ProCutter2 15kW Manual en

ProCutter 2 - 15 kW
with Lasermatic®
Operating Instructions
© Precitec GmbH & Co. KG en-uk 08/2023 D 255294

Imprint
Imprint
This documentation is protected by copyright law for Precitec GmbH & Co. KG
and must not be reproduced without the prior written consent of Precitec or used against the due inter-
est of Precitec. It is intended exclusively for internal use associated with setup and service work. Any
other use is not permitted. Any communication of this documentation to a third party requires the prior
express written permission of Precitec.
We reserve the right to change technical details in the descriptions, information and illustrations in this
documentation.
All in Light, Lasermatic, Laser Path Finder, LWM, the Precitec logo and precitec are registered trade-
marks in Germany and other countries.
This product group is protected by the patents and utility models below:
DE 10108955
DE 102015101263
DE 202014105807
JP 2017539636
CN 1981976
CN 204867829
EP 1130361
EP 3250958
HK 1105388
KR 1465200
KR 1020177023993
US 6469523
(Further patents pending.)
Responsible for the content

Precitec GmbH & Co. KG
Draisstraße 1
D - 76571 Gaggenau - Bad Rotenfels
Tel.: +49 (0)7225 684-0
Fax: +49 (0)7225 684-900
E-mail: precitec@precitec.de
Translation of the original operating instructions
Printed in the Federal Republic of Germany
2 / 108 © Precitec GmbH & Co. KG ● en-uk 08/2023 D 255294

Table of Contents
Table of Contents
1 Safety notes and typographical conventions.......................................... 7

1.1 About this documentation................................................................................................. 7
1.2 Warranty and liability.......................................................................................................... 7
1.3 Typographical conventions................................................................................................ 8
1.4 Intended use........................................................................................................................ 8
1.5 Basic standards.................................................................................................................. 9
1.6 Electromagnetic compatibility (EMC)............................................................................... 9
1.7 Obligations of operator and personnel............................................................................ 9
1.8 Normal operation safety measures................................................................................... 10
1.8.1 Protection against electric shock.......................................................................................... 10
1.8.2 Risk of injury from moving parts........................................................................................... 10
1.8.3 Risk of injury from explosion................................................................................................ 10
1.8.4 Risk of injury from laser radiation......................................................................................... 11
1.8.5 Corrosion in the water cooling circuit................................................................................... 11
1.8.6 Noise occurring during the laser cutting process................................................................. 11
1.9 Storage and transport........................................................................................................ 11
1.10 What to do in emergency situations................................................................................ 11
2 Product description.................................................................................... 13
2.1 Product overview................................................................................................................ 13
2.2 Product characteristics...................................................................................................... 14
2.3 Protective and monitoring equipment.............................................................................. 15
2.4 Technical specifications..................................................................................................... 17
2.5 Meaning of LED indicators................................................................................................ 18
2.6 Mechanical dimensions...................................................................................................... 20
2.7 Media connections.............................................................................................................. 22
2.8 Accessories.......................................................................................................................... 23
2.9 ProCutter App...................................................................................................................... 24
3 Installation.................................................................................................... 25
3.1 Safety notes......................................................................................................................... 25
3.2 Checking package contents.............................................................................................. 25
3.3 Integration into the machine.............................................................................................. 27
3.3.1 Fitting the ceramic part and nozzle...................................................................................... 27
3.3.2 Connecting the laser fibre..................................................................................................... 28
3.3.3 Fixing the cutting head to the machine................................................................................ 30
3.3.4 Grounding the laser head..................................................................................................... 31
D 255294 © Precitec GmbH & Co. KG ● en-uk 08/2023 3 / 108

Table of Contents
3.3.5 Checking the protective window COL for any contamination............................................... 32

3.4 Connecting gas and water................................................................................................. 32
3.4.1 Connecting the cutting gas................................................................................................... 33
3.4.2 Connecting the cooling gas system...................................................................................... 34
3.4.3 Connecting the auxiliary gas system.................................................................................... 35
3.4.4 Connecting the cooling water system................................................................................... 36
4 Commissioning - I/O operation.................................................................. 39

4.1 Safety notes......................................................................................................................... 39
4.2 Running cables.................................................................................................................... 40
4.3 Component summary......................................................................................................... 42
4.4 Connecting the laser head to the machine...................................................................... 45
4.5 Connecting the ProCutter App.......................................................................................... 49
4.6 Interface description........................................................................................................... 50
4.7 Configuring the laser head................................................................................................ 55
4.7.1 Setpoint voltage & characteristic curves............................................................................... 55
4.7.2 Setting the focal position...................................................................................................... 57
4.7.3 Reading the focal position.................................................................................................... 57
4.7.4 Adjusting the laser beam...................................................................................................... 58
4.7.5 TCP offset correction............................................................................................................ 60
5 Commissioning - Fieldbus mode.............................................................. 61

5.1 Safety notes......................................................................................................................... 61
5.2 Running cables.................................................................................................................... 62
5.3 Component summary......................................................................................................... 63
5.4 Connecting the laser head to the machine...................................................................... 69
5.5 Connecting the ProCutter App.......................................................................................... 72
5.6 Interface description........................................................................................................... 73
5.7 Configuring the laser head................................................................................................ 78
5.7.1 Focal position variable & characteristic curves.................................................................... 78
5.7.2 Setting the focal position...................................................................................................... 80
5.7.3 Reading the focal position.................................................................................................... 81
5.7.4 Adjusting the laser beam...................................................................................................... 82
5.7.5 TCP offset correction............................................................................................................ 84
6 Maintenance................................................................................................. 85
6.1 Safety notes......................................................................................................................... 85
6.2 Maintaining the ceramic part and nozzle......................................................................... 86
6.3 Maintaining the protective window cartridge FOC.......................................................... 87
6.4 Maintaining the sensor insert............................................................................................ 90

Table of Contents
7 Troubleshooting........................................................................................... 91
7.1 Safety notes......................................................................................................................... 91
7.2 General malfunctions.......................................................................................................... 92
7.3 Electrical malfunctions....................................................................................................... 93
7.4 Mechanical malfunctions.................................................................................................... 100
8 Appendix...................................................................................................... 103
8.1 Conversion of Units............................................................................................................ 103
8.2 Gas quality (ISO 8573-1).................................................................................................... 103
8.3 Cooling water dew point temperature.............................................................................. 104
8.4 Parts available..................................................................................................................... 105

Safety notes and typographical conventions

About this documentation
1 Safety notes and typographical conventions
1.1 About this documentation

These operating instructions contain the most important information for safely operating the product.
Observe all instructions and guidelines in this documentation. In addition, accident prevention regula-
tions and instructions applicable to the area of use must be observed.
1.2 Warranty and liability

Precitec GmbH & Co. KG's General Terms of Delivery apply to our products.
We reserve the right to modify designs to improve quality or extend the fields of use and to make mod-
ifications for manufacturing reasons.
Dismantling the product may result in warranty claims becoming null and void. However, this does not
apply to the replacement of components that are subject to normal wear and tear and require mainte-
nance or setup work, unless expressly stated otherwise in this documentation.
We cannot accept any warranty claims or liability if unauthorised modifications are made to the prod-
uct or if unsuitable spare parts are used. We urgently recommend that only spare parts (hereinafter
referred to as “original spare parts”) supplied by Precitec be used and that these parts be installed by
Precitec or by a specialist designated by Precitec.

Typographical conventions
1.3 Typographical conventions

In these operating instructions the following typographical conventions are used:
Danger!
Indicates an immediate hazardous situation that, if not avoided, will result in death or very serious
injuries.
Observe the instructions to avoid hazardous situations.
Warning!
Indicates a potentially hazardous situation, that, if not avoided, could result in death or very serious
injuries.
Caution!
Indicates a potentially hazardous situation, that, if not avoided, could result in minor or moderate
injuries.
Attention!
Indicates a potentially harmful situation, that, if not avoided, could result in equipment or property
damage.
Tip: Provides useful information.
Prerequisite:
Describes the conditions that must be fulfilled to perform the relevant action.
1. Describes the steps that the user must carry out to achieve the objective.
Indicates the results of successful actions.
1.4 Intended use

The laser head has been designed for integration into a laser cutting machine. The laser head is used
for cutting metals with solid-state and diode lasers.
Any use which deviates from that which was originally intended is regarded as improper use. Precitec
shall not be liable for any damage caused by the improper use of the unit.

Basic standards
1.5 Basic standards

Below you will find a summary of basic national and international standards and regulations that apply
to Precitec products. Precitec does not guarantee that this summary is complete.
DIN VDE 0100: Regulations for setting up power current installations with rated voltages up to
1000 V
DIN EN 207: Personal eye protection: Filters and eye protectors against laser radiation (laser gog-
gles)
DIN EN ISO 12100: Safety of machinery - General principles for design - Risk assessment and risk
reduction
DIN EN 60204-1: Safety of machinery: Electrical equipment of machines, Part 1: General require-
ments (IEC 60204-1)
DIN EN 60825-1: Safety of laser machines: Part 1 (IEC 60825-1)
DIN EN 61000-6-2/ -6-3: Electromagnetic compatibility (EMC): (IEC 61000-6-2 / -6-3) Generic stan-
dards on interference emission/immunity, Part 2: Industry
BGV A3: Accident prevention regulation: Electrical systems and equipment
BGV B2: Accident prevention regulation: Laser radiation
1.6 Electromagnetic compatibility (EMC)

Both as a standalone device or in combination with the relevant devices and cables stated in this doc-
umentation, the product complies with the EN 61000-6-2 and EN 61000-6-3 standards as specified in
the current EMC Directive. It is intended for industrial use.
It is possible that these standards may not be met when using units or cables provided by the client.
Only use the parts, units supplied or original spare parts and adhere to the instructions in the accom-
panying manuals relating to EMC-compliant installations.
If the product is integrated into a system and operated together with other units, the whole system
must comply with the current EMC Directive so that a general operating permit can be granted.
1.7 Obligations of operator and personnel

The operator of the product is obliged to ensure that the personnel working at the machine
are familiar with the basic safety at work and accident prevention regulations and been instructed
on how to operate the product.
have read and understood the basic safety notes and the operating instructions and have con-
firmed this with their signature.
Observe the manufacturer’s and supplier’s regulations. Use the prescribed protective equipment.
Personnel must be instructed according to the regulations and safety notes and informed of potentially
hazardous situations.
Precitec shall not be liable for any damage caused by not complying with or having insufficient knowl-
edge about the information contained in the operating instructions.

Normal operation safety measures
1.8 Normal operation safety measures

Only use the parts supplied or original spare parts and do not connect any other units or cables.
The product must only be operated in compliance with the specifications stated in the Technical Data
sheet.
Only use the product in dry working environments.
If it has been decided that safe operation is no longer possible, the product or machine must be
switched off. The product or the machine must be protected against unintended use.
1.8.1 Protection against electric shock
For operational reasons, components of the laser head such as nozzle body, sensor body, sensor
inserts and nozzle electrodes as well as the accompanying fitting parts such as union nuts etc. cannot
all be connected to protected earth. These components can carry low voltage.
When carrying out any installation work, make sure that the electrical equipment is available and indi-
viduals are protected against electric shock.
The regulations contained in EN 60204-1, especially those included in Sections 6 'Protection against
electric shock' and 6.4 'Protection by PELV' (Protective Extra Low Voltage) must be met.
Use a safety transformer in compliance with DIN EN 61588-2 (IEC 61558-2).
Earth the machine according to the regulations.
Disconnect the machine from mains before carrying out any maintenance or service work.
1.8.2 Risk of injury from moving parts
When lowering the linear drive or robot hand to which the laser head is fitted, there is a risk of injury or
damage to equipment.
Never put your hands or other parts of the body under the laser head.
Repair or maintenance work must only be carried out with the power supply switched off.
1.8.3 Risk of injury from explosion
Laser heads are loaded with gas under pressure depending on their intended use.
The specified maximum pressure must never be exceeded.
To ensure that individuals are not harmed, the laser head must always be kept in perfect condition.
Any connecting elements such as screws and nuts must be tightened firmly.

Normal operation safety measures
1.8.4 Risk of injury from laser radiation
Caution - Laser beam!

The laser head does not emit any laser radiation. However, laser radiation is guided through the laser
head. During commissioning the machine may operate in laser class 4. There is a risk of injury.
Avoid radiation to eyes or skin caused by direct or scattered radiation.
Do not look directly at the laser beam even using optical instruments.
Use laser goggles complying with DIN EN 207 and BGV B2 that are designed for the wavelength
of the connected laser.
The machine must be switched off when carrying out any installation or maintenance work.
1.8.5 Corrosion in the water cooling circuit
To avoid any corrosion observe the instructions and maintenance intervals prescribed by the machine
manufacturer, laser source manufacturer or cooling unit manufacturer.
To protect the water cooling circuit (stainless steel) against electro-chemical corrosion, copper or brass
connections must not be used. Only stainless steel or plastic connections can be used.
For pure stainless steel circuits only use water with a conductivity value prescribed by the laser manu-
facturer.
1.8.6 Noise occurring during the laser cutting process
With high cutting gas pressure the noise level is >75 dB(A). Noise emitted by the cutting gas depends
on the operating conditions. To ensure that individuals are not harmed by noise, the manufacturer of
the system / machine must implement relevant safety measures. These measures must be observed
by the machine operator.
1.9 Storage and transport

To prevent damaging the unit during storage or transport observe the following basic rules:
Keep the storage temperature within the range specified in the Technical Data sheet.
Adopt suitable measures to avoid damage due to humidity, vibration or impact.
Do not store the product within or in the vicinity of magnetic fields (e.g. permanent magnet or strong
alternating field).
1.10 What to do in emergency situations

► Disconnect the machine from the power supply; set the main switch to AUS ('OFF').
► Only use Class B extinguishers to extinguish fires, e.g. CO2 extinguishers (carbon dioxide).

What to do in emergency situations

Product description
Product overview
2 Product description
2.1 Product overview
1 13
7
12 14
8
9
10
2
11
3 15
4 16
10
6
1 Fibre socket 9 Nozzle cooling gas connection
2 Collimating unit 10 Auxiliary gas connection
3 Focusing unit 11 BNC connection
4 Protective window cartridge FOC 12 Water connections (collimating area)
5 Sensor insert 13 Water connections (fibre socket)
6 Nut, ceramic part 14 BNC connection
7 Cutting gas connection 15 Adjusting screws
8 Protective window cartridge COL 16 Status LEDs

Product description
Product characteristics
For more detailed information on the connections, please refer to "Media connections", page 22.
2.2 Product characteristics

Laser head
The laser head is used for the distance-controlled laser cutting of metals using fibre-coupled lasers on
flat bed machines. It is precisely engineered, rugged, service-friendly and can be adjusted easily.
All connections are located at the top of the laser head.
Fibre plug-in connection

The fibre socket is fitted firmly to the laser head. Precitec offers fibre sockets for its laser heads for
connecting conventional fibre optic cables.
Water cooling system

Stainless steel water cooling systems cool the fibre socket and collimating unit.
On the laser head fittings for hoses are used for cooling water outflow and inflow.
Nozzle cooling
If required, cooling gas outlets in the nut enable additional nozzle cooling, e.g. when laser cutting
highly reflective materials. The nozzles have a large collar to increase the area to be cooled by the
gas.
Focal position adjustment

The laser head features a drive for the motor-controlled adjustment of the focal position. This can be
used to cut sheet metal of various thicknesses without having to carry out manual adjustment.
In order to specify the required focal position the device interface sends an external analogue signal
from 0.3 to 9.7 V.The focal position can also be set using a fieldbus variable.
Cutting gas
The laser head is operated using cutting gas. The gas also cools the protective window.
The maximum cutting gas pressure is 25 bar (2.5 MPa).
The purer the cutting gas is the longer the protective window will last. For optimum operation the cut-
ting gas quality must be comply with ISO 8573-1:2010; Solid particles - Class 2, Water - Class 4, Oil -
Class 3 (see (see "Gas quality (ISO 8573-1)", page 103).
Sensor insert
The sensor insert (SE) is fixed with screws to the laser head and can be removed. A ceramic part is
fitted to the integral sensor insert from below. It locks into place firmly as it can only be fitted in one
direction and is secured by a union nut (MU).
Nozzle
The nozzle (DE) is screwed into the ceramic part and can be replaced easily if worn. Precitec nozzles
and sensor inserts are very precisely engineered. Because of the minimum concentricity tolerance any
re-adjustment work can be reduced or avoided when replacing these parts.

Product description
Product characteristics
Precise fitting
Bore holes are used to fix the laser head to the machine. Pin holes at the back enable the unit to be
positioned precisely and in such a way that this position can be reproduced.
Lasermatic® distance sensor system

For distance-controlled cutting, the laser head is equipped with the capacitive Lasermatic® distance
sensor system. Together with the other control loop components the system guarantees a constant
standoff distance (focal position) between the nozzle electrode and the workpiece during laser beam
cutting if there are no edges or large workpiece surface bulges in the sensor's scanning range.
2.3 Protective and monitoring equipment

Error monitoring and output
The device interface (DI) can query different parameters and process data (e.g. temperature, pres-
sure, stray light, humidity). Their limit values are monitored by the machine controller (PLC). The user
must determine and set these limit values.
Errors are displayed by the relevant device interface (see "Interface description", page 50 for the I/
O interface and "Interface description", page 73 for the fieldbus interface).
Status LEDs
LED indicators on the laser head also inform the user about any error conditions. If an LED lights up
red, the system must be stopped immediately (noting the process condition) and the cause must be
checked. For a detailed description of the LED indicators, please refer to "Meaning of LED indicators",
page 18.
1 2 3 4
1 Focal position 3 Pressure
2 Temperature/humidity 4 Protective window/stray light

Product description
Protective and monitoring equipment
Protective window COL

The protective window cartridge is located underneath the collimating unit.
The protective window monitoring device detects when the protective window cartridge is pulled out. In
this case a collective error is generated.
Process protective window

The protective window cartridge is located underneath the focusing unit.
The protective window monitoring device detects when the protective window cartridge is pulled out
and the protective window is very dirty. In these cases a collective error is generated.
The temperature and stray light monitoring devices detect soiled protective windows. Current temper-
ature values can be queried by the controller. Individual user interaction can be requested by the con-
troller if process-specific limit values are stored. A collective error is generated if the temperature is
higher than about 80° C or if stray light radiation exceeds 80 %.
Use the ProCutter App to set the customer’s system to a smaller limit value if necessary.
Temperature monitoring
Temperature sensors monitor the laser head. A collective error is generated if the laser head tempera-
ture is about 55° C or higher.
Temperature sensors monitor the lenses installed in the laser head. A collective error is generated if
the collimating lens temperature exceeds 100° C and the temperature of the focusing lens is 80° C or
higher.
Stray light monitoring

A sensor monitors any divergent laser radiation inside the beam path. If stray light radiation exceeds
the 80 % threshold, a collective error is generated.
Humidity monitoring
The humidity sensor measures the humidity of the air inside the laser head (not outside!). We recom-
mend that you adjust the limit value individually when the laser head has been fully integrated into the
laser cutting machine (see "Interface description", page 73).
Pressure monitoring
A precision pressure sensor measures the cutting gas pressure in the laser head. The controller can
query the pressure value via the device interface (DI). If the cutting gas pressure is >25 bar (2.5 MPa),
a collective error is generated.
The process process protective window is also monitored for any leaks. If the pressure on the protec-
tive window exceeds 3 bar (0.3 MPa), a collective error is generated.

Product description
Technical specifications
2.4 Technical specifications
Characteristics Value
Laser wavelength 1030 … 1090 nm nm
Laser power max. 15 kW
Possible aspect ratios 100/150 & 100/200 mm
NA specification 99,5 % power enclosed at θ ≤130 mrad (θ → beam divergence - half

angle)
Average transmission >97 % at 15 kW
External acceleration max. 45 m/s²
Jolt max. 2100 m/s³
Modification speed - focal position max. 100 …233 (also depends on the aspect ratio)
Horizontal adjustment range ±1,5 mm mm
Vertical adjustment range

Aspect ratio 100/150 -16 … +10 mm
Aspect ratio 100/200 -30... +15 mm
Fitting holes 4x ø6.6 (for M6 screws)
Pin holes 2x ø6F8, 8 mm deep
Cutting gas connection Fitting ø10, max. 25 bar (2.5 MPa)

(supply tubes with outer/inner diameter of ø10/ø7 mm)
Auxiliary gas connection M5, max. 5 bar
Cooling gas/shielding gas connection M5, max. 5 bar
Water cooling (fibre socket) Fitting ø6, max. 5 bar (0.5 MPa), volume flow min. 1.5 l/min
Water cooling device (collimating unit) Fitting ø8, max. 5 bar (0.5 MPa), volume flow min. 1.5 l/min
made of stainless steel
Distance sensor system connection BNC for Lasermatic®
I/O interface operating voltage 24 V ±10%, max. 6 A
Operating temperature 5... 55 °C
Storage temperature -25... +55° C (+70° C for a short time)
Humidity 30... 95%, no dew
Dimensions s. "Mechanical dimensions", page 20
Weight approx. 6,1 … 6,9 kg

Product description
Meaning of LED indicators
2.5 Meaning of LED indicators

The status indicators inform the user about the condition of the laser head and its components, based
on the data received from the integrated monitoring electronics. The LEDs are numbered from left to
right (1-4). If an LED lights up red, the system must be stopped immediately (noting the process con-
dition) and the cause must be checked. For more detailed information on how to correct any errors,
please refer to "Electrical malfunctions", page 93.
LED 1( focal position)
Colour Meaning
Green Ready for operation (reference travel completed successfully, focal

position within the permitted tolerance range (target position))
Red Faulty reference travel
Servo overload
Focal position malfunction
OFF (does NOT light up) Linear drive not within the target value range
No power supply
Faulty connection
LED 2( temperature/humidity)
Colour Meaning
Green Ready for operation (no error)
Orange Increased head temperature (colour changes at 5° below the
upper limit)
Increased lens temperature (colour changes at 10° below the
upper limit)
Red Temperature/humidity limit value exceeded:
lights up permanently: temperature - whole laser head
flashes 1 x per second: temperature - focusing lens
flashes 3 x per second: temperature - collimating lens
flashes 10 x per second: humidity
OFF (does NOT light up) No power supply
Faulty connection

Product description
Meaning of LED indicators
LED 3 (pressure)
Colour Meaning

Red Pressure exceeded:
lights up permanently: protective window pressure leak
flashes 1 x per second: cutting gas pressure exceeded
Faulty connection
LED 4 (protective window/stray light)
Colour Meaning

Orange Increased head temperature (colour changes at 10° below the
upper limit)
Red Malfunction:
lights up permanently: protective window temperature exceeded
flashes 1 x per second: protective window not inserted
flashes 3 x per second: one of the protective window cartridges
missing
flashes 10 x per second: stray light limit value exceeded
(process protective window or beam path)
Faulty connection

Product description
Mechanical dimensions
2.6 Mechanical dimensions

LLK-D version
X
S
Focusing length (mm) L [mm] X [mm] S [mm]
150 372 117 80

200 424 168 132

Product description
Mechanical dimensions
FCH-16 version
X
S
Focusing length (mm) L [mm] X [mm] S [mm]
150 368 117 80

200 419 168 132

Product description
Media connections
2.7 Media connections
1 4
2 5
1 Cutting gas - ø10 4 Water cooling circuit (collimating area) - ø8
2 Nozzle cooling gas - M5 (6 mm deep) 5 Water cooling circuit (fibre socket) - ø6
3 Auxiliary gas - M5 (6 mm deep)

Product description
Accessories
2.8 Accessories
Adjust box (EG)
The adjust box EG8050A/EG8050C is the analysing electronics for the tried and tested Lasermatic®
sensors. The adjust box optionally delivers an analogue control voltage or a linear distance signal. The
adjust box also provides an analogue signal for monitoring the sensor insert temperature or plasma
activity. It also creates digital signals, e.g. if a cable is broken, the nozzle touches the workpiece or
interfering contours, the nozzle is lost, the standoff distance is too high etc.
Depending on the operating mode, the correct adjust box must be used, either the EG8050A for I/O
operation or the EG8050C for fieldbus operation.
I/O CAN adapter
The I/O CAN adapter enables the device interface DI to communicate with the primary controller
(PLC), using digital 24 V-I/Os and analogue input and output signals.
The supply voltage connections are protected by fuses. Two green LEDs indicate that the unit is sup-
plied with power.

Product description
Accessories
Optics Service Case
The optics service case is used to store replacement optics and accessories (cleaning materials, pro-
tective covers, auxiliary tools) required for the maintenance of the beam shaping optics (P0001-000-
Q0002).
2.9 ProCutter App

The Precitec ProCutter App 2.0 (Android) shows the laser head condition during operation and queries
any error messages.
As an option, the app can also be used to set some sensor value parameters. The following parame-
ters can be set: temperature of the beam shaping optics and laser head, cutting gas pressure, amount
of stray light in the beam path.
The App is available in the Google Playstore.

Installation
Safety notes
3 Installation
3.1 Safety notes
Danger –Electrical voltage!

Electrical voltage can cause life-threatening electric shocks.
► The system must be switched off and protected against being switched on again before carrying
out any commissioning work.

During commissioning the laser machine may operate in laser class 4. The laser beam may cause
eye damage.
► Use laser goggles complying with DIN EN 207 and BGV B2.
► Do not look directly at the laser beam even using optical instruments.
Caution - Machine movement!

Unexpected machine movement can cause crush injuries.
► During all commissioning work, no hands or other body parts should be in the proximity of the lin-
ear drive or under the laser head.
Notice - Contaminated optics!

Dust and firmly adhering dirt can lead to burn marks on the optics or damage them.
► Only touch the non-sensitive parts on the optical components.
► Only carry out any work in a clean workplace.
In addition to these specific instructions the general instructions contained in "Safety notes and typo-
graphical conventions", page 7also apply.
3.2 Checking package contents

The following checks should be carried out before fitting the laser head:
Are the parts supplied complete (see the delivery note)?
Is there any visible damage?
Package contents
Basically, you will need the following installation parts:
Laser head with integrated beam shaping optics (collimating and focusing lenses, protective win-
dow) and sensor insert SE pre-assembled (version as stated on the delivery note)
I/O CAN connection adapter and control cable
Sensor cable
Analysing electronics (version as stated on the delivery note)

Installation
Checking package contents
Checking for visible damage
Caution - Explosion caused by overpressure

An overpressure of up to 25 bar (2.5 MPa) can be supplied to the laser head through the relevant
connection point. Damaged parts can cause accidents.
► Check the laser head for any visible damage.
► Replace damaged parts.
► If parts are damaged, the laser head must be protected against accidental use until repair work
can be carried out.

Installation
Integration into the machine
3.3 Integration into the machine
3.3.1 Fitting the ceramic part and nozzle
This step is only necessary in the case of individual parts delivery.
Prerequisites:
The protective window cartridge is installed.
The beam path is closed.
The workplace is clean.
The parts below are ready at hand: ceramic part (KT X) with O-ring (ø13.00x1.50 Viton) and nozzle
(DE)
1. Insert the O-ring into the groove on the sensor insert (1).
2. Insert the ceramic part (2) into the sensor insert carefully.
Note the locating pin on the sensor insert when doing this – it must engage into the ceramic part.
3. Screw the ceramic part to the sensor insert hand-tight using the nut (3).
The nut must only be tightened by hand. Otherwise the ceramic part could be damaged. Do not
use any tools.
4. Screw the nozzle (4) into the ceramic part hand-tight.
You can use a tool for this step. Tighten the nozzle with a maximum torque of 3 Nm.
The ceramic part and nozzle are installed.

Installation
3.3.2 Connecting the laser fibre

FCH-16 fibre socket
1. Remove the protective film/protective cap from the fibre socket.

2. Align the fibre socket pin (1) and the notch on the fibre socket (2).
3. Push the locking cap in the direction of the laser head and hold.
4. Insert the fibre plug into the fibre socket up to the stop.
5. Release the locking cap. The cap will snap into place in the direction of the fibre and lock.
Locking or unlocking the socket is not permitted when the plug is not inserted.
The laser head is connected to the laser fibre.

Installation
Optimum sealing
Processes where a large amount of dust occurs may require the fibre plug/fibre socket interface to be
sealed. The workflow below describes the individual steps using the example of the QBH laser fibre.
Prerequisite:
The ambient temperature is 5 to 50°C.
The workplace and the fibre plug on the laser head are clean.
Prerequisite:
The ambient temperature is 5 to 35°C.
The workplace and the fibre plug on the laser head are clean.
1. Cut a strip of adhesive tape. The adhesive tape is very flexible. You will only need a small strip
(about 1/2 of the fibre socket diameter).
2. Remove the protective film from the adhesive tape.
3. Apply the adhesive tape under the water connections in such a way that the two ends have the
same length and stretch it.
4. Firmly wrap the adhesive tape around the fibre connection. Keep it stretched while doing this.
5. Tape the two ends together.
They should overlap by about 1/3 of the diameter. A larger overlap does not provide better protec-
tion against contamination.
The connection between the laser head and laser fibre is better protected against any contamina-
tion.

Installation
3.3.3 Fixing the cutting head to the machine
Warning - Risk of vibration!

Laser head vibration may cause minor injury.
► Take appropriate measures to prevent the laser head from vibrating.
1. Position the laser head using the pin holes (2x ø6F8, 8 mm deep) at the back as required.
2. Fix the laser head to the machine using the relevant bore holes (4x ø6.6 (for M6 screws)).
Basic version
PierceTec version

Installation
3.3.4 Grounding the laser head
Attention - Malfunction caused by improper earthing!

Improper earthing may cause sensor system malfunctions and damage the machine (moving parts).
► Earth the laser head (and machine) as described.
1. Connect the non-anodised areas shown in the figure to the machine mass (PE).

Installation
3.3.5 Checking the protective window COL for any contamination
1. Loosen the screws on the cover (1) (4 x M2.5x8 - size 2).

2. Remove the cover and place it on a clean pad.
3. Loosen the screws on the cartridge (2) (2 x M2.5x8 - size 2).
4. Pull out the cartridge until the protective window is completely visible.
5. Check the protective window for any contamination. Blow away any dirt with clean air (pressurised
air can). Repeat until the surface is clean.
If the protective window can no longer be cleaned or if it is damaged, the cartridge must be replaced.
Call service engineer.
3.4 Connecting gas and water
Notice - Open connections!

Open connections prevent the laser head from working properly. Gas and liquid can get into it.
► Close all connections that are not being used with screw plugs.

Installation
Connecting gas and water
3.4.1 Connecting the cutting gas
The maximum pressure on the laser head is 25 bar (2.5 MPa).

To ensure that the cutting gas pressure is high enough check that:
the hose diameter is large enough.
the hose is as short as possible.
the hose is run in a straight line (do not use any elbow pieces etc.).
fittings to reduce the hose diameter are installed as close to the laser head connection as possible.
Attention - Unsuitable gas!

Unsuitable gas may prevent the laser head from working properly. The purer the cutting gas is the
longer the protective window will last.
► Only use clean, dry gas.
Gas quality must comply with ISO 8573-1:2010; Solid particles - Class 2, Water - Class 4, Oil -
Class 3 (see "Gas quality (ISO 8573-1)", page 103).
1. Connect the gas to connection (1) using a hose with ø10 mm.
The connection is glued and must not be replaced!

Installation
3.4.2 Connecting the cooling gas system
If required, outlets in the nut enable additional nozzle cooling. We recommend that you use the addi-
tional gas nozzle cooling device when cutting highly reflective and thick materials. When delivered, the
connection is closed with a locking screw.
The cooling gas flow rate and pressure mainly depend on the laser power used for cutting. Therefore
we cannot recommend a gas pressure value. The correct pressure can, however, be determined by
carrying out tests. Optimum cooling can already be achieved from about 0.5 bar (0.05 MPa).
The maximum pressure for cooling the nozzle is 5 bar (0.5 MPa).

Unsuitable gas may prevent the laser head from working properly.
► Use only clean, dry gas (no O2).
1. Connect the gas hose to connection (1) (M5, 6 mm deep).

The connection must not be sealed using sealing tape or sealing material.

Installation
3.4.3 Connecting the auxiliary gas system
The auxiliary gas connection and the relevant outlet orifice can be used to supply additional gases or
liquids to the working area (see the customer adapter hole pattern).
When delivered, the connection is closed with a locking screw. Sealing the fittings - sealing tape or
sealing material is not permitted!
The maximum pressure is 5 bar (0.5 MPa).

Unsuitable gas may prevent the laser head from working properly.
► Use only clean, dry cooling gas (no O2).
1. Connect the auxiliary gas hose to connection (1) (M5, 6 mm deep).
2. Use a customer adapter to supply the auxiliary gas from the outlet orifice (2) to the nozzle.
Example:

Installation
3.4.4 Connecting the cooling water system
The maximum pressure for the cooling water is 5 bar (0.5 MPa).
The minimum cooling water flow rate is 1.5 l/min.
Notice - Unsuitable cooling water!

Unsuitable cooling water may prevent the laser head from working properly.
► For pure stainless steel circuits only use water with a conductivity value prescribed by the laser
manufacturer. If water cooling circuits consist of different metals, adhere to the laser manufac-
turer's instructions.
Notice - Condensation on the optics!

With an unsuitable temperature inside the water cooling circuit condensation can form on the optics.
► The temperature inside the water cooling circuit must be set in such a way that condensation can-
not form on the optics (see "Cooling water dew point temperature", page 104).
Notice - Corrosion in the cooling circuit!

Corrosion in the water cooling circuit may prevent the laser head from working properly.
► Observe the instructions and maintenance intervals prescribed by the machine manufacturer,
laser source manufacturer and cooling unit manufacturer.
1 2
1. Connect the cooling water hoses to the relevant connections on the collimating unit (1).
Supply lines with an external/internal diameter of ø8/ø6 mm.
2. Connect the cooling water hoses to the relevant connections on the fibre socket (1).
Supply lines with an external/internal diameter of ø6/ø4mm.
Precitec recommends that you use a suitable distributor so that the two cooling circuits can be
installed in parallel and as close as possible to the laser head.

Installation
The water cooling circuit flow direction can be freely selected.
The order in which Precitec recommends connecting the hoses is not mandatory.

Installation

Commissioning - I/O operation
Safety notes
4 Commissioning - I/O operation
4.1 Safety notes


eye damage.



Running cables
4.2 Running cables
Attention – Unsuitable cables!

Unsuitable or wrongly assembled cables can have a negative effect on sensor system functionality.
► Only use original Precitec cables.
Cable layout must be planned and designed to conform to applicable standards to ensure the
machine’s trouble-free, permanent operation. Please note the following:
Observe the relevant DIN regulations (Safety, EMC).
In general, the DIN EN 50173 applies for usage-neutral wiring (or cabling) and the DIN EN 50174
applies for communication cabling.
Only use suitable installation systems.
To comply with EMC standards use suitable materials and carry out any work in a professional
manner.
If possible, install electrical Precitec devices such as controllers or I/O adapters in such a way that
these devices are separated from other electrical components, e.g. servo amplifiers or power sup-
ply units. This helps to reduce any interferences.
Run the sensor cables separately from electrically live cables.
Run the analogue signal cables and digital signal cables separately (see the separate adjust box
documentation).
The basic rules below must be observed when fitting the cables:
When fitting cables, all movements relating to the specific application must be
observed (max. displacement, max. rotation angle). Avoid extreme robot hand rota-
tion when teaching a process path.
Avoid any strain on cables and plug-in connections.
Cables must not be bent below the minimum bending radius specified in the technical
data sheet.
Cables must not be twisted in such a way that the maximum angle of twist specified in
the technical data sheet is exceeded.
Cables where no angle of twist is indicated must not be twisted.
Wind cables around rotating parts in such a way that the prescribed minimum and
maximum bending radii are observed and cables are not twisted.

Running cables
Bifilar winding
Do not wind the sensor cables. Cables may only be wound in a bifilar pattern. This type of winding
results in a net magnetic field of zero.

Component summary
4.3 Component summary

The I/O operation mode requires:
EG8050A
I/O CAN adapter
suitable cables
3 4
2
1
1
6
5 - =
8
10
9 - =
1 Laser head 6 I/O cable
2 Control cable (max. 20m) 7 Adjust box
3 I/O CAN adapter 8 Sensor cable (max. 20m)
4 Programmable logic controller (PLC) 9 24V power supply unit
5 24V power supply unit 10 I/O cable

Component summary
Adjust box
1 Steckerleiste I/O-Schnittstelle 4 Anschluss CANopen (Kundenschnittstelle)
2 Stecker BNC (Sensor-Anschluss) 5 Anschluss PBus (interne Schnittstelle)
3 Steckerleiste Versorgung 6 PE-Anschluss
I/O CAN adapter
1
2
3
4
5
1 Stecker PBus (10-polig) 4 Sicherung F1
2 Stecker Steuerkabel (19-polig) 5 I/O-Leiste
3 Sicherung F2 6 Klammern, Tragschiene
Notice – Unsuitable fuses!

Unsuitable fuses can prevent the device from working properly.
► If fuses must be replaced, only use fuses of the same type and rating.
F1 – Littelfuse 02163.15MXP

Component summary
PIN assignment - I/O CAN adapter
Input/
PIN Out- Signal Remarks
put
1 I 24V POWER
Laser head / 24 VDC ±10%, max. 6 A
2 I 0V POWER
3 I 24V I/O
I/O interface / 24 VDC ±10%, max. 0.5 A
4 I 0V I/O
5 I OUTP.SELEC Accept the 'ANALOG-IN' output value
6 O ANALOG-OUT (0 … 20 mA)
7 I REF.TRAVEL Carry out reference travel
8 I AUTOMATIC Accept the focal position
9 O /ERROR Collective error detected
10 O POS.REACHED Position setpoint reached
11 I ANALOG-IN +
ANALOG-IN (0…10 V)
12 I ANALOG-IN –

Connecting the laser head to the machine
4.4 Connecting the laser head to the machine

1. Install the I/O CAN adapter in the control cabinet using the clips.
2. Connect the 19-pin connector and the I/O CAN adapter using the control cable.
documentation).
3. Connect the laser head BNC connection and the EG BNC plug using a sensor cable. The sensor
cable is limited to a max. of 20 m.
4. Connect the I/O CAN adapter to the EG using a PBus flat cable.

5. Connect the I/O plug (A, 20-pin) and the PLC.

Make sure to run the digital and analogue cables separately.
6. Connect the EG PE connection to the machine mass.
7. Connect the 24V power supply unit to the EG power supply connector strip.
PIN assignment: Pin 1 - 0 V / Pin 2 - 24 VDC
See the Adjust Box (EG A) Operating Instructions, Chapter “Connections, interfaces”.
PIN 2, 24 V
PIN 1, 0 V

8. Refer to the "I/O connection diagram", page 48 and connect the I/Os to the PLC.
Use shielded cables for the analogue input connections (Pin 11+12).
Green LEDs indicate that the unit is supplied with power.
9. Switch on the adjust box and the laser head at the same time to ensure that the two devices can
communicate without any errors.
For detailed information in the event of an error, please refer to "Electrical malfunctions",
page 93.

I/O connection diagram
Notice - Current flow too high!

The device may be damaged if the current on the switching outputs is too high.
► The current at the switching outputs (PIN-9 & PIN-10) must be limited by a suitable external resis-
tor circuit to a max. of 30 mA.
1 24 V POWER( max. 6 A) 7 REF.TRAVEL
2 0 V POWER( max. 6 A) 8 AUTOMATIC
3 24 V (optocoupler) 9 /ERROR
4 0 V (optocoupler) 10 POS.REACHED
5 OUTP.SELECT 11 ANALOG-IN + (shielded)
6 ANALOG-OUT 12 ANALOG-IN – (shielded)

Connecting the ProCutter App
4.5 Connecting the ProCutter App
Prerequisite:
The mobile device is not connected to a network.
Make sure that mobile data and wifi are turned off or flight mode (airplane mode) is on.
1. On the ProCutter read the information below:
mobile network name (1)
password (2)
2. On the mobile device turn on the following functions:

Wifi (do NOT connect to an existing network)
location
3. Start the ProCutter App 2.0.
When you have installed the app for the first time, you must accept the Terms and Conditions.
Scroll down to the end and select the check box. Otherwise the app will be closed.
4. Open the CONNECTION screen (main menu).
5. Tap on “Search device” [button].
The app searches the devices in the network. Devices can be identified based on the SSID mobile
network name (e.g. PC-AB12345).
6. Select the required ProCutter based on the mobile network name.
7. Enter the password.
The laser head’s wifi network will only accept one subscriber at a time. If the laser head is already
connected to a mobile device, an error message will appear and the login procedure will be aborted.

Interface description
4.6 Interface description

The device interface (DI) can query different parameters and process data. Their limit values are moni-
tored by the machine controller (PLC).
The ‘/ERROR‘ bit monitors the system for any errors. In normal operation ‘/ERROR‘ is enabled. If limit
values or measuring range limits are exceeded, a collective error is generated ('/ERROR is disabled).
A specific current value on the device interface indicates the specific error condition. If more than one
error is present at the same time, error output depends on the current value defined for each error
code.
If the focal position is not correct (faulty), reference travel must be carried out to reset the error (see
"Error reset (reference travel)", page 54). All the other errors are reset automatically once the
cause of the error has been rectified.
Errors are also output for 2 seconds for short-term error events (Status LEDs). This enables short-term
errors to be analysed.
The error limits for specific parameters depend very much on the process. The customer’s control sys-
tem must therefore switch the machine off if customer-specific limit values are exceeded. (The mea-
suring range limit values do not define the maximum permissible operating range).

Parameters available
The parameters below can be read.
To restrict the number of I/O lines to a minimum, all parameters are output via the analogue output. To
select the correct parameter a selection voltage is applied to the analogue input.
When the operating voltage has been switched on and the system has been referenced, the signal for
“Protective window contamination” is output.
Function Parameter Selection Scaling

voltage[V] [0…20 mA]
Protective window temper- Protective window contamination 0.625 0…200 °C

ature
Pressure - Cutting gas Cutting gas pressure 1.25 0…25 bar
(0 = 1 bar abs.)
Protective window pres- Protective window cartridge seal- 1.875 0… 000 mbar
sure leak ing (0 = 1013 mbar abs.)
Collimating lens tempera- Collimating lens contamination 2.50 0…100 °C
ture
Temperature - Focusing Focusing lens contamination 3.125 0…100 °C
lens
Housing temperature Laser head temperature 3.75 0…100 °C
Current focal position Focal position 4.375 0… 0 V
Laser stray light in the Dirty optics, incorrect adjustment 5.00 0…100%
beam path (back reflection)
Setting the Z position Focus offset 6.25 0…100%
Humidity inside the laser Humidity inside the laser head 7.50 0…100%
head
Stray laser light, protective Protective window contamination 8.125 0…100%
window
Stray laser light, protective Protective window contamination 8.75 0…100%
window COL COL
Fixed output 0 mA 0 value, analogue output 9.375 -
Fixed output 20 mA Analogue output maximum value 10.00 -

Reading parameters
1. Read the selection voltage for the required parameter from the table.
2. Apply the selection voltage to the analogue inputs 'ANALOG-IN+' (PIN 11) and
'ANALOG-IN–' (PIN 12) and keep it stable.
Disable the digital input 'AUTOMATIC' (PIN 8).
3. Wait for at least 3 ms. Then enable the digital input 'OUTP.SELECT' (PIN 5) and keep it on for at
least 5 ms. The signals (step 2) must be available as long as 'OUTP.SELECT' is enabled.
min. 3 ms
AUTOMATIC
ANALOG-IN
min. 5 ms
OUTP.SELECT
min. 10 ms
e.g. 14 mA
ANALOG-OUT e.g. 4 mA
When a selection has been made, it takes at least 10 ms until the output value (0…20 mA) is avail-
able on the analogue output ‘ANALOG-OUT‘ (PIN 6).
Because of the delay we recommend that you update the analogue value first and activate the con-
troller’s digital output during the next machine cycle.

Error conditions
If a parameter exceeds or falls below the limit value defined by the PLC, an error will be generated:
'/ERROR' is disabled. If focal position errors occur, 'POS.REACHED' will also be disabled.
When an error occurs, stop the machine immediately and correct the error.
A current value on the analogue output 'ANALOG-OUT' (PIN 6) indicates the specific error condition:
Error(General ERROR) Current

value
[mA]
Protective window cartridge: not available * 19.375

Protective window: not available * 18.75
Protective window: max. temperature exceeded * 18.125
Drive malfunction: overload * 17.5
Drive malfunction: no communication with servo * 16.875
Drive malfunction: supply voltage too low * 16.25
Drive: faulty reference travel * 15.625
Collimating lens: max. temperature exceeded * 15.0
Focusing lens: max. temperature exceeded * 14.375
Laser head: max. temperature exceeded * 13.75
Laser stray light: max. level exceeded * 13.125
Pressure - Cutting gas max. pressure exceeded 12.5
Leak - Protective window: max. pressure exceeded 11.875
Protective window cartridge not available * 11.25
COL:
Protective window stray light: max. level exceeded * 10.625
Humidity: max. level exceeded 9.375
EG8050A: Malfunction * 8.125
The errors marked with an * lock the focal position adjustment device. Only reference travel can still be
carried out.
The analogue interface can only display one error type at a time. If more than one error is present at
the same time, the current value for the next will be output once the cause of the previous error has
been rectified.

Error reset (reference travel)

When the focal position adjustment error has been corrected, a reference travel procedure must be
carried out to reset the error.
1. Enable 'REF.TRAVEL' (PIN 7) and keep for at least 5 ms.
pprox
pprox
After a successful reference travel procedure, 'POS.REACHED' (PIN 10) and '/ERROR' (PIN 9) are
enabled. From now on, new input signals will be processed.
To start a new reference travel procedure disable 'REF.TRAVEL' and wait for at least 3 ms.
When power is switched on and reference travel has been completed successfully, the laser head
will move to the default position (focal position = 0 mm and aspect ratio of ).
Recommendations
Built-in temperature and stray light sensors are not calibrated. However, they provide useful refer-
ence values for evaluating the laser head’s condition. We recommend that you adjust the limit val-
ues individually when the laser head has been fully integrated into the laser cutting machine.
The sensor values can change significantly if new replacement and wearing parts - in particular
lenses and protective windows - have been installed. In this case, Precitec recommends that you
check the limit values and adjust them again if necessary.
The humidity sensor measures the humidity of the air inside the laser head (not OUTSIDE). When
you open the laser head (by pulling the protective window cartridge for instance) the humidity
present in the ambient air penetrates into the laser head. If the laser head is cooled, the amount of
relative humidity can increase.
The customer's system can also be set to an individual limit value if necessary.
The relative humidity value [%] changes significantly depending on the air temperature inside the
laser head (warm air can hold more water vapour than cold air for example). The air temperature
inside the laser head depends significantly on the temperature of the cooling water, i.e. relative
humidity drops if the cooling water temperature rises.
If the relative humidity exceeds 80%, always check the cooling water temperature. To reduce rela-
tive humidity, increase the cooling water temperature.
If the relative humidity exceeds 90%, switch the laser machine off and contact the service team.

Configuring the laser head
4.7 Configuring the laser head
4.7.1 Setpoint voltage & characteristic curves

Reading optics configuration
To configure the laser head correctly, its optics configuration (ratio between collimating focal length (fC)
and focusing focal length (fF)) must be available.
The optics configuration can be read on the laser head.
Setpoint voltage
An external analogue signal (0.3 to 9.7 V, ) on ANALOG-IN‘ (PIN-11 and PIN-12) sets the focal posi-
tion (also known as TCP or Tool Center Point). This analogue signal is called setpoint voltage. The
software monitors the upper and lower limit positions (which are not approached in normal operation).
The default focal position setting is 1 mm below the nozzle (this position is also called TCP0).
A scaling formula describes the relationship between the setpoint voltage and the resulting focal
position. This formula is also used to specify the characteristic curve. Scaling formula and characteris-
tic curve are different, depending on the aspect ratio.
When power is switched on and reference travel has been completed successfully, the laser head will
move to the default position (focal position = 0 mm).
Aspect ratio 100/150
Scaling formula Setpoint voltage [V] = focal position [mm] * (-0.36153) + 3.915
Setpoint range ±0.15 mm
Offset adjustment range ±1.5 mm
Setting limits: -16... +10 mm
Characteristic curve

Scaling formula Setpoint voltage [V] = focal position [mm] * (-0.2089) + 3.4333
Offset adjustment range ±3 mm
Setting limits: -30... +15 mm

4.7.2 Setting the focal position
1. Calculate the required setpoint voltage using the scaling formula.

2. Apply the setpoint voltage to the analogue inputs 'ANALOG-IN‘ (PIN 11 and PIN 12).
Disable the digital input ‘OUTP.SELECT‘ (PIN 5).
3. After step 2 wait for at least 3 ms. Then enable the digital input ‘AUTOMATIC‘ (PIN 8) and keep it
on for at least 5 ms.
min. 3 ms
OUTP.SELECT
ANALOG-IN
min. 5 ms
AUTOMOTIC
POS.REACHED min. 50 ms
The digital output ’POS.REACHED’ (PIN 10) is disabled automatically for at least 50 ms. When the
new focal position has been reached, ’POS.REACHED’ is enabled automatically. Positioning will
take longer if focal position changes involve larger adjustment ranges. In this case, the new focal
position must be reached before ’POS.REACHED’ is enabled.
Each time the focal position is changed, the 'POS.REACHED’ (PIN 10) digital output will be dis-
abled even if the new focal position is already within the setpoint range. This status signal can
then be analysed (handshake).
If the set focal position is outside the setting limits, the approached focal position will be the same
as the focus limit and the 'POS.REACHED' signal will not be sent.
If a focal position has been set that is within the settings limits but outside the guaranteed focus
range, a ‘POS.REACHED‘ signal will be sent but the head will only move slightly beyond the guar-
anteed focus range. Avoid this setting as it can lead to process errors.
4.7.3 Reading the focal position
1. Read the “focal position” parameter as described in "Reading parameters", page 52 .

Selection voltage: 4.375 V
2. Read the current value and enter it in the formula below:
Aspect ratio Formula
100/150 Focal position [mm] = current [mA] * (-1.383) + 10.829

100/200 Focal position [mm] = current [mA] * (-2.3936) + 16.4362

4.7.4 Adjusting the laser beam
Caution –Laser beam!

eye damage.
Attention –Laser beam not adjusted correctly!

If the laser beam is not adjusted correctly, parts of the laser head can be destroyed during laser cut-
ting.
► Follow the instructions and centre the laser beam carefully.
Attention –Laser beam obstructed!

Damage can occur if the laser beam is obstructed.
► When adjustment is complete, make sure that the laser beam is not obstructed in any way. The
laser beam must be in the centre of the nozzle (nozzle with the correct opening diameter for the
cutting process).
Please note the laser or machine manufacturer's adjustment instructions and use the sample recom-
mended by him for system setup (commissioning).
Prerequisites:
The laser head is not under pressure.
The distance controller is switched off.
The laser head does not have any play.
The laser power recommended by the laser or machine manufacturer has been set.
1. Screw in a nozzle with a large nozzle opening.
The nozzle opening should be considerably larger than the laser beam diameter at the nozzle
opening.
2. Glue the sample under the nozzle.
3. Trigger a low power laser pulse.
4. Judge the penetration in the sample. The penetration must be round and in the centre of the nozzle
opening. If not, the lens must be centred.
good bad

5. Centre the lens using the adjusting screws on the laser head.
Use an Allen key (size 4). The maximum adjustment range is ±1.5 mm.
6. Use a new sample. Trigger a low-power laser pulse and judge the penetration in the sample again.
Repeat this procedure until the penetration is good.
7. Screw in a nozzle with a smaller nozzle opening.
8. Centre the lens again as described above.

4.7.5 TCP offset correction
Any focal position offset caused by fibre socket tolerances can be corrected using the focus offset
parameter. The parameter can be set in the ProCutter App or on the EG.

eye damage.
1. Approach the standard focal position (1 mm below the nozzle, TCP0).

2. Note down the position.
3. Remove the nozzle and ceramic part.
4. Move to the position noted down for the laser head.
5. Place a sample under the laser head at the focal plane.
6. Trigger a (low-power) laser pulse and judge the penetration in the sample.
7. Change the focus offset several times to find the smallest penetration. Use either the ProCutter
App (“Settings/ Optics/ Customer offset) or the EG.
8. Set the focus offset to the smallest penetration value.

Commissioning - Fieldbus mode
Safety notes
5 Commissioning - Fieldbus mode
5.1 Safety notes


eye damage.



Running cables
5.2 Running cables
Attention – Unsuitable cables!

Unsuitable or wrongly assembled cables can have a negative effect on sensor system functionality.
► Only use original Precitec cables.
Cable layout must be planned and designed to conform to applicable standards to ensure the
machine’s trouble-free, permanent operation. Please note the following:
Observe the relevant DIN regulations (Safety, EMC).
In general, the DIN EN 50173 applies for usage-neutral wiring (or cabling) and the DIN EN 50174
applies for communication cabling.
Only use suitable installation systems.
To comply with EMC standards use suitable materials and carry out any work in a professional
manner.
If possible, install electrical Precitec devices such as controllers or I/O adapters in such a way that
these devices are separated from other electrical components, e.g. servo amplifiers or power sup-
ply units. This helps to reduce any interferences.
Run the sensor cables separately from electrically live cables.
documentation).
The basic rules below must be observed when fitting the cables:
When fitting cables, all movements relating to the specific application must be
observed (max. displacement, max. rotation angle). Avoid extreme robot hand rota-
tion when teaching a process path.
Avoid any strain on cables and plug-in connections.
Cables must not be bent below the minimum bending radius specified in the technical
data sheet.
Cables must not be twisted in such a way that the maximum angle of twist specified in
the technical data sheet is exceeded.
Cables where no angle of twist is indicated must not be twisted.
Wind cables around rotating parts in such a way that the prescribed minimum and
maximum bending radii are observed and cables are not twisted.

Running cables
Bifilar winding
Do not wind the sensor cables. Cables may only be wound in a bifilar pattern. This type of winding
results in a net magnetic field of zero.
5.3 Component summary

The fieldbus operation mode requires:
EG8050C
I/O CAN adapter
suitable cables
With fieldbus CANopen the EG8050C can be connected to the PLC directly. Otherwise a fieldbus
gateway must be used.

Component summary
Overview (without gateway)
3 4
2
1
1
6
5 - = 11
8
10
9 - =
1 Laser head 7 Adjust box
2 Control cable (max. 20m) 8 Sensor cable (max. 20m)
3 I/O CAN adapter 9 24V power supply unit
4 Programmable logic controller (PLC) 10 Fieldbus cable
5 24V power supply unit 11 Flat cable
6 I/O cable
With long bus response times Precitec recommends that you analyse the analogue signal OUT1
between the EG8050C and the PLC (item 11, Acon - A18/19).

Component summary
Overview (with gateway)
3 4
1
2
1
5 =
6
-
7 12
10
11
9 -
=
1 Laser head 7 Adjust box
2 Control cable (max. 20m) 8 Sensor cable (max. 20m)
3 I/O CAN adapter 9 24V power supply unit
4 Programmable logic controller (PLC) 10 Fieldbus cable
5 24V power supply unit 11 2-pin cable, shielded (OUT1)
6 PBus cable 12 Fieldbus gateway
With long bus response times Precitec recommends that you analyse the analogue signal OUT1
between the EG8050C and the PLC (item 11, Acon - O18/19).

Component summary
Adjust box
1 Steckerleiste I/O-Schnittstelle 4 Anschluss CANopen (Kundenschnittstelle)
2 Stecker BNC (Sensor-Anschluss) 5 Anschluss PBus (interne Schnittstelle)
3 Steckerleiste Versorgung 6 PE-Anschluss
A fieldbus adapter (X2 plug) is connected to CANopen (4). This adapter features a standard D-Sub
socket (9-pin). A bus termination is integrated in the fieldbus adapter.
For detailed information on the interface pin assignment and fieldbus, please refer to the adjust box
documentation.

Component summary
I/O CAN adapter
1
2
3
4
5
1 Stecker PBus (10-polig) 4 Sicherung F1
2 Stecker Steuerkabel (19-polig) 5 I/O-Leiste
3 Sicherung F2 6 Klammern, Tragschiene
Notice – Unsuitable fuses!

Unsuitable fuses can prevent the device from working properly.
► If fuses must be replaced, only use fuses of the same type and rating.
PIN assignment - I/O CAN adapter
Input/
PIN Out- Remarks
put Signal
1 I 24V POWER
Laser head / 24 VDC ±10%, max. 6 A
2 I 0V POWER
3 I 24V I/O
I/O interface / 24 VDC ±10%, max. 0.5 A
4 I 0V I/O
5 I - not connected
6 O - not connected
7 I - not connected
8 I - not connected
9 O - not connected
10 O - not connected
11 I -
not connected
12 I -

Component summary
PIN assignment - Fieldbus adapter (D-SUB-9)
PIN Signal Remarks
1 - not connected
2 CAN-L CANopen (fieldbus)
3 GND CANopen (fieldbus)
4 - not connected
5 - not connected
6 - not connected
7 CAN-H CANopen (fieldbus)
8 - not connected
9 - not connected

5.4 Connecting the laser head to the machine

1. Install the I/O CAN adapter in the control cabinet using the clips.
2. Connect the 19-pin connector and the I/O CAN adapter using the control cable.
(EG) documentation).
3. Connect the laser head BNC connection and the EG BNC plug using a sensor cable. The sensor
cable is limited to a max. of 20 m.
4. Connect the I/O CAN adapter to the EG using a PBus flat cable.

5. Connect the EG PE connection to the machine mass.
6. Connect the 24V power supply unit to the EG power supply connector strip.
PIN assignment: Pin 1 - 0 V / Pin 2 - 24 VDC
See the Adjust Box (EG A version) Operating Instructions, Chapter “Connections, interfaces”.
PIN 2, 24 V
PIN 1, 0 V
7. Recommendation: Connect the OUT1 analogue signal cable to the PLC.

8. Connect the 24 V power supply unit to the I/O CAN adapter (see "I/O connection diagram",
page 71).
9. Connect the fieldbus adapter to the EG or gateway using a fieldbus cable.
10.Switch on the adjust box and the laser head at the same time to ensure that the two devices can
communicate without any errors.
For detailed information in the event of an error, please refer to "Electrical malfunctions",
page 93.
Attention –Faulty connection!

If the laser head does not detect the connection to the EG, the laser head operates in I/O mode.
► Switch on the power supply on the laser head and EG simultaneously.
► If the connection has been interrupted during operation, carry out a “PBUS_RESET”. For detailed
information, please refer to the EG8050C documentation.

I/O connection diagram
Notice - Current flow too high!

The device may be damaged if the current on the switching outputs is too high.
► The current at the switching outputs (PIN 3 & PIN4; optocoupler) must be limited by a suitable
external resistor circuit to a max. of 30 mA.
1 24 V POWER 7 not connected
2 0 V POWER 8 not connected
3 24 V optocoupler 9 not connected
4 0 V optocoupler 10 not connected
5 not connected 11 not connected
6 not connected 12 not connected

Connecting the ProCutter App
5.5 Connecting the ProCutter App
Prerequisite:
The mobile device is not connected to a network.
Make sure that mobile data and wifi are turned off or flight mode (airplane mode) is on.
1. On the ProCutter read the information below:
mobile network name (1)
password (2)
2. On the mobile device turn on the following functions:

Wifi (do NOT connect to an existing network)
location
3. Start the ProCutter App 2.0.
When you have installed the app for the first time, you must accept the Terms and Conditions.
Scroll down to the end and select the check box. Otherwise the app will be closed.
4. Open the CONNECTION screen (main menu).
5. Tap on “Search device” [button].
The app searches the devices in the network. Devices can be identified based on the SSID mobile
network name (e.g. PC-AB12345).
6. Select the required ProCutter based on the mobile network name.
7. Enter the password.
The laser head’s wifi network will only accept one subscriber at a time. If the laser head is already
connected to a mobile device, an error message will appear and the login procedure will be aborted.

5.6 Interface description

A preconfigured fieldbus interface can query different parameters and process data. Their limit values
are monitored by the machine controller (PLC).
The ‘HEAD_GLOB_ERR‘ bit indicates collective errors. In normal operation this bit is disabled. If an
error occurs, the bit is enabled. Specific error bits indicate the error type. Errors can be read using the
fieldbus (Object HP State) or the ProCutter app.
If the focal position is not correct (faulty), reference travel must be carried out to reset the error (see
"Error reset (reference travel)", page 77). All the other errors are reset automatically once the
cause of the error has been rectified.
Errors are also output for 2 seconds for short-term error events (Status LEDs). This enables short-term
errors to be analysed.
The error limits for specific parameters depend very much on the process. The customer’s control sys-
tem must therefore switch the machine off if customer-specific limit values are exceeded. (The mea-
suring range limit values do not define the maximum permissible operating range).

Parameters available
On the fieldbus the parameters below can be read using the relevant variable name:
Function Parameter Variable Scaling
Protective window temper- Protective window cont- WIN_TEMP_PROC 0…2000 [0.1°C]

ature amination
Pressure - Cutting gas Cutting gas pressure GAS_PRES 0 … 250 [0.1 bar]
(0 = 1bar abs.)
Leak - Protective window Protective window car- PRES_LEAK 0…100 [50 mbar]
tridge sealing (0 = 1bar abs.)
Temperature - Collimating Collimating lens conta- COLL_TEMP 0…100 °C
lens mination
Temperature - Focusing Focusing lens contami- FOCL_TEMP 0…100 °C
lens nation
Housing temperature Laser head temperature HOU_TEMP 0…100 °C
Current focal position Focal position ACT_FOC_POS Depending on the
optics configuration
[10 μm]
Scaling as per the
setpoint value
Laser stray light in the Dirty optics, incorrect STRAY 0…100%
beam path adjustment (back reflec-
tion)
Amplification factor, pro- Dirty optics, sensitivity ACT_GAIN_STRAY 1, 2, 3 [ ]
tective window stray light
sensor
Setting the Z position Focus offset ACT_FOC_OFFSET Up to ±500 [10 μm]
(depending on the
optics configuration)
Humidity inside the laser Humidity inside the HUMIDITY 0…100%
head laser head
Stray laser light, protective Protective window cont- STRAY_WIN_PROC 0…100%
window amination
Stray laser light, protective Protective window cont- STRAY_WIN_COL 0…100%
window COL amination COL

Limit values
The limit values for the variables below can be adapted using the associated parameter.
Function Variable Parameter Threshold value
Default Min. Max.
Temperature - Pro- WIN_TEMP_PROC MAX_WIN_PROC_TEMP 90 [°C] 40 [°C] 90 [°C]

tective window
Temperature - Colli- COLL_TEMP MAX_COLL_TEMP 100 [°C] 40 [°C] 100 [°C]

mating lens
Temperature - FOCL_TEMP MAX_FOCL_TEMP 80 [°C] 40 [°C] 80 [°C]

Focusing lens
Temperature - Laser HOU_TEMP MAX_HOU_TEMP 55 [°C] 35 [°C] 55 [°C]

head
Pressure - Cutting GAS_PRES MAX_GAS_PRES 250 20 250

gas [0.1 bar] [0.1 bar] [0.1bar]
Leak - Protective PRES_LEAK MAX_PRES_LEAK 150 100 150

window [50 mbar] [50 mbar] [50 mbar]
Stray light - Beam STRAY MAX_STRAY 100 [%] 20 [%] 100 [%]
path
Stray light - Protec- STRAY_WIN_PROC MAX_STRAY_WIN_PROC 100 [%] 20 [%] 100 [%]
tive window
Stray light - Protec- STRAY_WIN_COL MAX_STRAY_WIN_COL 100 [%] 20 [%] 100 [%]
tive window COL
Humidity HUMIDITY MAX_HUM_INSIDE 100 [%] 20 [%] 100 [%]

Error conditions
If a parameter exceeds or falls below the limit value defined by the PLC, an error will be generated:
The ‘HEAD_GLOB_ERR‘ bit will be enabled. If focal position errors occur, 'FOC.REACHED' will also
be disabled.
When an error occurs, stop the machine immediately and correct the error.
Depending on the error type, the associated error bit is enabled. The assignment is as follows:
Error(General ERROR) Error bit
Protective window car- not available * NO_PROC_CAR_ALARM

tridge:
Protective window: not available * NO_PROC_WIN_ALARM
Protective window: max. temperature * WIN_PROC_TEMP_ALARM
exceeded
Drive malfunction: overload * DRIVE_OVLD
Drive malfunction: no communication with * DRIVE_NO_COM
servo
Drive malfunction: supply voltage too low * DRIVE_SUPL_ERR
Drive: faulty reference travel * DRIVE_NO_REF
Collimating lens: max. temperature * COLL_TEMP_ALARM
exceeded
Focusing lens: max. temperature * FOCL_TEMP_ALARM
exceeded
Laser head: max. temperature * HOU_TEMP_ALARM
exceeded
Laser stray light: max. level exceeded * STRAY_ALARM
Pressure - Cutting gas max. pressure exceeded GAS_PRES_ALARM
Leak - Protective window: max. pressure exceeded PRES_LEAK_ALARM
Protective window car- not available * NO_COL_CAR_ALARM
tridge COL:
Protective window stray max. level exceeded * STRAY_WIN_PROC_ALARM
light:
Humidity: max. level exceeded HUM_INSIDE_ALARM
The errors marked with an * lock the focal position adjustment device. Only reference travel can still be
carried out.

Error reset (reference travel)

When the focal position adjustment error has been corrected, a reference travel procedure must be
carried out to reset the error.
1. Enable 'REF.TRAVEL' and keep for at least 5 ms.
min. 3 ms min. 5 ms
REF_TRAVEL
REF_BIT_HI
FOC_REACHED
DRIVE_GLOB_ERROR max. 8 s
After a successful reference travel procedure, 'FOS.REACHED' will be enabled.

'DRIVE_GLOB_ERROR' will be disabled. From now on, new input signals will be processed.
To start a new reference travel procedure disable 'REF_TRAVEL' and wait for at least 3 ms.
move to the default position (focal position = 0 mm and aspect ratio of 1.6).
Recommendations
Built-in temperature and stray light sensors are not calibrated. However, they provide useful refer-
ence values for evaluating the laser head’s condition. We recommend that you adjust the limit val-
ues individually when the laser head has been fully integrated into the laser cutting machine.
The sensor values can change significantly if new replacement and wearing parts - in particular
lenses and protective windows - have been installed. In this case, Precitec recommends that you
check the limit values and adjust them again if necessary.
The humidity sensor measures the humidity of the air inside the laser head (not OUTSIDE). When
you open the laser head (by pulling the protective window cartridge for instance) the humidity
present in the ambient air penetrates into the laser head. If the laser head is cooled, the amount of
relative humidity can increase.
The customer's system can also be set to an individual limit value if necessary.
The relative humidity value [%] changes significantly depending on the air temperature inside the
laser head (warm air can hold more water vapour than cold air for example). The air temperature
inside the laser head depends significantly on the temperature of the cooling water, i.e. relative
humidity drops if the cooling water temperature rises.
If the relative humidity exceeds 80%, always check the cooling water temperature. To reduce rela-
tive humidity, increase the cooling water temperature.
If the relative humidity exceeds 90%, switch the laser machine off and contact the service team.

5.7 Configuring the laser head
5.7.1 Focal position variable & characteristic curves

Focal position variable
The ‘FOC_POS‘ variable sets the focal position (also known as TCP, Tool Center Point). The head’s
adjustment range defines the variable’s adjustment range. The software monitors the upper and lower
limit positions (which are not approached in normal operation).
The default focal position setting is 1 mm below the nozzle (this position is also called TCP0).
A scaling formula describes the relationship between the ‘FOC_POS‘ variable and the resulting focal
position. This formula is also used to specify the characteristic curve. The scaling formula is a linear
formula. This means that changing the variable value by 100 results in a focus shift of 1 mm. The valid
adjustment range of the ‘FOC_POS‘ variable depends on the head’s optics configuration.
move to the default position (focal position = 0 mm).
Scaling formula ‘FOC_POS‘ = focal position [mm] * (–100) + 30000
Setting limits -16... +10 mm
Top 'FOC-POS’ limit 31600
Bottom 'FOC-POS’ limit 29000
Offset adjustment range ±1.5 mm

Setting limits -30... +15 mm
Top 'FOC-POS’ limit 33000
Bottom 'FOC-POS’ limit 28500
Offset adjustment range ±3 mm

5.7.2 Setting the focal position
Prerequisite:
The required focal position is within the guaranteed focus range of the current aspect ratio.
1. Calculate the required 'FOC_POS’ variable value using the scaling formula:
'FOC_POS' = focal position [mm] * (–100) + 30000
Example: required focal position = 3 mm → 3 * (-100) + 30000 = 29700
2. Set the variable value.
3. Enable the control bit FOC_CTRL.
If the 'FOC_CTRL’ bit is enabled permanently, the new focal position setpoint value will be applied
immediately each time the 'FOC_POS’ variable is changed.
FOC_CTRL
Adjustment
-
FOC_POS
range
FOC_REACHED
A B B C
A The 'FOC_REACHED’ bit is disabled automatically for at least 50 ms. When the new focal posi-
tion has been reached, 'FOC_REACHED' is enabled automatically. Positioning will take longer if
focal position changes involve larger adjustment ranges. In this case, the new focal position must
be reached before 'FOC_REACHED' is enabled.
B If the 'FOC_CTRL’ bit is enabled permanently, the new focal position setpoint value will be applied
immediately each time the 'FOC_POS’ variable is changed. The 'FOC_REACHED’ bit is disabled
for at least 50 ms and enabled again once the new focal position has been reached.
C If the set focal position is outside the setting limits, the approached focal position will be the same
as the focus limit and 'FOC_REACHED' will not be enabled.
Attention –Wrong focal position

If the set focal position is within the settings limits but outside the guaranteed focus range,
'FOC_REACHED' will be enabled but the head will only move slightly beyond the guaranteed focus
range limit. This may lead to wrong focal positions.
► Only set a focal position that is within the focus ranges guaranteed for the aspect ratio (see "Focal
position variable & characteristic curves", page 78).
Each time the focal position is changed, the 'FOC_REACHED’ bit will be disabled even if the new
focal position is already within the setpoint range. This status signal can then be analysed (hand-
shake).

5.7.3 Reading the focal position
1. Read the 'ACT_FOC_POS’ variable value and enter it into the formula below:
Focal position [mm] = (read value – 30000) / -100

5.7.4 Adjusting the laser beam

eye damage.
Attention –Laser beam not adjusted correctly!

If the laser beam is not adjusted correctly, parts of the laser head can be destroyed during laser cut-
ting.
► Follow the instructions and centre the laser beam carefully.
Attention –Laser beam obstructed!

Damage can occur if the laser beam is obstructed.
► When adjustment is complete, make sure that the laser beam is not obstructed in any way. The
laser beam must be in the centre of the nozzle (nozzle with the correct opening diameter for the
cutting process).
Please note the laser or machine manufacturer's adjustment instructions and use the sample recom-
mended by him for system setup (commissioning).
Prerequisites:
The laser head is not under pressure.
The distance controller is switched off.
The laser head does not have any play.
The laser power recommended by the laser or machine manufacturer has been set.
1. Screw in a nozzle with a large nozzle opening.
The nozzle opening should be considerably larger than the laser beam diameter at the nozzle
opening.
2. Glue the sample under the nozzle.
3. Trigger a low power laser pulse.
4. Judge the penetration in the sample. The penetration must be round and in the centre of the nozzle
opening. If not, the lens must be centred.
good bad

5. Centre the lens using the adjusting screws on the laser head.
Use an Allen key (size 4). The maximum adjustment range is ±1.5 mm.
6. Use a new sample. Trigger a low-power laser pulse and judge the penetration in the sample again.
Repeat this procedure until the penetration is good.
7. Screw in a nozzle with a smaller nozzle opening.
8. Centre the lens again as described above.

5.7.5 TCP offset correction
Any focal position offset caused by fibre socket tolerances can be corrected using the focus offset
parameter. The parameter can be set in the ProCutter App or on the EG.

eye damage.
1. Approach the standard focal position (1 mm below the nozzle, TCP0).

2. Note down the position.
3. Remove the nozzle and ceramic part.
4. Move to the position noted down for the laser head.
5. Place a sample under the laser head at the focal plane.
6. Trigger a (low-power) laser pulse and judge the penetration in the sample.
7. Change the focus offset several times to find the smallest penetration. Use either the ProCutter
App (“Settings/ Optics/ Customer offset) or the EG.
8. Set the focus offset to the smallest penetration value.

Maintenance
Safety notes
6 Maintenance
6.1 Safety notes


eye damage.



Maintenance
Maintaining the ceramic part and nozzle
6.2 Maintaining the ceramic part and nozzle

Check and clean the ceramic part and nozzle.
Replace the ceramic part/nozzle if damaged. After a collision the nozzle must be replaced.
Replacing the ceramic part

1. Loosen and remove the nozzle (4).
2. Loosen and remove the nut (3).
An adjustable hook spanner size 40/42 can be used for easy removal.
3. Carefully remove the ceramic part (2) and the O-ring from the sensor insert.
4. Insert a new O-ring into the groove on the sensor insert (1).
5. Insert the new ceramic part into the sensor insert carefully.
Note the locating pin on the sensor insert when doing this – it must engage into the ceramic part.
6. Fix the ceramic and nut to the sensor insert.
Do not use a tool to tighten the nut.
7. Screw the nozzle into the sensor insert by hand.
When using a tool, tighten the nozzle with a maximum torque of 3 Nm.
Replacing the nozzle

1. Loosen and remove the nozzle.
2. Screw the new nozzle into the sensor insert by hand.
When using a tool, tighten the nozzle with a maximum torque of 3 Nm.
For spare part order numbers, please refer to "Parts available", page 105.

Maintenance
Maintaining the protective window cartridge FOC
6.3 Maintaining the protective window cartridge FOC
You should have a replacement cartridge ready at hand before you start removing the old one. If
no second protective window cartridge is available, we recommend that you order one from Pre-
citec (see Appendix) or immediately affix a suitable protective film over the aperture to cover it (see
MOCAP's product range for instance).
Removing and installing the cartridge
1. Loosen the locking elements .

2. Pull out the cartridge(1) and place it on a clean pad.
3. Carry out any maintenance work.
4. If the protective window cartridge must be replaced: Remove the protective film from the replace-
ment cartridge.
5. Insert the protective window cartridge into the laser head until it locks in to place. Secure it.
Note the orientation of the cartridge. A wrongly inserted cartridge will not click into place.

Maintenance
Maintaining the protective window
1. Put the cartridge on a clean pad.

2. Carefully lift off the clamping ring from the protective window frame (cartridge) and remove the pro-
tective window.
3. Clean the protective window using a cleaning pad soaked in methanol. Then blow away any dirt
with clean air (pressurised air spray can). Repeat until the surface is clean.
If the protective window can no longer be cleaned or if it is damaged, it must be replaced.
4. Carefully insert the clean (new) protective window into the cartridge.
5. Insert the clamping ring and protective window.
Always keep the cartridge (with protective window installed) in a horizontal position when carrying
it.
For protective window order numbers, please refer to "Parts available", page 105.

Maintenance
Maintaining the axial gasket

To keep the laser head working reliably in normal operation Precitec recommends that you check the
sealing ring for wear once a year. Worn or damaged seals must be replaced.
1. Remove the old sealing ring if necessary.

2. Click the replacement sealing ring into the cartridge.
Notice – Faulty seal!

Different materials such as aluminium, steel and plastic have different thermal expansion coefficients.
Temperature variations can have a negative effect on the seal.
► If the ambient temperature drops below 10°C, you must check that the sealing ring is positioned
correctly, especially when replacing the cartridge.

Maintenance
Maintaining the sensor insert
6.4 Maintaining the sensor insert
2
3
4
Removal
1. Remove the screws (4) (4x hexagon key, size 4).
2. Remove the spatter protection plate (3).
3. Remove the screws (2) (4x hexagon key, size 5.5).
4. Remove the sensor insert(1).
Depending on the temperature and condition of the O-rings, the sleeve above the sensor insert
may come off. In this case the O-rings and sleeve must be inserted again.
Cleaning
1. Use a suitable cleaning pad (swab) from the optics service case and soak it with methanol.
2. Clean the sensor insert and the inner groove with the cleaning pad (swab) soaked in methanol and
blow away any dirt with clean air.
If the sensor insert can no longer be cleaned, it must be replaced.
Fitting
1. Attach the sensor insert to the connection head and tighten the four screws with a torque of 10 Nm.
Make sure the sensor insert is positioned correctly – it must not get stuck!
If the O-ring on the sensor insert is positioned wrongly or defective, the laser head may leak. Make
sure that the O-rings are positioned correctly.
2. Fit the spatter protection plate again and screw it on.
When the sensor insert has been replaced, we recommend that you install a new ceramic part (see
"Maintaining the ceramic part and nozzle", page 86).

Troubleshooting
Safety notes
7 Troubleshooting
7.1 Safety notes


eye damage.



Troubleshooting
General malfunctions
7.2 General malfunctions
Malfunction Cause Action to be taken
Laser head cannot be No power supply ► Check the I/O CAN adapter’s
switched on fuses (see "I/O CAN adapterI/
O CAN adapter", page 43).
► Check the power pack and
wiring.
Laser head does not react Internal hardware error ► Send the laser head back for
repair.
Adjust box (EG): PBus Error The connection of the two units ► Perform Res-PBus on the EG
has been interrupted during (knob) or switch the EG off and
operation. on again.
► Check the flat cable between
the communication adapter (I/
O interface) and the EG.
Distance display is wrong Sensor cable damaged or ► Replace the sensor cable or fix
and changes depending loose plug-in connection the plug-in connection.
on the position of the
machine
Minor standoff distance Sensor temperature drift ► Repeat reference point/two
changes Worn nozzle point calibration, incl. [Noz-
zLost].
Contamination
Measuring distance of dis- Ceramic part contaminated or ► Clean and dry off the ceramic
tance sensor system too wet part.
small, large laser head dis- ► Check the cooling gas.
tance when approaching
the workpiece

Troubleshooting
Electrical malfunctions
7.3 Electrical malfunctions

LED indicators on the laser head inform the user about any error conditions.
1 2 3 4
1 Focal position 3 Pressure
2 Temperature/humidity 4 Protective window/stray light
If an LED lights up red, an error is generated depending on the operating mode (in I/O operating
mode: current at analogue output, in fieldbus operating mode: error bit enabled).

Troubleshooting
Status indicator
LED indicator I/O output Fieldbus output Cause Action to be taken

[mA]
All LEDs OFF, laser head not - - No power supply ► Check the F2 fuse at the I/O CAN adapter
operational (see "I/O CAN adapterI/O CAN adapter",
page 43).
► Check the power pack and wiring.
LEDs 1, 2, 3, 4 = ORANGE Mal- - - Internal hardware error ► Send the laser head back for repair.
function:
(light up permanently ( t > 30 s))
LED 1 and LED 3 = RED, LED 2 8.125 - Lasermatic® analysing electronics (EG) not ► Perform Res-PBus on the EG (knob) or
and LED 4 = OFF detected: switch the EG off and on again.
The laser head power supply has been ► Check the flat cable between the I/O CAN
switched on after the EG. adapter and the EG.
The connection of the two units has been
interrupted during operation.
LED 1 = flashes RED, 16.875 DRIVE_NO_COM Internal hardware error (no communication ► Send the laser head back for repair.
LED 2, LED 3 and LED 4 = OFF with servo unit)
LED 1 - LED 4 = light RED alter- - - Firmware is being updated ► Do not interrupt the laser head power sup-
nately ply.
(firmware update)

LED 1 – focal position
LED indicator I/O output [mA] Fieldbus output Cause Action to be taken
always OFF (does NOT light up) - - Focal position setpoint < 0.3 V or > 9.7 V ► Check the focal position setpoint.
RED (drive malfunction) 17.5 DRIVE_OVLD Drive overload ► Carry out reference travel. If this does not
Drive unit short circuit correct the error, send the laser head back
for repair.
RED (drive malfunction) 16.875 DRIVE_NO_COM Internal positioning error ► Carry out reference travel. If this does not
correct the error, send the laser head back
for repair.
RED (drive malfunction) 16.25 DRIVE_SUPL_ERR Power supply (Power PIN 1, 2) too low ► Adjust the power supply unit’s current limi-
tation.
► Check the power supply unit's rating.
RED (drive malfunction) 15.625 DRIVE_NO_REF Faulty reference travel, drive cannot move ► Switch the laser head ON/OFF.
to the required position ► Carry out reference travel. If this does not
correct the error, send the laser head back
for repair.

Troubleshooting
LED 2 – temperature/humidity

[mA]
flashes RED [3 x per second] 15.00 COLL_TEMP_ALARM Collimating lens temperature threshold too ► Adjust the temperature threshold.
low ► Reduce the laser power.
Laser power too high ► Send the laser head back for repair.
Optics damaged
Sensor faulty or cannot be reached (App ► Send the laser head back for repair.
shows 111° C)
flashes RED [1 x per second] 14.375 FOCL_TEMP_ALARM Focusing lens temperature threshold too ► Adjust the temperature threshold.
low ► Reduce the laser power.
Laser power too high ► Send the laser head back for repair.
Optics damaged
shows 111° C)
flashes RED [10 x per second] 9.375 HUM_INSIDE_ALARM Humidity level too low ► Set the humidity threshold.
Faulty seal ► Maintain the seal. If this does not correct
the error, send the laser head back for
repair.
shows 100 %)
always RED 13.75 HOU_TEMP_ALARM Head temperature threshold too low ► Set the temperature threshold.
Laser power too high ► Reduce the laser power.
Ambient temperature too high
Cooling circuit interrupted

[mA]
► Reduce the ambient temperature.
► Check the cooling water connections. If
this does not correct the error, send the
laser head back for repair.

Troubleshooting
LED 3 – pressure

[mA]
flashes RED [1 x per second] 12.5 GAS_PRES_ALARM Cutting gas pressure threshold too low ► Adjust the pressure threshold.
Max. pressure exceeded ► Check the gas supply.
Sensor faulty or cannot be reached ► Send the laser head back for repair.
(App shows 25.5 bar)
always RED 11.875 PRES_LEAK_ALARM Protective window pressure threshold too ► Adjust the pressure threshold.
low ► Maintain the axial gasket.
Faulty seal (protective window cartridge)
(App shows 4050 mbar)

LED 4 – protective window/stray light

[mA]
flashes RED [10 x per second] 13.125 STRAY_ALARM Stray light level (beam path) too low ► Adjust the beam path stray light threshold.
Strong backreflection ► Check and maintain the optics in the Flow-
Optics defective box.
► Send the laser head back for repair.
flashes RED [10 x per second] 10.625 STRAY_WIN_PROC_ Stray light level (protective window) too low ► Adjust the protective window stray light
ALARM Protective window contamination threshold.
► Clean or replace the protective window.
(App shows 100 %)
flashes RED [3 x per second] 19.375 NO_PROC_CAR_ALARM Protective window cartridge missing or not ► Install the protective window cartridge cor-
ANALOG-OUT (PIN-6 = mA) screwed in firmly enough rectly..
flashes RED [3 x per second] 11.25 NO_COL_CAR_ALARM Protective window cartridge COL missing ► Install the protective window cartridge COL
or not screwed in firmly enough correctly.
flashes RED [1 x per second] 18.75 NO_PROC_WIN_ALARM Protective window missing ► Insert the protective window.
always RED 18.125 WIN_PROC_ Protective window dirty ► Clean or replace the protective window.
TEMP_ALARM Sensor faulty or cannot be reached ► Send the laser head back for repair.
(App shows 111° C)

Troubleshooting
Mechanical malfunctions
7.4 Mechanical malfunctions
Cutting gas pressure does not build up Cutting gas hose not connected properly ► Connect the cutting gas hose properly (see "Con-
necting the cutting gas", page 33).
Protective window cartridge loose or protective win-► Replace the protective window cartridge or push in
dow damaged until it clicks into place (see "Maintaining the pro-
tective window cartridge FOC", page 87).
Sealing ring on the protective window cartridge ► Replace the worn seal (see "Maintaining the axial
leaks gasket", page 89).
Seals between connection head and sensor insert ► Replace the worn seal (see "Maintaining the
leak ceramic part and nozzle", page 86).
Seals between ceramic part and sensor insert leak ► Send the laser head back for repair.
Cutting gas escapes somewhere else ► Send the laser head back for repair.
Nozzle gets too hot Nozzle cooling gas hose is not connected properly ► Connect the cooling gas hose properly (see "Con-
necting the cooling gas system", page 34).
Cutting gas escapes somewhere else ► Send the laser head back for repair.
Laser beam obstructed (bad laser beam position) ► Check the laser beam position.
Gases and liquids do not reach the cutting Gas and liquid hoses are not connected properly ► Connect the gas and liquid hoses properly
point (see "Connecting gas and water", page 32).
Seals between connection head and sensor insert ► Replace the gasket set (see "Maintaining the
leak ceramic part and nozzle", page 86).
Gases and liquids escape at other places ► Send the laser head back for repair.
Axial focal position adjustment device difficult Thread on lens centring device is damaged or dirty ► Send the laser head back for repair.
to turn
Lens centring device difficult to turn Thread on lens centring device is damaged or dirty ► Send the laser head back for repair.

Focal position cannot be found in the adjust- Wrong focal length of the focusing lens or focusing ► Replace the laser head.
ment range of the vertical adjustment device lens damaged ► Send the laser head back for repair.
Bad cut Focus diameter too large ► Send the laser head back for repair.
Wrong focusing lens installed in the laser head
Bad focal position/ laser beam position ► Check the focal position/ laser beam position and
remove the error if necessary (see "Setting the
focal position", page 57 or "Setting the focal posi-
tion", page 80).
Protective window dirty ► Clean the protective window and replace if neces-
sary (see "Maintaining the protective window car-
tridge FOC", page 87).
Influence of the workpiece alloy ► Adapt the cutting parameters.

Troubleshooting
Mechanical malfunctions

Appendix
Conversion of Units
8 Appendix
8.1 Conversion of Units
1.0 mm = 0.03937"
25.4 mm = 1.0"
1.0 kg = 2.20 lb (pounds)
1.0 bar = 0,1 MPa
= 14,50 psi (pounds/square inch)
= 0,99 atm (atmosphere)
1.0 l (litre) = 1.06 qt (quarts US)
= 0.88 qt (quarts Imp)
0.0284 l = 1.0 fl oz (fluid ounce)
8.2 Gas quality (ISO 8573-1)
Class (residual dust) (pressure dew point) (aerosol liq-

[°C] uid, vapour)
Max. concen- Max. size [µm]
tration [mg/m3] [mg/m3]
1 0.1 0.1 -70 0.01

2 1 1 -40 0.1
3 5 5 -20 1
4 8 15 +3 5
5 10 40 +7 25
6 -- -- +10 --

Appendix
Cooling water dew point temperature
8.3 Cooling water dew point temperature
Air Dew point temperature[°C](relative humidity)

temp.
20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 90%
[°C]
15 - - -2 0 2 4 5 6 7 9 10 11 12 13
20 - - 2 4 6 8 10 11 12 14 15 16 17 18
25 1 4 7 9 11 13 14 16 17 18 19 20 21 23
30 5 8 11 13 15 17 19 20 22 23 24 25 26 27
35 9 12 15 17 20 21 23 25 26 28 29 30 31 36
40 13 17 19 22 24 26 28 30 31 32 34 35 36 46
45 17 21 24 26 28 30 32 34 36 37 38 40 41 59
50 21 25 28 30 33 35 37 39 40 42 43 45 46 75
55 25 29 32 35 37 39 41 43 45 46 48 49 51 82

Appendix
Parts available
8.4 Parts available
Name Designation P number
Protective window cartridge (complete) ZM ProCutter 2.0 WK OG P0595-89009

Protective window cartridge COL (com- ZM ProCutter 2.0 WK OG COL P0595-92804
plete)
Protective window (OG) OG Y D37 d7 P0595-58601
Sealing ring DF (axial gasket) ZM ProCutter DF P0595-69532
Clamping ring (protective window) ZM ProCutter WK OG PR P0595-73925
Spatter protection plate (PP) ZM ProCutter 2.0 P0595-88832
Spatter protection plate (PP) ZM ProCutter 2.0-30 P0595-105703
Sensor insert (SE)
SE F150 ProCutter 2.0 KTX P0595-92159
SE F200 ProCutter 2.0 KTX P0595-92660
SE ProCutter 2.0 F200 X P0595-92660
Ceramic part (KT X) KT X P0595-92036
Nut (MU X) MU X P0595-92039
Nozzles (DE) - (nozzle electrodes)
DE PC KTX Ø5.0 SW24 P0595-92741
DE PC KTX Ø3.5 SW24 P0595-92738
DE PC KTX Ø3.0 SW24 P0595-92737
DE PC KTX Ø2.5 SW24 P0595-92736
DE PC KTX Ø2.0 SW24 P0595-92735
DE PC KTX Ø1.7 SW24 P0595-92734
DE PC KTX Ø1.5 SW24 P0595-92733
DE PC KTX Ø1.2 SW24 P0595-92688
DE PC KTX Ø1.0 SW24 P0595-94263
DE PC KTX DUO Ø5.0 SW24 com- P0595-92917
plete
plete
plete
plete

Appendix
Parts available
Name Designation P number

plete
plete
DE PC KTX DUO Ø2,3 SW24 com- P0595-92904
plete
plete
plete
plete
plete
plete
plete
plete
Optics Service Case ZO BOX CLEAN II P0001-000-Q0002
I/O CAN adapter ZE I/O ProCutter P0595-62407
Control cable (19-pin) KC LD30C 20m gw ext P0660-185-2000

The Market´s Choice
Available for you worldwide!

You can find the contact details of our
subsidiaries and representatives at
www.precitec.com
© Precitec GmbH & Co. KG Printed in the Federal Republic of Germany

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ProCutter 2 - 15 kW

© Precitec GmbH & Co. KG en-uk 08/2023 D 255294

Responsible for the content

2 / 108 © Precitec GmbH & Co. KG ● en-uk 08/2023 D 255294

1 Safety notes and typographical conventions.......................................... 7

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3.3.5 Checking the protective window COL for any contamination............................................... 32

4 Commissioning - I/O operation.................................................................. 39

5 Commissioning - Fieldbus mode.............................................................. 61

4 / 108 © Precitec GmbH & Co. KG ● en-uk 08/2023 D 255294

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6 / 108 © Precitec GmbH & Co. KG ● en-uk 08/2023 D 255294

1 Safety notes and typographical conventions

1.1 About this documentation

1.2 Warranty and liability

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1.3 Typographical conventions

Tip: Provides useful information.

1.4 Intended use

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1.5 Basic standards

1.6 Electromagnetic compatibility (EMC)

1.7 Obligations of operator and personnel

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1.8 Normal operation safety measures

1.8.1 Protection against electric shock

1.8.2 Risk of injury from moving parts

1.8.3 Risk of injury from explosion

10 / 108 © Precitec GmbH & Co. KG ● en-uk 08/2023 D 255294

1.8.4 Risk of injury from laser radiation

Caution - Laser beam!

1.8.5 Corrosion in the water cooling circuit

1.8.6 Noise occurring during the laser cutting process

1.9 Storage and transport

1.10 What to do in emergency situations

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2.1 Product overview

1 Fibre socket 9 Nozzle cooling gas connection

2 Collimating unit 10 Auxiliary gas connection

3 Focusing unit 11 BNC connection

4 Protective window cartridge FOC 12 Water connections (collimating area)

5 Sensor insert 13 Water connections (fibre socket)

6 Nut, ceramic part 14 BNC connection

7 Cutting gas connection 15 Adjusting screws

8 Protective window cartridge COL 16 Status LEDs

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2.2 Product characteristics

Fibre plug-in connection

Water cooling system

Focal position adjustment

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Lasermatic® distance sensor system

2.3 Protective and monitoring equipment

1 Focal position 3 Pressure

2 Temperature/humidity 4 Protective window/stray light

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Protective window COL

Process protective window