spection). If there are powder residues in the pipe, the muffler must be
cleaned.
Fig. 7.4-27 Muffler unit
A Tube
B Hose clip
C Elbow joint
D Muffler
1. Undo hose clip (B) and pull off hose (A).
2. Unscrew elbow joint (C).
3. Remove muffler (D).

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4. Undo casing bolts and dismantle muffler (D).
Fig. 7.4-28 Dismantled muffler
E F G H I
E Base with casing bolts

F Mesh sleeve
G Inner sleeve
H Mesh
I Cap
J Nuts
5. Clean parts
z Blow off or wash out mesh sleeve (F).
z Blow off inner sleeve (G).
Use only air, never water, to clean the inner sleeve.
6. Assemble the muffler.
7. Insert muffler and fit elbow joint (C).
8. Re-connect pipe (A) and tighten hose clip (B)

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7.4.9 Supply unit
Every 1 000 operating hours, replace the coarse filter (40 μm).
Every 1 000 operating hours, replace the fine filter (5 μm)
Fig. 7.4-29 Coarse and fine filters on the supply unit
A Coarse filter (40 μm)

B Fine filter (5 μm)

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7.5 Cleaning or replacing the lens
The lens surfaces are specially coated. Damage to the coating reduces the
beam quality.
Special care must therefore be taken when handling optical components.
Damage can occur in the following ways:
particles of dirt burnt on by the laser beam
particles of dirt that leave scratches on the surface during cleaning
erosion of the coating from the lens surface.
CAUTION
Damage to optical components and parts
Improper handling will soil or damage optical compo-
nents.
Always wear disposable gloves when cleaning, replacing
or checking the lens (type: powdered Latex, non-sterile,
EN 455 class 1). Make sure that the work place is clean.

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Smoking is strictly forbidden when working with optical elements.

Take utmost care, and work to the highest standards of cleanliness
when handling optical elements. It is essential to have a clean work en-
vironment (if possible an office), a clean work surface and clean materi-
als and tools.
Wear latex disposable gloves
WARNING
Damage to a lens
Take utmost care if a lens is damaged as the lens con-
tains zinc selenide and thorium. If lenses are intact, no
radioactive material can escape. However, if the lens is
badly scratched or thermally damaged, radioactive ma-
terial can escape into the environment. These materials
may cause damage to health if inhaled.
Wear breathing mask and gloves.
Do not stir up dust.
Materials that have come into contact with the broken
lens or lens dust must be cleaned thoroughly with wa-
ter or disposed of as hazardous waste!
Return damaged lenses to the manufacturer of the la-
ser cutting machine.
After cleaning, wash your hands thoroughly under
running water.

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7.5.1 Equipment
The following items are required when fitting and removing a lens:
Tool kit (in tool box)
– Lens wrench
– Circular rod
Lubrication set (in tool box)
Cleaning kit (in tool box)
Fig. 7.5-1 Lens wrench and circular rod
B C
A Lens wrench
B Threaded pin (fixes handle extension)
C Inner piece of circular rod
D Outer piece of circular rod

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7.5.2 Construction of cutting head
Fig. 7.5-2 Cutting head
A
B
A Cutting head
B 5" lens holder (see Fig. 7.5-3)
The lens holder is different depending on the focal length of

the cutting head. Note the engraving (5") when assembling.

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Fig. 7.5-3 Lens holder
E
F
G
A Lens holder O-ring

B Lens holder
C Lens holder O-ring
D Lens
E O-ring
F Clamping ring
G Lens nut

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7.5.3 Removing the lens holder
1. Place cutting head on a clean surface.
2. Unscrew fixing screws on lens holder and pull the lens holder out of
the cutting head by hand.
Fig. 7.5-4 Removing the lens holder
A Lens holder
B Fixing screws
Do not twist the lens holder as you pull it out.

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3. Check lens holder O-ring. Replace damaged O-rings.
Apply minimal grease to O-ring before fitting (Synthe-

so Proba 270).
No residual grease should be visible.
4. Place the lens holder on a clean surface (with the lens nut facing up-
wards).

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7.5.4 Removing the lens
1. Remove handle extension from lens wrench. The handle extension is

not needed to exert the required torque to undo/tighten the lens.
Fig. 7.5-5 Removing the handle extension
A Lens wrench
B Handle extension
2. Clean lens wrench with compressed air.

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3. Unscrew the lens nut using the lens wrench.
Fig. 7.5-6 Remove the lens nut
A Lens holder
B Lens wrench for 5" lens nut
C Lens nut

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4. Position the outer part of the circular rod in the lens holder.
Fig. 7.5-7 Circular rod in position
A Lens holder
B Outer piece of circular rod

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5. Rotate the lens holder through 180° and carefully lift it off. If the lens
does not come away from the lens holder, press down lightly on the
lens from above with a cotton bud (inserted in the inner part of the
circular rod).
Fig. 7.5-8 Using a cotton bud to exert gentle pressure if lens is stuck fast
A Inner piece of circular rod

B Cotton bud
C Lens
D Outer piece of circular rod

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6. After removal, the clamping ring and the lens are located on the cir-
cular rod. Replace scratched or damaged lens. Clean soiled lens.
Fig. 7.5-9 Dismantled lens
A Lens
B Clamping ring
C Outer piece of circular rod
7. Position the dismantled lens in the lens holder1).
Fig. 7.5-10 Lens placed in mount for optical elements
1) Included in cleaning set

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7.5.5 Lens cleaning
The equipment required for cleaning is kept in the cleaning case. Cleaning
instructions are placed in the lid of the cleaning case.
Fig. 7.5-11 Lens cleaning kit
A B C D E F
G H I J K
A Lens cleaning paper 15.2 × 22.8 cm

B Makeup-remover cotton wool pads
C Disposable gloves (type: powdered Latex, non-sterile, EN 455
class 1), size M
D De-ionized water, 100 ml bottle
E Acetic acid with separate pipette, 100 ml bottle
F Q-Tips cotton buds
G Optical component holder
H Acetone with separate pipette, 100 ml bottle
I Lens polish, 60 ml bottle
J Air bulb
K Lens cleaning paper, 7 × 12 cm

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The following points must be observed when working with op-

tical elements:
Smoking is strictly forbidden when working with optical ele-
ments.
Never clean the surface of the lens dry.
Never treat the lens with compressed air. Contaminants in
the compressed air can penetrate the surface.
Store cleaning paper, cotton buds and cotton pads in a
dust-free environment. Dispose of after use.
Always use only the cleaning materials provided. Replace
caps on bottles after use.
Wear disposable gloves. Finger prints reduce the lifetime of
lenses.
Set up workplace away from the laser module. Do not allow
solvent vapor to enter the beam path.
Check the labeling on the lenses. Re-attach detached la-
bels.
Fit cleaned lenses immediately. Observe direction of instal-
lation.

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7.5.5.1 Cleaning in the case of light soiling
Light soiling means particles that can be removed by blowing them off.
Use air bulb to blow off dirt (dry nitrogen is also allowed). Never use a
blow gun.
Blowing dirt from lenses using an air bulb in heavily contaminat-

ed workshops must be tried on a case-by-case basis.
In order to prevent the optical surface ending up even dirtier,
you must proceed to the next cleaning step (acetone).

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7.5.5.2 Cleaning in the case of moderate soiling
If lenses cannot be cleaned adequately using the air bulb, proceed as fol-
lows:
1. Place lens in the mount (included in the cleaning kit).
Fig. 7.5-12 Lens placed in mount for optical elements
2. Place lens cleaning paper (7 × 12 cm) on the lens and drop 2 to 3

drops of acetone onto it.
Fig. 7.5-13 Lens cleaning paper with 2 to 3 drops of acetone
3. Draw the lens cleaning paper slowly and horizontally over the lens,
avoiding smears and leaving a dry clean surface.
Smears lead to irregular absorption of the laser beam.
Fig. 7.5-14 Draw the lens cleaning paper over the lens.

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4. The procedure can be repeated more than once. Use a fresh lens
wipe each time.
5. Use cotton buds to clean the lens surface if soiling is more severe.
Take particular care when using this cleaning method.

Apply only light pressure.
Avoid scratching the surface with dirt particles that ad-
here to the cotton buds.
The cotton buds must be prepared before use so that they are as soft
as possible for the optical element to be cleaned.
Before using each cotton bud, pull the cotton wool apart slightly with
your fingers and then re-twist in the opposite direction. Wear dispos-
able gloves.
6. Sprinkle lens cleaner (acetone) on a clean cotton bud and clean the
lens for no longer than 30 seconds, working from the inside out.
Only exert gentle pressure on the surface of the lens. Turn the cotton
bud steadily about its longitudinal axis so as to remove as much dirt
as possible.
Fig. 7.5-15 Lens cleaning using an acetone-soaked cotton bud
A Direction of rotation of cotton bud

B Circular movement to clean lens

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7. Finally, to remove any smears, clean the lens again using lens clean-
ing paper as described in step 2 and step 3.

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7.5.5.3 Cleaning in the case of heavy soiling
If lenses cannot be cleaned adequately using the air bulb, and subsequent
cleaning with acetone does not give a satisfactory result, use acetic acid to
clean the lens surface.
Take particular care when using this cleaning method. Apply

only light pressure.
Avoid scratching the surface with dirt particles that adhere to
the cotton buds.
Do not let the edges of the lens come into contact with the
acetic acid.
1. Do not perform the cleaning process for longer than 30 seconds. Ap-
ply only light pressure.
Fig. 7.5-17 Lens cleaning using a cotton bud soaked in acetic acid
A Direction of rotation of cotton bud

B Circular movement to clean lens
2. To remove any residual acetic acid or smears, clean the optical ele-
ment using lens cleaning paper and acetone as described in section
7.5.5.2 ›Cleaning in the case of moderate soiling‹ (step 2 and
step 3).

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7.5.5.4 Cleaning in the case of stubborn dirt
Polishing has an abrasive action and is only used when all other cleaning
attempts described in section 7.5.5.1, 7.5.5.2 and 7.5.5.3 have failed to
give the desired result.
CAUTION
Damage to the lens
The polish has an abrasive action and can attack the
lens coating if not used properly.
Polishing the surface of the optical element for too long,
too often or with too high a pressure wears away the op-
tical coating. This modifies the properties of the coating,
identifiable by a change in color of the surface of the
lens.
Polish the lens surface for no more than 30 seconds.
Perform no more than 2 polishing operations.
Avoid exerting high pressure.
1. Shake the polish well before use.
2. Sprinkle a few drops of the lens polish onto a cotton wool pad (eye
make-up remover pad).
3. Move the cotton pad carefully over the surface, using only the pres-
sure of its own weight and making circular movements, for not long-
er than 30 seconds.
Do not let the polish dry onto the surface of the lens.
4. Soak a fresh cotton pad (make-up remover pad) with de-ionized wa-
ter and use it to remove the polish carefully. Repeat this process with
a fresh cotton ball, including the edge of the optical element in the
action.

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5. Moisten a fresh cotton bud with acetic acid. Use this to remove any
polish still remaining by cleaning from the inside out with circular
movements (see Fig. 7.5-17).
6. Moisten a cotton bud with acetone. Use it to clean again in circular

movments, working from the center outwards.
7. Moisten a fresh cotton bud with acetone. Wipe the cotton bud in
overlapping movements gently over the surface of the lens until all
polish residues have been loosened.
Fig. 7.5-19 Lens cleaning using an acetone-soaked cotton bud
8. Place a piece of lens cleaning paper on the lens; drop 2 to 3 drops of

acetone onto the paper and wipe the element by sliding the paper off
sideways to leave a dry and clean surface (see section
7.5.5.2 ›Cleaning in the case of moderate soiling‹).
If cleaning with polish is still unsuccessful or if burn marks in

the coating are visible, the optical element must be replaced.

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7.5.6 Fitting the lens
The lens holder is different depending on the focal length of the cutting
head. Note the engraving (5") when assembling.
1. Check O-ring for damage. Replace if necessary.
The O-ring must not be greased.
2. Place clamping ring with O-ring, right side up, on the circular rod.
Fig. 7.5-21 Clamping ring with O-ring
A O-ring
B Clamping ring
3. Place lens on the O-ring with the curvature facing upwards.
Tab. 7.5-1 Clamping ring and lens located on the circular rod

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D Lens
4. Slide the lens holder over the prepared package and push it in as far
as the end stop.
Fig. 7.5-22 Inserting the lens in the lens holder
5. Turn the lens holder through 180° and remove the circular rod.

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6. Grip the lens holder firmly in one hand. With the other hand, use the
lens wrench to screw in the lens nut, applying continuous force to
tighten.
Fig. 7.5-23 Screw in the lens nut and tighten
E Lens holder
F Lens wrench for 5" lens nut
G Lens nut
Do not tighten the lens nut with a jerking action. Sharp

jerking movements cause jolts to the lens, which can
damage it.

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The clamping ring is tensioned correctly when the four slits are closed (see
Fig. 7.5-24).
Fig. 7.5-24 Correct seating of lens
Tightening the clamping ring too severely may damage the

lens.
Poorly fitted lens

A poorly fitted lens will cause cutting problems and ultimately destroy the
lens.

Repair ByVention
7.5.7 Fitting the lens holder
The lens holder is different depending on the focal length of the cutting
head. Note the engraving (5") when assembling.
Fig. 7.5-25 Lens holder
A Cutting head
B Lens holder
C Fixing screws on the lens holder
1. Place cutting head on a clean surface.
2. Check lens holder O-ring. Replace damaged O-rings.
Apply minimal grease to O-ring before fitting (Synthe-

so Proba 270).
No residual grease should be visible.

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3. Slide the lens holder into the cutting head by hand until it reaches
the second O-ring.
4. Align the fixing-screw holes on the circle of holes.
5. Push the lens holder in as far as the end stop.
Do not twist the lens holder in this position.
6. Tighten the fixing screws on the lens holder using a ball-end screw
driver.
7. Insert the cutting head in the Z-axis and center the nozzle (see sec-
tion 5.5.5 ›Centering the nozzle‹).

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7.5.8 Measuring the focus reference setting
After cleaning or fitting a new lens, the focus reference setting must be re-
measured. This is done by cutting a test part.
Fig. 7.5-26 Test part for measuring the focus reference setting
80 mm
Material: Structural steel

Thickness: 2 mm
Cutting gas: Oxygen O2
80 mm
Fig. 7.5-27 Cutting plan: Test_Stahl_2mm_22M_O2.ncp
1 000 mm
500 mm

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1. Select Residual sheet production (see section 5.6.4 ›Residual sheet

production‹).
2. Set the focal position on the cutting head to 6 - 00.
3. Load a residual sheet onto the cutting table. See Fig. 7.5-27 for min-
imum dimensions.
4. Start cutting process using Start part function.
Do not change the cutting parameters.
5. Adjust the focal position up and down in steps of 0.5 mm (in total
± 3 mm).
6. Cut a part after each adjustment. Note the focal position on the re-
spective part.
7. Assess the optimum focal position by looking at the cut surface (see
section 9.9 ›Cut evaluation‹).
Tab. 7.5-2 Example for assessing the cut quality
Focal position Assessment of cut quality
0 - 30 Cut no longer possible
0 - 40 Sheet no longer cut through
0 - 45 Course cut and burring
0 - 50 Fine bead formation on the underside of the sheet
6 - 00 Good
6 - 05 Good
6 - 10 Excellent
6 - 15 Good
6 - 25 Coarse bead formation on the underside of the sheet

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8. If the measurement results in a new focus reference setting:

z Select Maintenance functions, enter the measured value for the fo-
cus reference setting in the Focal default setting input field, and
save
z Attach a new label to the cutting head showing the measured val-
ue
Fig. 7.5-28 Measured focus reference setting
A new focus reference setting must be entered This is

used as a basis for cutting other materials.

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7.6 Laser module
7.6.1 Check the vacuum-pump oil level.
Check the oil level at the level indicator every 150 operating hours.. The
oil level must lie between the two markings on the level indicator. Top up
with oil if necessary.
Fig. 7.6-1 Level indicator on the vacuum pump
A Laser module
B Vacuum pump
C Level indicator

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7.6.2 Top up oil in the vacuum pump
Always use the compressor oil G32 supplied (order code 1973601).
Instructions for use and the safety data sheet are kept in the Supplier
documentation folder.
Fig. 7.6-2 Vacuum pump
B
A
A Vacuum pump
B Cap
C Level indicator

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1. Shut down the laser cutting machine and switch off at the main pow-
er switch.
2. Allow vacuum pump to cool down.
3. Remove cap from top-up hole.
4. Clean rim of top-up hole and filling funnel.
Make sure that no particles of dirt fall into the top-up

hole.
5. Top up with oil. Check oil level (level indicator).
6. Refit cap on top-up hole.

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7.7 Gas supply
The gas cylinders can be replaced during operation. It is essential to use

gas of the correct quality. Never use a lower gas quality than specified
(see installation instructions).
CAUTION
Handling gas bottles
Make sure that you replace bottles carefully and cleanly
to avoid dirt entering the gas pipeline.
Secure gas bottles in place.
Always screw on safety caps to unconnected bottles be-
ing stored.
Close bottle valves before handling.
Always open stop valves slowly.
Observe guidelines for handling gas.
WARNING
Risk of explosion
Do not oil or grease oxygen connections.
This could lead to an explosion from a chemical reaction.
Never completely empty gas bottles. Always return the bottles with a
residual pressure of at least 1 atmosphere above atmospheric pressure.
The cutting process is stopped if the cutting gas runs low. An error mes-
sage is shown on the operator console.
The cutting process is stopped and the laser excitation is switched off if
the laser gas runs low. An error message is shown on the operator con-
sole.
Also signaled by the indicator lamp on the laser module (see section
4.1.1 ›Indicator lamp‹).

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7.7.1 Cutting gas
7.7.1.1 Cylinder pressure reducer
Fig. 7.7-1 Cylinder pressure reducer for cutting gas
A B
D D
F
E E
A Gage (high pressure)

B Gage (reduced pressure)
C Pressure reducing valve
D Stop valve (high pressure)
E Bottle connection
F Supply to laser cutting machine

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7.7.1.2 Changing gas cylinders during operation
CAUTION
Eye injuries from swirling
dirt particles
The cutting-gas cylinders are under pressure (200 bar).
Always wear safety goggles when blowing off a valve.
1. Check that the stop valve (D) to the full bottle is closed.
2. Open the cylinder valve on the new cylinder briefly to blow out dirt
from the valve.
3. Close stop valve (D) to the empty bottle.
4. Connect line to full bottle.
5. Open stop valve (D) to the full bottle.
6. Adjust reducing valve (C) (25 bar max.).

z to 18 bar for oxygen (O2)
z to 25 bar for nitrogen (N2)
7. Close the bottle valve on the empty bottle.
8. Remove the empty bottle from the cabinet and fit the protective cap.
Insert new bottle and secure in place.
The bottle valves must be closed if the system is to be out of

operation for a prolonged period (longer than 8 hours).
Otherwise, a pressure build-up can result from leaky valves.
This can destroy the pressure regulator valve in the cutting
carriage.

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7.7.2 Laser gas
Fig. 7.7-2 Location of laser gas bottle
A B
A Laser module
B Combined cooling and filtration unit
C Laser gas bottle

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7.7.2.1 Cylinder pressure reducer
Fig. 7.7-3 Cylinder pressure reducer for laser gas
B C
A H
F
G
A Gas bottle connection

B Gage (cylinder pressure)
C Pressure gage (operating pressure)
D Stop valve
E Laser module supply
F Safety valve
G Pressure reducing valve
H Purge valve

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7.7.2.2 Changing gas bottles during operation
If the white indicator lamp is flashing, the pressure in the laser gas bottle
has dropped to 2 bar. An error message is shown on the operator console.
Finish working through a cutting plan already in progress and then change
the laser-gas bottle.
CAUTION
Eye injuries from swirling
dirt particles
The laser gas cylinders are under pressure (200 bar).
Always wear safety goggles when blowing off a valve.

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7.7.2.3 Removing an empty gas cylinder
Fig. 7.7-4 Laser gas bottle with bottle pressure regulator
A B C
E D
A Bottle valve
B Hexagonal nut
C Stop valve
D Purge valve
E Cap nut
F Protective cap
G Safety chain

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1. Close cylinder valve (A) of empty cylinder.
2. Close shut-off valve (C) to laser module.
3. Open purge valve (D) to release residual pressure.
4. Close purge valve (D).
5. Unscrew cylinder pressure reducer from bottle valve. Hex nut (B) SW
32 mm
6. Screw on cap nut (E).
7. Screw on protective cap (F).
8. Undo safety chains (G).
9. Remove empty gas cylinder.

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7.7.2.4 Connecting a full gas cyclinder
Fig. 7.7-5 Laser gas bottle with bottle pressure regulator
B H C
A
E D
A Bottle valve
B Hexagonal nut
C Stop valve
D Purge valve
E Cap nut
F Protective cap
G Safety chain
H Pressure gage (operating pressure)

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1. Put full laser gas bottle in place (see Fig. 7.7-2).
2. Secure bottle with safety chains (G).
3. Screw on protective cap (F).
4. Unscrew cap nut (F).
5. Screw cylinder pressure reducer onto the bottle valve. Hex nut (B)
SW 32 mm
6. Fully open bottle valve (A) and re-close again immediately.
7. Check bottle connection for leaks using leak detection spray.
8. Purge bottle pressure regulator to remove any air that may have en-
tered when changing the bottle.
z Slowly open bottle valve (A) briefly and re-close again immediate-
ly.
z Slowly open purge valve (D) briefly to release the pressure, and
re-close again immediately. There must be minimum residual
pressure.
9. Repeat step 8 at least five times. Close the purge valve (D) after
purging.
10. Open the bottle valve (A).
11. Slowly open the stop valve (C) to the consumer.
12. Check the operating pressure at the pressure gage (H).

Operating pressure: 5 bar (72.50 psi)
After changing the laser gas bottle, the laser module must be
calibrated (see section 5.8.2.1 ›Calibrating the optical pow-
er‹).
The bottle valve must be closed if the system is to be out of

operation for a prolonged period (longer than 8 hours).

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7.8 Circuit diagrams, drawings
Circuit diagrams are held in the Equipment diagram folder, and drawings
in the Spare parts catalog.

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7.9 Customer service information
The manufacturer's Customer Services department is available in the

event of problems. Please have the following information ready before
calling the department, so that problems and queries can be dealt with as
quickly as possible:
Company / Address
Contact person
Order and equipment number (see type plate)
The contact address appears in the front of these operating instructions.

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ByVention
Chapter 8
8 Disposal
This chapter describes the environmentally friendly disposal of the product

and its operating resources. It also contains notes on handling replace-
ment assemblies (e.g. replacement parts).

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ByVention Disposal
8.1 Introduction
The country-specific regulations and standards must be observed for all

components requiring disposal.
Also observe the manufacturer’s regulations for working materials and
cleaning agents.
Use specially trained personnel for proper disposal.

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8.2 Disposal
8.2.1 Packing
Packing material accrued on delivery must be disposed of according to

country-specific regulations and standards.
8.2.2 Operating resources
Lubricants must be sent to a treatment plant or disposed of as hazardous

waste.
Observe the manufacturer’s regulations for all working materials. Further
information can be found in the safety data sheets in the Supplier docu-
mentation folder.
Dispose of all operating resources in accordance with country-

specific regulations and standards!

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8.3 Components suitable for disposal
8.3.1 Material groups
Metals and plastics must be separated and taken for recycling or disposal.
Dismantle the machine and electrical controls and provide for correct dis-
posal.
The machine contains parts in the following materials:

Mineral casting
Steel casting
Steel
Nonferrous metals (aluminum, copper etc.)
Rubber
Plastics
The electrical controls contain parts in the following materials:

Steel
Plastics
Non-ferrous metals (aluminum, copper)
Protective varnish on circuit boards
Electrical and electronic components
Batteries
Dispose of all materials in accordance with national regula-

tions and standards.

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8.4 Disposal centers, authorities
8.4.1 Return to manufacturer
The manufacturer takes back various components. This particularly con-

cerns components which are replaced by repaired units within the lifetime
of the product.
8.4.2 Notification of government agencies and manufacturer
The manufacturer should be informed when you decommission the sys-

tem.

ByVention
Chapter 9
9 Cutting technology
This chapter provides information on the fundamentals of cutting with the

laser cutting machine. In addition, it contains information on special appli-
cations, material coatings and alloys.

Cutting technology ByVention

ByVention Cutting technology
9.1 General information
This chapter describes laser cutting technology. It gives information on the

factors that influence the cutting result.
Design options and limits
The influence of working methods and procedures
The effects of various factors and parameters on the cutting result
The influence of programming
Rules, advantages and tips
An optimum cutting result is largely determined by following certain de-

sign rules for ideal cutting back at the part design stage. It is important
that the designer knows the capabilities of the laser cutting machine.
The person responsible for creating the cutting plans must have a thor-
ough knowledge of the laser cutting machine. Only then can cutting plans
be designed optimally to suit the laser cutting machine and its procedures.
Practice has also shown that it is best to locate the programming worksta-
tion close to the laser cutting machine. This encourages a constant trans-
fer of knowledge between the operator and the programmer.
This chapter builds upon the basic knowledge of machine opera-

tion and programming.

9.2 Design guidelines
When designing the parts to be cut the following guidelines should be ob-
served. This can greatly simplify manufacture.
9.2.1 Sheet formats
The main sheet formats are:

3 000 x 1 500 mm
2 500 x 1 250 mm
2 000 x 1 000 mm
120 x 60 inches
96 x 48 inches
72 x 40 inches
9.2.2 Kerf width for laser cutting
The width of the cutting kerf is a function of the focal length and the sheet
thickness. The width cannot be altered. However, the tool radius cutting
parameter can be used to compensate for it (to guarantee dimensional
tolerances).
Tab. 9.2-1 Guide values for the kerf width
Sheet thickness 1 3 5 8
in [mm]
Width of cutting kerf 0.15 0.20 0.25 0.40

in [mm]
It is possible just to make a cut in the width of the cutting kerf.

This is used for strain relief cuts in the region of bends, for ex-
ample.

9.2.3 Orthogonality of the cut surface
In laser cutting, the cut face does not lie exactly square to the sheet sur-
face. Per 10 mm of sheet thickness, the cut plane can be up to 0.1 mm
out of square.
Fig. 9.2-1 Orthogonality when cutting with oxygen O2

10 mm
10 mm
0.1 mm 0.1 mm
Fig. 9.2-2 Orthogonality when fusion cutting with nitrogen N2
0.1 mm
10 mm
The above geometries (Fig. 9.2-1 and Fig. 9.2-2) result from the selected
cutting process and cannot be altered.
The orthogonality is assessed according to DIN EN ISO 9013 (Classifica-
tion of thermal cuts).
As a rule, the orthogonality with laser cutting is significantly better than
with plasma cutting or thermal cutting.

9.2.4 Roughness of the cut surface
The roughness of the cut surface increases with increasing material thick-
ness.
As a general guide, roughness values of tolerance class 2 as per
DIN EN ISO 9013 are achieved with laser cutting.
The roughness of the cut surface can be influenced by changing the cut-
ting parameters.
The following diagrams (Fig. 9.2-3, Fig. 9.2-4 and Fig. 9.2-5) show a
simple summary. For more precise information, measurements must be
carried out on the actual workpiece.
Fig. 9.2-3 Guide values for structural steel with Laser 2200
Mean roughness Rz in [μm]
I
B
II
Sheet thickness in [mm]
A DIN EN ISO 9013 tolerance class 1

B DIN EN ISO 9013 tolerance class 2
C DIN EN ISO 9013 tolerance class 3
Roughness curves in structural steel
I Cutting gas nitrogen N2

II Cutting gas oxygen O2

Fig. 9.2-4 Guide values for rust and acid resistant steel with Laser 2200
Fig. 9.2-5 Guide values for aluminum with Laser 2200

A ISO tolerance class 1

B ISO tolerance class 2
C ISO tolerance class 3

9.2.5 Contour radii
Always avoid acute contours in laser cutting. It is far simpler to cut a radi-
us of 1 ... 2 mm, for example, when changing direction. This has the fol-
lowing advantages:
corners do not burn
time saving thanks to continuous process,
clean laser part
reduced risk of injury by the part.
Tab. 9.2-2 Guide values for minimum radii in [mm]
Material Cutting Sheet thickness

gas in [mm]
... 4 5 ... 6 8
Structural steel Oxygen 0.8 1.0 1.2

O2
Rust and acid-resistant steel Nitrogen 0.8 1.2 ⎯

N2
Aluminum 0.8 ⎯ ⎯
Structural steel 0.8 ⎯ ⎯
The radii can be set to be greater than the minimum values in the table. If
the design does not allow for a radius, the corner is meant to be pointed.
Radii smaller than 0.8 mm are more difficult to manufacture than pointed
corners.
Parts quality may suffer or parts may be rejected if radii are less than the
minimum radii.
Bysoft provides an easy method for rounding corners.

9.2.6 Sheet thickness
Select small sheet thicknesses

As far as rigidity allows, the most effective material saving is achieved by
reducing the sheet thickness. Not only does this lead to less weight, but
cutting and handling times are also shortened drastically.
However, the reduction in material thickness is only justified if it is not
achieved at the cost of additional manufacturing effort, such as welded re-
inforcements.
Select identical sheet thicknesses

For single piece production it is expedient to fabricate all sheet compo-
nents of an assembly from as few different sheet thicknesses as possible.
Production times can be vastly reduced in this manner.
9.2.7 Common cut edges
Common cut edges are not possible. The minimum parts separation for a
reliable process is 10 mm. See section 9.3.3 ›Minimum parts separation‹
Fig. 9.2-6 Single piece production (each piece is cut separately)

10 mm

9.2.8 Hole as a paint coating aid
A hole enables the part to be hung for painting. Care should be taken that
these holes are made near the edge of the workpiece, so that hooks can
be inserted easily.
Min. hole diameter for lightweight parts: ∅4 mm

Min. hole diameter for heavy parts: ∅6 mm
9.2.9 Edge deformations
On the edge faces of sheets, deformation of the edges can occur due to
compression of the material during bending. A corner relief must therefore
be cut when:
The face needs to lie flat
A slot will accommodate a flat plate after bending
Fig. 9.2-7 Corner reliefs

r
t
t
Sheet thickness Radius and corner relief

in [mm] in [mm]
r t
up to 3.0 8.0 1.0
3.0 ... 8.0 15.0 2.0

9.2.10 Cut-outs
For limbs bent together or offset limbs, a relief is provided in the corner.
Radius r = sheet thickness
Fig. 9.2-8 Corner relief for limbs bent against each other
Fig. 9.2-9 Corner relief for offset limbs

r
r
Bysoft provides a straightforward tool for making cut-outs.

9.2.11 Tongues (bent parts only)
Incisions for tongues should always be drawn as continuous lines made at

the correct gap width. This ensures simple manufacture.
The tongue width should not be less than 50 mm. Gap width x = sheet
thickness
Fig. 9.2-10 Incisions for tongues
50 x
poor design good design
9.2.12 Strain relief cuts
Holes and slots located too close to the bent edge are deformed during
bending. If the minimum limb length cannot be achieved even with a
smaller bottom tool, a strain-relief slot must be cut.
Fig. 9.2-11 Strain-relief cut
A Strain-relief cut
B Bend edge

9.2.13 Discontinuous limb
In profiles with discontinuous limbs, the edge must be set back by at least
1.5 × sheet thickness s.
Fig. 9.2-12 Set-back edge in profiles with discontinuous limbs
correct incor-
1.5 × s

9.2.14 Connections
Aligning, centering and crimping prior to welding can be saved by using

tongue and groove joints.
Ensure that the tongue and groove joint is manufactured with approx.
0.5 mm play, so that individual parts can be easily fitted together.
Examples
Fig. 9.2-13 Straight joint
Fig. 9.2-14 Right-angled joint
Fig. 9.2-15 Multipart holder

9.2.15 Labeling similar parts
Labeling is performed using the Engrave function. This is a simple way to

add part numbers, positioning aids and the like to parts in the same work
cycle as the laser cutting (also see section 9.7.8 ›Engraving‹).
Examples
Fig. 9.2-16 Engraved part number
laser engraved
Fig. 9.2-17 Engraved positioning aid
laser engraved
Making engraved markings and labels increases the production

time.

9.3 Definitions and ranges
9.3.1 Minimum distance from sheet edge.
The minimum distance from the sheet edge for a reliable process is
10 mm. The distance should not be set lower than this.
Fig. 9.3-1 Distance from sheet edge.

Y+
X+
10 mm
10 mm 10 mm

9.3.2 Minimum distance of parts from severance cut
The minimum distance from the severance cut for a reliable process is
10 mm. The distance should not be set lower than this.
Fig. 9.3-2 Distance from severance cut

Y+
10 mm
10 mm
X+

9.3.3 Minimum parts separation
The minimum parts separation for a reliable process is 10 mm. The dis-
tance should not be set lower than this.
Fig. 9.3-3 Parts separation
10 mm
10 mm

9.3.4 Minimum hole diameters
Parts quality may suffer or parts may be rejected if hole diameters are
less than the minimum hole diameters.
Tab. 9.3-1 Minimum hole diameters
Sheet thick- Minimum hole diameter

ness [mm]
[mm]
Structural steel
Oxygen O2 Nitrogen N2
1.0 1.00 1.00
1.5 1.00 1.00
2.0 1.00 1.00
2.5 1.25 1.25
3.0 1.50 1.50
4.0 2.00 ⎯
5.0 2.50 ⎯
6.0 3.00 ⎯
8.0 4.00 ⎯
Sheet thick- Minimum hole diameter

ness [mm]
[mm]
Rust and acid-resistant Aluminum
steel
1.0 1.00 1.00
1.5 1.00 1.50
2.0 1.00 2.00
2.5 1.25 2.50
3.0 1.50 3.00
4.0 2.00 4.00
5.0 2.50 ⎯
6.0 3.00 ⎯
8.0 ⎯ ⎯

9.3.5 Minimum web width
Parts quality may suffer or parts may be rejected if web widths are less
than the minimum web widths.
Fig. 9.3-4 Web width
x x
x = minimum web width
Tab. 9.3-2 Minimum web width
Sheet thick- Minimum web width

ness [mm]
[mm]
Structural steel
Oxygen O2 Nitrogen N2
1.0 2.00 2.00
1.5 3.00 2.00
2.0 4.00 3.00
2.5 5.00 3.00
3.0 6.00 4.00
4.0 8.00 ⎯
5.0 10.00 ⎯
6.0 12.00 ⎯
8.0 16.00 ⎯

Sheet thick- Minimum web width

ness [mm]
[mm]
Rust and acid-resistant Aluminum
steel
1.0 2.00 2.00
1.5 2.00 2.00
2.0 3.00 3.00
2.5 3.00 3.00
3.0 4.00 4.00
4.0 5.00 5.00
5.0 6.00 ⎯
6.0 8.00 ⎯
8.0 ⎯ ⎯

9.4 Laser cutting
In laser cutting, a focused laser beam is directed at the sheet to be cut.

The energy density at the focal point rapidly raises the temperature of the
material to be cut to its melting point.
Basically, we can divide laser cutting into three areas.
Fig. 9.4-1 Laser cutting areas
Laser cutting
Laser Laser Laser

fusion cutting gas cutting sublimation cutting

9.4.1 Laser fusion cutting
In the fusion cutting process the work piece is melted locally and the melt
is blown out by a gas jet (nitrogen N2). The material is only transported in
the liquid or molten phase, which is why the process is called fusion cut-
ting.
Fig. 9.4-2 Focal position for fusion cutting
A
C
A Laser beam
B Approximate location of the focal point
C Upper face of sheet
D Lower face of sheet
Characteristics:
Cutting gas: Nitrogen (N2) or argon

Laser power: 80 ... 100% of maximum power
Gas pressure: 10 ... 20 bar
Focal position: Approximately on the lower face of the sheet
A very pure, inert cutting gas is supplied to the laser beam, which ejects
the melted material from the cutting gap, but does not itself participate in
the cutting process.
Laser fusion cutting is suitable for producing oxide-free cuts in ferrous
materials.

9.4.2 Laser gas cutting
Laser gas cutting differs from laser fusion cutting by the use of oxygen as
cutting gas. The interaction of oxygen with the heated metal causes a re-
action that heats up the material even more.
Thanks to this effect, speeds can be achieved when cutting structural steel
that are much greater than for fusion cutting in sheet thicknesses from
approx. 6 mm upwards.
Fig. 9.4-3 Focal position for gas cutting
B
C
A Laser beam
B Approximate location of the focal point
C Upper face of sheet
D Lower face of sheet
Characteristics:
Cutting gas: Oxygen O2

Laser power: 25 ... 80% of maximum power
Gas pressure: 0.5 ... 5 bar
Focal position: Approximately on the upper face of the sheet
However, this process can lead to diminished cut quality compared to fu-
sion cutting. The result may be wider cuts, increased surface roughness,
deeper heat affected zones and diminished cut edge quality. The cut edge
oxidizes heavily.
Oxygen cutting is critical when cutting fine contours and acute geometries
(risk of burn-off). However, the amount of heat input can be limited by
pulsing.

9.4.3 Laser sublimation cutting
With laser sublimation cutting, the material is vaporized directly in the cut,
without a liquid phase.
Laser sublimation cutting is not used in the present laser cutting

machine and is therefore only mentioned here for the sake of
completeness.

9.4.4 Cutting process
A machining process is undrestood to mean the interaction between laser

beam, cutting gas and workpiece.
Fig. 9.4-4 Process parameters
Process parameters
for
Material Laser Cutting gas Axis movement
The zone in which this process occurs is known as the cutting front or cut
front. The laser power applied at the cutting front must heat up the mate-
rial to the temperature required for phase transition of the material to
melt and vapor.
The cutting front is a practically perpendicular surface heated and melted
by the absorbed laser beam.
In laser gas cutting, this melt zone is heated up further by the flow of
oxygen blown into the kerf and reaches temperatures close to the boil-
ing point of the material. This causes strong vaporization and ablation
of the material. The jet of cutting gas is used simultaneously to blow
out molten material from the underside of the workpiece.
In fusion cutting the gas blows out the molten material and protects the
kerf from oxidization.
The molten zone progresses in the direction of cutting. This ensures a con-
tinuous kerf.
Many important processes in laser cutting occur in this zone. Analyzing
these processes provides important information on laser cutting. For ex-
ample, it is possible to estimate cutting speed and explain the formation
of characteristic striation marks.

9.4.5 Gas parameters
Gas type
Gas purity
Gas pressure
Nozzle diameter
Nozzle geometry
Gas pressure and nozzle geometry affect the roughness of the cut edge
and the creation of whiskers.
Cutting gas consumption depends on the nozzle diameter and the gas
pressure.
For low-pressure cutting applications gas pressure is up to 5 bar, and
up to 20 bar in the high-pressure range.
The conventional cutting nozzle has a circular, conical aperture.
The distance between the nozzle orifice and the workpiece surface must
be as small as possible. The smaller the distance, the greater the vol-
ume of gas actually entering the kerf. Clearance distances typically
range from 0.5 to 1.5 mm.

9.5 Programming
Optimum programming makes the cutting process far simpler and reduces
manufacturing times while retaining maximum part quality. It is therefore
important that the programmer is familiar with the laser cutting machine
and exchanges experiences with the operating personnel.
Bysoft version 6.7.x or higher is used for programming. This

version contains the range of functions required for the laser
cutting machine.
9.5.1 Technology wizard
The technology wizard provides support when programming parts. This

means that the programmer requires less knowledge of the technology.
An optimum cutting result is achieved substantially faster.
The following technologies are set up automatically for each laser type,
sheet type, sheet thickness and geometry:
Type of lead-in and lead-out (straight cut / straight cut with arc)
Length of lead-in and lead-out
Piercing type (CW / pulse)
Cutting type (CW / pulse / process macro 1) as a function of the sheet
type, thickness and the area to be cut
The cutting parameters of the laser cutting machine are opti-

mized for the wizard technologies. In general, the technology
wizard should be used. This allows optimum exploitation of the
various options.
Changes to the Technology Wizard are not allowed.

Fig. 9.5-1 Specifying the technology (in Bypart)
A Select material
B Select sheet thickness
C Select laser cutting machine
D Select technology table

9.5.2 Technology table in Bysoft
A column is reserved for each material type and thickness. In the col-
umns, the technologies and the ranges of validity are defined.
Tab. 9.5-1 Technology table
Thickness 8
Lead-in 1 up to and including hole diameter 5.5
Piercing open contours Pulsed
Lead-in 1 settings
Type Straight orthogo-
nal
Length 4
Radius 0
Operating mode Follow-on element
Piercing Pulsed
Standard lead-in settings
Type Straight with arc
Length 8
Radius 1
Operating mode Follow-on element
Piercing normal
Lead-out settings
Type Directly on con-
tour
Length 0
Radius 0
Cutting
Conditions
Pulsed up to and including hole diameter 5.5
Process macro 1 up to and including hole diameter 30
Tool correction Normala)
Operating mode for open contours Cutting
a) Generally applicable for cutting
= Selection

Fig. 9.5-2 Example of using technology table for structural steel, 8 mm thick
Detail X
Detail Y
Setting Meaning
Lead-in 1 Define lead-ins (initial cuts) for pulsed holes or

small contours.
Standard lead-in Define standard lead-ins (standard initial cuts). All

lead-ins that do not meet the criteria for lead-in 1
are standard lead-ins. The boundary between lead-
in 1 or a standard lead-in is determined in the sec-
ond row of the technology table.
Lead-out Define lead-out (final cut). Lead-outs are not nor-

mally used for laser cutting.
Cutting The technology is selected according to the area. A

value of zero (0) means that the technology is not
selected.

9.5.3 Piercing and lead-ins
The lead-ins will always be made as long as specified and must be placed
accordingly.
Piercing causes the sheet to heat up very strongly. Careful positioning of
piercing points and adequate lead-in lengths can help prevent heat build-
up.
Fig. 9.5-3 Poor choice of lead-in position
Heat build-up; cut quality may deteriorate
Fig. 9.5-4 Good choice of lead-in position with additional radius lead-in

9.5.3.1 Outer contour
The pierce hole is generally located outside of the contour (see Fig. 2 and
Fig. 3). The path between the pierce and the contour is referred to as the
lead-in line or lead-in for short.
A change in direction of the laser beam between the end of the lead-in and
contour, and the end of a cut, are visible on the workpiece as an irregular-
ity in the cut edge.
Fig. 9.5-5 The lead-in can be seen as an irregularity in the cut
The lead-in to the outer contour should therefore be programmed as an

extension of a geometry elements (see Fig. 3).
Tab. 9.5-2 CW pierce hole
Parts requiring fin- Normal case Thick sheet option

ishing
Fig. 1 Fig. 2 Fig. 3
CW pierce hole in con- CW pierce outside con- CW pierce outside con-

tour tour. tour.
Corner damaged Move into contour in a
line.
Minor markings on
part

Various types of lead-in can be employed within a part. This allows an

acute corner (A), for example, to be cut optimally.
Fig. 9.5-6 Various types of lead-in
9.5.3.2 Inside contour (cut-outs)
With small inside contours it is important that the heat input during pierc-
ing can flow away before cutting begins. The lead-in line must not be pro-
grammed in tight corners and should be designed with the largest possible
angle to the contour. This helps the heat to flow away more easily.
Fig. 9.5-7 Small inner contours
not suitable suitable

9.5.4 Programming process macros
Contours assigned a process macro during programming with Bysoft can

be cut with other cutting parameters. This has the advantage that difficult
parts or sections of contour (e.g. gear teeth) can be optimized.
Fig. 9.5-8 Gear teeth, cut with process macro 1
One process macro is available (macro 1). The Bysoft technology wizard
automatically assigns process macro 1 to small contours (based on the
technology table). The cutting parameters are adapted accordingly.
Process macro 1 is assigned automatically based on the area.

For contour cuts such as the gear teeth in Fig. 9.5-8, process
macro 1 must be assigned manually.

9.5.5 Machining strategies
9.5.5.1 Strategy A
The sheet segment to be cut is separated from the main sheet by a con-
tinuous severance cut at the start of the cutting plan. Then the parts on
the sheet segment are cut.
Fig. 9.5-9 Continuous severance cut
C A
B
Y+
X+
A Sheet
B Cut sheet segment
C Continuous severance cut
9.5.5.2 Strategy B
Parts in the sheet segment to be cut extend into the main sheet. This
means that, depending on the parts geometry, more parts may be nested
on the sheet. It also reduces the size of off-cuts.
The severance cut is divided into several steps. These are performed be-
fore cutting the parts. The sheet segment is severed from the main sheet
as the parts are cut.
Not all parts are suitable for using machining strategy B. If it is difficult to
separate the sheet segment from the main sheet when the cutting table is
lowered, machining strategy A must be used. This may be the case, for

example, when complicated parts geometries get caught in the main

sheet when the cutting table is lowered.
Machining process B works best with flat sheets having minimum internal
stresses. Other sheet qualities may prevent a reliable process or lead to a
larger number of rejects.
Fig. 9.5-10 Discontinuous severance cut
A
C
Y+
X+
A Sheet
B Cut sheet segment
C Discontinuous severance cut
It is up to the parts programmer to ensure that the lead-in is

positioned on the parts in the current sheet segment.
Otherwise the automatic setting of microjoints prevents the
cut sheet segment from being severed correctly from the
main sheet.

9.5.6 Cutting-time calculation
The result of the cutting-time calculation is only a rough guide to the ex-
pected process time on the laser cutting machine. The effective process
time can differ significantly from this however.
The result from the cutting-time calculation must not be used

as a basis for quotations.

9.6 Cutting parameters
Cutting parameters are provided for authorized materials and cuttable

sheet thicknesses.
The user cannot create new cutting parameters.
The default parameters are given for metric sheet thicknesses. Countries
using different dimensional units (e.g. inches, Gauge No.) must use the
next closest metric cutting parameters (see section 9.6.5 ›Cutting param-
eters for different dimensional units‹).
The cutting parameters assume a minimum radius for each geometry (see
section 9.2.5 ›Contour radii‹). Parts quality may suffer or parts may be re-
jected if parts have a smaller radius.
9.6.1 General information
For selective editing of the cutting parameters, it is vital to know how a

part is programmed and where a particular technology is employed. The
example below shows a part for which the technologies selected by the
technology wizard are highlighted.
Fig. 9.6-1 Example: Structural steel, 8 mm thick

A Text Engraving
B Hole ∅ 4 mm Pulsed piercing, pulsed cutting
C Banana hole Pulsed piercing, cutting with process
macro 1
D Gear teeth Pulsed piercing, cutting with process
macro 1
E Outer contour Pulsed piercing, CW cutting
It is important to observe carefully during cutting to identify those opera-

tions for which a parameter needs to be edited. Only in this way can im-
mediate and targeted changes be made.

9.6.2 Adjusting cutting parameters
Cutting parameters are parameters which have a direct influence on the

cutting process. These parameters are not optimized for maximum cutting
speed, but for process reliability.
A set of cutting parameters is supplied with every laser cutting machine.
They are optimized to cut certain materials. Nevertheless, the parameters
may not deliver satisfactory cutting results. Below, the requirements and
the procedure for obtaining better cutting results in such cases are de-
scribed.
For laser cutting, there are numerous parameters that influence one an-
other to some extent. The five main parameters that can be used to opti-
mize the cut quality are listed here:
Focal position
Feed rate
Laser power, cutting
Gas pressure
Changes considered here apply only to simple contours such as straight

lines.
The cutting quality is only evaluated in a cut-out comprising

straight lines (directions X+, X-, Y+ and Y-). Interpolated cut di-
rections such as radii, diagonal cuts or lead-ins are not included.
Changes to cutting parameters for complex contours such as
acute-angled corners, radii, small contours, lead-ins/lead-outs
and holes are not included in this chapter.

9.6.2.1 Reasons for adjusting parameters
Differences in alloys
Tolerance variation in the sheet thickness
Differing nature of surfaces
Different composition of material
Large temperature differences in the material used
(reference temperature = +20 °C)
9.6.2.2 Conditions to be met before adjusting parameters
The following conditions must be met in order to obtain a good cut quality
by adjusting the main parameters:
laser cutting machine is in a fault-free condition
lens in cutting head must be in perfect condition (see section
7 ›Repair‹)
cutting head and nozzle must match the details given in the respective
cutting parameters
Changed cutting parameters can be saved (see section

5.6.7 ›Saving cutting parameters‹).

9.6.3 Procedure for optimizing the cutting parameters
Before a new material is cut, a cutting test must be carried out. If prob-
lems with the cutting quality occur in this test, they can be rectified by ad-
justing the original cutting parameters.
When optimizing, change only one cutting parameter at a time and then
observe the effect on the cut part (see also section 9.9 ›Cut evaluation‹).
Follow the order given below.
Tab. 9.6-1 Order in which to adjust the cutting parameters
Cutting with Cutting with Cutting with

Step
oxygen (O2) nitrogen (N2) compressed air

(Air)
1 Focal position Focal position Focal position
2 Laser power Feed rate ± 10% OK Feed rate ± 10% OK
3 Gas pressure Laser power Laser power
4 Feed rate ± 10% OK Gas pressure Gas pressure

9.6.4 Cutting parameters on the laser cutting machine
On the user interface, seven different cutting parameters can be changed.
In addition, the focal point must be set manually on the cut-

ting head according to the material type and sheet thickness.
The standard functions contain the cutting parameters for CW cutting.
Fig. 9.6-2 Cutting parameters, standard functions
The advanced functions contain the cutting parameters for CW, Macro
and Pulsed.
Fig. 9.6-3 Cutting parameters, advanced functions

9.6.4.1 Focal position, cutting
The focal position is the position of the point where the laser beam reach-
es its smallest diameter and thus its highest power density.
The laser beam is focussed by the lens in the cutting head. Depending on
the material being cut, the focal point is located:
On the workpiece (A)
In the workpiece (B)
Below the workpiece (C)
Fig. 9.6-4 Focal position of the laser beam
Focal position A Focal position B Focal position C
The focus position basically depends on the cutting gas used.
Gas type Laser cutting Focal position

methoda)
Oxygen O2 laser cutting Focal position in the upper region of

the material to be cut.
Focal position A
Compressed air Fusion cutting Focal position in the center of the

material to be cut.
Focal position B
Nitrogen N2 Fusion cutting Focal position in the lower region of

the material to be cut.
Focal position C
a) Information on the laser cutting methods can be found in section 9.4 ›Laser cutting‹.

Altering the focal position

The focusing must be adjusted manually, by turning the setting ring.
Fig. 9.6-5 Changing the focal position
A A
B B
Turning counter-clockwise moves Turning clockwise moves the fo-
the focal point lower. cal point higher.
A Setting Ring
B Focal position
The focal position alters with the condition of the lens. Soiling or an old
lens shifts the focal position upwards. This shift can reach several millime-
ters. It is therefore important to clean the lens regularly.
See section 9.9 ›Cut evaluation‹ for details of the effect of the
focal position on different materials.

9.6.4.2 Feed rate, cutting
This parameter defines the feed rate during cutting in continuous opera-
tion (CW).
The Feed rate, cutting parameter can be altered as follows:
1. On the user interface, select the cutting parameter view.
2. Select the parameter Feed rate, cutting and increase or decrease

the value by turning the rotary knob.
The change will be shown in [%].
3. Wait for a few seconds. The changed parameter is automatically

By reducing the feed rate by 10…20% the quality or process reliability can
be greatly improved in almost all cases.
cutting feed rate on various materials.

9.6.4.3 Laser power, cutting
This parameter defines the laser power during cutting in continuous oper-
ation (CW).
The Laser power, cutting parameter can be altered as follows:
2. Select the parameter Laser power, cutting and increase or de-

crease the value by turning the rotary knob.

laser power on various materials.

9.6.4.4 Gas pressure, cutting
The gas pressure depends on the cutting gas used.
Parameter Used for
Cutting pressure, Gas type 1 Cutting with oxygen (O2)

Maximum pressure 10 bar
Cutting pressure, Gas type 2 Cutting with nitrogen (N2)

Cutting pressure, Gas type 3 Cutting with compressed air

For oxygen (O2), a higher value produces a higher cutting temperature

and a rougher cut face.
With nitrogen (N2) and compressed air (Air) the material is ejected better
and cooled more.
The Cutting pressure parameter can be altered as follows:
2. Select the appropriate parameter for the cutting gas pressure (Gas
type 1, Gas type 2 or Gas type 3) and increase or decrease the
value by turning the rotary knob.


gas pressure on various materials.

9.6.4.5 Width of microjoints
Microjoints prevent cut parts from tilting up or dropping down. The micro-
joints are automatically inserted by the control system (see section
9.7.10 ›Microjoints‹). The width of the microjoints can be varied.
Increasing the width: the parts are more firmly attached.

Reducing the width: the parts are easier to detach. When processing
standard sheets, it must always be ensured that
the width of the mcrojoint is sufficient to prevent
parts tipping up or falling.
The Width of microjoints parameter can be altered as follows:
2. Select the parameter Width of microjoints and increase or de-



9.6.4.6 Tool radius
The tool radius is used to alter the position of the kerf relative to the con-
tour. The tool radius equals half the width of the kerf.
Tab. 9.6-2 Guide values for the tool radius in [mm].
Material thickness Tool radius
1…5 mm 0.10 mm
6…8 mm 0.15 mm
Usage
To optimize the dimensional accuracy for precision parts.
If the tool radius is increased, the outer contour becomes larger and the
inner contours smaller (assuming that the tool correction was correctly
programmed in Bysoft).
When the tool radius is decreased, the outer contour becomes smaller
and the inner contour larger.
The Tool radius can be changed as follows:
2. Select the parameter Tool radius and increase or decrease the value
by turning the rotary knob.
The change will be shown in [mm].


9.6.4.7 Pulse width, piercing
The Pulse width, piercing can only be changed for pulsed piercing. CW
piercing cannot be changed.
Increasing the Pulse width, piercing parameter increases the amount of
energy input during piercing. This speeds up piercing but increases the
piercing hole size.
With larger pierced holes, a large amount of material from the piercing is
deposited on the sheet. This can lead to problems with feeding the sheet.
The Pulse width, piercing parameter must therefore be optimized so
that the pierced hole appears as shown in Fig. 9.9-14.
The Pulse width, piercing parameter can be altered as follows:
2. Select the parameter Pulse width, piercing and increase or de-



9.6.4.8 Laser power, engraving
The Laser power, engraving parameter determines the contrast of an

engraving. In structural steel, this parameter can be used to control the
depth of the engraving.
Fig. 9.6-12 Fine engraving on structural steel with reduced laser power
Fig. 9.6-13 Deep engraving on structural steel with increased laser power
The Laser power, engraving parameter must be adjusted to suit the

surface finish of the sheet and the desired visibility.

The Laser power, engraving can be altered as follows:
2. Select the parameter Laser power, engraving and increase or de-



9.6.4.9 Protective film vaporization
This parameter is used to define the laser power for vaporizing protective
films from rust and acid-resistant steel.
This parameter is only active when Vaporization has been programmed in
Bysoft.
The Laser power, vaporization parameter can be altered as follows:
2. Select the parameter Laser power, vaporization and increase or

decrease the value by turning the rotary knob.

The thickness of the protective film may vary. Optimum vapor-

ization can be achieved by adjusting the Laser power, vapor-
ization parameter.

9.6.5 Cutting parameters for different dimensional units
The default parameters are given for metric sheet thicknesses. Countries
using different dimensional units (e.g. inches, Gauge No.) must use the
next closest metric cutting parameters as shown in Tab. 9.6-3.
Tab. 9.6-3 Cutting parameters to use for different dimensional units
Sheet thickness
in [mm] in [inches] in [Gauge No]
1.0 0.040 19
1.5 0.060 16
2.0 0.074 14
2.5 0.104 12
3.0 0.125 11
4.0 0.160 8
5.0 0.187 7
6.0 0.250 ⎯
8.0 0.312 ⎯

9.6.6 Structure of saved default parameters
The default parameters are saved using the following code.
Fig. 9.6-16 Structure of parameter set names.
F H
A B C D E G I
A Machine type and sheet format

B CNC version
C Laser power in [W]
D Material number using DIN convention
E Sheet thickness in [mm]
F Focal length of cutting head
G Cutting gas
H Additional information
I File extension for cutting parameters
Material number using DIN convention
1.0161 St 37-2 Structural steel

1.0332 Stw 22 Sheet steel
1.4301 X5CrNi18 -10 Rust and acid-resistant steel
3.3535 AlMg3 Peraluman 300

Sheet thickness
1 1.0 mm 4 4.0 mm
1.5 1.5 mm 5 5.0 mm
2 2.0 mm 6 6.0 mm
2.5 2.5 mm 8 8.0 mm
3 3.0 mm
Focal length of cutting head
5 Focal length 5 inches
Cutting gas
N2 Nitrogen
O2 Oxygen
Air Compressed air
Additional information
HOT DIP GALVANIZED hot galvanized

GALVANIZED electro-galvanized
PLASTIC FOIL film-coated

9.7 Cutting process
9.7.1 Summary of the various technologies
Tab. 9.7-1 Operating modes and applications
Operating mode Usage Example
Continuous wave Low-pressure cutting Structural steel cut with

(CW) High-pressure cutting oxygen (O2)
Aluminum cut with nitro-
gen (N2)
Rust and acid-resistant
steel cut with nitrogen
(N2)
Continuous cutting pro-
duces a relatively fine cut
Continuous operation Low-pressure cutting Small and medium-size con-

(Process macro 1) High-pressure cutting tours
Continuous operation Protective film vaporiza- Rust and acid-resistant steel

(Process macro 5) tion with protective film
Thickness 1 to 3 mm
Cutting gas: Nitrogen N2
Normal pulsed (NP) Piercing Mild steel example:

Cutting tight contours Small piercing point on
contour (after microjoint)
small holes down to ∅ 1/2
material thickness
Fine contours
Engraving Labeling and marking See 9.7.8 ›Engraving‹.

9.7.2 Cutting structural steel with oxygen (O2)
This material can be cut with oxygen to produce good quality cuts. The la-
ser is operated in CW mode.
If oxygen is used as the cutting gas the cut face is slightly oxidized.
Complex contours and holes (diameter smaller than material thickness)
are cut in pulsed mode. This prevents burn-off on acute-angled corners
and thin webs.
The higher the carbon content of the steel, the greater the hardening of
the cut edge and the more sharp corners are burnt off.
Sheets with higher alloy content are more difficult to cut than sheets
with low alloy content.
An oxidized or sand-blasted surface will produce a far poorer cut quali-
ty.
Colored marks on the surface of the sheet have a negative effect on the
cutting result.
Use only fully killed steel where possible. Contaminants in un-killed
steel significantly impairs the cutting result. Dress rolling and internal
stresses also influence the cutability.

9.7.3 Oxide-free cutting of structural steel with nitrogen (N2)
Structural steel is also cut using nitrogen (N2) for the following reasons:
Oxide-free cut edge. This is particularly important if the parts are to be
powder coated, varnished or painted. This guarantees that the coating
adheres to the cut face. This is not guaranteed on a cut edge oxidized
by oxygen (O2).
Trouble-free cutting of high-alloy steels, which cannot be cut to a good
quality using oxygen.
Higher cutting speeds. Much faster cutting is possible up to a thickness
of 1.5 mm.
Reducing the heat input.
Fig. 9.7-1 Example: Gear teeth in structural steel, thickness 3 mm, cut using nitrogen
Optimum cut quality thanks to strong cooling effect of nitrogen. The pro-
duction time is only 1/4 of the pulsed time using oxygen.
When using nitrogen (N2), gas consumption is substantially

higher than with oxygen (O2).

9.7.4 Cutting structural steel with normal pulse
In pulsed cutting the laser is switched on and off at short intervals. The
advantage of this is that, on average, there is less heat input to the mate-
rial. Higher quality is achieved in small holes and difficult shapes.
Because the cutting and piercing process is interrupted during the pulse
interval, the cutting and piercing speed is slower than for continuous CW
cutting and piercing.
Fig. 9.7-2 Sequence during pulsed cutting
A
B C D
A Laser power in [W]

B Cycle
C Pulse pause
D Pulse width
E Pulse frequency in [Hz]
9.7.4.1 Pulsed cutting (application examples)
Holes and openings smaller than sheet thickness, e.g. a hole with
∅3 mm in a steel sheet, thickness 6 mm
Cutting sharp tips and corners without radii
9.7.4.2 Pulsed piercing (application examples)
Piercing with lower heat input

Piercing without piercing crater
Piercing directly on the contour, so that both inner and outer part can
be used

Tab. 9.7-2 Difference between pulsed and continuous cutting
criterion Pulsed cutting or Continuous cutting

piercing (CW)
Cutting speed Low High
Heat input to the Low High

sheet
Cut quality Rough, brown color Fine
Piercing Small, fine, within the kerf Large, with crater

width

9.7.4.3 Programming for pulsed contours
There are two ways of defining whether pulsed mode is used to cut/pierce
contours:
Automatically: using the Technology Wizard. This contains the most im-
portant rules on how to machine which contour (exception: gear teeth
are not automatically recognized).
This has the advantage of shortening the programming time.
Manually ⎯ the programmer selects the individual contours based on
personal experience of the machine.
If only portions of the contour are cut pulsed, e.g. the teeth in the follow-
ing figures, the programming must be carried out so that there as few
changeover points as possible (A).
Fig. 9.7-3 Poor programming (two changeover points)
A Two changeover points (A)

A
Normal — pulse — normal
Fig. 9.7-4 Good programming (one changeover point)
One changeover point

Because of the optimum positioning of the initial cut, only one changeover
point from normal to pulsed cutting is necessary. This improves the part
quality.

Parts programming has a major impact on good pulsed results:

Pulsing should, where possible, be switched on after CW cutting (not
the other way round). This improves the transitions on the cut face.
Changeover points from CW to pulsed mode should be positioned so
that the changeover takes place at a change of direction or in a corner.
Do not changeover on straight edges or in curves. Changing over from
one mode to another causes a small chip.
Fig. 9.7-5 Cutting in CW and pulsed mode
not suitable suitable
B B
A
A A
B B
C C
A
C C
A A A A
B B B B
A Changeover point
B CW cutting
C Pulsed cutting
The cutting sequence should be selected so that the complex

contours on a part are always cut first, i.e. the smallest first
(usually the pulsed ones). Bysoft selects this strategy automat-
ically.

9.7.5 Oxide-free cutting of rust and acid-resistant steel
The following points should be noted when cutting rust and acid-resistant
steel.
Cutting with nitrogen to achieve oxide-free and burr-free cut edges for
post-processing without further treatment.
An oiled sheet surface improves piercing without reducing the machin-
ing quality (see Fig. 9.9-17).
When cutting rust and acid-resistant steel, rust and acid-re-

sistant steel support grids must be used.
If steel grids are used, steel splashes can fuse with the cut
part at the support points. These will subsequently oxidize.
9.7.5.1 Technology table for rust and acid-resistant steel
The default parameters refer to the most commonly used alloy

(X5CrNi 18-10) with material number 1.4301.
Suitable adjustment of the focal position, feed rate, laser power and
gas pressure allow almost all rust and acid-resistant steels to be cut. To
begin with, the default parameters (1.4301) should always be used.
Adjust the cutting parameters based on the information given in section
9.6.3 ›Procedure for optimizing the cutting parameters‹. Compare the
cutting results achieved with the figures in section 9.9 ›Cut evaluation‹.

9.7.5.2 Rust and acid-resistant steel with protective film
In order to protect brushed, polished or processed surfaces, protective

films are stuck onto the surface of sheets up to thickness 3 mm.
Only cut sheets that have a protective film on one side. The
protective film must always lie uppermost during cutting.
Fig. 9.7-6 Metal sheet with protective film
A Cutting grate
B Sheet
C protective film
The process reliability when cutting sheets protected by a film basically

depends on the adhesive strength of the bond between film and sheet.
The pressure of the cutting gas detaches poorly bonded films from the
sheet, stopping the cutting process.
Nitrogen N2 must be used as the cutting gas.
The adhesive strength of the protective film diminishes over

time. Do not store sheets with protective films over prolonged
periods.
Only use sheets protected by films specifically designed for
laser cutting.

Example 1: protective film with good adhesion
The parts can be cut directly using the optimized parameters for rust and acid-
resistant steel with protective film (additional information: PLASTIC FOIL).
The protective film is only vaporized on the lead-in cuts.
Ensure that the correct nozzle is used.
Fig. 9.7-7 Protective film with good adhesion
Example of a suitable cutting parameter set:

VENTION3015_8120_2200_1.4301_2_5_N2_PLASTIC FOIL.PAR
Example 2: protective film with moderate adhesion
The protective film comes away from the sheet in places. Process reliability is
not guaranteed using the optimized cutting parameters (as used in example 1).
In a first pass, the protective film is vaporized on the lead-in cuts and over
the whole parts contour. This is performed at maximum machine speeds.
The parts are actually cut in the second pass using the standard cutting pa-
rameters for rust and acid-resistant steel. These parameters include the pa-
rameters for film vaporization.
Ensure that the correct nozzle is used.

VENTION3015_8120_2200_1.4301_2_5_N2.PAR
Vaporization of the protective film is programmed in Bysoft (see section

9.7.5.3 ›Protective film vaporization‹).

Example 3: protective film with poor adhesion
The protective film must be removed by hand before cutting. The standard cut-
ting parameters for rust and acid-resistant steel are used for cutting the parts.
Disadvantage: the sheet surface is not protected.
Fig. 9.7-8 Protective film with poor adhesion

VENTION3015_8120_2200_1.4301_2_5_N2.PAR

9.7.5.3 Protective film vaporization
Vaporization is enabled in Bysoft, in the Postprocessor 2 tab of the Job

parameters menu.
The following options are available depending on the adhesive strength of
the protective film:
No vaporization
complete part
Lead-in only
Fig. 9.7-9 Enabling protective film vaporization
B
A
A Postprocessor 2 tab
B Selection of vaporization type
9.7.5.4 Recommended protective films
Laserguard 3100H5 and Laserquard 3100H3 Light from the Nitto Denko
company, which have the following excellent properties for laser cutting:
Excellent adhesion during cutting. No need to pre-vaporize the protec-
tive film before cutting.
Parts look cleanly cut without black discoloration around the edges.
No fraying of the protective film near the edges.
High tear strength when detaching from the sheet (even after a bend-
ing operation)1)
Minimal adhesive residues on the sheet
1) This is a very important property. Approximately 80% of parts cut with a laser undergo
subsequent bending.

9.7.6 Oxide-free cutting of aluminum alloys
The default parameters refer to the most commonly used alloy (AlMg3)
with material number 3.2323. This alloy is also good for bending.
The cutting gas employed is nitrogen.
With suitable adjustment to the focal position, feed rate, laser power
and gas pressure, almost all aluminum alloys can be cut. To begin with,
the default parameters (3.2323) should always be used.
Adjust the cutting parameters based on the information given in section
9.6.3 ›Procedure for optimizing the cutting parameters‹. Compare the
cutting results achieved with the figures in section 9.9 ›Cut evaluation‹.
Aluminum is a highly reflective material. If the laser beam is no longer

cutting the sheet, the laser power will be reflected. This can shorten the
life of the lens. It is recommended to monitor the production process
when cutting aluminum and its alloys.
The softer and purer an aluminum alloy is, the more difficult it is to cut
with a laser. This can be recognized by the presence of burrs, even on
sheets under 3 mm thick. In addition, the feed rate must be drastically re-
duced. With pure aluminum (Al 99.5%), the feed rate must be reduced by
up to 40% of the default value.

9.7.7 Laser cutting using compressed air
Laser cutting using compressed air is a mixture of fusion cutting with ni-
trogen (N2) and gas cutting with oxygen (O2).
However, since air contains more nitrogen than oxygen, the cutting be-
havior is more like fusion cutting with nitrogen (N2).
Applications: Up to a material thickness of 2 mm, it is possible to

cut structural steel, rust and acid-resistant steel
and aluminum with compressed air.
Advantages: With economically produced compressed air, the

production costs can be reduced.
Sometimes the cutting performance is higher
than with oxygen (O2) or nitrogen (N2).
Disadvantages: Because of the oxygen content, the cut edge is

oxidized, This is usually undesirable, especially
in the case of rust and acid-resistant steel.
The underside of the sheet can be burred.
9.7.7.1 Providing the compressed air
For occasional cutting with compressed air, this can be obtained from the
gas supplier (for specification, see section 3.14.2 ›Compressed air quali-
ty‹). The price in this case, however, is often higher than for nitrogen from
a tank. There is thus no production cost advantage.
A suitable solution for the low-cost production of compressed air is an as-
sembly with compressor and filter units capable of producing the required
volume and quality of compressed air (for specification, see section
3.14.2 ›Compressed air quality‹). This system should preferably be placed
immediately adjacent to the laser cutting machine. It has its own line, di-
rectly to the connection point on the laser cutting machine. The gas sup-
plier or the manufacturer's Customer Services is available in the event of
problems.

Standard compressors and in-house compressed air supplies are not suit-
able for laser cutting. These installation do not deliver the required air pu-
rity.
Cutting with dirty compressed air can damage the machine.

Compressed air quality must comply with the specifications in
section 3.14.2 ›Compressed air quality‹.

9.7.8 Engraving
9.7.8.1 General points
Engraving is available as an auxiliary function of every machine. Examples

of use are:
labeling parts
marking positions (hole centers),
marking bending edges
pre-positioning of sheets or parts
Engraving is chiefly used on sheets of rust and acid-resistant steel and

structural steel. It is possible to engrave using nitrogen or oxygen. The
same gas should be used for engraving as for cutting to avoid the need for
purging.
Highly reflective materials such as copper, brass or shiny surfaces are not
suitable for engraving.
The cutting parameters supplied by the laser cutting machine manufactur-
er include engraving data. Engraving is easy to program in Bysoft.
The depth of engraved contours or lettering should not be less

than a minimum height of 8 mm. This ensures good legibility.
9.7.8.2 Assessment of engraving quality

The depth and quality of the engraving is determined partly by the param-
eter settings, partly by the sheet surface finish. Moreover, each person
judges the quality of an engraving differently.
Thus, the saved parameters should be considered simply as guidelines.
Using them as a starting point, the values can be changed to adjust the
depth of the engraving. See Chapter 9.6.4.8 ›Laser power, engraving‹.

9.7.9 Machining with process macros
Process macros are additional parameters to assist optimum cutting of

complex contours. The process macros are programmed in Bysoft. The
cutting parameters must be altered on the laser cutting machine. A pro-
cess macro is available.
Fig. 9.7-10 Example with process macros
A Small contour (hole) using process macro 1
9.7.9.1 Process macro 1
Process macro 1 is automatically called by the Bysoft technology wizard

according to the rules for small contours.
The cutting parameters are also determined for small contours (e.g. the
small hole in Fig. 9.7-10).

9.7.9.2 Example with process macro
In the following example, the individual sections are cut using different
technologies (process macro 1 and CW).
Fig. 9.7-11 Structural steel, 6 mm thick, with different technologies
B A B
A A
B A B
A Holes, ∅6,5 mm, cut with process macro 1

B Banana holes and outer contour cut with CW
The part can thus be cut at optimum quality and in minimum

time.

9.7.10 Microjoints
Parts must not tip up on end, otherwise there will be problems removing
the cut parts using the unloading table. This problem is prevented by mi-
crojoints.
The microjoints are automatically placed in accordance with the rules be-
low.
Tab. 9.7-3 Rules for automatic microjoints
Rule Description
If the part contour in the X and Y directions is smaller than 40 mm,

no microjoints are set.
If the part size in the X and Y directions is between 40 mm and

140 mm, microjoints are set.
If the part size in the X or Y directions is between 40 mm and

140 mm, microjoints are set.
If the parts in the X and Y directions are larger than 140 mm, no
microjoints are set.

If, despite the rules according to Tab. 9.7-3, cut parts do tip up, additional
microjoints (from Bysoft) must be programmed to secure them. This
need would mainly arise for parts with an offset center of gravity.
Fig. 9.7-12 Programmed microjoints
A A
A Programmed microjoint
B Common axis of rotation for twisting out the part
When cutting a new cutting plan, it must be ensured that the

cut parts remain lying flat. If cut parts tip up, the cut sheet
segment cannot be removed with the unloading table.
When cutting leftover sheets, microjoints do not need to be
set (cut material is removed manually). To omit microjoints,
set the microjoint width to zero (0) in the cutting parameters.

Fig. 9.7-13 Application example
Geometries without microjoints

Geometries with microjoints
Cut part
Rules for placing microjoints in accordance with Tab. 9.7-3

9.8 Materials
9.8.1 Material properties
The cutting result on the work piece is either a clean cut or a frayed cut
edge with a burr. The main factors influencing cut quality are:
Alloy elements
Microstructure
Material surface
Surface treatment
Beam reflection
Thermal conductivity
Melting point
9.8.2 Alloy components
Alloy constituents have a substantial influence on the strength, weldabili-

ty, oxidation resistance and acid resistance of the materials.
The main alloy constituents of steels are carbon, chromium, nickel, mag-
nesium and zinc.
The higher the carbon content, the more difficult is the material to cut
(critical limit at about 0,8% carbon). The following carbon steels can be
cut well with the laser:
St 37-2, Stw 22
Cutting quality and cutting performance depend on alloy constituents. In

structural steel, a greater content of Si creates a rough cut edge and in-
creases slag formation and burring. Carbon contents > 0.16% can lead to
poor results on sharp edges and small holes.
Recommendation: use laser sheets having controlled alloy constituents
when working at the extreme sheet-thickness range.
Tab. 9.8-1 C and Si content
Material C content Si content
RAEX 250 0.12% 0.01%
RAEX 420 0.13% 0.01%

9.8.3 Microstructure
Generally speaking, the finer the grain of the material structure, the bet-
ter the quality of the cut edge.
9.8.4 Sheet surface finish
The surface finish of a sheet has a major impact on cutting results and cut
quality.
9.8.4.1 Unwanted surface finishes
Loose rolling skin

Rust
Scale
Uneven surface with troughs and irregularities
General soiling
Steel stamping, scrap marks
Colored marks
Example:
cheap ST52 sheets that have been exposed to weathering.
9.8.4.2 Preferred surface finishes
Fine, even surfaces with microscale

Sheet lightly oiled
Pickled sheets
Hot-rolled oiled sheets
Sandblasted and shot-blasted surfaces are only suitable to a limited ex-
tent but still better than rusty surfaces.

9.8.5 Surface treatment
The sheet may have the following surface treatments:

protective film
protective zinc coating
anodic coating
paint
primer
lacquer
etc.
All these and similar surface treatments usually have a negative impact on
cutting results. Oxygen and e.g. paint react in the kerf during cutting. This
results in a very rough, frayed cut. Another problem is the difference in
layer thickness in one sheet. Different thicknesses of protective coating
cause errors in the capacitive detection.
Solution:
Thicknesses ... 3 mm: Cut with nitrogen (N2)
9.8.5.1 Oiled surfaces
Piercing splashes adhere less well to oiled surfaces. This means that ca-
pacitative scanning is disrupted less. Oiling can be carried out in a number
of ways:
Purchase oiled sheets
Oil dry sheets by hand
WARNING
Risk of fire
The oil on the sheet surface can be ignited by the laser
beam.
Flammable oils should not be used.
Always use welding protection oil
(MOTOREX PROWELD 264)

9.8.6 Beam reflection
The beam reflection from the workpiece surface is dependent on the ma-
terial, surface roughness, focusing and surface treatment. The beam re-
flection is higher for rust and acid-resistant steel, pure aluminum and
aluminum alloys. The higher the reflectance, the more difficult to cut the
material.
Fig. 9.8-1 Comparison of beam reflectance for focal position
Large area Small area
Higher beam reflectance due to Low beam reflection due to higher

lower focal point. Setting the focus focal point (lower output coupler
too low can increase the output temperature)
coupler temperature.
9.8.7 Thermal conductivity
Materials with low thermal conductivity require less energy to melt them
than materials with high thermal conductivity.
For example, the power required for stainless steel is less than the values
for structural steel, despite the lower absorption at the process tempera-
ture.
On the other hand, copper, aluminum and brass, for example, conduct
away a large amount of the heat generated by absorption of the laser
beam. The heat is quickly conducted away from the focal point of the laser
beam, making it harder to melt the material at this spot.

9.8.8 Heat affected zone
During laser cutting, material alterations can occur at the boundaries of

the material being cut.
Tab. 9.8-2 Guide values for the extent of the heat-affected zone as a function of the base material and
the sheet thickness
Sheet thickness Heat affected zone

in [mm] in [mm]
Structural Rust and acid- Aluminum

steel resistant steel
1 0.05 0.05 0.10
2 0.10 0.10 0.20
3 0.15 0.15 0.30
4 0.20 0.25 0.40
5 0.25 0.35 ⎯
6 0.30 0.55 ⎯
8 0.40 ⎯ ⎯
In low-carbon and rust and acid-resistant steels the hardening of the

heat-affected zone is minor.
In high-carbon steels (e.g. Ck60) the boundary zones are hardened.
In hard-rolled aluminum alloys, the heat affected zone is slightly softer
than the rest of the material.

9.9 Cut evaluation
The following images are enlarged up to 10x. This is why striations and ir-
regularities can even be seen on the optimum cuts.
The measures taken can also be extrapolated to other sheet thicknesses
9.9.1 Cutting with oxygen (O2)
9.9.1.1 Structural steel St 37-2, 4 mm thick
Fig. 9.9-1 Optimum CW cut
Cut:
Fig. 9.9-2 Nozzle diameter too large
Cut:
Situation: Very coarse cut surface in approximately the upper

third of the cut.
Action: Use smaller nozzle (∅1.7 mm was used instead of
∅1.2 mm).
The correct nozzle is shown on the user interface
when starting a job.

Fig. 9.9-3 Laser power and gas pressure too low, nozzle diameter too small
Cut:
Situation: Cut parts do not fall out of the sheet independently. A

bead of slag is found on the underside of the sheet.
Good cut face except the lower third.
Action: Increase the laser power for cutting. Increase the gas
pressure for cutting. Use larger nozzle.
Fig. 9.9-4 Optimum pulsed cut surface
Cut:
Situation: Rough, but regular cut surface (brown discoloration in

the lower third). Pulsed cut.
Action: The figure shows an optimum pulsed cut surface. It is
always rougher than the cut surface of a CW cut.

9.9.2 Cutting with nitrogen (N2)
9.9.2.1 Structural steel, hot galvanized, 2 mm thick
Fig. 9.9-5 Optimum cut
Cut:
Situation: The cut face is always considerably rougher than

without zinc. The cut changes with varying zinc layer
thickness. The thicker the zinc layer, the rougher is
the cut surface.
Slight burr on the underside of the sheet. Electro-gal-
vanized sheets produce a much finer cut.
Fig. 9.9-6 Feed rate too great
Cut:
Situation: Irregular, deep fissures in the cut face.Brown discol-

oration from the middle of the cut down.
Action: Reduce feed rate.
Fig. 9.9-7 Laser power too high
Cut:
Situation: Irregular, heavy cracks in the cut surface.

Action: Reduce the laser power for cutting.

9.9.2.2 Rust and acid-resistant steel 1.4301, 6 mm thick
Fig. 9.9-8 Optimum oxide-free cut
Cut:

9.9.2.3 Aluminum AlMg3, 3 mm thick
Fig. 9.9-9 Optimum cut
Cut:
Situation: Optimum cut.
Fig. 9.9-10 Gas pressure too high
Cut:
Situation: Severe chips in the cut. Blue flashes in kerf when cut-
ting.
Action: Reduce the gas pressure for cutting (in the figure it is
3 bar too high).
Fig. 9.9-11 Laser power too high
Cut:
Situation: Severe chips in the cut. Blue flashes in kerf when cut-
ting.
Action: Reduce the laser power for cutting.

Fig. 9.9-12 Focal position too high
Cut:
Situation: Fine cut surface in the upper two thirds of the cut sur-
face.
Heavy drag in the lower third of the cutting area.
Hard, difficult to remove burr on the underside of the
sheet.
Action: Set the focal position, cutting further down (in the
figure it is 2 mm too high).
Fig. 9.9-13 Focal position too low
Cut:
Situation: Clean cut surface. Bead formation on the underside of

the sheet.
Action: Set the focal position, cutting further up (in the figure
it is 2 mm too low).

9.9.3 Piercing with oxygen (O2)
9.9.3.1 Structural steel St 37-2, 6 mm thick
Fig. 9.9-14 Standard piercing in structural steel of thickness 4 mm or greater
Pulsed
piercing:
Comments: Standard piercing. The piercing hole is only slightly

larger than the cut. Only a small amount of material
is heated and ejected. Both criteria increase process
reliability.
Fig. 9.9-15 Uncontrolled piercing at high power
CW piercing:
Comments: Uncontrolled piercing at high power creates a large

piercing hole.

9.9.4 Piercing with nitrogen (N2)
9.9.4.1 Rust and acid-resistant steel 1.4301, 2 mm thick
Fig. 9.9-16 Piercing on dry sheet
CW piercing:
Comments: The melt blown upwards during piercing is ejected

onto the sheet surface in a star shape. This can ad-
here very strongly.
When cutting small holes this can interfere with ca-
pacitive sensing. This reduces the quality.
Fig. 9.9-17 Piercing on oiled sheets
CW piercing:
Comments: Practically no splash on the sheet. The upwardly

ejected melt cannot adhere due to the oil film, and
runs off.
High process reliability and quality even for small
holes.

9.9.5 Quality of the cut edge
9.9.5.1 Structural steel
Cutting gas Thick- Cut edge

ness
[mm]
Oxygen 1 ... 8 Oxidized surface without burring on the sheet

O2 underside. The oxidized surface is not suitable
for subsequent surface treatment (painting,
varnishing, staining, galvanizing etc.).
The layer of oxide must be removed before
subsequent surface treatment.
Nitrogen 1 ... 3 Oxide-free surface without burring on the

N2 sheet underside.
Compressed air 1 ... 2 Oxidized surface with possible burring on the

Air sheet underside. The oxidized surface is not
suitable for subsequent surface treatment
(painting, varnishing, staining, galvanizing
etc.).
The layer of oxide must be removed before
subsequent surface treatment.
9.9.5.2 Rust and acid-resistant steel

ness
[mm]
Nitrogen 1 ... 4 Oxide-free surface without burring on the

N2 sheet underside.
Nitrogen 5 ... 6 Oxide-free surface with possible burring on the

N2 sheet underside.
Compressed air 1 ... 2 Oxidized surface with possible slight burring on

Air the sheet underside.

9.9.5.3 Aluminum

ness
[mm]
Nitrogen 1 ... 2.5 Oxide-free surface without burring on the

N2 sheet underside.
Nitrogen 3 ... 4 Oxide-free surface with possible burring on the

N2 sheet underside.
Compressed air 1 ... 2 Oxidized surface with possible slight burring on

Air the sheet underside.
The microstructure of the cut edge is affected when com-

pressed air is used as the cutting gas.
Advance clarification must be sought as to whether this is
permitted for the part to be made.

9.10 Troubleshooting
Optimum cut quality can only be achieved if the following conditions are
met:
maintenance as per maintenance schedule
operating resources meet specified requirements
workpiece surface is rust and flake-free (etched, pickled or polished),
9.10.1 Cutting head
Nozzle shape must match parameters

Clean lens
Nozzle centered accurately
Focal position
Lens mounted correctly and fixed in place


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ByVention

Issued on: 10.2007

Operating Instructions © Bystronic Laser AG, 2006 0-1

0-2 © Bystronic Laser AG, 2006 Operating Instructions

ByVention with 2 200 W laser module

Operating Instructions: ByVention_2200_BA_V04_en.fm

Purpose of the operating instructions

Operating Instructions © Bystronic Laser AG, 2006 0-3

0-4 © Bystronic Laser AG, 2006 Operating Instructions

Czech Republic England

Operating Instructions © Bystronic Laser AG, 2006 0-5

Netherlands North America

Russia / Ukraine and Rest CIS Singapore

Slowakei South Africa

South Korea Spain / Portugal

0-6 © Bystronic Laser AG, 2006 Operating Instructions

Taiwan Rest of the World

Operating Instructions © Bystronic Laser AG, 2006 0-7

0-8 © Bystronic Laser AG, 2006 Operating Instructions

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Operating Instructions © Bystronic Laser AG, 2006 0-9

2.1 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . 2–3

0 - 10 © Bystronic Laser AG, 2006 Operating Instructions

3 Design and operation

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

Operating Instructions © Bystronic Laser AG, 2006 0 - 11

3.8 Cutting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 39

0 - 12 © Bystronic Laser AG, 2006 Operating Instructions

4.1 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

Operating Instructions © Bystronic Laser AG, 2006 0 - 13

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

0 - 14 © Bystronic Laser AG, 2006 Operating Instructions

5.6.5 Start and Stop functions . . . . . . . . . . . . . . . . . . . . . 5 – 53

Operating Instructions © Bystronic Laser AG, 2006 0 - 15

5.9.3 Operating-hours counter . . . . . . . . . . . . . . . . . . . . . 5 – 90

0 - 16 © Bystronic Laser AG, 2006 Operating Instructions

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

Operating Instructions © Bystronic Laser AG, 2006 0 - 17

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

0 - 18 © Bystronic Laser AG, 2006 Operating Instructions

7.4.5.3 Linear guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 29

Operating Instructions © Bystronic Laser AG, 2006 0 - 19

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

0 - 20 © Bystronic Laser AG, 2006 Operating Instructions

9.1 General information . . . . . . . . . . . . . . . . . . . . . . . . 9–3

Operating Instructions © Bystronic Laser AG, 2006 0 - 21

9.5.5 Machining strategies . . . . . . . . . . . . . . . . . . . . . . . . 9 – 36

0 - 22 © Bystronic Laser AG, 2006 Operating Instructions

Operating Instructions © Bystronic Laser AG, 2006 0 - 23

0 - 24 © Bystronic Laser AG, 2006 Operating Instructions

Operating Instructions © Bystronic Laser AG, 2006 1-1

1-2 © Bystronic Laser AG, 2006 Operating Instructions

1.1.1 Overall view

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

Operating Instructions © Bystronic Laser AG, 2006 1-3

1.1.2 Intended use

Tab. 1.1-1 Permitted materials and surface treatments

Material Surface treatment

Rust and acid-resistant X5CrNi18 -10 ⎯ ⎯

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

The information given in these operating instructions and the

1-4 © Bystronic Laser AG, 2006 Operating Instructions