User Manual

H-Series Fiber Laser Cutting Machine

Foreword
Sincerely thank you for purchasing our H-Series Fiber Laser Cutting Machine, and we
dedicate to provide you with high-quality products and comprehensive services.

This product integrates laser, machinery, and electricity, and is completely developed
and manufactured by our company, SENFENG LEIMING. H-Series is characterized
by its compact structure, high precision, long lifespan, elegant appearance, both
economically and practically meaningful for users. For the better use and maintenance
of this equipment, please read through this manual carefully before starting to use this
product.

Many pictures are used in the manual so that users can be well-informed and
understand all contents easily. To ensure the safety of personnel and the machine, and
to avoid improper operations and incorrect abnormality handling, please get to know
the working principles, the structure, the daily maintenance and the safety
management of this machine, get proficient with correct operating procedures, and
improve the ability to handle the abnormality in an emergency.

For questions and problems, please do not hesitate to contact us. Please do not operate
on the machine before problems are resolved.

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Contents

1. PREFACE................................................................................................................... 6

1.1 BRIEF INTRODUCTION................................................................................................ 6

1.2 COMPANY PROFILE.................................................................................................... 6

2 PRODUCT INTRODUCTION .................................................................................... 8

2.1 OVERVIEW ................................................................................................................. 8

2.3 MAIN USES AND APPLICATION SCOPES .................................................................... 12
2.4 USE CONDITIONS ..................................................................................................... 12
2.5 IMPACTS ON THE ENVIRONMENT AND ENERGY ........................................................ 13
2.6 PRODUCT STRUCTURE AND WORKING PRINCIPLES .................................................. 13
2.6.1 OVERALL STRUCTURE AND WORKING PRINCIPLES AND CHARACTERISTICS................. 14
2.6.2 STRUCTURE, FUNCTION AND WORKING PRINCIPLES OF MAIN COMPONENTS OR
FUNCTIONAL UNITS ................................................................................................................. 15
2.6.2.1 Bed Section.................................................................................................................. 15
2.6.2.2 Beam Section ............................................................................................................... 15
2.6.2.3 Z-axis Equipment ........................................................................................................ 15
2.6.2.4 Electrical Control System ............................................................................................ 16
2.6.3 ELECTROMECHANICAL CONNECTIONS AND FAULT ALARM SYSTEMS BETWEEN EACH
UNIT STRUCTURE .................................................................................................................... 20
2.6.4 FUNCTIONAL STRUCTURES, WORKING PRINCIPLES AND WORKING CHARACTERISTICS
OF AUXILIARY DEVICES .......................................................................................................... 21

2.6.4.1 Gas Path System .......................................................................................................... 21

2.6.4.2 Water Path System ...................................................................................................... 21
2.6.4.3 Oil Lubrication System................................................................................................ 22

3 SAFETY INSTRUCTIONS AND PRECAUTIONS ................................................... 23

3.1 OVERVIEW ............................................................................................................... 23

3.2 INVOLVED SAFETY STANDARDS ............................................................................... 23
3.3 INSTRUCTION TO SAFETY WARNING SIGNS .............................................................. 23
3.4 SAFETY MANAGEMENT ............................................................................................ 23

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3.5 SAFETY NOTICES ABOUT LASER ............................................................................... 23
3.5.1 PROTECTION FOR EYES AND SKINS ................................................................................ 24
3.5.2 FIRE PREVENTION ........................................................................................................... 24
3.6 SAFETY INSTRUCTIONS FOR ELECTRICAL UNITS ...................................................... 24
3.7 SAFETY NOTICES ON OPTICAL INSTRUMENTS .......................................................... 25
3.8 PROTECTIVE MEASURES FOR THE MACHINE............................................................ 25
3.9 QUALIFICATION OF OPERATORS .............................................................................. 26

4 INSTALLATION AND COMMISSIONING ............................................................. 27

4.1 DELIVERY CHECK .................................................................................................... 27

4.1.1 PRECAUTIONS FOR UNPACKING...................................................................................... 27
4.1.2 CHECKING LIST ............................................................................................................... 27
4.2 METHODS AND PRECAUTIONS FOR INSTALLATION ................................................... 27
4.2.1 LIFTING AND MOVING OF THE MACHINE TOOL ............................................................. 27
4.2.2 INSTALLATION AND COMMISSIONING OF THE CHILLER ................................................. 28
4.2.3 CONNECTION OF AUXILIARY GASES .............................................................................. 29
4.2.4 INSTALLATION OF DUST REMOVAL DEVICE................................................................... 30
4.2.5 CONNECTION OF ELECTRICAL DEVICES ......................................................................... 30
4.3 METHOD AND INSTRUCTIONS OF COMMISSIONING ................................................... 31
4.3.1 ADJUSTMENT OF THE LASER AND OPTICAL PATH .......................................................... 31
4.3.2 ADJUSTMENT METHOD OF INDEPENDENT CAPACITIVE SENSOR .................................... 35
4.3.2.1 Introduction to BCS100 Independent Capacitive Sensor ............................................ 35
4.3.2.2 Operating Introduction ................................................................................................ 36
4.3.3 FUNCTIONS AND ADJUSTMENT OF NOZZLES .................................................................. 61
4.3.3.1 Nozzles ........................................................................................................................ 61
4.3.3.2 Nozzles’ Influences on the Cutting Quality and Directions for Choosing the Nozzle
Aperture ................................................................................................................................... 62
4.3.4 ADJUSTMENT OF LASER BEAM FOCUS ........................................................................... 63
4.3.4.1 Introduction ................................................................................................................. 63
4.3.4.2 Relationship between the Focus Position and the Cutting Section.............................. 63
4.3.5 SETTING THE DISTANCE BETWEEN THE NOZZLE AND THE WORKPIECE ........................ 64
4.3.6 SETTING THE LASER CUTTING SPEED............................................................................. 64
4.3.7 THE SELECTION OF CUTTING GAS AND GAS PRESSURE ................................................. 66
4.3.8 LASER POWER’S INFLUENCES ON CUTTING QUALITY.................................................... 66

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4.3.9 THE ALTERNATING LOADING SYSTEM ........................................................................... 67
4.4 ITEMS, METHODS AND JUDGEMENT STANDARDS OF ACCEPTANCE TEST AFTER
INSTALLATION AND COMMISSIONING ............................................................................ 67

5 MAINTENANCE AND TROUBLESHOOTING ....................................................... 68

5.1 MAINTENANCE......................................................................................................... 68
5.2 MALFUNCTION ANALYSIS AND TROUBLESHOOTING ................................................. 68
5.2.1 PROBLEMS OF THE FOLLOWER ....................................................................................... 68
5.2.1.1 Alarm and Analysis ..................................................................................................... 68
5.2.1.2 Analysis of Common Problems ................................................................................... 71
5.2.2 OTHER PROBLEMS AND TROUBLESHOOTING ................................................................. 73

6 TRANSPORTATION, SHIPPING, AND STORAGE ................................................ 76

6.1 PACKING.................................................................................................................. 76
6.2 METHODS AND PRECAUTIONS FOR TRANSPORTATION AND SHIPPING ...................... 76
6.3 METHODS AND PRECAUTIONS FOR STORAGE ........................................................... 76

APPENDIX A TECHNICAL SPECIFICATIONS ........................................................ 78

APPENDIX B LIST OF CONSUMABLES AND VULNERABLE PARTS .................. 79

APPENDIX C CONTACT OF SENFENG LEIMING LASER ..................................... 80

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1. Preface

1.1 Brief Introduction

Thank you for purchasing our H-Series Fiber Laser Cutting Machine. If you are using
this product for the first time, please read through this instruction manual carefully
before installation.

For the safety of your own and people around you, and for the correct use of the
product, please pay special attention to any content marked with “Danger”, “Warning”
or “Attention”.

• Danger
Any incorrect operation may instantly lead to serious or even life-
threatening personal injury!
• Warning
Any incorrect operation may lead to serious or even life-threatening
personal injury!
• Attention
Any incorrect operation may lead to personal injury or equipment
damage!

1.2 Company Profile

SENFENG LEIMING LASER is one of the largest laser equipment manufacturers in
China and specializes in the R&D, manufacturing, and selling of various high-power
laser processing equipment, including high-power laser cutting machines, laser
welding machines and multi-functional laser processing machines. SENFENG
LEIMING LASER dedicates to provide customers with a personalized and
professional solution to laser processing systems. Full power laser cutting machines,
laser marking machines, laser processing machines are the company’s star products,
which are widely used in industries of steel metallurgy, non-ferrous metals,
automobiles and parts, aerospace, military electronics, precision instrumentation,
machinery manufacturing, hardware tools, integrated circuits, solar energy, and so on.

Placing the interests and needs of customers at first, SENFENG LEIMING LASER is
committed to creating value for customers and creating benefits for society.

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SENFENG LEIMING LASER has completely intellectual property rights, and
advanced technology guarantees the high quality of products. It also has established a
sound and effective quality management system and internal control system. Taking
prevention as direction strategy, SENFENG LEIMING LASER ensures its high-level
operation with the collection of customers’ feedback, continuous improvement, rapid
response to customers’ problems, accurate and efficient solutions, in order to help
customers to maximize their benefits. SENFENG LEIMING LASER’s highly valued
products are sold all over China and overseas. SENFENG LEIMING LASER is
willing to work together with all partners to achieve progress and win-win
development and to establish the largest manufacturing and R&D base of high-power
laser processing equipment in China.

• Products

SENFENG LEIMING LASER provides a complete set of laser processing

solutions and related facilities for domestic and foreign customers. Focusing
on industrial laser equipment and parts, its main product lines include fiber
laser marking machine series, laser welding machine series, fiber laser cutting
machine, and are widely used in industries of advertising, sheet metal,
instrumentation, printed circuits, computer manufacturing, mobile
communications, auto parts, precision equipment, building materials, clothing,
urban lighting, gold and silver jewelry, craft gifts, printing plate and so on.

• Quality Control

Based on the IS09001 quality control system, SENFENG LEIMING LASER

imposes strict control over the whole materials-manufacturing-shipment
process, to ensure the performance and quality of the final products.

• Service

SENFENG LEIMING LASER sets up a marketing management center. With

its 2 branches and more than 100 offices across China, and more than 10
branches overseas, SENFENG LEIMING LASER’s engineers can provide
customers with comprehensive services and supports covering the whole pre-
sales, during the sales, and after-sales process. Where there is a laser product
of SENFENG LEIMING LASER, there is a good service from SENFENG
LEIMING LASER!

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2 Product Introduction

2.1 Overview
Laser cutting is the most extensively used method in the laser processing industry.
The H-Series Laser Cutting Machine developed and produced by SENFENG
LEIMING LASER adopts high-power, high-performance fiber laser with international
advanced technology, CypCut high-grade CNC system, imported original AC servo
motor, German original gears and racks, imported high-precision linear guide and
other high-efficiency transmissions. The product is stable and reliable, with good
dynamic performance and strong load capacity. It is a high-tech product integrating
laser cutting, precision machinery, and numerical control technology, with
characteristics of high speed, high precision, high efficiency, and high performance-
cost ratio.

Please read through this instruction manual carefully before installation.

During the use please do contact us if there is any problem you can’t solve. We will
deliver a satisfactory answer as soon as possible.

When unpacking the box, please check the manual in the accessory box. If the manual
is incomplete, please contact us in time.

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2.2 Product Features and Appearance

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FIGURE 1. MACHINE APPEARANCE

Note: Without special explanation, all pictures in this manual are for reference only. Final products
are subject to the actual product.

a) The gantry structure, integrally welded bed and aluminum extruded beam ensure
the high rigidity, stability and shock resistance of the machine.

b) With precision linear guides and imported gears and racks as transmission
components, the machine can perform with high precision and fast speed. The
maximum running speed (no-load) is 120m/min, the positioning accuracy is
±0.05mm/m, and the repeating positioning accuracy is ±0.03mm.

c) CNC adopts CypCut control system, which is powerful and can meet requirements
for processing various plates. Its AC servo motor has small inertia and good
dynamic performance.

d) The servo motor drives the transmitting axis through the reducer (backlash less
than 3 arcmins), which effectively ensures the reliability of the transmission
accuracy.

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e) The laser is installed with the host to ensure the stability of the optical path.

f) The industrial computer can be installed with CAD/CAM, which is convenient for
drawing and programming in production and maximizing material saving.

g) Cutting wastes are dropped into the waste car by the funnel, which is convenient
for the operator to clear regularly.

h) The X-axis, Y-axis rack and guide rail are protected by side plates and protective
surface, to prevent dust from polluting the linear guide rail and rack of the
machine, and to prolong the lifespan of the machine. Oil nozzles can be found on
the seat of X-axis and Y-axis linear guide rails, where lubricating oil can be filled
in regularly so that rails can be lubricated.

i) The Z-axis motor is controlled by the capacitive sensor, so that the motor can
drive the cutting head up and down with a constant laser focal length (nozzle)
from the cutting plate during cutting, ensuring the quality of the cutting. The
capacitive sensor also enables the position of the focus can be adjusted according
to the material and thickness of the plate, which ensures the quality of the cutting.
The cutting head adopts the drawer-type focusing mirror seat, which makes it easy
for the replace and clean of the lens.

j) Movements along X-axis, Y-axis, and Z-axis are controlled by limit switches. At
the same time, the limit positions on each axis are protected by elastic cushions,
which effectively ensures the safety of movements.

k) The design of the closed optical path ensures the lifespan of the lens.

l) The machine is equipped with an automatic focusing system and can operate fast
and accurately.

m) With all its components imported, the whole gas path system adopts the high-
pressure resistant design, which is advanced and reliable. Three different cutting
gases can be used. When cutting stainless steel plates, the nitrogen pressure can
reach 2.5Mpa, which ensures the stability of the system, improves the reliability
of the cutting machine, and ensures the quality of the cutting surface.

n) The operation console is comfortable and beautiful.

o) The loading and unloading device is designed in the alternating table type, and the
table exchange can be completed within 10 seconds, which effectively saves the

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 loading and unloading time.

p) The closed work area is both safe and environmentally friendly.

2.3 Main Uses and Application Scopes

Laser cutting is an advanced processing method used in material processing. The H-
Series laser cutting machines produced by SENFENG LEIMING LASER are high-
tech products, which integrate the technology of laser cutting, precision machinery,
numerical control, etc. The H-Series products are equipped with medium power fiber
laser, transmission parts like precision linear guide rails and high-precision gears and
racks, and the CypCut CNC system. H-Series products run with high precision, high
efficiency and high performance-cost ratio, and are mainly used for cutting and
forming normal carbon steel plate, stainless steel plate, galvanized sheet, aluminum
alloy plate, copper plate, etc.

Note: the cutting range varies with the power of the chosen laser.

2.4 Use Conditions

Taking 3015H model and 1000W laser as an example, the use conditions are

a) Power supply: three-phase five-wire system, 380V 50Hz.

b) The total load of the main engine: ≤18KVA.
c) Laser and chiller: ≤5.5KVA.
d) Power quality: Three-phase unbalance <2.5%, line voltage fluctuation <5%.
e) Grounding protection: the machine should be placed on the ground; should be
connected to the ground pile aside the machine, or directly connected to the
ground wire. Ground resistance ＜4Ω.
f) The site environment should be well-ventilated, dust-free, non-corrosive, and
non-polluting.
g) There should not be large vibrations around the foundation for the machine.
Earthquake ditches should be dug.
h) Environmental temperature for laser: ≤20 ℃ (refer to instructions for laser).
i) The chiller is specific equipment that provides cooling circulating water to the
laser and the cutting head lens. The volume of the water: ≥12L/min. Only
high-quality pure water or distilled water can be used as cooling circulating
water.

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 j) As for fire prevention, the processing site should be equipped with appropriate
fire extinguishers and places for fire escape.
k) Distance
a. Distance between the wall and the left and back side of the machine: ≥
1.2M.
b. Distance between the wall and the laser: ≥ 1.5M.
c. Chillers and air compressors can be placed outdoors, the distance
between them and the laser: ≤ 3M.
l) As core components of the machine, the control unit, the servo unit, the
display, and the control panel have specific requirements for the environment.
To ensure the normal operation, the machine should be free from
electromagnetic interference, which for example is generated by arc welding
and electric discharge machine.

2.5 Impacts on the Environment and Energy

The laser of this machine is a fiber laser generator, which generates exhaust gas when
cutting, so air extractors should be turned on when cutting.

The laser of this machine belongs to the class 4 laser product, and the beam emitted
by the laser, or the beam reflected and diffusely reflected by the lens may cause
damage to the human body (especially to the eye). The personnel present should pay
attention to self-protection and to fire prevention.

This machine is a high-energy-consuming device, and its total power supply demand
is about: three-phase 380V 50Hz, 18KVA (for a machine with 1000W continuous
type laser and laser chiller). Power demand varies with the type of laser.

2.6 Product Structure and Working Principles

Main components of H-Series CNC Laser Cutting Machine are the main engine of the
machine tool, the control system, the laser, the chiller, the exhaust fan and the loading
system. Individual manual or operating instructions are provided for those main
components, except chiller and exhaust fan. Following is a detailed description of the
structure and composition of the main engine and the control system. For the rest,
please refer to those individual manuals.

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The main engine of machine tool: It is the most important part of the whole laser
cutting machine, and is responsible for the cutting function and cutting accuracy. The
main engine is made up of 9 parts: the bed, the laser, the beam part, the Z-axis
equipment, the workbench, the alternating loading system, the table holder，auxiliary
parts (including shield, gas path system, water cooling system, and lubrication
system), and operating table. Refer to section 2.6.2 for details.

Electrical control part: it is important for the high quality and accuracy of the cutting,
and usually it is composed of the numerical control system and the low voltage
electrical system.

This machine adopts the CypCut high-grade CNC system, which is stable and reliable.
The system is based on WINDOWS operation platform and contains a 32-bit
microprocessor and Ethernet communication interface. The system has characters of
fast interpolation, convenient operation, good dynamic performance, and large load
capacity.

The electric control cabinet is the control part of the low-voltage electrical system. All
components in the electric control cabinet are made by well-known domestic and
international manufacturers, and they guarantee the stable and reliable process
capacity and the sensitive response ability of the whole machine. Drive motors are AC
servo motors, which are used to drive the X-axis gantry, Y-axis slide and Z-axis of the
machine tool. The AC servo motor is characterized by good acceleration performance
and fast response, and its maximum positioning speed can reach 120m/min. The Z-
axis is also driven by the AC servo motor, therefore, the Z-axis cutting head can
respond well in dynamic.

Other peripheral auxiliary equipment, including large and small chillers and exhaust
systems, are introduced in section 2.6.2.

2.6.1 Overall Structure and Working Principles and Characteristics

The main engine of the machine tool is the most important part of the whole laser
cutting machine and is responsible for the cutting function and cutting. The main
engine is made up of the bed (X-axis), beam (Y-axis), Z-axis equipment, the
alternating loading system, workbench, gas path system, water cooling system and
other parts.

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2.6.2 Structure, Function and Working Principles of Main Components or
Functional Units

2.6.2.1 Bed Section

The bed with a welded structure is made of high-strength, and annealing eliminates its
internal stress. The roughing → vibration aging → semi-finishing → vibration effect
→ finishing process ensures that stress elimination is thorough, which reduces the
deformation of the machine tool, and ensures the accuracy of the machine tool for a
long time.

AC servo motors are controlled by the CypCut CNC system, and drive the coaxial
beam reciprocates in the X direction to realize fast moving and feeding motion. To
improve the reliability in operation, the rack and the linear guide are designed as
closed dustproof devices, wherein the dust cover is light in weight. The gear rack and
the linear guide are imported precision products, which can effectively guarantee the
accuracy of the transmission. For the movement safety of the machine tool, software
limit switches and elastic buffers are fixed at both ends of the stroke.

2.6.2.2 Beam Section

The beam section is integrally cast from high-strength aluminum alloy. The solution
treatment - artificial aging - machining process ensures the beam’s overall rigidity and
strength. The specific processing flow is roughing → vibration aging → semi-
finishing → vibration aging → finishing. The beam is mounted on the support rails of
the bed (there are linear guide rails and flat rails). The beam is equipped with high-
quality linear guides. The Schneider/Delta servo motor drives the gears to rotate
through the reducer so that the Z-axis slides can reciprocate in the Y direction. During
the movement, software limit switches, limit switches, power-off limits, and buffers
ensures the safety of the system operation. The upper and the sides of the beam are
closed by the outer cover. The retractable organ-type protective cover between the
beam and the horizontal slide ensures that the rack and the linear guide operate in a
totally closed environment and are not affected by the external environment.

2.6.2.3 Z-axis Equipment

The Z-axis equipment is responsible for moving the cutting head. The numerical
control system controls the servo motor, and the motor drives the ball screw to drive

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the Z-axis slide plate to reciprocate. The Z-axis stroke is 220mm. Proximity switches
at the upper and lower ends of Z-axis to control the stroke. Elastic cushions at both
ends of the ball screw ensure movement safety. Both the ball screw and the linear
guide are high-quality products, contributing to the accuracy of the transmission.

To meet different requirements, the Z-axis can be used as a CNC axis for its
independent interpolation movement; it can be linked with the X and Y axes; it can be
switched to the following control model through the electronic control part of the
cutting head. The Z-axis following is controlled by the numerical control system,
resulting in high accuracy and good stability of the following, furthermore, high
quality of the cutting. The cutting head is sealed with elastic cushioning to ensure the
long lifespan of the cutting head.

The capacitance sensor of the Z-axis equipment (mounted on the cutting head) detects
the distance from the nozzle to the surface of the plate, feeds to the control system,
and then the control system controls the Z-axis motor to drive the cutting head to
move with a constant distance between the nozzle and the plate, effectively ensuring
the quality of the cut. The cutting head has a device for adjusting the position of the
focus according to the material and the thickness of the plate, thereby a good cutting
section can be obtained.

The nozzle is one of the wearing parts, and users can reserve some nozzles with
different apertures for replacement.

Oil nozzles can be found on the linear guide seat and the screw seat, where lubricating
oil can be filled in regularly.

2.6.2.4 Electrical Control System

The electrical control system of H-Series CNC laser cutting machine is mainly
composed of a numerical control system, servo system, and low voltage electrical
system. The CypCut high-grade CNC system based on WINDOWS operation
platform has characters of fast interpolation and convenient operation. The servo
system is Delta/Schneider AC servo motor and driver, stable and reliable, having
good dynamic performance and large load capacity.

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FIGURE 2 CNC O PERATION SURFACE

a) Easy for operation

The machine has six function soft keys and eight operation soft keys. In
different operation modes, the operation soft keys have different, which
reduces the number of operation buttons and simplifies the operation panel.
In every operation mode, the operation function is displayed by the menu,
making the operation easier.
The HELP system of the machine allows the operator to operate under the
direction of the CNC system.
b) Dedicated laser power control
According to the speed/power function curve set by the operator, the laser
power can be precisely adjusted to ensure that the machine can still obtain the
corresponding optimal laser cutting power at different speeds during
acceleration and deceleration.
c) Strong processing capability
The machine possesses a variety of processing and auxiliary instructions,
which can be used to edit for various complex graphics.

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 d) High processing accuracy
The machine has good electromechanical driving dynamic performance,
contributing to the good processing followability and high precision.
e) Graphics display
The machine possesses an analog graphics display and dynamic graphics
tracking display function for the edited part program, making the processing
intuitive and easy to be monitored and controlled.

FIGURE 3 ANALOG PROCESSING AND DYNAMIC T RACKING

f) A variety of alarm functions

The CNC system has alarm and self-protection functions against problems,
which are detected during the self-checking and from external conditions.

FIGURE 4 ALARM F UNCTION

g) According to the installation position, the electrical control part of the laser
cutting machine can be divided into the CNC system, machine operation
panel, low voltage electrical system, motor, and machine tool.
h) CypCut CNC system
The CypCut CNC system is a high-grade CNC system, which is dedicated to

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 laser machining machines.
The system adopts an integrated structure with its central control and display
operation unit compact and installed on the operation platform.
The system is based on WINDOWS operation platform and contains a 60G
hard disk, 400KB RAM for part program and Ethernet communication
interface. The system can control three feed axes and one spindle. The display
unit provides a good human-machine interface, with its 17-inch TFT LCD
color LCD screen for displaying various operational information, with its
keyboard and function keys for inputting information and operating the
machine.
i) Operation panel for height adjustment
The operation panel for machine height adjustment is installed in the electric
control cabinet, at the upper right corner of the left side.
j) Low voltage electrical system
As the interface of the electrical control of the whole machine, the low-voltage
electrical system is located in the electrical control cabinet of the machine
tool. The power supply, the relay, the circuit breaker, the contactor and the
servo drive system required by the electrical control system are installed in the
electric control cabinet.
The main power switch is located on the left side of the electric control
cabinet.
k) Motors and electrical appliances of the machine tool
AC servo motors are used to drive the machine axes, which are mounted on
the corresponding motion axes, namely the X-axis beam, the Y-axis slide, and
the Z-axis cutting head. Electrical appliances of the machine tool include
switches of each motion axis, pneumatic solenoid valve, pressure switch and
so on.

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2.6.3 Electromechanical Connections and Fault Alarm Systems between
each Unit Structure

Chiller Stable power Laser

Gas Machine CNC

Air-drying machine

Compressor

FIGURE 5 CONNECTION OF UNIT STRUCTURE

As shown in Figure 5, units of the machine are closely linked to and complement each
other, guaranteeing the smooth process of the machine. The regulated power supply
provides high-quality power for the chiller, the laser, and the main engine. The chiller
provides cooling for the laser and the main engine. All other parts of the machine
serve the cutting machine. (The compressor and air-drying machine are not standard,
and are self-equipped by the user).

Each part of the electrical circuit is protected from overcurrent by an air switch. There
are mechanical limits, electrical software limits and hard limits protection in each axis
direction. The electrical hard limit can stop the axis operation and the machine, and
send an alarm. The mechanical limit guarantees the safety of the machine and the

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personal safety of the operator under accidental conditions. The system itself also has
protection against motor overload and over temperature. For the list of alarm prompts,
please refer to Section 5 and 6 and the Operation Manual.

2.6.4 Functional Structures, Working Principles and Working

Characteristics of Auxiliary Devices

2.6.4.1 Gas Path System

The gas path system has two parts. One part is the cutting gas supplied to the cutting
head, which can be clean and dry compressed air, high purity oxygen and high purity
nitrogen. The other part is the auxiliary gas, all of which is clean and dry compressed
air.

For compressed air, the air goes through the compressor, the air storage tank and the
cold dryer then passes through a precise air treatment system and becomes the clean
and dry air, which is divided into two paths, one for cutting gas, and the other for the
cylinder. The operating pressure is adjusted by the corresponding pressure regulating
valve.

According to different materials and requirements, three gases, that are compressed
air, oxygen and nitrogen can be selected for cutting. Oxygen is mainly used to cut
ordinary carbon steel; nitrogen is mainly used to cut stainless steel and alloy steel;
compressed air is mainly used to cut thin sheets when the customer’s requirements on
the cutting surface are not very high. In addition, the pressure sensor in the cutting gas
path system ensures that the machine can stop working in time when the gas pressure
is insufficient, and avoid a scrap of parts. The air pressure threshold can be set by
adjusting the upper screw of the pressure sensor, and the compressed air and oxygen
used for cutting can also be adjusted by the proportional valve.

Compressed air is used to 1. drive the clamping cylinder, clamp the table, and keep
the table from moving during the cutting process, ensuring the cutting to proceed
smoothly. 2. aid feeding. 3. aid cutting, remove smoke and clean the cutting surface.

2.6.4.2 Water Path System

The water path system of the laser cutting machine also includes two parts: one part
of the cooling water comes out of the chiller, enters the radiator in the laser to cool the

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laser, and then returns to the chiller; the other part cools the optical system and the
cutting head.

2.6.4.3 Oil Lubrication System

The oil lubrication system of the laser cutting machine consists of pipelines and an
automatic oil pump. The pump pumps oil in every 4 working hours (adjustable), and
one pump lasts 10 seconds (adjustable). When the oil level is too low, the system
would sound an alarm, then standard lubricating oil should be added to the oil pump.

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3 Safety Instructions and Precautions

3.1 Overview
Before operating the machine and performing routine maintenance, the operator must
read this section carefully to get a thorough understanding of safety measures and
requirements and should comply with the relevant safety precautions.

3.2 Involved Safety Standards

This laser processing machine and operations on it should comply with two national
standards: GB7247-2012 Radiation Safety, Equipment Classification, Requirements
and User's Guide for Laser Products and GB10320-2011 Electrical Safety for Laser
Equipment and Facilities.

3.3 Instruction to Safety Warning Signs

Refer to Maintenance Manual.

3.4 Safety Management

The safety administrator is to be appointed, and the scope of his duties must be
clarified. Laser processing operators should be trained in terms of safety operations
and safety protection.

The laser safety management area should be formulated, and warning signs should be
set up at the entrance and exit of the management area, and the content of these
warning signs should include the power of the laser processing machine, the type of
the laser, the prohibition of entry by outsiders, required eye protection measures and
the name of the safety administrator.

Operators of the laser cutting machine must be specially trained. When they have
obtained certain operation knowledge and skills, they can be put into operation with
the safety administrator's consent.

3.5 Safety Notices about Laser

Any part of the body, especially eyes and skins that are exposed to laser would be
burnt.

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To avoid injury caused by misuse, no part of the body should be placed in the light
path of the laser device.

3.5.1 Protection for Eyes and Skins

The fiber laser used in the processing is likely to damage the retina of the eye.
Because of its wavelength, this type of laser has higher transmittance to the eye and
result in greater damages. The laser exposures can cause cataracts and skin burns.
Therefore, when adjusting the laser, the corresponding protective measures should be
adopted according to the type of laser.

3.5.2 Fire Prevention

Oxygen is often used in laser cutting processes, which with splashed sparks during the
cutting can easily cause a fire. Therefore, there should be no flammable or explosive
materials in the work area, and corresponding preventive measures should be taken.

3.6 Safety Instructions for Electrical Units

Do not touch any switches with wet hands to avoid electric shock. The parts of the
machine tool with lightning signs, such as the protective cover of the servo motor, the
junction box behind the column, the machine transformer cabinet, the door of the
electrical cabinet, etc., indicate that these parts have high-voltage electrical appliances
or electrical components. To avoid electric shock, operators should take extra care
when getting close to these parts or opening the repair.

Read the manual carefully and thoroughly and get familiar with the functions of the
machine and operation methods of the corresponding keys.

Do not open the electrical cabinet door under normal situation. Users are forbidden to
change the set of parameters of the machine tool, the potentiometer, and the timer. If
changes are necessary, they must be operated by a professional, who has been trained
by SENFENG LEIMING LASER and has acquired certain assessment certifications.
The values of parameters prior to the change must be recorded so that the original
condition can be restored if necessary.

Do not touch any electrical component in the electrical cabinet during power-on, such
as numerical control devices, servos, transformers, fans, etc.

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 Warning

After the power is turned off, you must wait for more than 5
minutes before touching any terminal.

After the power is turned off, a high voltage is left between the
power line terminals for a period of time. To avoid electric
shock, please do not touch and terminal immediately.

3.7 Safety Notices on Optical Instruments

Optical instruments for laser, such as focusing lenses are manufactured with the
chemical vapor deposition method. When the temperature of these optical instruments
is above the burning point, there is a highly toxic is a toxic Se steam. Also to increase
the transmittance, a film of a compound which contains radioactive substance
ruthenium is coated on the lens. Therefore, to avoid harm to the environment when
the lens is damaged, it should be sent to a professional manufacturer (or the original
manufacturer) for treatment.

3.8 Protective Measures for the Machine

The safety administrator is to be appointed, and the scope of his duties must be
clarified. Laser processing operators should be trained in terms of safety operations
and safety protection.

The laser safety management area should be formulated, and warning signs should be
set up at the entrance and exit of the management area, and the content of these
warning signs should include the power of the laser processing machine, the type of
the laser, the prohibition of entry by outsiders, required eye protection measures and
the name of the safety administrator.

To avoid the injury caused by a misuse, when the machine is not in use, its switch key
should be pulled out and kept by an appointed person.

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The smoke and laser working gas generated during the processing should be
discharged to the outside through the exhaust pipe. All cylinders should be placed
neatly and stably.

3.9 Qualification of Operators

Operators of the laser cutting machine must be specially trained. When they have
obtained certain operation knowledge and skills, they can be put into operation with
the safety administrator's consent.

The operator of this machine or any person approaching the laser during the use of
laser should wear appropriate laser goggles. In the area where laser goggles are
required, there must be good indoor lighting for the smooth operation of the operator.

To protect the operator, it is necessary to set up a processing room or a protective

screen. In the processing room, there should be a device that protects the laser from
diffusion; when the processing room opens, the laser shutter should be turned off.

The inlet pressure of the auxiliary gas should not exceed 2.5MP, and the stamping
pressure of the normal cylinder should be above 10MP. When opening the auxiliary
gas switch, the operator should pay attention to the indicated pressure on the
barometer of the inlet gas and ensure that the pressure reduces to below 3MP. If the
operator doesn’t operate properly and the high gas pressure leads to broken pipelines
and damaged machine components, then our company reserves the right to refuse free
warranty service. The company also assumes no liability for any casualties.

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4 Installation and Commissioning

4.1 Delivery Check

4.1.1 Precautions for Unpacking

Please open the wooden box according to the instructions outside the box, in order to
avoid damage to the equipment inside the box. Do not use sharp objects to wrap the
protective film of equipment such as machine tools, so as to avoid scratches on the
surface of the equipment and damage to the protection circuit for the electrical
installation. Damage caused by the customers incorrect is not covered by the warranty.

4.1.2 Checking list

After opening the package, please check if it is the product you purchased.

Check if there is any damage during the transport.

Check according to the list of items to see if all parts are complete and free of damage.

If there is an inconsistency the product model, lack of accessories or transport damage,

please contact our company in time.

4.2 Methods and Precautions for Installation

4.2.1 Lifting and Moving of the Machine Tool

The machine tool can be moved by the forklift, and position for the fork is shown as
follows.

FIGURE 6 POSITION FOR FORK

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Note: When using the forklift, the fork could be inserted only from the side of the machine
without the tank chain, in order to avoid damage to the tank chain and inside cable fiber. (The side
of the H3-Series without the side door is the side without a tank chain).

4.2.2 Installation and Commissioning of the Chiller

• Flow rate: minimum 3.5L/min, maximum 13L/min.

• Cooling capacity: 14483Btu / h.
• The pressure difference between inlet and outlet water: ≥ 3kgf/cm2.
• Temperature control accuracy: within ±0.5°.
• Cooling water: high quality purified water, distilled water or deionized water.
• Valves and pipes: All should be stainless steel products or high-pressure hoses,
and stainless steel clamps for pipe joints; galvanized materials are not allowed.
• External water pipes for lasers: pressure-resistant rubber pipes with an inner
diameter ≥6 mm and an outer diameter ≥ 8 mm, plastic (PVC) pipes, stainless
steel pipes, and copper pipes are also usable. If the chiller pipe length exceeds
10 meters, increase the pipe diameter. The water pressure difference required
by the laser must be ensured.
• Cooling water pipe for the external light path: Pressure resistance of PU-pipe
pressure ≥6kgf/cm2, and pipe joints should be sealed.
• Filter: It is better to use plastic transparent filter hole with the 100um diameter.
The filter element between the chiller and the laser must use the standard filter
element which meets the requirement of the manufacturer.
a) Installation condition
The chiller should be placed stable and with a distance from the wall. Its
installation position must have sufficient space to inlet and outlet the air, to
ensure the heat dissipation.
b) Machine inspection
Check to make sure there is no loose joint in the water system. Check to make
sure that the filter element of the chiller is tightened.
c) Method of installation
Before connecting the water pipes, make sure that the external pipes of the
chiller are free of garbage and other unrelated items. Connect the water
pipeline to the corresponding port of the chiller, and pay attention to the
direction of the inlet and outlet. Connect the inlet and outlet pipes of the

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 chiller to the inlet and outlet connection ports of the laser according to the sign
on the outer casing of the chiller, and pay special attention to the direction of
the inlet and outlet.
d) Water quality standard
Open the inlet valve and add water to the tank. The water level should be or
below the indicated maximum level to prevent water from overflowing from
the tank. Only high-quality pure water, distilled water or deionized water can
be used as cooling water. Ordinary tap water is not allowed for use, because it
would cause scaling in the chiller and the radiator of the laser, and damage the
components of the machine. Do not add any corrosive liquids.
e) Commissioning
Check and ensure that the wires (for different models of machines, wiring
methods differ) in the machine are connected correctly. Check and ensure the
water pipes are connected correctly. Turn on the power, check and ensure that
there is no leaking problem, then wait for the water temperature in the water
chiller to rise to a suitable temperature.
f) Notes
a. When the water temperature reaches the set temperature, the chiller
would automatically keep the water at this constant temperature, and
the water pump in the unit will continue to operate.
b. The laser can only be turned on after the temperature of the cooling
water and the pressure difference between the inlet and outlet water
reach the required values.
c. When the operating environment is below 0 °C, the cooling water may
freeze and damage the laser. Customers can add 30% absolute alcohol
to the water, then the freezing point of the cooling water would be
within -10 °C.

4.2.3 Connection of Auxiliary Gases

Prepare nitrogen, oxygen or compressed air for cutting. Firstly, check the nameplate
on the cylinder for compliance with the gas requirements of the machine, such as the
purity and pressure of nitrogen and oxygen. Secondly, connect the cylinder to the
machine tool in the correct way, and gradually unscrew the cylinder coupling valve. A
water separator should be added between the oil-free air compressor and the cold

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dryer. The machine’s standard accessories include a nitrogen pressure relief valve and
an oxygen pressure relief valve that can be connected between the machine and the
gas supply. As shown below:

FIGURE 7 CONNECTION OF AUXILIARY G ASES

4.2.4 Installation of Dust Removal Device

The connection port of the dust removal fan is shown as follows:

The connection port of the dust removal

FIGURE 8 CONNECTION PORT OF THE DUST REMOVAL FAN

4.2.5 Connection of Electrical Devices

a) Check to make sure that air switches of the main power supply, of each sub-
power supply, and of the emergency are sensitive.
b) Check to make sure that the power supply cord for the laser is correctly
connected. The 380VAC power supply in the workshop should be connected

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 to the QF0 port (inlet) of the air switch of the main power supply.
c) Check to make sure that air switches of the main power and of sub-power
(such as the main engine, the laser machine, the air compressor, etc.) must
meet the marked capacity.
d) The wire diameter of the power cable, ground wire, and neutral wire must not
be less than the required wire diameter.
e) Check to make sure that the ground wire of the power cord is connected
properly.
f) Check to make sure that all strong current terminals (especially the input and
output points of the power transformer) are reliable and secure, and all plugs
and inserts are securely connected.

Warning

The ground wire of the power cord must be firmly

grounded. Otherwise, the signal inside the machine
cabinet will be disturbed, and it will be dangerous when it
encounters leakage.

4.3 Method and Instructions of Commissioning

Machine tool commissioning should be conducted by professional staff. Before
commissioning, please read relevant technical materials and get to know the functions
of this machine, then commission the machine strictly following relevant instructions
and regulations. Correct commissioning is the basis for the smooth operation of the
machine. If there is any ambiguity, please contact us in time. We would give you a
satisfactory answer as soon as possible.

Note: This commissioning method is under the assumption that the machine is
correctly powered on. Please refer to Section 4.2.5 for the electrical connection of the
machine.

4.3.1 Adjustment of the Laser and Optical Path

a) Installation Precautions
1) Please read through the user manual carefully before using the product.

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 If you have any questions, please contact the staff of SENFENG
LEIMING LASER;
2) Use the original power cord and ensure that the laser case is
electrically connected to the ground. Before the power is turned on, a
multimeter can be used to detect whether the laser case is effectively
connected with the ground (yellow-green line);
3) The laser’ voltage must meet the technical requirements of the product,
otherwise, the product would be irreparably damaged. Therefore,
before the laser is powered on, please check whether all voltage signals
meet the product requirements.
4) During the process of installing the optical fiber, please protect the
optical fiber and the optical fiber output head. Do not bend or stress.
These parts are fragile, please pay attention to protection;
5) During the process of unpacking and installing the laser, please protect
the lens of the laser fiber output head from dust. If there is dust, clean
it according to instructions of cleaning the lens. (a. use anhydrous
ethanol, whose purity ≥ 99.9%; b. use dust-free cotton swab; do not
use ordinary cotton swabs, because they are easy to lose cotton wool,
causing secondary pollution of the lens);
6) The sequence of starting: water-cooler machine works normally (the
water temperature is suitable, about 25 °C) - laser powers on - control
software starts - gas circuit works normally - control system works
normally - laser is ready to emit light - safety protection works
normally- the cutting system works.
7) The sequence of shutdown: turn off the device control system - turn off
the laser control signal - turn off the laser power supply - the water
cooler stops working.
8) Other Precautions
i. During the working process of the laser, please check whether
the water path system, gas path system and electrical system
are working normally. If not, please detect the cause of the
fault.
ii. If any fault occurs during laser operation, please record the
time, the phenomenon, the system working state at that time.

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 Then detect the cause of the fault. If you have any question,
please contact the SENFENG LEIMING LASER staff.
b) Adjust the coaxiality of the nozzle hole and the laser beam, and adjustment
steps are as follows:
1) Apply ink (better in red) on the exit end of the nozzle, and attach the
self-adhesive tape to the end face of the nozzle. As the picture shows.

white self-adhesive tape

FIGURE 9 ADJUSTMENT OF COAXIALITY

2) Manually operate the machine to punch with 10~20 watts of power.

3) Remove the self-adhesive tape and check dots on the non-adhesive side
of the tape.
4) If no problem with the coaxility of the nozzle and the laser beam, a
black dot will be left on the adhesive tape, which is burnt by the laser.
However, if the center of the nozzle is too far from the center of the
laser beam, the black spot will not be visible (the laser beam hits the
wall of the nozzle).

FIGURE 10 T HE CENTER OF T HE NOZZLE IS FAR FROM THE CENTER OF THE

L ASER

If the size of the dots is inconsistent, check whether the operating

conditions are consistent and whether the focusing mirror is loose.

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 No problem with coaxility
FIGURE 11 DOTS WHEN THE FOCUSING MIRROR IS L OOSE

Adjust the nozzle position according to the direction in which the black
dot deviates from the center of the nozzle.

Adjust the screw

FIGURE 12 ADJUST THE POSITION OF THE NOZZLE UNTIL IT IS COAXIAL WITH

THE L ASER BEAM

5) Nozzle aperture
The size of the nozzle aperture has a critical impact on the quality of
cutting and perforating.
If the nozzle aperture is too large, the melt that splashes around during
the cutting may pass through the nozzle hole, and spatter the lens. The
larger the aperture, the higher the probability of this spattering.
Thereby, the less protection that is given to the focusing mirror, the
shorter the life of the lens would be.

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4.3.2 Adjustment Method of Independent Capacitive Sensor

FIGURE 13 BCS100 INDEPENDENT CAPACITIVE SENSOR

4.3.2.1 Introduction to BCS100 Independent Capacitive Sensor

a) Overview
The BCS100 Independent Capacity Accelerator (hereafter referred to as
BCS100) uses a closed-loop control method to control the laser cutting
capacitor follower. It is a capacitor heightening device with high
performance. In addition to control methods adopted by other similar
products, the BCS100 also provides a unique Ethernet communication
(TCP/IP protocol) interface, which can be easily combined with our
CypCut laser cutting software to complete automatic live focus, segmented
piercing, progressive piercing, edge seek cutting, frog style lift, arbitrarily
setting the height of the cutting head, flight optical path compensation, and
other functions. It has a fast response speed. In terms of the servo control,
the BCS100 adopts the speed position double closed-loop algorithm, and
its running speed and accuracy are obviously superior to similar products
at home and abroad.
b) Performance
1) Sampling rate: 1000 times per second.
2) Static measurement accuracy 0.001 mm, dynamic response accuracy 0.05
mm.

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 3) Height follow-up range is 0-10 mm.
4) The upper limit of the following speed depends on the upper limit of the
servo motor speed and the lead of the screw. With 3000 rpm servo and 5
mm screw, the maximum following speed can reach 375 mm/sec.
5) With the signal transmission cable length up to 100 meters, the signal is
not attenuated. Its anti-interference ability is strong.
6) Support network communication and U disk online upgrade.
7) It can be matched with any cutting head and nozzle, and the capacitance
parameters are adaptive.
8) Alarm, when the nozzle touches the plate or the follower goes beyond the
edge.
9) Support edge detection and automatic edge seek.
10) One-button calibration process, quick and easy for operation.
11) Support frog style lift, segmented piercing, and arbitrarily setting the
height of the cutting head.
12) Support oscilloscope, which can detect capacitance and height change in
real time.

4.3.2.2 Operating Introduction

1) Key description
Key Type Function and Use

Functional keys

The function is displayed by the interface prompt.

number keys

Decimal point

Backspace key

Used to enter numbers, mainly for input parameters

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Key Type Function and Use

Arrow keys

Used to switch the cursor and jog the floating head, the
SHF key can switch the jog speed.

Control keys

• FOLLOW and SHUT: Manually turn the

following on or off. After the following is
turned off, the cutting head is automatically
raised to the docking height.
• FAST and SLOW: Adjust the speed setting
of the following motion in real time.
• +0.1 and -0.1: Adjust the height of the
following motion in real time.
• STOP: Stop all movements.
• ORG: Return to the origin immediately and
correct the machine coordinates.
• ENT: Confirm the current operation.
• ESC: Cancel the current operation or return.

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 2) Hierarchy diagram of system functions
As shown below

Servo calibration

Calibration Floating head

calibration
Automatically
adjustment
Technic

Speed

Origin

Jog
Parameters

Main interface Mechanic

Network

Alarm

Edge
Test Function test

Product info

Alarm record

Advanced Settings Restart

System set

Config file

FIGURE 14 HIERARCHY DIAGRAM OF S YSTEM FUNCTIONS

3) Main interface
After the system is powered on and the initialization is completed, it will
automatically enter the [Main Interface]. As shown below:

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 Following speed Dynamic Function
Level
Current state error
1~9

Following height

Z coordinate

Current capacity
Jog speed [L: low H: high]
Features displayed on the main interface include:
1) Current state: Shows the current motion state of the following system. There
are several types of motion:
A. Stopp: Z-axis is in an idle state.
B. Decel: There will be a very short transition state for a slow stop after
receiving a stop instruction in motion state. It will change into “stop” state
after completely stopping.
C. Moving: It is the movement of Z-axis while lifting up during processing.
D. Follow: The follower follows the board while conduct punching and
cutting operations.
E. Origin: Go back to the mechanical origin of Z-axis.
F. Jogging: Manually jog Z-axis.
G. Lift up: It is the process to shut the follower off and lift it to the stop
position.
2) Following gain level: The follow-up gain level is from 1 to 30, and the default
is 15 levels. The higher the level, the smaller the average error of the follow-
up, the faster the following motion, and the stronger the ability to climb the
slope. However, if the gain is too strong, the system will generate self-
oscillation. This parameter can be obtained by automatically adjustment.
3) Current height: Press <+0.1><-0.1> on the main interface to adjust the actual
following height in 0.1mm steps. You can also set the following height by
pressing <F2> to enter the parameter interface. Press <FOLLOW> or
<SHUT> to control whether to follow under the current situation. After the
following stops, the Z-axis will automatically be lifted to the docking
coordinates (the default is Z = 0, you can also modify the docking coordinates
by pressing <F2> to enter the parameter interface).

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 In addition, in the controlled by Ethernet mode, the following height is set by
the CypCut software.
4) Dynamic error: In the following state, this value reflects the real-time error of
the following motion.
Distance between the floating head and the board surface H: Within the
capacitance measurement range (calibration range), H= “set following height”
+ “dynamic error”. When the measurement range is exceeded, “set follower
height” + “dynamic error” is equal to the calibration range.
5) Z coordinate: After cutting head returns back to ORG, the mechanical
coordinate system of Z-axis is built. The downward motion increases the
coordinates.
6) Current Capacity: The principle of the system sampling is to calculate the
distance by measuring the capacitance between the floating head and the plate.
The closer the floating head is to the plate, the larger the capacitance value.
When the floating head hits the plate, the capacitance will change to zero.
7) Jog speed: L for low jog speed, H for high jog speed. Press the <SHF> button
to switch the jog speed gear. Press the <↑><↓> button to perform the jog.

Hidden functions of the main interface

Key Function

<3> Displays following parameters (it requires a password from the

manufacturer to modify parameters)

<4> Oscilloscope for the real-time error of the following.

<5> Oscilloscope for real-time monitoring of capacitance.

<6> Oscilloscope for the calibration curve of capacitance

<7> Records the current capacitance for viewing the temperature drift.

<8> Simulates the signal of Input 1 and starts to follow.

<9> Turns on the following for edge seek cutting.

<0> Sets the current Z-axis coordinate as 0.

4) Calibration interface
In the main interface, press <F1> to enter the [Calibration interface]. As

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 shown below:

When using BCS100 for the first time, the user must first perform the servo
calibration, then the floating head calibration, and at last the automatically
adjustment. After the first use, if there is a temperature drift, the floating head
calibration should be done, but the servo calibration and automatically
adjustment can be omitted.
a) Servo calibration
The purpose of servo calibration is to eliminate the zero drift of the servo
motor. Press <1> to enter the [Servo calibration] interface. As shown below:

In the process of the servo calibration, the motor will oscillate back and forth
in small amplitudes. Therefore, first, it is necessary to jog to the middle of the
stroke, in order to prevent the stroke from being exceeded during the
oscillation. Then press <ENT> to start calibration.

After the system is automatically calibrated, return to the previous interface.

b) Floating head calibration
The purpose of the floating head calibration is to measure the corresponding
relationship of the capacitance and the position between the floating head and

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 the plate. Press <2> to enter the [Floating head calibration] interface. As
shown below:

If any setting has not been conducted, please enter <4> and set calibration
parameters.

Parameter Description

The calibration records the capacitance data in this range,

Calibration range
which defaults to 15mm.
When the Z-axis stroke is too short, the user can set this
value a little lower.
When the speed is greater than 250mm/s, it is necessary
to increase the calibration range appropriately so that the
floating head has sufficient deceleration distance.

Capacitance when the When calibrating materials with small changes in

capacitance such as acrylic and plastic, it is necessary to
nozzle touches the plate
set the touching plate calibration first. In the calibration
interface, let the floating head gently touch the surface of
the material and press [F1] to set the current capacitance
value as the touching plate capacitance.

Intelligent detection of When this function is activated, a method of intelligently

identifying the change in capacitance will be used to
touching plate
determine whether the floating head touches the plate.

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Parameter Description

With this method, calibration of non-metallic objects can

be achieved without setting the touching plate
capacitance. If there is a large interference in the
environment (such as a DIF value greater than 30), please
turn off this function. Otherwise, Otherwise, the floating
head may be lifted without touching the plate surface.

Press <ENT> to save these parameters and return to the previous interface.

Before calibration, first, jog the floating head close to the plate surface (about 1~5mm
away from the plate surface), and keep the plate still and not vibrate. Press <ENT>
again to start calibration.

The calibration process is completed automatically, which takes about ten seconds.
During this process, the user can press the “STOP” button to force the calibration to
end. When the calibration is completed, there are 2 indicators, each of which has four
grades, “excellent”, “good”, “not good” and “poor” The automatic calibration process
is briefly divided into the following steps:

i. The floating head slowly moves downward to detect for touching the
plate.
ii. After the nozzle touches the plate, the floating head moves up a little to
detect the stability of the sensor.
iii. The floating head slowly moves downward again to detect for touching
the plate.
iv. After the nozzle touches the plate, the floating head moves upwards till to
obtain the set calibration distance from the plate, then detect the
smoothness and characteristic curve of the sensor.

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If the above steps are not implemented and there will be an alarm after the calibration,
there may be a problem with the hardware or the cable.

A simple way to determine the problem is to touch the nozzle with a metal plate to see
if the capacitance will change. If the capacitance change is small or constant or
always 0, indicate that there may be a connection error or abnormal operation of the
sensor. In addition, considering factors such as safety and electrostatic breakdown, it
is not recommended to directly touch the nozzle by hand when it is charged.

The calibration results show:

The stability, which reflects the static characteristics of the capacitance. If the
calibrated result is not within the acceptable range, there may be plate vibration or
external interference.

The smoothness, which reflects the dynamic characteristics of the capacitance change
during calibration.

Indicators of these two above calibration parameters need to be at least “medium”,

otherwise the system may not work properly. The ideal situation for these two
indicators is that they are “excellent” or “good”.

After pressing <ENT> to save the settings, the capacitance-position curve is displayed.
The normal curve should be as smooth as follows:

If the curve is not smooth, there are undulations or burrs, it indicates that the result is
not ideal and needs to be recalibrated. If the result after repeated calibration is still not
satisfactory, the user needs to re-check the hardware installation and connection of the
system. In addition, the user can also view the calibration curve by pressing <6> on
the main interface.

During the floating head calibration, if the calibration fails, various alarms will appear,
as listed below:

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Alarm Description

Hit board overtime During the calibration, this alarm is triggered when it is not
detected for a long time that the downward moving floating
head has touched the plate. When this alarm occurs, first
confirm that the floating head is close to the plate surface
(usually within 5mm) before calibration; secondly, confirm
that the sensor is connected and working properly. If the Z-axis
does not move down, it is necessary to consider that the
resolution of the analog quantity is not enough, and the speed
gain parameter needs to be modified.

Leave board In the first step of the calibration, if the nozzle directly lifts up
overtime before it touches the plate surface, the system may assume that
the nozzle keeps in the state of touching the plate, then this
alarm is triggered. When this alarm occurs, first, confirm that
the sensor is connected and working properly; secondly, check
whether the plate capacitance parameter is correctly set. If the
plate is a metal plate, the plate capacitance is set to 0.

Sample overtime This alarm is triggered when no enough samples have been
collected during the calibration. Please recalibrate.

Always hit board Refer to “Leave board overtime”

Capacity changes When this alarm occurs, please jog the floating head close to
abnormally the plate surface (within 5mm) before calibration.

c) Automatically adjustment
Press <3> to enter the [Automatically adjustment] interface, as shown below:

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 Before automatically adjustment, make sure:
• Servo calibration has been conducted.
• The servo has just returned to the origin, and the coordinate system is
correct.
• Floating head calibration has been conducted.
• Below the floating head, there is a plate for following.

The process of automatically adjustment is repeating the switch following and

optimizing the internal parameters automatically. After optimization, as shown below:

Press <ENT> to save the parameters. The parameters of the automatically adjustment
have the following meanings:

Parameter Description

Downward The downward gain level is from 1 to 30, and the default is 15 levels.
gain level The higher the level, the faster the downward following action. But if
the gain is too strong, the instantaneous deceleration will be too large.
This parameter can only be set automatically after the automatic
adjustment. The following gain level is also automatically set after the
automatically adjustment (it can also be set manually at the main
interface ).

Differential The default value of this parameter is 40. The smaller this parameter,
time the easier it is to overshoot, but the movement is faster. After the

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Parameter Description
constant automatic adjustment, the value of this parameter can be obtained.

5) Parameters interface
In the main interface, press <F2> to enter the [Parameter Interface]. As shown
below:

All these above parameters, especially the mechanical parameter must be set
correctly, otherwise, the system will not work properly. The mechanical
parameter of this machine has been set at the factory, and no customer setting
is required.
a) Technic parameters
Press <1> to enter the [Technic] interface, and its page 1 as shown below:

The description of each parameter is shown in the following table:

Parameter Description

Set the distance between the floating head and the plate
Punching height
when piercing.

Aligning position Set a coordinate and press [←] [→] on the main interface
can move to this coordinate.

Set the target position for lifting the head after processing
Dock position
the entire program.

Z Range Set the Z-axis stroke. In the operation, the processing will

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Parameter Description

be stopped immediately when it exceeds the Z-axis

stroke, and generate an alarm “ exceeds the Z-axis
stroke”.

When “Docking Coordinates” or “Z-Axis Stroke” is selected, a menu “[F1]

Assign” appears on the right. Press [F1] at this time to set the parameter by jog
mode.

Press <ENT> to continue setting the process parameters. Page 2 is as follows:

These parameters are mainly used when the IO port mode is used for control.
These parameters do not take effect in Ethernet control mode.

The description of parameters is shown in the following table:

Parameter Description

IN1 follow Shows whether [F1] Direct (direct following) or [F2] Punchfirst,
(piercing-delay-following) or [F3] Approach (progressive piercing)
is used when input 1 is active.

Punch delay Delay time during piercing

Punch speed Speed when progressively follow to the cutting height.

When the nozzle descends to the piercing position, output 4 gives a 200ms valid
in-position signal. When nozzle descends to the cutting height, output 1 gives a
continuous valid in-position signal.

b) Speed parameters

Press <2> to enter the [Speed] interface, as shown below:

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 The description of the parameter is as follows:

Description
Parameter
The speed at which the floating head descends and lifts up when not
Move speed
perforating or cutting. It is recommended to set the servo motor to
run near the rated speed to improve efficiency and ensure the smooth
operation of the system. In addition, when the set movement speed is
high, it is necessary to increase the calibration range accordingly, so
that there is enough deceleration area for the downward following to
avoid the collision. If the speed is set above 250mm/s, the calibration
range needs to be 15mm or more.

Set the floating head’s acceleration of following and air movement.

Acceleration

c) Origin parameters
Press <3> to enter the [Reset Parameters] interface, as shown below:

The description of the parameter is as follows:

Parameter Description

Yes/No Org when Set whether return to the origin automatically after power on.
Set this option to ‘Yes’ after the commissioning is complete.
power on

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Parameter Description

Yes/no Return dock Set whether return to the set docking position after returning
to the origin.
position after org
Set the speed of back to the dock movement.
Org speed
Set the return distance after hitting the home switch. This
Return distance
position is the coordinate 0 point.

d) Jog parameters
Press <4> to enter the [Jog Parameters] interface, as shown below:

The description of the parameter is as follows:

Parameter Description

Jog speed low Set the speed of the type-L jog movement.

Set the speed of the type-H jog movement.

Jog speed high
Set whether to activate the software limit when jogging. If the
Software limit
software limit is on, it is not allowed to jog the floating head to
the negative coordinate or below the following height, in order to
avoid touching the collision between the nozzle and limit switch
or the plate. The software limit protection function only can be
set on the main interface.

Only the jog function in the [Test] interface is the jog of the open loop. When the
encoder signal is abnormal, it does not affect the jog function in the function test
interface.

e) Mechanic parameters
Press <5> to enter the [Mechanical Parameters] interface. The first page is as
follows:

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 Press <ENT>, page 2 as shown below:

Press <ENT>, page 3 as shown below:

The description of the parameter is as follows:

Parameter Description

Set the stroke per revolution of the used transmission

Lead screw thread
component. For the screw is to set the screw lead. In theory, the
larger the screw lead, the faster the Z-axis moves. It is
recommended to use a ball screw with 5 mm lead.

Set the number of pulses fed back by the encoder per revolution
Pulse per round
of the servo motor. This number must be consistent with the set
parameter in the drive.

Set the actual speed per volt. This speed must be consistent with
Speed-voltage gain
the set parameter in the drive. The recommended value is 500
rpm per volt.

Set the allowable upper rotating speed limit of the servo motor,
Max RPM
according to characteristics of the motor and of the load. Under

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Parameter Description

normal circumstances, it does not exceed 4500 rpm.

Set the rotation direction of the servo. The default value is 0.

Servo direction
Set the feedback direction of the encoder pulse. The default
Encoder direction
value is 0.

0 represents the servo of the Panasonic A5 series. 1 Represents

Servo type
the servo of Schneider or Delta ASDA series. 2 Represents the
servo of Teco JSDEP series. Zero speed clamping principles,
logic of input and output signals, and system control parameters
of different servos are different.

Set the logic of the limit input port (IN5~6) (0: normally open /
Limit input logic
1: normally closed).

Set the logic of the general input port (IN1~4) (0: normally open
General input logic
/ 1: normally closed).

Set whether to use the input port IN3 as a separate interface for
Use lift up input
the lift-up signal. If it is set to 0, following is turned on when
IN1 is valid and turned off when IN1 invalid. If it is set to 1,
when IN1 is invalid, only after the IN3 is set as valid, then lift-
up is possible (This parameter is ignored when using network
communication method)

f) Network settings
Press <6> to enter the [Network] interface, as shown below:

With the CypCut software, advanced functions such as arbitrarily setting the
height of the cutting head, frog style lift, segmented piercing, flight optical
compensation, etc can be easily set through the network. Refer to the

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 description of the CypCut software for details. Users who do not use the
CypCut software should turn off the network function, otherwise, the boot
process will be slower.
For connecting with the network, it is recommended to connect the PC and
BCS100 directly via a crossover cable. The IP address of the PC side should
be set in the same network segment as the BCS100 (10.1.1.xxx, which cannot
be duplicated with the BCS100). The gateway also needs to be set on this
network segment, and the last digit is 1, such as 10.1.1.1. As follows:

Note:
1. When different network devices, such as IPG fiber laser (network
connection mode) share one computer, each network connection must be set to
a different network segment. For example, set separately: 10.1.2.x,
192.168.1.x.
2. After the computer’s network card resets the IP, the network card must be
disabled – enabled again to make IP settings take effect.
g) Alarm settings
Press <7> to enter the [Alarm Settings] interface, as shown below:

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Parameter Description

When the duration of the touching plate reaches this time, the
Hit board delay
floating head will automatically lift for protection and an alarm
signal will be sent out.

Max follow The maximum follow deviation allowed by the BCS100. After
the cutting head in position, the controller will generate this
deviation
alarm when the follow deviation exceeds the set maximal value,
which can be caused by the movement beyond the boundary of
the plate or the sharp vibration of the plate.

Set the filter time to the max follow deviation alarm. The larger
Max follow delay
the set value, the slower the response and the stronger the ability
to filter out interference.

Limit alarm enable When set to 1, the upper and lower limit alarm function is turned
on. When the nozzle encounters the upper/lower limit, the
nozzle is automatically raised and the system sends out an alarm
signal. When set to 0, this feature is turned off.

h) Edge seek cutting settings

Press <8> to enter the interface of <edge settings>, as shown below:

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Parameter Description

The maximum forward speed when cutting out the

Saturation speed
boundary. The defined cutting range should be within
the range of this parameter to avoid the Z-axis
moving too deep.

When the height H is detected to be less than this set

Cut in check
value, the floating head is opened.

It is detected that the H height is greater than the set

Cut out check
“Cut out check” value for the time as long as the set
Cut out delay
“Cut out delay” value, and the floating head is
closed.

When the floating head descends for the first time to

[F1] Through cut height
the Z-axis coordinate as this “Through cut height”
defines, it opens the finding edge cutting.

6) Test interface
On the main interface, press <F3> to enter the interface of <Test>, as shown
below:

In this interface, the user can test whether the settings of keys, the state of
input and output ports and the rotation direction of the motor are correct. After
the first installation is completed, the user must enter the interface and perform
a switch jog to check whether the rotation direction of the motor and the

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 direction of the encoder signal are correct. If the motor direction is not correct,
modify the “servo direction” parameter in “Mechanic” parameter interface.
Then perform the open-loop jog to check whether the direction of the encoder
signal is correct. If it is wrong, modify the “Encoder direction” in the
“Mechanic” parameter interface.
The input and output ports of the interface are defined as below:

Input Definition Output Definition

port port

IN1 Follow to the cutting height Out1 Signal for following in position

IN2 Follow to the piercing height Out2 Signal for follower error

IN3 Lift-up signal Out3 Signal for alarm output

IN4 Stop signal Out4 Signal for piercing in position

IN5 Negative limit Out5 Eliminate the servo alarm (servo

signal)

IN6 Positive limit Out6 Servo enabled (servo signal)

IN7 Servo alarm (servo signal) Out7 Zero speed clamping (servo signal)

Press←→button to switch the analog input /output port. Press the numeric keys
to simulate the opening/closing the corresponding input/output port.

7) Advanced settings
On the main interface, press <F4> to enter the interface of <advanced
settings>, as shown below:

a) Product information
Press <1> to enter the interface of <Product info>, as shown below:

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 The information shown in this interface is listed in the following table.

Information Description

Version The version number of BCS100 program, such as V500, (2D) means
that it can be used for cutting plane items. (3D) means that with the
mechanical hand it can be used for 3D cutting.

ID Global unique sequence number of BCS100.

Expiration The rest usable time for BCS100, such as 30 days, or unlimited.

The factory default usage time of the BCS100 is unlimited. However, when
the service time of BCS100 expires, alarm information (service time expires)
will be displayed in the main interface. Press [F1] to enter the [Register
Interface] and register, as shown below:

After entering the correct registration code, you can reset the remaining usage
time of the system.
b) Alarm record
Press <2> to enter the interface of <Alarm record>, as shown below:

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 In this interface, the previous alarm events are displayed in a list. At most, the
recent 9 alarm events can be recorded by the system. Users can clear the alarm
list after pressing <F1>. For the meaning of each alarm, please refer to
Chapter 5.
c) Restart
The BCS100 controller can be restarted by pressing <3>. This operation is
equivalent to that the system is powered down and then powered on again. For
system upgrade, please first insert USB disk to BCS100 and restart the system,
then the upgrade will be completed with restart function.
8) Oscilloscope
The oscilloscope function is one of the unique features of the BCS100. Press
<5> on the main interface to enter the [capacitance oscilloscope] interface.
The principle of this oscilloscope is actually to display the C capacitance value
in real time. The interface displays the maximum value (MAX), the minimum
value (MIN), the difference between the maximum and minimum values
(DIF), and the average value (AVE) of the measured capacitance for a period
of time. As shown below:

Please observe the change in capacitance while keeping the cutting head and
the plate stationary. The larger the DIF value, the greater the interference, or
the more unstable the capacitance measurement. The interference intensity is
shown below:

DIF value Interference intensity

0~10 No

10~20 Tiny

20~30 Less intensive than general

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 30~50 General

>50 More intensive than general

9) Edge seek cutting function

As shown below:

Floating
head

Cut the plate into 2 pieces

The edge seeking cutting function is widely used for cutting corners, splitting
and residual material cutting. This function allows the cutting head to cut from
the edge of the plate and leave from the edge of the plate. This feature is only
available when CypCut software is used.
Before cutting, it is necessary to move the cutting head to the position near the
cutting point of the plate, then set this position as “Through cut height”. In the
following, turn on the edge seek cutting function in the CypCut software.
In operation, the floating head descends first to the “Through cut height”, then
starts the edge seek cutting process. When the system detects the distance
between the floating head and the plate is less than the value of the set “Cut in
check” parameter, cutting starts. When the system detects the distance between
the floating head and the plate is greater than the value of the set “Cut out
check” parameter for the time as long as the set “Cut out delay” value, the
cutting ends, and the floating head lifts up to the “Through cut height”.
When this function is used, the following need to note:
• Please sure that the “Through cut height” has been set before the first
cutting.
• Make sure the Z-axis coordinate deviation between each cut-in point is
less than 5mm, so as to avoid the case that some cut-in points are not
sensed, while others are sensed too early when cutting.
• When cutting in, if the floating head starts to follow earlier, the set

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 value of the “Cut in check” parameter should be decreased; if the
floating head starts to follow later or fails to follow, the set value of the
“Cut in check” parameter should be increased.
• When the slope of the plate is large and the cutting speed is fast, it is
necessary to appropriately increase the set value of the “Cut out check”
parameter.
• If the interference by the capacitance sampling is large, or the spark is
large and the plate vibration is intensive, the set value of the “Cut out
delay” parameter should be appropriately increased.
• By adjusting the set value of the “Saturation speed” parameter, the
probing depth of the laser head can be suppressed. However, if the
parameter is set too small, the respond speed of following will be
affected.
• When the edge seek function is enabled, and the “Cut out check”
condition is met, the floating head lifts up to the “Through cut height”
and continues to cut.
10) Preamplifier
The uniquely designed preamplifier amplifies and converts the capacitive
signal of the cutting head into a digital signal, allowing the signal to be
transmitted over long distances. When the transmission cable length is 100
meters, there is basically no parasitic capacitance, which ensures that the
signal does not attenuate and its stability is strong. The appearance of the
preamplifier is shown below.

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FIGURE 15 PREAMPLIFIER

When using the sensor, please pay attention to the following:

1) Use a dry, clean auxiliary gas for cutting work. When the gas contains
impurities such as water and oil, the working gap will change, and even the
sensor will malfunction.
2) The sensor should be cleaned if it has been stained. Also, clean it with a clean,
dry cotton cloth. Do not use liquid to clean the cutting head and ceramics.
After cleaning, connect and assemble them correctly.
3) Nozzles, ceramic bodies, cables can be replaced at any time. The nozzle can
be replaced with one of any shape and type, but the capacitance calibration of
the floating head must be redone after replacement.

4.3.3 Functions and Adjustment of Nozzles

4.3.3.1 Nozzles

The nozzle is a consumable product. The shape of the nozzle, the manufacturing
accuracy of the nozzle and the jet flow state directly affect the cutting quality. The
main functions of the nozzle are:

• The nozzle can prevent cutting debris and other debris from bouncing up into
the cutting head, which will damage the focusing lens.
• The nozzle can change the condition of the ejected cutting gas and control the
area and size of the gas diffusion, thereby affecting the cutting quality. The
following figure shows the situation in which the gas is jetted when the nozzle
is installed and the nozzle is not installed.

Nozzle

Without nozzle With nozzle

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4.3.3.2 Nozzles’ Influences on the Cutting Quality and Directions for Choosing the
Nozzle Aperture

If there is a non-coaxiality problem between the nozzle and the laser beam, high
cutting quality can’t be guaranteed.

• The cutting section is affected. The non-coaxiality would lead to uneven gas
volume when the cutting gas is ejected so that the cutting section is more
likely to have one side with slag and the other side without slag. For cutting
thin plates of 3mm or thinner, the influence on the cutting section is small.
When cutting plates thicker than 3mm, the influence is serious, and sometimes
cutting is even not possible.
• The quality of corner cutting is affected. When cutting a workpiece with a
sharp corner or with a small angle, with this non-coaxiality problem partial
over-slag is likely to occur. When cutting a thick plate, the cutting maybe not
even possible.
• Piercing is affected. This non-coaxiality problem leads to instability during the
piercing and over-melting by thick plate cutting. Also, it is difficult to control
the piercing time and conditions. By think plate cutting, the influence is small.

In summary, the coaxiality between the nozzle and the laser beam is one of the
most important influential factors on the cutting quality. The thicker the
workpiece is, the bigger its influence would be. Therefore, for high cutting quality,
this coaxiality must be ensured through adjustment.

Note: When the nozzle is deformed or there is slag on the nozzle, the influence on
the cutting quality is the same as described non-coaxiality. Therefore, the nozzle
should be placed carefully to avoid deformation; the melt stain on the nozzle
should be cleaned up in time. High manufacturing accuracy and correct
installation are required for nozzles. If cutting parameters need to be changed due
to the poor quality or worn nozzle, this nozzle should be replaced in time.

For choosing the nozzle aperture, the following table shows the relationship
between the nozzle aperture and the auxiliary gas flow rate.

Nozzle aperture Gas flow rate Ability to remove slag

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 Small Fast Strong

Big Slow Weak

If the nozzle aperture is too large, the melt that splashes around during the cutting
may pass through the nozzle hole, and spatter the lens. The larger the aperture, the
higher the probability of this spattering. Thereby, the less protection that is given to
the focusing mirror, the shorter the life of the lens would be.

4.3.4 Adjustment of Laser Beam Focus

4.3.4.1 Introduction

During the cutting process, the relative position of the laser beam focus to the cutting
plate surface has a great influence on the cutting quality. It is very important to adjust
the focus position correctly. The focus position can be adjusted by rotating the
rotating nut on the laser head, and the optimal position of the focus can be obtained by
trial cutting.

4.3.4.2 Relationship between the Focus Position and the Cutting Section

The table below lists recommended focus positions for cutting plates of different
materials and of different thickness. The influences on the cutting section and the
plate piercing are also listed.

Recommended focal Materials and cutting section

length

Zero focal length Used to cut workpieces SPC, SPH, SS41

The focus is on the The upper surface of the cutting section is smooth, and
surface of the plate. the under surface is not.

Used to cut carbon steel, aluminum, etc.

Positive focal length
Compared to cutting with zero focal length, the range of
The focus is between the
smooth surface is larger, the cutting width is wider, the
upper and lower surface
gas flow volume during cutting is larger, and the piercing
of the plate.
time is longer.

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 Used to cut carbon stainless steel plate.
Negative focal length
When cutting stainless steel, high-pressure nitrogen is
The laser focus is on the
used for cutting and blowing off the slag to protect the
lower surface of the
cutting section. The cutting width is widened as the
workpiece.
thickness of the workpiece increases.

4.3.5 Setting the Distance between the Nozzle and the Workpiece

FIGURE 16 DISTANCE BETWEEN THE NOZZLE AND THE W ORKPIECE

After the sensor box is adjusted, following distance between the nozzle and the plate
is determined by technic parameters, please refer to the [Technic] parameters table.

4.3.6 Setting the Laser Cutting Speed

The laser cutting speed should be set according to the material and thickness of the
plate. The cutting speed has a great impact on laser cutting quality. Correctly set
cutting speed not only improves the efficiency of the cutting but also leads to high
cutting quality. The effect of different cutting speeds on cutting quality is discussed
below:

• If the cutting speed is set too high,

o cutting maybe not even possible and too many sparks appear on the
surface;
o the plate cannot be completely cut through;
o the cutting section is much rough but without slag.

As shown below, the cutting speed is set too high, so the plate cannot be cut off in
time and a diagonal stripe path appears on the cut section. Slags also appear on the
lower half.

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 nozzle

workpiece auxiliary gas

oblique angle because cutting can’t be completed in slag

time
FIGURE 17 CUTTING EFFECTS WITH CUTTING S PEED SET TOO HIGH

• If the cutting speed is set too slow,

o the over-melting phenomenon occurs, and the cutting section is rough.
o the cutting is wider, and the entire area of a small rounded corner or
sharp corner would be melted, and the desired cutting effect cannot be
obtained.
o low cutting efficiency affects production capacity.

Instructions for adjusting to the optimal cutting speed:

Adjust the set cutting speed according to the situation of sparks：

• if the cutting sparks are diffused from top to bottom, the set cutting speed is
optimal.
• if the cutting sparks are tilted, the set cutting speed is too high.
• if there are few cutting sparks, and they condense together and do not spread,
the set cutting speed is too slow.

As shown below, with the optimal cutting speed, the cut section shows a smooth
line and there is no slag on the lower half.

smooth
line

sparks diffused sparks sparks do

from top to not
tilted
bottom spread
FIGURE 18 S PARKS AND CUTTING S PEED

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4.3.7 The Selection of Cutting Gas and Gas Pressure

The required cutting gas and its pressure should be determined according to the
material of the cut plate. This choice has a great impact on the cutting quality. The
function of the cutting gas includes combustion and heat dissipation, timely blowing
off the melt generated by the cutting, preventing the cutting slag from rebounding into
the nozzle, and protecting the focusing lens.

1) The effect of cutting gas pressure on cutting quality is discussed below:

• When the gas pressure is insufficient, slags are generated during cutting,
and the cutting speed cannot meet the production efficiency requirement.
• When the gas pressure is too high, the cutting surface is rough and the
cutting is wide; at the same time, the cut section is partially melted, and a
good cutting section cannot be obtained.
2) The effect of cutting gas pressure on piercing is discussed below:
• When the gas pressure is insufficient, the laser cannot easily penetrate the
plate, and the piercing time increases, resulting in low productivity.
• When the gas pressure is too high, the penetration point is melted, forming
a large melting point, thereby affecting the cutting quality.

For laser piercing, generally, higher gas pressure is applied to perforate thin plates,
and lower gas pressure is applied to perforate thick plates.

When cutting ordinary carbon steel, the thicker the plate is, the lower the cutting gas
pressure is required. When cutting the stainless steel with nitrogen, the cutting gas
pressure should be maintained at a high-pressure state and relatively increase with the
thickness of the material.

In short, the cutting gas and its pressure must be selected according to the actual
situation. Different cutting parameters should be selected according to specific
conditions.

4.3.8 Laser Power’s Influences on Cutting Quality

The laser power also has an influence on cutting quality. The laser power needs to be
determined according to the material and thickness of the plate. If the power is too
high or too low, a good cutting section cannot be obtained.

• If the laser power is set too low, the cutting may not be possible.

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 • If the laser power is set too high, the entire cutting surface will be melted, the
cutting will be too wide, and high cutting quality cannot be obtained.
• If the set laser power is insufficient, slags will occur and there will be scars on
the cutting section.

With appropriate settings of laser power, cutting gas and gas pressure, good cutting
quality can be obtained, and no slags will occur.
4.3.9 The Alternating Loading System

The alternating loading system enables the automatic exchange of two cutting tables,
which saves time and increases productivity.

This loading system transfers the corresponding cutting table into the cutting position
or out to the unloading position. This loading system is composed of a frequency
converter, a three-phase asynchronous motor and a gear chain. The electric control
signal controls the motor to rotate in the forward or backward direction to drive the
gear chain to rotate, so as to transfer the cutting table forward or backward. After the
CypCut system is installed and opened according to the CypCut operation manual,
you can control the movement of the upper and lower tables by selecting “CNC”
Toolbar → “Table Exchange” in the operation. As shown below:

4.4 Items, Methods and Judgement Standards of Acceptance

Test after Installation and Commissioning
Follow the Equipment Acceptance List.

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5 Maintenance and Troubleshooting

5.1 Maintenance
See Maintenance Manual for details.

5.2 Malfunction Analysis and Troubleshooting

5.2.1 Problems of the Follower

5.2.1.1 Alarm and Analysis

1) Z+/Z- limit enable

This alarm is generated when the system detects that the upper or lower limit
photoelectric switch or contact sensor of the Z axis is active.
After this alarm appears, you should pay attention to the following:
• Whether the signal line of the limit is normally connected
• Whether parameters of “limit signal type” are correctly set. The limit
signal can be set often open/ normally closed.
• Whether the Z+/Z- sensor detects something and send out a valid level
signal.
• Whether the Z+/Z- sensor is broken or contaminated by oil or dust.
2) Out of Z range
This alarm is generated when the Z-axis coordinate is greater than the set
stroke. If a false alarm occurs, it is necessary to pay attention to whether the
system is correctly reset, whether stroke parameters are correctly set, and
whether the feedback of the encoder is normal.
3) Z- limit continue enable
During returning to the origin, the cutting head encounters the Z- limit and
then moves backward, but it cannot leave the Z- limit area. Then this alarm is
generated.
4) Servo alarm
When the system detects that the IN14 ALM is enabled, which reflects the
input of a servo alarm signal, this alarm is shown on the screen. You should
check the servo motor drive, to see if there is an alarm, if any, power on again.
5) Encoder moves abnormally

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 When the system is not working, but changes are detected in the feedback
value of the encoder. Then this alarm is generated. The causation of this alarm
includes:
• Outside force leads the axis to vibrate.
• Poor wiring exists, and the zero speed signal is invalid.
• The encoder line is disturbed, and ensure that the machine is connected
to the ground correctly
6) Encoder no response
The system sends out simulation command, but the feedback value of the
encoder doesn’t change at all. Then this alarm is generated. The causation of
this alarm includes:
• Poor wiring.
• The simulation signal is not sent to the servo.
• Zero speed clamp signal is always in effect.
• The encoder feedback signal is not correctly sent back to the height
controller.
7) Encoder deviation large
This alarm is generated when the system detects that the difference between
the feedback back position and the target position is too large. The appearance
of this alarm generally indicates that the servo system cannot properly follow
the position loop command of the height controller. The causation of this
alarm includes:
• The encoder direction is reversed.
• The position loop of the system does not form negative feedback, and
the parameters need to be modified at this time.
• Poor wiring, interference, etc. cause the encoder feedback to be
abnormal.
• The Z-axis mechanically jams and the system instantaneous torque
increases, but the position is not reached.
8) Capacity is 0
When the system cannot measure the capacitance correctly, the capacitance
value will become 0. The following reasons may cause the capacitance to
change to 0:

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 • The floating head touches the board surface.
• There is water in the cutting head.
• The local capacitance of the cutting head is too large and excesses the
detection range.
• The amplifier is damaged.
• Poor wiring in the amplifier/cutting head.
• Inside the cutting head, the positive (nozzle) and negative (case) of the
sensing capacitor are short-circuited.
9) Local capacity small
This alarm is generated when the system detects that the local capacitance has
become smaller than a certain range. Reasons include:
• Some parts have been replaced, the connection has been moved or the
characteristics of the component randomly change. Recalibrate in such
cases.
• The laser scatters on the nozzle, causing the nozzle temperature to rise
sharply, creating a temperature drift.
• Puffing causes a change in the gap between the positive electrode
(nozzle) and the negative electrode (the cutting head outer casing).
• Poor wiring of the amplifier, the nozzle and so on.
• The calibration distance is set too small (less than 10mm for 3D
cutting, less than 15mm for 2D cutting).
10) Local capacity large
When the follower is turned on, this alarm is generated because the local
capacitance becomes larger, causing the follower to keep moving upward. The
reasons for this alarm include:
• Some parts have been replaced, the connection has been moved or the
characteristics of the component randomly change. Recalibrate in such
cases.
• The laser scatters on the nozzle, causing the nozzle temperature to rise
sharply, creating a temperature drift.
• Puffing causes a change in the gap between the positive electrode
(nozzle) and the negative electrode (the cutting head outer casing).
• Poor wiring of the amplifier, the nozzle and so on.

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 11) Capacity abnormally large
This alarm is generated when the system detects that the capacitance exceeds
the maximum capacitance of the calibration or the set touching plate
capacitance. The reasons for this alarm include:
• The floating head touches the plate.
• There is water in the cutting head.
• The laser scatters on the nozzle, causing the nozzle temperature to rise
sharply, creating a temperature drift.
• Puffing causes a change in the gap between the positive electrode
(nozzle) and the negative electrode (the cutting head outer casing).
12) Follow deviation large
When the system checks the H height (the distance between spray and plate)
becomes larger in a short time in the following state, this alarm is generated.
The reasons for this alarm include:
• Cutting beyond the scope of the plate, and there is no object below the
floating head.
• The plate vibrates heavily.
13) Expiration of time
The system setup time is up.

5.2.1.2 Analysis of Common Problems

1) There are significant vibration and mechanical shock during the following.
• Poor contact between amplifier housing or controller FG pin and
machine housing.
• The outer casing of the machine is the negative pole of the to-be-tested
capacitor. When the amplifier casing and the casing of the machine are
poorly conductive, the AC impedance between the positive and
negative terminals of the capacitor is large. The measured circuit load
will change, resulting in a large measurement error. If mechanically
good connections are not possible, an additional wire can be placed
between the amplifier and the metal outer casing of the machine to
reduce the AC impedance, but the AC impedance of this single-point
connection is still greater than that of a mechanically good connection.
The specific indicator is that the DC impedance is less than 10 ohms.

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 • Follow level is set to high, which will lead to the vibration during
movement. It is to be set 10 ~18.
• The floating head calibration result is “not good” or “poor”. The
stability and smoothness of the capacitance-position data that is stored
in the BCS100 are poor, the following motion may vibrate. At this
point, please re-do the floating capacitance calibration until the
stability and smoothness are “excellent” or “good”.
• If there is a big disturbance at the site, please reduce the “Following
Gain” parameters appropriately.
2) During the following, the plate often collides.
• The calibration range is set too small or the Z-axis speed is set too
large. Smaller setting value for the calibration range means that the
deceleration distance following the motion is shorter. At the same time,
if the Z-axis speed is set too large, the Z-axis speed hasn’t fallen to 0
when Z-axis is in place, then overshoot will occur. The greater the Z-
axis speed, the greater the overshoot. When the Z-axis speed is set
greater than 100mm/s, the calibration range is recommended to be set
to 15mm. When the Z-axis speed is set greater than 250mm/s, the
calibration range is recommended to be set to 20~25mm.
• Servo rigidity is set too small, then the servo will respond with a lag to
the control signal of the height controller, which results in the collision
with the plate.
• There are capacitance calibration problems. When the difference
between the stored valued and the measured value is too large, the
collision with the plate may occur. The large difference may be caused
by the abnormally high nozzle temperature or the poor wiring. First,
identify the causation and solve the problem, then conduct the
calibration again.
• Ceramic body lock nuts are not tightened, which will lead to unstable
measured capacitance.
3) The following height does not match the set height.
• There are calibration problems. After replacing the nozzle, no floating
head capacitance calibration is conducted, then the above phenomenon

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 often occurs.
• Reasons such as the laser scattering onto the nozzle or the abnormal
puffing lead to the abnormally high nozzle temperature (above
100 °C), which changes the cutting head’s capacitance.
• The plate is not touched when conducting the intelligent detection of
touching plate, then the actual following height will be higher than the
set height. Turn off the intelligent detection option and conduct the
calibration again.
4) The lift height is abnormal.
• During cutting, the lift height gets lower and lower. Pay attention to
whether the machine is slipping or the mechanical connection is not
normal.
5) During upgrading the software, “parity error, ARM failed to upgrade” is
prompted.
• The upgrade file may be infected by the virus.
6) During the floating head calibration, the floating head lifts up before it touches
the plate.
• The touching plate capacitance is set incorrectly. When calibrating the
metal plate, the touching plate capacitance should be set to 0 and the
intelligent detection option should be turned off.

5.2.2 Other Problems and Troubleshooting

Problem Causation Troubleshooting Method
No auxiliary gas 1. The gas pressure is 1. Check the gas line pressure.
output insufficient. 2. Check whether the gas line
2. The gas channel is parameters are set correctly.
selected incorrectly. 3. Check the solenoid valve and
3. The solenoid valve related circuit.
is damaged, or there
is no control voltage
output.
Abnormal sound 1. Lubricating oil for 1. Add lubricating oil.
when axes move axis parts is run out. 2. Check the running path of these

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Problem Causation Troubleshooting Method
2. The moving moving components.
components
interfere with the
fixtures.
No laser or 1. CNC signal is not 1. Check the connection between the
insufficient laser delivered. CNC laser and the machine
power 2. The lens is dirty or console.
damaged. 2. Check the protection for the lens.
3. The nozzle is 3. Replace the nozzle.
damaged or blocked. 4. Adjust the optical path.
4. The optical path is 5. Restart the laser machine. Or the
incorrect. temperature of the water cooler is
5. There is a laser too low, restart the laser machine
alarm. after this temperature reaches the
required level.

Size between the 1. Program input error 1. Check the program.

finished exists. 2. Check the accuracy of the
workpiece and the 2. The positioning machine.
graphics accuracy influences 3. Check the servo motor. If it is
the cutting. damaged, please replace it.
3. The servo motor is 4. Check the servo driver. If it is
damaged. damaged, please replace it.
4. The servo driver is
damaged.
Floating head 1. The cable of the 1. Fasten the cable.
alarm amplifier, etc.is 2. Fasten the nozzle or the magnetic
loose. ring.
2. The nozzle or the 3. Conduct the floating head
magnetic ring is calibration again.
loose. 4. Replace or clean the nozzle.
3. There are system
problems.

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Problem Causation Troubleshooting Method
4. The nozzle is
damaged or
contaminated by
slags.
Motor alarm 1. The motor is not 1. Power on the motor and remove
powered. the alarm.
2. Motor alarms. 2. Check the servo driver alarm
information (See Table 1), and
repower the motor to remove the
alarm. If this alarm occurs
repeatedly, please contact us.

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6 Transportation, Shipping, and Storage

6.1 Packing
To protect against damage from external objects, the laser of the H-Series laser
cutting machines is packed in wooden cases, the small parts are packed in cartons, and
the other parts are wrapped with polyethylene foam and protective film on the outside.

6.2 Methods and Precautions for Transportation and Shipping

a) When transporting the machine tool, it should avoid rain, moisture,
inclination, rat damage, potholes, etc., and ensure good ventilation. The
temperature should be in the range of -10 °C ~ +40 °C, and the relative
humidity should not be more than 80%. If transportation and storage time does
not exceed 24 hours, the ambient temperature should not exceed 70 °C. Long-
term open storage is prohibited. If the machine has to be temporarily stored in
the open air for various reasons, in addition to the above requirements, the
storage location and packaging status should be checked at all times to ensure
that the machine is not damaged.
b) Do not climb, stand or place heavy objects on the product packaging.
c) Do not use the cable connected to the product to drag or carry the product.
d) Collision and scratches on the panel and display are forbidden.
e) Product packaging should be protected from moisture, exposure, and rain.
f) Lift the machine carefully and avoid the collision. Make sure that the lifting
rope doesn’t scratch the machine, and the lifting rope should be isolated from
the machine with soft materials.

6.3 Methods and Precautions for Storage

For the storage of the machine tool, it should avoid rain, moisture, inclination, rat
damage, potholes, etc., and ensure good ventilation. The temperature should be in the
range of -10 °C ~ +40 °C, and the relative humidity should not be more than 80%. If
transportation and storage time does not exceed 24 hours, the ambient temperature
should not exceed 70 °C. Long-term open storage is prohibited. If the machine has to
be temporarily stored in the open air for various reasons, in addition to the above

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requirements, the storage location and packaging status should be checked at all times
to ensure that the machine is not damaged.

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Appendix A Technical Specifications
Indicator H-Series

Plate size (mm) 3000*1500 /4000*2000)

X-axis stroke (mm) 3000 /4000

Y-axis stroke (mm) 1500/ 2000

Z-axis stroke (mm) 220

X- and Y-axis positioning accuracy (mm) ±0.03/1000

X- and Y-axis repeated positioning accuracy (mm) ±0.02/1000

Max. running speed (mm/min) 120000

CNC CypCut

Worktable maximum load (kg) 800

Machine weight (ton) 5

Dimensions (mm) 8420*2860*2250

Switchboard power (with 1000w laser) 18KVA

Power transmit three-phase power

Power supply rated voltage 380V

Frequency 50HZ

Total power protection rating IP54

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Appendix B List of Consumables and Vulnerable Parts
Type Name Details

Consumable Nozzle Under normal use, the service life varies from 15
days to 6 months depending on the material and
thickness of the cut plate.

Consumable Ceramic ring Under normal use, the service life varies from 6
to 12 months depending on the material and
thickness of the cut plate.

Consumable Protective lens Under normal use, the service life varies from 15
days to 6 months depending on the material and
thickness of the cut plate.

Vulnerable part Amplifier wire

Vulnerable part Focusing lens

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Appendix C Contact of SENFENG LEIMING LASER
SHANDONG LEIMING CNC LASER EQUIPMENT CO., LTD

Building 1, No.6333 North Lingang Road, Hi-tech District, Jinan, China.

Tel:+86-531-88737005 Email:sale@lmcnclaser.com

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