Part02 07-02-57-6001 Manual BIMO-FSC 160407 en

HIGHYAG
BIMO−FSC laser cutting head

Document no.: 07−02−57−6001

Version: 00
Date of issue: 07/04/2016
HIGHYAG
HIGHYAG
Table of contents

Revision directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0 Address and contact information . . . . . . . . . . . . 11
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Information on this Operator’s Manual . . . . . . . . . . 13
1.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Other applicable documents . . . . . . . . . . . . . . . . . . 14
1.4 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Change Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7 Declaration of incorporation . . . . . . . . . . . . . . . . . . . 15
1.8 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.2 Operating environment . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.3 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1.4 Qualifications of personnel . . . . . . . . . . . . . . . . . . . . 20
2.1.5 Working close to BIMO−FSC laser cutting head . 21
2.2 Information on special dangers . . . . . . . . . . . . . . . . 22
2.2.1 Exposure to laser light and reflection! . . . . . . . . . . 22
2.2.2 Risk of fire and explosion . . . . . . . . . . . . . . . . . . . . . 23
2.2.3 Risks associated with harmful gases, dusts and 3
vapours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.4 Risks associated with high−energy UV radiation . 24
2.2.5 Risk associated with compressed air and cutting
gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.6 Injury hazard due to moving parts! . . . . . . . . . . . . . 25
2.2.7 Risk of injury caused by sharp edges! . . . . . . . . . . 25
2.2.8 Risk of injury due to hot surfaces! . . . . . . . . . . . . . . 26
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2.2.9 Risks associated with the noise level . . . . . . . . . . . 26

2.3 Responsibilities of the operating company . . . . . . 27
2.4 Information on warranty . . . . . . . . . . . . . . . . . . . . . . 28
2.5 Standards and regulations . . . . . . . . . . . . . . . . . . . . 29
2.6 Explanation of symbols and information . . . . . . . . 30
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3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1 Principles of optics . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1.1 Straight optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.2 Angled optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.3 Optics with the process light emission . . . . . . . . . . 33
3.1.4 Focusing diameter and imaging ratio . . . . . . . . . . . 34
3.1.5 Divergence and imaging ratio . . . . . . . . . . . . . . . . . 34
3.1.6 Maximum permissible divergence angle . . . . . . . . 34
3.2 Principles of operation of laser beam cutting . . . . 35
3.2.1 Fusion cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2.2 Oxygen cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.3 Coordinate system for defining the directions on the
BIMO−FSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.4 Basic principles of focus setting . . . . . . . . . . . . . . . 38
3.4.1 Focus positioning in the z−direction . . . . . . . . . . . . 39
3.4.2 Focus diameter adjustment . . . . . . . . . . . . . . . . . . . 40
3.5 Design of the BIMO−FSC laser cutting head . . . . 42
3.5.1 Overview of the main assemblies . . . . . . . . . . . . . . 42
3.5.2 Collimation system . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.5.2.1 Laser light cable receiver . . . . . . . . . . . . . . . . . . . . . 44
3.5.2.2 Aperture module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.5.2.3 Cover slide module with a cover slide drawer . . . . 45
3.5.2.4 Collimation module with an electric drive unit . . . . 45
3.5.3 Base module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.3.1 Focusing unit with x− and y−adjustment . . . . . . . . 48
3.5.3.2 Cover slide module with a cover slide drawer and a
4 cover slide monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5.3.3 Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.5.3.4 Base module housing and cutting−gas guiding
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.5.4 Cutting attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.5.5 Cutting nozzle adapter and cutting nozzle . . . . . . 50
3.6 Opportunities for electrical integration of the
BIMO−FSC into a laser cutting system (overview) 51
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3.6.1 Digital integration through CHC . . . . . . . . . . . . . . . . 52

3.6.2 Analogue integration . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.7 Controlling the motordriven collimation system via
analogue integration . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.7.1 Changing the focus position in the z direction for
configurations with Z and MZ collimation systems 55
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3.7.2 Changing the focus diameter (adjusting the focus

diameter) for configurations with MZ collimation
systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.7.3 Mutual influence of the parameters imaging ratio and
focus position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.7.3.1 Configurations with a Z collimation system . . . . . . 57
3.7.3.2 Configurations with a MZ collimation system . . . . 58
3.8 Cover slide and cutting attachment monitoring with
KSGM C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.8.1 Cover slide monitoring . . . . . . . . . . . . . . . . . . . . . . . 59
3.8.2 Cutting attachment monitoring . . . . . . . . . . . . . . . . . 59
3.9 Capacitive distance measuring with FJB . . . . . . . . 60
3.10 Pressure monitoring of the interior . . . . . . . . . . . . . 60
3.11 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.11.1 Coolant specifications . . . . . . . . . . . . . . . . . . . . . . . . 61
3.11.2 Coolant quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.11.3 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.11.4 Biological contamination . . . . . . . . . . . . . . . . . . . . . . 62
3.11.5 Risk of condensation . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.11.6 Monitoring recommendation . . . . . . . . . . . . . . . . . . . 62
3.11.7 Coolant connection diagram . . . . . . . . . . . . . . . . . . 63
4 Assembly, Installation and Setup . . . . . . . . . . . . 65

4.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2 Installation site requirements . . . . . . . . . . . . . . . . . . 66
4.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.4 Assembly of the BIMO−FSC laser cutting head and 5
the accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.4.1 Assembly of the laser cutting head . . . . . . . . . . . . . 67
4.4.2 Fitting the accessories (option) . . . . . . . . . . . . . . . . 68
4.4.3 Fitting the pressure switch (option) . . . . . . . . . . . . . 69
4.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.5.1.1 Digital controlling and monitoring via CHC
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(Digital integration) . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.5.1.2 Analogue control via the system controller and
monitoring via accessories (analogue integration) 72
4.5.2 Connecting the coolant supply . . . . . . . . . . . . . . . . 74
4.5.3 Connecting the cutting−gas supply . . . . . . . . . . . . . 76
4.5.4 Connecting the cutting head controller CHC for digital
integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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4.5.5 Connecting the electric drive unit for analogue

integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.5.6 Fitting the FJB distance measuring module
(option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.5.7 Connecting the KSGM C compact cover slide
monitor (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.5.8 Fitting the pressure switch (option) . . . . . . . . . . . . . 81
4.5.9 Connecting the laser light cable . . . . . . . . . . . . . . . 82
4.5.9.1 QBH laser light cable receiver . . . . . . . . . . . . . . . . . 83
4.5.9.2 Auto laser light cable receiver . . . . . . . . . . . . . . . . . 84
4.6 Assembly inspection . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.7 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.7.1 Setting up the electrical drive system . . . . . . . . . . . 87
4.7.1.1 Control via CHC for digital integration . . . . . . . . . . 87
4.7.1.2 Control via the system controller for analogue
integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.7.2 Aligning the laser beam in relation to the cutting
nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.7.3 Setting up the FJB and KSGM C accessory devices
(optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.8 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . 93

5.1 Scheduling of inspection and maintenance work . 95
5.1.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.2 Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6 5.2.1 Lubricating the collimation system . . . . . . . . . . . . . 96
5.2.2 Checking and replacing the cover slides . . . . . . . . 96
5.2.2.1 Replacing the cover slide drawer in front of the
collimation module . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.2.2 Replace the cover slide drawer in the base
module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2.3 Replace the cover slides and elements of the cover
slide drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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5.2.3.1 Cover slide drawer in front of the collimation unit 101

5.2.3.2 Cover slide drawer in the base module . . . . . . . . . 103
5.2.4 Maintaining the cutting attachment . . . . . . . . . . . . . 105
5.2.4.1 Removing and installing the cutting attachment . . 105
5.2.4.2 Cleaning the outside of the cutting attachment . . 107
5.2.4.3 Cleaning the inside of the cutting attachment . . . . 107
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5.3 BIMO−FSC Removing and installing . . . . . . . . . . . 109

5.3.1 Disconnecting the laser light cable . . . . . . . . . . . . . 109
5.3.1.1 QBH laser light cable receiver . . . . . . . . . . . . . . . . . 110
5.3.1.2 Auto laser light cable receiver . . . . . . . . . . . . . . . . . 111
5.3.2 Disconnecting and connecting cables and hoses 112
5.3.2.1 Plug−type connection for cooling water . . . . . . . . . 112
5.3.2.2 Plug−type connectors for purging air, cutting gas
and pressure monitoring . . . . . . . . . . . . . . . . . . . . . . 113
5.3.3 BIMO−FSC removal . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.4.1 Replacing the cutting attachment or the cutting
nozzle adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.4.1.1 Replacing the cutting attachment and the cutting
nozzle adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.4.1.2 Changing a broken cutting nozzle adapter . . . . . . 116
5.4.2 Replacing the cutting−gas guiding system . . . . . . 116
5.4.3 Replacing the cover slide monitoring unit . . . . . . . 118
5.4.4 Change the cover slide drawer cover . . . . . . . . . . . 120
5.4.5 Changing the turn knobs for x− and y−adjustment 121
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.1 No cutting or insufficient cutting quality . . . . . . . . . 124
6.2 Laser processing head is getting hot . . . . . . . . . . . 126
6.3 Service life of the cover slides is insufficient . . . . . 128
6.4 Cover slide soiled
(message via CHC or KSGM C) . . . . . . . . . . . . . . . 128
6.5 Cover slide is heavily soiled or damaged
(message via CHC or KSGM C) . . . . . . . . . . . . . . . 129 7
6.6 Cover slide or cutting attachment are not available or

not properly placed
(message via CHC or KSGM C) . . . . . . . . . . . . . . . 129
6.7 Pressure switch B561 is triggered . . . . . . . . . . . . . 130
6.8 Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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BIMO−FSC laser cutting head HIGHYAG
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HIGHYAG
Revision directory

Revision Revision Notes
no. date
00 07/04/2016 First edition
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HIGHYAG
0 Address and contact information

Manufacturer:
HIGHYAG Lasertechnologie GmbH
Hermann−von−Helmholtz−Str. 2
14532 Kleinmachnow
Germany
Tel.: +49 33203 883−0
Fax: +49 33203 883−22
Sales: highyag.info@II− VI.com
Service: highyag.service@II− VI.com
URL: www.highyag.de
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1 Introduction

1.1 Information on this Operator’s Manual
The purpose of this Operator’s Manual is to provide information

that ensures safe integration, application, as well as safe and reli-
able operation of the product.
To avoid errors in the installation and operation and to ensure
trouble−free operation of the product it is necessary that the con-
tent of the entire manual as well as the applicable documentation
has been read and understood. All instructions, in particular relat-
ing to the assembly, commissioning, operation, maintenance and
repairs should be complied with consistently.
In addition to the directives and regulations referred to in the Op-
erating Instructions, the applicable accident prevention regula-
tions and safety provisions, as well as any other applicable laws
and provisions must be complied with.
The work described in this manual is described in such a way that
it can only be understood and performed by a technical expert.
In the definition, based on the EN 60204−1, a technical expert is
a person who can detect potential hazards and avoid and profes-
sionally perform the work based on his/her technical training,
knowledge and expertise, and the knowledge of the relevant stan-
dards and regulations that are used for assessing the work trans-
ferred to him/her.
The Operating Instructions are part of the product specified on the
title page. The Operating Instructions shall be kept on file at the
place of use of the product and must be accessible at all times to
authorized personnel.
13
The illustrations provided in this manual are not to scale. They are
used exclusively for the clarification of technical contexts. Single
figures may differ from the actual appearance of the product sup-
plied as the product is available in different configurations. The
described work should be carried out accordingly.
Subject to technical modifications, errors and omissions.
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1.2 Abbreviations

All abbreviations used in this manual are explained in this section.
Abbreviation Explanation
CHC Cutting Head Controller
(Control and monitoring equipment for cutting
heads)
FJB Capacitive distance measurement device
KSGM C Compact cover slide monitor for cutting heads
LLK Laser light cable
PLC Programmable Logic Control unit
1.3 Other applicable documents
In addition to this User’s Manual, the following documents must

be observed for the integration and application of the product:
− Data sheet
− User manual for CHC Cutting Head Controller
or, alternatively, user manual for the CHC :
− User manual for KSGM C compact cover slide monitor and
− user manual for FJB capacitive distance measuring
furthermore:
− List of spare/wear parts
− Electric circuit diagram
− Signal flow chart
14 − Pneumatic circuit diagram
− Technical drawing
− Manufacturer ’s documentation for the integrated third−party
products
− Declaration of incorporation in compliance with EC Directive
2006/42/EC
All relevant documents are compiled by HIGHYAG in accordance
with the configuration of the product. These documents form the
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technical documentation of the product which is supplied with the

product.
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1.4 Copyright protection

This manual has been compiled by the Technical Documentation
HIGHYAG Lasertechnologie GmbH department.
All rights, especially rights for duplication and circulation and
translation, are reserved by HIGHYAG Lasertechnologie GmbH.
This Operating Manual is part of the product specified on the title
page and may be utilised, processed and duplicated by the user
of the product for internal purposes only. HIGHYAG Lasertechno-
logie GmbH is not liable for the results of this processing or dupli-
cation.
The disclosure to third parties without the express authorization of
the HIGHYAG Lasertechnologie GmbH is permissible.
1.5 Customer Service
Should you require technical assistance, please contact our cus-

tomer service team.
Furthermore, the manufacturer would be delighted to receive in-
formation and experience resulting from the use of the products
and that can be of significance for their improvement.
Information about the competent contact person can be obtained
via phone, fax, email or via the Internet.
The manufacturer’s address and contact details are listed at the
beginning of this manual.
1.6 Change Service
The manufacturer reserves the changes in terms of technical im- 15

provements of the product. The updates of technical documenta-
tion passed on by the manufacturer to the operator are to be in-
troduced and replaced in the appropriate places.
1.7 Declaration of incorporation
Should a declaration of incorporation is required for the country of

delivery in compliance with the EC Directive 2006/42/EC, it is pro-
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vided as a separate document.

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1.8 Limitation of liability

All instructions and specifications contained within this manual

have been compiled in accordance with the pertinent standards
and regulations, the state of the art and on the basis of our long−
standing knowledge and experience.
The manufacturer shall assume no liability in the following cases:
− failure to comply with these Operating Instructions,
− improper use,
− change in technical parameters,
− operation with parameters outside the specified range,
− deployment of untrained personnel
− unauthorised structural modifications,
− use of non−approved spare parts.
The actual scope of delivery may deviate from the explanations
and illustrations in this manual if a special model or optional
equipment has been ordered or if more recent technical modifica-
tions have been implemented.
The obligations agreed upon in the supply contract, the General
Terms and Conditions, as well as the terms of delivery issued by
manufacturer and the legal provisions applicable at the time of the
conclusion of the contract shall apply.
The manufacturer expressly reserves the right to technical
changes in order to improve the performance characteristics and
the development of the product.
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2 Safety

The information contained in this section is intended to provide
guidelines for safe handling of the BIMO−FSC laser cutting head.
For proper operation of the equipment, it is however necessary
that the content of the entire manual as well as the relevant docu-
ments has been read and understood.
The products manufactured and supplied by HIGHYAG are based
on the latest state of the art in terms of development, design, pro-
duction, as well as generally accepted safety regulations. How-
ever, improper use of the equipment and failure to comply with the
instructions described in this manual may lead to severe or fatal
injuries of the operating personnel and damage to the equipment.
The applicable EU directives and/or their transposition into na-
tional (German) law were applied in the design of the equipment
and the preparation of this operating manual. In this context, the
safety aspect was also addressed in much detail.
The information contained herein is based on a risk assessment
of the BIMO−FSC and the experience of HIGHYAG Lasertechno-
logie GmbH. However, it is not possible at this point to make any
final statement concerning the conditions of use and the safety
measures to be taken because this requires an analysis of the
overall context of the equipment within the scope of a risk analy-
sis. The manufacturer and/or user of the laser equipment is re-
sponsible for this.
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2.1 Intended use

The BIMO−FSC laser cutting head may be used for the following
applications only and under the conditions listed below. Use for
applications other than those specified is considered improper
use and will absolve the manufacturer from liability in the event of
damage.
2.1.1 Definition
The BIMO−FSC laser cutting head is intended for installation in a

laser cutting machine and for further processing of metal
workpieces by means of high−energy laser light conducted to the
laser cutting head through the laser light cable, as well as through
supply of cutting gas. Thus, the BIMO−FSC laser cutting head is
an incomplete machine as defined in Article 2 (g) of the European
Machinery Directive 2006/42/EC.
The BIMO−FSC laser cutting head consists of several intercon-
nected modules that correspond to a specific device configuration
in terms of size and arrangement. The configuration is described
in the respective data sheet relating to each BIMO−FSC. Acces-
sories include: Cables and connectors for the power supply and
communication, lines for the media, such as cooling water, com-
pressed air and cutting gas, various cutting nozzle adapters and
accessories for control and monitoring, such as, pressure switch,
CHC, KSGM C and FJB.
2.1.2 Operating environment
18 The BIMO−FSC laser cutting head may be operated only in a sys-

tem that meets the requirements of laser equipment of laser class
4 in accordance with EN 60825−1. The measures described in
this standard relating to the protection of persons and equipment
against hazardous laser radiation, as well as the applicable occu-
pational safety regulations, must be implemented. Any and all
risks associated with escaping laser light must be ruled out.
The BIMO−FSC must only be operated if all protective and
safety−related devices are fully functional.
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The BIMO−FSC laser cutting head must only be used together

with a handling machine in an appropriately set up laser process-
ing area. Entering the pivoting area of the handling machine may
lead to severe injuries and must therefore be ruled out. The in-
structions given in the handling machine manual must be ob-
served.
HIGHYAG
Using a laser cutting head that is not attached to a guide machine

with a laser connected is forbidden.
Cables and hoses to the equipment have to be routed to prevent
any risk of accident (e.g., tripping hazard) for personnel, as well
as to ensure that they do not get damaged in the course of in-
tended operation of the laser cutting head.
2.1.3 Operating conditions
The BIMO−FSC may be operated in a technically perfect condi-

tion only.
The product may only be operated within the parameters speci-
fied in the data sheet. This, in particular, applies to the permissible
characteristics of the laser light and laser light cables.
The BIMO−FSC laser cutting head must not be used for handling
flammable or explosive materials, and no flammable and explo-
sive substances may be present in the operating environment. If
oxygen is used as cutting gas, there is a fire and explosion haz-
ard during the machining process, for instance, due to oil, grease
or dust in the machining environment or in the piping. If oxygen is
used as cutting gas, the supply lines must at least be oil−,
grease− and dust−free.
The BIMO−FSC laser cutting head may only be operated with a
suitable controller that checks the sensors of the device and eval-
uates the signals in a suitable manner. At the same time, the
product must be integrated into the whole system, if necessary
the programmable logic control (PLC), in such a way that it can be
switched off immediately in the event of malfunctions. Ensure that
it cannot be switched back on. Malfunctions must be eliminated
properly before it is started up again. 19
The equipment may only be operated while the cooling system is
on. A suitable monitoring functionality must be foreseen to this
effect. We recommend fitting the reflow circuit at the cooler with a
flow monitor because this is capable of detecting faults through-
out the entire cooling circuit.
The BIMO−FSC may not be operated with soiled optical ele-
ments, such as lenses, mirrors, cover slides, cover slide drawers
and their support surfaces, as well as the interior of the laser light
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cable receiver. Contamination in these areas may result in the

product damage or even destruction. The only exception would
be the process−side surface of the cover slide in the base mod-
ule. Minor soiling in this area can be tolerated as long as it does
not affect the process. The manufacturer recommends monitoring
the condition of the cover slide via the cutting head controller
HIGHYAG
CHC or compact cover slide monitor KSGM C, and determining

the appropriate thresholds for the replacement of the cover slide.

Do not operate the BIMO−FSC with the optical system open (e.g.
with the cover slide drawer pulled out). Hazardous laser radiation
can escape, or the optics may get dirty.
Prior to commissioning of the BIMO−FSC, make sure that the
cover slide drawer is properly inserted in the base module, and
the cover before the cover slide drawer is closed. Otherwise, the
cover slide drawer can fire out of the laser cutting head after
switching on cutting gas. This can cause severe injuries to by-
standers.
2.1.4 Qualifications of personnel
All work on the laser cutting head, such as installation, connec-

tion, commissioning, operation, maintenance, repairs or retrofitting
must be carried out by appropriately qualified and trained techni-
cal personnel only. The personnel must have read and under-
stood the content of this manual. The information described in the
applicable documents, such as electric circuit diagrams and pneu-
matic circuit diagrams, must be observed.
A technical expert, as defined in EN 60204−1, is a person who
can detect potential hazards and avoid and professionally perform
the work based on his/her technical training, knowledge and ex-
pertise, as well as the knowledge of the relevant standards and
regulations that are used for assessing the work transferred to
him/her.
Retrofitting as well as maintenance and repair work usually re-
quire additional qualification that can be acquired through training
20 by the manufacturer. Improperly performed work may damage the
product and/or lead to laser light escaping unchecked and thus to
hazards.
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HIGHYAG
2.1.5 Working close to BIMO−FSC laser cutting head

Only modifications, extensions and conversions described in this
manual may be performed on the laser cutting head. Any further
unauthorised modifications, extensions and conversions will ab-
solve the manufacturer from any liability. The guarantee will be
null and void.
Any modification of the laser cutting head, such as drilling additio-
nal boreholes is forbidden. Laser light may escape. The cooling
system and optical components may be irreparably damaged.
Do not remove the red marked screws, unless expressly permit-
ted in this manual. The optical system may be damaged or com-
plex adjustments may be affected. This will void the warranty.
When inserting and removing the laser light cable, there is a risk
of dirt penetrating the optical system. To prevent this, follow the
corresponding instructions described in this manual.
In principle, opening of the optical system is not permitted unless
the necessary qualification has been obtained for this purpose
through the corresponding training provided by the manufacturer.
However, this will void the warranty in any case. When used in
this manual, ”optical system” refers to an area inside the laser cut-
ting head between the cover slide in the base module and the co-
ver slide in the collimation module.
Exceptions to the above prohibition is the replacement of the
cover slide drawers and the replacement of the monitoring unit of
the tactile cover slide monitoring. Make sure you observe the pro-
cedures described in these instructions. If, however, the optical
system gets contaminated or its parts get damaged, this will void
the warranty.
The inspection and maintenance intervals specified in this manual 21
must be observed and the appropriate actions should be carried
out in accordance with the specifications.
For the purpose of compliance with the warranty claims, solely
original spare parts must be used for repairs.
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HIGHYAG
2.2 Information on special dangers

2.2.1 Exposure to laser light and reflection!
The laser emits a beam of light in an invisible wave length range

of approx. 1 mm an is classified as laser class 4. The light in the
near−infrared spectral range emitted by the laser is invisible and
can inflame clothes and objects and cause irreversible personal
injury, in particular, damage to eyes, skin and hair.
Unlike a conventional light source, a laser radiates in a very small
solid angle. The laser beam penetrates the optically non−refract-
ing media of the eye (cornea, aqueous humour, lens and vitreous
body) and focusses on the retina. The focus diameter there is
only a few micrometres (a bulb is about 0.1 mm). And so with
laser radiation the power density is about 1,000,000 greater than
that of a bulb. Therefore, this power density may damage the
eyes if it accidentally comes into contact with them.
Reflections that may strike workpiece and other reflective sur-
faces randomly have a comparable effect. Materials that appear
rough in visible light may have a reflective effect in longer wave
infra red light. As long as the roughness of such a surface is lower
than the wavelength of the used radiation, this may to all intents
and purposes appear to be a good reflector.
Danger to the skin from direct radiation must be considered to be
significantly lower than danger to the eyes. Also, skin is a visually
transparent medium and so the penetration depth and remission
must be noted. Damage to the subcutaneous area may also oc-
cur.
D The protective measures for accident prevention pursuant to
22 BGV B2 and DIN EN 60 825 must be observed.
D Never look at the laser beam. When handling class 4 laser
equipment, wear protective goggles suitable for laser equip-
ment (BGV B2).
D Only properly trained operating, maintenance and safety per-
sonnel may enter the laser processing area. The operating
company must ensure that all personnel who work on and with
the laser system and, if necessary, on the peripheral equip-
ment, have read and understood these operating instructions,
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particularly the safety instructions, and can also implement

them. This also applies to personnel only working on it occa-
sionally, e.g. for maintenance purposes.
D Access restrictions must be established for persons who do
not work on and/or with the laser system.
HIGHYAG
D Improper installation and integration into the system can

cause an escaping laser light hazard. Therefore, the installa-
tion and integration of the BIMO−FSC and the laser light cable
may be performed by qualified personnel only.
D Do not operate the BIMO−FSC with the optical system open
(e.g. with the cover slide drawer pulled out). Hazardous laser
radiation can escape, or the optics may get dirty.
2.2.2 Risk of fire and explosion
Combustible materials exposed to excessive heat generated in

the laser material processing, as well as process splashes and
sparks, can ignite and cause injuries to personnel.
Furthermore, there is an explosion hazard due to the formation of
gases, vapours and dusts. If oxygen is used as cutting gas, there
is a fire and explosion hazard during the machining process, for
instance, due to oil, grease or dust in the machining environment
or in the piping. Exploding or flying parts can cause injury.
D There must be no inflammable or explosive materials in the
laser beam operating area.
D The gas pipes must be thoroughly purged after each cutting
gas replacement The cutting gas to be used for purging de-
pends on the cutting gas that was used in the process and the
gas that is to be used in the forthcoming machining process.
D If the cutting gas pipes, the purging air pipes and the cutting
attachment are purged with compressed air, then oil−free
compressed air must be used.
D Appropriate extraction systems must be installed in the laser
processing area. Suitable filtering measures for the exhaust 23
air must be provided.
D Please observe the safety rules when handling oxygen and
other gases.
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HIGHYAG
2.2.3 Risks associated with harmful gases, dusts and vapours

Life−threatening dust, gases, and vapours may occur when pro-

cessing materials with laser beams. In addition, the accumulation
of air with gases, such as nitrogen, may lead to a lack of oxygen
in the laser processing area.
D Appropriate measures must be taken, in consideration of the
relevant standards and guidelines, to prevent hazards to per-
sons. This involves, for instance, providing appropriate sealing
for the laser processing area and installing suitable extraction
and exhaust filtration systems.
2.2.4 Risks associated with high−energy UV radiation
The formation of plasma, for example, during the laser machining

process, can lead to high−energy UV radiation. This can cause
injuries to skin.
D Appropriate measures for shielding the high−energy UV radia-
tion must be taken.
2.2.5 Risk associated with compressed air and cutting gas
The cutting gas used for laser material processing is under high
pressure (up to 2.5 MPa). The purging air and coolant pipes are
pressurised.
If the maximum permissible pressure is exceeded, parts or lines
can be blown off which may cause injuries to personnel or dam-
age to property.
24 D Make sure you read the information relating to pressure de-
scribed in the Data Sheet.
Insufficiently secured parts may get loose and may cause injuries
to personnel or damage to property due to pressurisation of the
laser cutting head.
D Before connecting compressed air and cutting gas, make sure
that the cutting gas and compressed air hoses are properly
connected and secured, and unneeded connections are se-
curely closed.
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D Prior to commissioning of the BIMO−FSC, make sure that the

cover slide drawer is properly inserted in the base module,
and the cover before the cover slide drawer is closed. Other-
wise, the cover slide drawer can fire out of the laser cutting
head after switching on cutting gas.
HIGHYAG
Once loosened, pressurized lines can fly off uncontrollably and

cause injuries to bystanders.
D Before removing the compressed−air, cutting−gas or coolant
hoses, turn off the supply and depressurise the system.
Cutting gas can churn up dust and dirt particles. This can lead to
eye injuries.
D Wear protective goggles when working on the equipment with
the pressure switched on.
The cutting gas exiting from the cutting nozzle under high pres-
sure, forms a sharp beam that may cause injuries.
D Never touch underneath the cutting nozzle when the cutting
gas supply is switched on.
2.2.6 Injury hazard due to moving parts!
The BIMO−FSC is installed on the handling machine. Entering the

pivoting area of the handling machine may lead to serious in-
juries.
D Stay clear of the operating area of the handling machine, e.g.,
during the process set−up. The instructions in the guide ma-
chine manual must be observed.
D Before commencing with maintenance work make sure that
the system has been shut−off and secured against power−up.
2.2.7 Risk of injury caused by sharp edges!
The cutting nozzle adapter of the BIMO−FSC normally has a pre-

25
determined breaking point that is intended to prevent significant
damage to the sensitive optics upon collision with the workpiece.
If the cutting nozzle adapter breaks at this point, sharp edges may
arise which may result in cutting injuries.
D Wear protective gloves when carrying out cleaning and as-
sembly work on a cutting attachment with a broken cutting
nozzle adapter.
D Use pliers to unscrew the cutting nozzle adapter.
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Broken cover slides may have sharp edges.

D Exercise the utmost care when replacing broken cover slides.
D Wear safety gloves as needed.
HIGHYAG
2.2.8 Risk of injury due to hot surfaces!

Parts of the BIMO−FSC laser cutting head, in particular, the cut-

ting nozzle and the cutting attachment, can become very hot dur-
ing the machining process.
D Let the laser cutting head cool down before working on it.
D Check the temperature of the laser cutting head.
2.2.9 Risks associated with the noise level
The use of compressed air and cutting gas can lead to an in-
creased noise level.
D Precautions to avoid hearing damage must be taken, such as
wearing suitable hearing protection (e.g., ear plugs or ear
muffs).
26
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HIGHYAG
2.3 Responsibilities of the operating company

The operating company of a laser cutting system with the BIMO−
FSC laser cutting head is responsible for ensuring that the laser
cutting head is used as prescribed and all relevant safety regula-
tions for handling the BIMO−FSC laser cutting head are complied
with.
The BIMO−FSC must only be operated in equipment that com-
plies with laser class 4. The operating company is responsible for
labelling the workplace in accordance with laser protection classi-
fications.
Prior to commissioning the Class 4 equipment, notify the employ-
er’s liability insurance association and the competent authorities
responsible for health and safety at work.
A laser protection officer must be appointed in writing prior to
commissioning the laser equipment. The laser protection officer is
responsible for training the laser equipment operating personnel
(at least once a year) in the risks associated with laser radiation
and appropriate safety measures.
The protective measures for accident prevention pursuant to BGV
B2 as well as DIN EN 60 825 and other regulations (see also sec-
tion 2.5 of this User’s Manual) should be implemented.
Only trained operating, maintenance and safety personnel prop-
erly instructed in laser safety matters may access the laser pro-
cessing area. Access restrictions must be established for persons
who do not work on and/or with the laser system.
The operating company must ensure that the personnel operat-
ing, assembling, maintaining or repairing the laser cutting head is
appropriately qualified and trained, and have read and under-
stood the content of this manual.
27
The inspection and maintenance intervals for the laser cutting
head specified in this manual must be observed and the appropri-
ate measures should be carried out in accordance with the speci-
fications.
The operating instructions must always be kept handy at the
place where the product is being used.
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HIGHYAG
2.4 Information on warranty

Any warranty and liability claims for personal injury and property
damage will be null and void if at least one of the following cir-
cumstances has contributed to the injury and/or damage:
− Disregarding the information described in the Operator’s Man-
ual
− Improper use
− Inappropriate assembly, commissioning, operating, mainte-
nance and repairs
− Non−compliance with the inspection and maintenance require-
ments
− Operating with soiled optics
− Unauthorised modifications, extensions and conversions
− Any modification of the laser cutting head, such as drilling of
additional boreholes
− Loosening of red marked screws, unless expressly instructed
in this manual
− Opening of the optical system, unless expressly instructed in
this manual, e.g., for replacing the cover slides
− Use of non−approved spare and wear parts
− Inappropriate transportation and storage
28
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2.5 Standards and regulations

The standards and codes quoted provide an overview of the most
important sets of rules to be taken into consideration for integra-
tion into existing equipment and during operation. The list does
not claim to be complete.
Standard Title
2006/42/EC European Machinery Directive
2006/25/EC European Parliament and Council Directive on the mini-
mum health and safety requirements regarding the ex-
posure of workers to risks arising from physical agents
(artificial optical radiation)
EN 60825−1 Safety of laser products − Equipment classification and
requirements and user guidelines
EN 60825−4 Safety of laser products − Laser guards
EN ISO 11553−1 Safety of machinery − Laser processing machines −
Safety requirements
BGV B2 UVV Accident prevention regulations for laser radiation
EN 207 Personal eye protection filter and laser protection eye
wear
ISO 12100 Safety of machinery − General principles for design −
Risk assessment and risk reduction.
EN 60204−1 Safety of machinery
Electrical equipment of machinery
General requirements
BGV A3 Accident prevention regulations ”Electrical installations
and operating equipment
TRGS 900 Maximum workplace concentration 29
Hazardous substances regulations §§ 18, 19
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HIGHYAG
2.6 Explanation of symbols and information

The following designations and symbols are used to indicate dan-

gers in this manual.
Danger!
Indicates a dangerous situation.
Failure to comply with these instructions will most likely lead to
severe damage to health, as well as severe, life−threatening or
fatal injuries.
Danger! Electrical voltage!

Indicates a hazard due to electrical voltage.
Danger! Laser!
Indicates a hazard due to laser radiation.
Warning!
Indicates a potentially hazardous situation. Failure to comply with
these instructions may lead to serious health effects or even life−
threatening injuries.
Caution!
These instructions denote potentially hazardous situations. Fail-
ure to comply with these instructions may lead to slight injuries or
material damage.
30 Attention!
Indicates a potentially harmful situation. Failure to comply with
these instructions may lead to material or product damage.
Important!
Instruction with special importance for dealing with the product
properly.
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3 Product description

This section describes the basic functions of laser processing
optics, as well as the design and operation of the BIMO−FSC la-
ser cutting head.
3.1 Principles of optics
The illustrations below are schematic presentations which serve to

explain the basic functions of the optics. These illustrations do not
constitute any warranty with regard to the actual design of the op-
tics. Optical systems, such as collimation units or focusing sys-
tems, for example, are shown as one lens although practical sys-
tems of this kind can consist of different numbers of lenses,
depending on the design of the optics.
3.1.1 Straight optics
Laser light cable Collimation Focusing

receiver unit unit
31
1 2 3 4 5 6
Laser optics, such as that of the BIMO−FSC laser cutting head

basically consist of at least the following components: Laser light
cable receiver, collimation unit and focusing unit.
The laser light cable conducting the laser light from the laser to
the laser processing optics is connected through the laser light
cable receiver. The light emitted from the optical fibre (1) of the
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laser light cable forms a conical beam (2). This beam hits the colli-
mation optics (3) and is converted to a parallel beam (4). The fo-
cusing optics (5) focuses this laser light in the working point (6).
As a result the required energy density to perform the machining
process is achieved.
HIGHYAG
3.1.2

3 7
3
7
5 5
7
Single deflection Double deflection
The principle of operation of the angled optics corresponds to that

of the straight optics, however, after the collimation unit (3) the
32 laser light additionally hits one or more mirrors (7) which deflect
the light towards the focusing unit (5).
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3.1.3 Optics with the process light emission

6
The process light (2) coming from the processing level (1,
workpiece) hits a mirror (4), located between the focusing optics
(3) and collimating optics (5), which reflects the laser light, but is
permeable to the process light. The process light thus decoupled 33
from the beam path of the laser beam exits through an opening in
the housing and can be used for process monitoring via an appro-
priate device (6).
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3.1.4 Focusing diameter and imaging ratio

The diameter of the focus is the product of the magnification of

the optics (M, imaging ratio) and the fibre core diameter of the
laser light cable:
Øfocus = M x Øfibre.
The imaging ratio is the product of the ratio between the focal
lengths of the collimation optics fcol and the focusing optics ffoc:
M = ffoc/fcol
The imaging ratio M of the entire optics is specified in the Data
Sheet of the BIMO−FSC.
3.1.5 Divergence and imaging ratio
a Faser a Fokus
The angle of the beam cone emitted from the focusing unit results
from the divergence angle of the laser beam emitted from the
laser light fibre and the imaging ratio of the processing optics (fo-
cus head).
a fibre
a focus +
M
Half the divergence angle is usually used for calculation.
34
3.1.6 Maximum permissible divergence angle
The maximum divergence angle (half angle) emitted from the fi-
bre, which the optics can process, depends on the version of the
collimation module. This parameter is part of the specification for
each BIMO−FSC. It is stated in the Data Sheet of the BIMO−FSC.
In the BIMO−FSC it is limited through a hard aperture. This must
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be considered when selecting the laser. It is recommended to

consult the manufacturer of the optical system or the laser manu-
facturer in cases of doubt.
HIGHYAG
3.2 Principles of operation of laser beam cutting

ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
Laser
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ Gas
ÏÏÏÏÏÏÏ
1
ÏÏÏÏÏÏÏ
ÎÎÎÎÎÎÎ 3
ÏÏÏÏÏÏÏ
ÎÎÎÎÎÎÎ
ÏÏÏÏÏÏÏ
ÎÎÎÎÎÎÎ
ÏÏÏÏÏÏÏ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ 2
The laser beam (1) and a gas jet (2) are arranged coaxially to
each other and pass to the workpiece through the cutting nozzle
(3). The focused laser beam heats the material locally to melting
temperature. The gas jet drives the molten mass or steam out of
the kerf.
The main parameters for setting the cutting process are:
− Feed rate,
− Gas pressure,
− Nozzle diameter, 35
− Distance between cutting nozzle and workpiece,
− Laser power and laser beam parameters,
− Focus position and diameter.
The centering of the laser beam to the gas nozzle is crucial to an
optimal process. If the beam and gas jet are not concentric, this
leads to an uneven distribution of pressure in the cutting process
and thus to non−uniform blowing of the molten mass.
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3.2.1 Fusion cutting

When inert gases (Argon, nitrogen , etc.) are used, this is referred
to as fusion cutting.
Gas pressures of approx. 2.0 − 2.5 MPa max. (20 − 25 bar max.)
are usually set for fusion cutting. The precise gas pressure de-
pends on the process conditions. Refer to the data sheet for infor-
mation concerning the maximum gas pressure for the BIMO−FSC
used.
3.2.2 Oxygen cutting
Active gas is used for oxygen cutting.

Oxygen is usually used with more than 99 % purity at a pressure
of approx. 1 bar.
Materials that can react to oxygen, such as structural steel, can
be processed.
The laser beam heats the material up to ignition temperature at
which the material reacts with the oxygen used, i.e. burns.
The burning of the material brings additional, high energy into the
process. This energy results in additional melting of the material
and thus enables higher cutting speeds or the cutting of thicker
materials than with fusion cutting.
36
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HIGHYAG
3.3 Coordinate system for defining the directions on the

BIMO−FSC
A three−dimensional Cartesian coordinate system is used for

defining directions on the BIMO−FSC laser cutting head.
The coordinate origin is at the focus centre in the focus plane.
The individual axes are defined as follows:
x−axis: Parallel to the focus plane and parallel to the flange
plane
y−axis: Parallel to the focus plane and perpendicular to the
flange plane
z−axis: Perpendicular to the focus plane and parallel to the
flange plane The Z−axis is thus identical to the beam
axis of the laser beam coming from the optics.
37
+y +x
+z
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3.4 Basic principles of focus setting

The BIMO−FSC laser cutting head has a collimation system with

adjustable lenses. The position of the lenses in the direction of
the beam axis can be changed by means of an electric drive sys-
tem. This allows to influence the position and, depending on the
version, also the diameter of the focus.
The collimation system is available in two different versions:
− Collimation system with motorized focus positioning in the
z−direction (Z collimation)
z−direction and focus diameter adjustment (MZ collimation)
The principle of the two procedures for focus setting is explained
below.
In the illustration, it is assumed that the z−axis runs along the opti-
cal axis of the collimation unit. The positive z−direction is oriented
toward the work piece.
38
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3.4.1 Focus positioning in the z−direction

5 6 8 7
1 2 3 4
1 Optical fibre
2 Collimation optics in the 0 position
3 Focusing optics
4 Focus position with the collimation unit in the 0 position
5,6 End positions of the collimation optics
7,8 Focus position when changing the position (5 or 6) of the
collimation optics
To change the focus position in the z−direction, the position of the
collimation optics is moved along the z−axis with regard to the fi-
bre tip. This results in a beam that is no longer collimated.
If the collimation optics is moved to the fibre tip, a divergent beam
is created and the final focus position moves from the focusing
optics further in the positive z−direction. In contrast, if the collima-
tion optics is removed from the fibre tip, a convergent beam re- 39
sults and the focus moves in the negative z−direction towards the
focusing optics.
As a side effect, the focus diameter changes slightly when chang-
ing the focus position in the z−direction. The impact of this effect
on the machining process depends on the configuration of the la-
ser cutting head, as well as the selected operating range. Fore
more details, please refer to the sections relating to the control of
various collimation systems.
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3.4.2 Focus diameter adjustment

5 6 87
1 2 3 4
1 Optical fibre
2 Collimation optics in the 0 position
3 Focusing optics
4 Focus diameter with the collimation unit in the 0 position
5,6 End positions of the collimation optics
7,8 Focus diameter when changing the position (5 or 6) of the
collimation optics
The lenses of the collimation optics can be moved in such a man-
ner that the focal length of the collimation optics (fcol) changes.
Changing the focal length changes the imaging ratio M for the en-
tire optical system because:
M = ffoc/fcol
40 ffoc = focal length of the focusing unit
fcol = focal length of the collimation unit
The focus diameter Øfocus thus changes as follows:
Øfocus = M x Øfibre
M = imaging ratio of the entire optics
Øfibre= fibre core diameter of the
laser light cable used
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This means that the adjustment of the focus diameter is achieved

by changing the imaging ratio of the optics.
The imaging ratio M for the BIMO−FSC has a defined size. The
focus diameter, however, can be only determined when the fibre
core diameter of the laser light cable is known. Therefore, the fol-
lowing description given in this User Manual on operation of the
HIGHYAG
collimation system normally refers to the imaging ratio M of the

optics.
As a side effect, the focus position in the z−direction slightly
changes when changing the focus diameter. The impact of this
effect on the process depends on the configuration of the laser
cutting head, as well as the selected operating range. Fore more
details, please refer to the sections relating to the control of va-
rious collimation systems.
41
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3.5 Design of the BIMO−FSC laser cutting head

The following illustrations do not cover the entire range of possi-

ble configurations of the BIMO−FSC. Appearance of the delivered
product may differ from the illustration given in this manual, de-
pending on the configuration. For the configuration of the deliv-
ered BIMO−FSC, please refer to the corresponding data sheet.
3.5.1 Overview of the main assemblies
42
3
4
5
1 Collimation system
2 Base module
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3 Cutting attachment
4 Cutting nozzle adapter
5 Cutting nozzle
6 Deflection module (not shown in the figure)
HIGHYAG
3.5.2 Collimation system

The collimation system usually consists of:
1 Laser light cable receiver
2 Aperture module
1
3 Cover slide module with a cover slide
drawer
2 4 Collimation module with an electric
3 drive unit
The collimation system is typically available in two different ver-

sions:
z−direction (Z collimation)
z−direction and focus diameter adjustment (MZ collimation)
Other variants of the collimation system depend on the type of the
laser light cable receiver and the maximum permissible laser
power (see also the sections below).
Please refer to the data sheet to see what collimation system is 43
the supplied BIMO−FSC equipped with.
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3.5.2.1 Laser light cable receiver

The laser light cable is connected to the

1 BIMO−FSC through a laser light cable
receiver (1). Different variants of laser
light cable receivers are available.
2 2 For configurations with the MZ collima-
tion, the laser light cable receiver is syn-
chronised and calibrated by the manufac-
turer with the collimation system, and the
settings are fixed.
The laser light cable receiver is integrated
into the coolant system via the two
coolant connections (2).
Variants of the laser light cable re-
1 2 ceiver:
1 QBH laser light cable receiver
2 Auto laser light cable receiver
3.5.2.2 Aperture module

The aperture in the aperture module (1)
reduces the risk of a laser beam that is
outside the permitted parameters (e.g.
due to a defective laser light cable con-
nector) causing damage inside the laser
cutting head.
44 2 The aperture module is integrated into
the coolant system via the two coolant
1 connections (2).
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3.5.2.3 Cover slide module with a cover slide drawer

To protect of the collimation optics from
dirt, a cover slide module (1) with a re-
placeable cover slide drawer (2) is
mounted below the aperture module.
The cover slide (3) in the cover slide
drawer prevents dirt from penetrating into
1 the collimation unit when connecting and
removing the laser light cable.
2
3.5.2.4 Collimation module with an electric drive unit

The collimation module (2) incorporates
the collimation optics. The position of the
collimation optics lenses can be changed
in the direction of the beam axis by
means of the electrical drive unit (1).
By adjusting the collimation optics, de-
pending on the version, either the focus
position only can be changed in the beam
3 direction (Z collimation), or the focus posi- 45
1
tion as well as the imaging ratio M of the
entire optics can be changed (MZ collima-
tion).
Collimation modules that are designed for
use at higher laser power have additional
2
cooling plates (3).
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Variants of the collimation modules with an electric drive

unit:
1 2 3 4
1 Z collimation for a laser power of up to 6 kW,

Mcol = 1.0
2 Z collimation for a laser power of up to 8 kW (cooled),
Mcol = 1.0
3 MZ collimation for a laser power of up to 4 kW,
Mcol = 0.9 − 1.8
4 MZ collimation for a laser power of up to 6 kW (cooled),
Mcol = 0.9 − 1.8
46
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3.5.3 Base module

The base module consists of the following components:
1 Focusing unit with x− and y−adjust-
ment for the focus position
2 Cover slide module with a cover slide
drawer and a cover (shown as open)
as well as the cover slide monitoring
1
unit
2 3 Base module housing and cutting−
gas guiding system
3 5 4 Flange
4 The base module is available in various
versions.
Base modules that are designed for use
at higher laser power have an additional
cooling plate (5).
Variants of the base module:
1, 2 3, 4
47
1 Base module for a laser power of max. 6 kW, Mfoc = 1.5

2 Base module for a laser power of max. 6 kW, Mfoc = 2.0
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3 Base module for a laser power of max. 8 kW, cooled, Mfoc = 1.5
4 Base module for a laser power of max. 8 kW, cooled, Mfoc = 2.0
The connection for cutting−gas pressure monitoring (not included
in scope of delivery) can be designed either on the right (see vari-
ants 1 and 2) or the left (see variants 3 and 4).
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3.5.3.1 Focusing unit with x− and y−adjustment

The focusing unit (2) contains the focus-

ing optics. Focusing lenses with different
focal lengths are available.
1 The focusing optics can be adjusted in x−

1 and y−direction using the turn knobs (1),
so that the focus is concentrically aligned
2 to the cutting nozzle. The adjusting direc-
tion is indicated on a label next to the turn
knobs.
The turn knobs can be replaced as
needed.
3.5.3.2 Cover slide module with a cover slide drawer and a cover slide
monitor
The cover slide module (1) comprises the
1 cover slide drawer (3) with the cover slide
(2) and the components for the cover
slide monitoring.
2
The cover slide protects the valuable fo-
3 cusing optics against soiling.
The cover (4) of the cover slide drawer
protects it from damage and soiling.
4
The cover slide monitoring consists of an optical sensor for moni-

toring the degree of soiling of the cover slide, and a tactile sensor
that detects whether the cover slide and the cover slide drawer
48 are inserted.
The sensors are integrated into the moni-
toring unit (5) on the rear of the cover
slide module.
5
Cover slide drawer, cover slide, cover and
the monitoring unit are interchangeable.
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3.5.3.3 Flange

The flange (7) builds up a mechanical in-
terface for the assembly of the BIMO−
2 1 FSC on the handling machine.
Two support bolts (5) and 4 cylinder−
3 4 head screws M6 (4) are used for the safe
and accurate positioning and fastening of
the BIMO−FSC.
5
A seal (6) protects the cover slide monito-
ring unit from contamination, and can be
6 replaced if necessary.
4
In addition, there are connections for cut-
7
ting gas (1) and purge air (3) on the
flange. The cutting−gas pressure can be
monitored via a corresponding connection
(2). The cutting−gas pressure is moni-
tored by the user.
The purge air is used for purging of the cutting attachment in or-
der to reduce the contamination in this area.
3.5.3.4 Base module housing and cutting−gas guiding system

The cutting−gas guiding system (2) is lo-
cated in the interior of the base module
housing (1).
The cutting−gas guiding system improves
the cutting gas flow towards the nozzle
outlet. This allows to reduce the soiling of
the cover slide before the focusing unit.
The cutting−gas guiding system is re-
1 49
placeable.
2
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3.5.4 Cutting attachment

The cutting attachment (1) is mounted on

the underside of the base module. It is
used for directing the cutting gas to the
cutting nozzle, and the purging air to the
outlet openings. The cutting nozzle
adapter which in turn retains the cutting
nozzle is fitted on the cutting attachment.
2
The cutting attachment, together with cut-
1
ting nozzle adapter and cutting nozzle
build up the capacitive sensor for dis-
tance measurement.
An inductive sensor on the base module is used for monitoring
whether the cutting attachment is mounted correctly. If the cutting
attachment is missing or it is not tightened properly, an error mes-
sage is generated.
The cutting attachment can be quickly and easily removed from
the base module by means of the screw−in ring (2). Cutting gas,
purging air and the electric contacts for distance measurement
are directed through the base module to the cutting attachment.
This means that it is not necessary to additionally disconnect any
cables and pipes when detaching the cutting attachment.
3.5.5 Cutting nozzle adapter and cutting nozzle
The cutting nozzle adapter (1) is used for

retaining the cutting nozzle (2). In addi-
tion, it is also a part of the capacitive sen-
50 sor for distance measurement. A range of
cutting nozzle adapters are available, de-
pending on the cutting nozzle installed.
The cutting nozzle adapter is typically fit-
1 ted with a predetermined breaking point
(3). In the event of a collision in the noz-
2 zle area, the nozzle adapter will break at
the predetermined breaking point. This
reduces the risk of damage to the cutting
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attachment.
3
HIGHYAG
3.6 Opportunities for electrical integration of the BIMO−FSC

into a laser cutting system (overview)
The BIMO−FSC laser cutting head is a part of the entire system

for laser material processing. The illustrations below show the ma-
jor components of the system.
The electrical integration of the BIMO−FSC into the laser system
can be implemented in two different ways. They are as follows:
− Digital integration: The contol and monitoring of the laser cut-
ting head as well as the capacitive distance measurement are
carried out via the CHC accessory, which is integrated into the
bus system of the laser cutting system.
Ether CAT bus systems are supported.
or
− Analogue integration: The electrical drives of the laser cutting
head are controlled and monitored via the control unit of the
laser cutting system. Monitoring of the cover slide drawer and
of the cutting attachment as well as the capacitive distance
measurement are carried out through accessories.
Both possibilities are briefly described below:
51
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3.6.1 Digital integration through CHC

Laser power
CHC
Laser Control of the motordriven
collimation system
Capacitive distance mea-

surement (option)
Cover slide moni-

toring (option)
Coolant Cutting attachment
monitoring (option)
Supply Cutting gas
Purge air Pressure switch

(option)
BIMO−FSC
System controller
The Cutting Head Controller (CHC) is an accessory used for the

digital control of electric drives of the collimation system, as well
as for evaluating the signals of most monitoring systems.
The CHC can perform the following tasks:
− Digital control and monitoring of the electric drives of the colli-
mation system
− Capacitive distance measurement
52 − Cover slide monitoring
− Monitoring of the cutting attachment
The controlling and monitoring of the BIMO−FSC via the Cutting
Head Controller (CHC) is described in detail in the respective
CHC manual.
The pressure switch for monitoring the interior of the BIMO−FSC
is not evaluated by the CHC. It is connected directly to the system
controller.
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3.6.2 Analogue integration

Control of the motordriven
Laser power collimation system
Laser
FJB (option)
Capacitive distance
measuring
KSGM C (option)
Coolant Cover slide monitoring,
Cutting attach-
Supply Cutting gas ment monitoring
Purge air Pressure switch

(option)
BIMO−FSC
System controller
In this type of integration, the electric drives of the collimation sys-

tem are controlled directly by the system controller by providing
an analogue control voltage.
KSGM C accessory is used for the cover slide monitoring and
monitoring of the cutting attachment. This accessory evaluates
the signals coming from the sensors and generates the corre-
sponding warning or error messages.
The capacitive distance measurement is carried out by means of
the FJB accessory. Depending on the version, the analogue out- 53
put signal for the measured distance is either a voltage signal or a
frequency modulated signal.
The pressure switch for monitoring the interior is connected di-
rectly to the system controller. It generates an error message
when exceeding the set threshold.
The controlling and monitoring of the BIMO−FSC for analogue
integration is described in detail in the sections below.
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3.7 Controlling the motordriven collimation system via ana-

logue integration
The collimation system is directly connected to the system con-

troller. The system controller supplies defined control voltage val-
ues so that the drives in the collimation system adjust the optics
accordingly. For configurations with Z collimation a voltage signal
for the focus positioning in the z−direction is required . For config-
urations with MZ collimation, another voltage signal for changing
the imaging ratio M, and thus the focus diameter must be pro-
vided.
The drives in turn report operational readiness or generate an er-
ror signal back to the system controller in the event of a failure.
BIMO−FSC
0…10 V for focus positioning in the

z−direction (Z− and MZ collimation)
System 0…10 V for changing the imaging

ratio M (MZ collimation)
con-
troller
Motor condition z (Z− and MZ collimation)
Motor condition M (MZ collimation)
The focus position and/or the imaging ratio are calculated by a

formula on the basis of the control voltage supplied.
These formulas include specific coefficients which are determined
54 by the manufacturer for each BIMO−FSC.
The respective formula and the specific coefficients must be
downloaded into the system controller. The values of the coeffi-
cients change when the BIMO−FSC is replaced as well as the
collimation system is repaired or changed . This must be consid-
ered when the system controller is programmed.
The formulas and sample diagrams for the analogue control of the
motorized focus adjustment are outlined below.
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3.7.1 Changing the focus position in the z direction for configura-

tions with Z and MZ collimation systems
The following applies to the settings for

the focus position from the nozzle tip in
the z−direction (beam direction):
– negative value: Focus moves towards
BIMO−FSC
– positive value: Focus moves in the di-
rection of the workpiece
−z
The adjustment range depends on the
+z configuration of the BIMO−FSC, which is
specified in the data sheet.
Formula for calculating the focus position:
z foc + a U 2)b U)c

zfoc: Focus position in the z−direction [mm]
U: Control voltage [V]
a, b, c: Specific coefficients, see data sheet
Sample diagram for the relationship between control voltage and

focus position in the z−direction of a BIMO−FSC with a
Z collimation system:
20.0
Focus position in the z−direction [mm]
15.0
10.0
55
5.0
0.0
−5.0
−10.0
−1.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0
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Control voltage [V]

HIGHYAG
Sample diagram for the relationship between control voltage and

focus position in the z−direction BIMO−FSC with a

MZ collimation system:
40.0
30.0
20.0
10.0
0.0
−10.0
−20.0
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
Control voltage [V]
3.7.2 Changing the focus diameter (adjusting the focus diameter)

for configurations with MZ collimation systems
Formula for calculating the imaging ratio:
M+o U 2)p U)q

M: Imaging ratio of the BIMO−FSC
U: Control voltage [V]
56 o, p, q: Specific coefficients, see data sheet
The adjustment range depends on the configuration of the BIMO−

FSC, which is specified in the data sheet.
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Sample diagram showing the relationship between control voltage

and imaging ratio M
(for a BIMO−FSC with a MZ collimation system and a focal
length of the focusing optics ffoc = 150 mm):
3.5
3.0
2.5
Imaging ratio M
2.0
1.5
1.0
0.5
0.0
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
Control voltage [V]
3.7.3 Mutual influence of the parameters imaging ratio and focus

position
3.7.3.1 Configurations with a Z collimation system

The imaging ratio of the optics slightly changes in the event of the
z−adjustment of the focus position.
The imaging ratio is calculated based on the following formula: 57
M+m z foc ) n
M: the imaging ratio
zfoc: Focus position in the z−direction [mm]
m, n: Specific coefficients, see data sheet
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Sample diagram showing the influence of the focus position on

the imaging ratio for a BIMO−FSC with a Z collimation system and

a focal length of the focusing optics ffoc = 150 mm:
1.70
1.65
1.60
Imaging ratio M
1.55
1.50
1.45
1.40
−8.0 −6.0 −4.0 −2.0 0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0
3.7.3.2 Configurations with a MZ collimation system

When changing the focus position in the z−direction the imaging
ratio M of the optics slightly changes, and vice versa. The impact
of this effect on the processing depends on the configuration of
the laser cutting head, as well as on the selected operating range.
If necessary, the manufacturer can determine an adjustment table
for each of the BIMO−FSC’s configurations used, specifying the
necessary control voltages for certain settings of Z and M.
58
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3.8 Cover slide and cutting attachment monitoring with

KSGM C
3.8.1 Cover slide monitoring
The cover slide drawer between the focusing optics and the cut-
ting−gas guiding system in the base module of the BIMO−FSC is
fitted with sensors used for monitoring the following conditions:
− Cover slide drawer inserted (plug monitoring) and cover slide
in place (insertion monitoring)
− Degree of soiling of the cover slide.
The insertion and plug monitoring is carried out by means of a
tactile sensor. An optical sensor is used for monitoring the degree
of soiling.
The evaluation of the signals for analogue integration is carried
out via the compact cover slide monitor KSGM C.
This can be used for determining the individual thresholds for
generating a warning or an error message in the monitoring of the
soiling degree.
Further details are described in the KSGM C manual, as well as in
the electric circuit diagram.
3.8.2 Cutting attachment monitoring
An inductive sensor on the BIMO−FSC can be used for monitor-

ing whether the cutting attachment is mounted correctly. The sig-
nals for analogue integration are evaluated and forwarded via the
compact cover slide monitor KSGM C. 59
Further details are described in the KSGM C manual, as well as in

the electric circuit diagram.
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3.9 Capacitive distance measuring with FJB

Cutting nozzle, cutting nozzle adapter and parts of the cutting at-
tachment of the BIMO−FSC laser cutting head are designed as a
capacitive sensor used for determining the distance between the
cutting nozzle and the workpiece.
The distance signal can be used both for controlling and adjusting
the distance between the cutting nozzle and the workpiece.
The signals for analogue integration are evaluated via the FJB
accessory.
Further details are described in the FJB manual, as well as in the
electric circuit diagram.
3.10 Pressure monitoring of the interior
The interior of the BIMO−FSC above the cover slide can be moni-
tored through a pressure switch supplied. To do this, there is a
compressed air hose connection on the focusing unit, which is
connected to the pressure switch.
For example, if the pressure in the interior suddenly rises in the
event of a cover slide breakage, this would be detected by the
pressure switch. This triggers a corresponding signal to the sys-
tem controller. The signal can be used for immediately switching
off the laser and the cutting gas in the event of a significant rise in
pressure and thus for protecting the sensitive optics from contami-
nation and damage.
The pressure switch is connected with the system controller re-
gardless of the type of integration of the BIMO−FSC.
For further details, please refer to electric circuit diagram and
60
pneumatic circuit diagram.
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3.11 Cooling system

Caution! Risk of overheating
The laser cutting head can only be operated with the cooling sys-
tem connected.
An impaired function of the cooling system causes extremely high
temperatures and damages to the laser cutting head.
The customer/user is solely responsible for providing a cooling
system with sufficient cooling capacity.
3.11.1 Coolant specifications
Parameters Values
Water quality Fully desalinated (demineralised water,
deionised water)
with corrosion inhibitor,
(For corrosion protection see section 3.11.3)
Filter fineness < 100 mm
Temperature range +15 °C up to +35 °C (or see the data sheet)
Max. supply pressure 0.6 MPa (6 bar)
Required minimum flow rate 2 l/min
per cooling circuit
3.11.2 Coolant quality
Continuous faultless cooling can only be guaranteed if clean cool-

ing water is used. 61
Impurities and microbiological contamination of the cooling water
can lead to the cooling water pipes and channels being blocked
due to deposits or corrosion.
The much−used „industrial cooling water” must not be used be-
cause this is normally obtained from wells, ponds or rivers, and
therefore its composition is unregulated.
The manufacturer hence recommends using deionised water (fully
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desalinated water, demineralised water, deionised water) for cool-

ing of the temperature−sensitive system components, such as
beam guiding system or the laser cutting head.
A connection to the laser cooling system normally meets the re-
quirements for water quality.
HIGHYAG
3.11.3 Corrosion protection

As deionised water can absorb ions particularly easily, heavy cor-

rosion in the cooling system may occur because of electrochemi-
cal effects. Therefore, a suitable corrosion inhibitor should always
be added. The design and materials of the whole cooling system
(cooler, pipes, valves) etc. must be taken into consideration when
selecting and dosing this corrosion inhibitor. A generally effective
recommendation can therefore not be given.
3.11.4 Biological contamination
Over time, microbiological colonisation may occur particularly with

open cooling systems. It is therefore recommended that you
check the system for biological contamination at regular intervals.
In the event of contamination, suitable agents should be added,
such as a suitable biocidal agent.
3.11.5 Risk of condensation
If the humidity is too high and the temperature too low in the opti-
cal system this may lead to condensation on the optical compo-
nents.
The cooling water temperature must be set to a level which will
prevent condensation in the optical system. The coolant tempera-
ture must be higher than the dew−point temperature correspond-
ing to the ambient temperature. A dew point table is shown in the
data sheet of the BIMO−FSC.
62
3.11.6 Monitoring recommendation
As even the most careful maintenance of the cooling system will

not positively prevent the cooling system becoming blocked, it is
advisable to monitor the cooling water flow in the return line di-
rectly on the cooler. In this way blockages or major leaks in the
whole cooling system can be detected.
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3.11.7 Coolant connection diagram

The hose connections to the coolant consuming units in the ex−
works condition are implemented in a serial configuration as
shown in the block diagram below. The example shows the
coolant circuit of a BIMO−FSC, which is designed for a higher
laser power.
The type of the coolant consuming units connected to the cooling
circuit, depends on the configuration of the BIMO−FSC. The im-
plemented connection diagram is included in the data sheet.
Cooling diagram − example
Cooling OUT Cooling IN

(Return) (Supply hose)
1
Laser light cable
2 receiver
3
Aperture module
4
5
Cooling plate,
collimation unit
6
7
Cooling plate,
63
focusing unit
8
9
Cooling plate,
10 collimation unit
1 Input
2 Output
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Inward coolant channel

Outward connection hose

64
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4 Assembly, Installation and Setup

This section contains the information required to correctly prepare
the BIMO−FSC laser cutting head for commissioning.
The applicable safety instructions are compiled in the ”Safety in-
formation” section and must be observed.
4.1 Scope of delivery
The scope of delivery is heavily dependent on the configuration of

the BIMO−FSC and on the type of the intended integration in the
system control. Also observe the information given in the data
sheet, as well as the electric circuit diagram.
The scope of delivery normally contains:
− BIMO−FSC laser cutting head
− Set of cables and plugs for the connection of the BIMO−FSC,
as well as for the accessories included in scope of delivery
− Mounting tool for the cover slide replacement
− Documentation
Optional features include, for instance:
− Cutting Head Controller CHC
− FJB distance measuring module
− Compact cover slide monitor KSGM C
− Pressure switch with a connection hose and a cable
− Starter kit with cover slides and various cutting nozzles
The scope of delivery may differ as agreed to from case to case. 65
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4.2 Installation site requirements

A detailed list of the required media and connections can be

found in the data sheet.
The manufacturer recommends installing at least two additional
protective contact sockets (230 V, 10 A in accordance with DIN
49440) for peripherals and maintenance equipment in a suitable
place within the laser processing cell. If this is not possible, for
example, if the laser processing cell is too small, sockets must be
installed in the immediate vicinity of the cell.
4.3 Unpacking
The BIMO−FSC laser cutting head and the peripherals included in

scope of delivery are supplied in special transport containers that
ensure extensive protection.
Referring to the delivery bill, check the delivery for damage and
completeness after unpacking. The inspection should be carried
out with the help of the delivery note and the configuration over-
view provided in the data sheet.
Important!
Do not remove any protective caps and sealing plugs from the
laser cutting head until commencing assembly work or immedi-
ately before setting into operation.
66
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4.4 Assembly of the BIMO−FSC laser cutting head and the

accessories
4.4.1 Assembly of the laser cutting head
1 Assembly surface
4
2 Fastening screws
(4 pcs, M6x25, ISO 4762)
3 Support bolts
(2 pcs, ∅ 8 mm)
1 4 Cutting−gas connections
A fitting plate must be prepared for fitting
the laser cutting head to the handling ma-
3 2 chine. In the dimensioning of the moun-
ting plate, it should be noted that the cut-
ting−gas connections (4) slightly protrude
of the mounting surface of the BIMO−
FSC (see the figure below).
The exact dimensions of the mounting
4 surface are specified in the technical
drawing.
Hardened guiding sockets ∅ 8 F7 (such
as guiding sockets in accordance with
DIN 179) are recommended for retaining
the support bolts (3). By means of the
sockets and support bolts, the laser cut-
ting head can be mounted and disman-
tled in a reproducible position.
67
Assembly
Necessary tool: −Allen key, gauge 5
D Carefully clean the assembly surface.

D Position the laser cutting head on the mounting plate until the
mounting surface is flush on the mounting plate.
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D Provide the fastening screws with lock washers, insert them

into the mounting holes and tighten them as far as the stop.
The required tightening torque depends on the condition (material
and quality) of the mounting plate of the machine manufacturer
and should be defined by the same.
HIGHYAG
4.4.2 Fitting the accessories (option)

When selecting the place where to fit the accessories, the length
of the sensor cables supplied must be taken into consideration.
These cables must be used to connect the BIMO−FSC with the
equipment.
The length of the cables is specified in the respective manuals
and in the electric circuit diagram.
The manufacturer recommends fitting the accessories on the cut-
ting trolley.
Accessories are fitted with a flange with 4 boreholes (4) for
screws M4.
The drilling template for assembly and the dimensions of the
equipment are described in the respective manual or in the elec-
tric circuit diagram.
Necessary tool: − Allen key, gauge 3
1 CHC
1
2 KSGM C
3 FJB
4 4 Assembly boreholes
Assembly
D Clean the assembly surface.
D Secure the accessory unit with Allen
screws (4 pcs, M4, ISO 4762) includ-
2 ing washers and spring washers.
68
The required tightening torque depends
on the condition (material and quality) of
4 the mounting plate of the machine manu-
facturer and should be defined by the
same.
3
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4
HIGHYAG
4.4.3 Fitting the pressure switch (option)

When selecting the place where to fit the pressure switch, the
length of the sensor cable supplied must be taken into considera-
tion. This cable must be used to connect the pressure switch to
the system controller.
The manufacturer recommends fitting the pressure switch on the
cutting trolley.
The data sheet with fitting and operating instructions for the pres-
sure switch forms part of the technical documentation.
Assembly
D Carefully clean the assembly surface.

D Fasten the pressure switch with Allen screws
(2 pcs, M4, ISO 4762) and washers as well as spring washers
as needed.
The required tightening torque depends on the condition (material
and quality) of the mounting plate of the machine manufacturer
and should be defined by the same.
69
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HIGHYAG
4.5 Installation

This section describes the installation of the connections for medi-

a, control and monitoring.
Further information can be found in the electric circuit diagram,
the pneumatic circuit diagram and in the data sheet.
4.5.1 Overview
The type of connections to be established depends on the type of

integration of the BIMO−FSC in the system controller.
In addition, the configuration of the supplied laser cutting head
should be observed.
The supplied cables and plugs correspond to the type of integra-
tion and configuration of the product.
4.5.1.1 Digital controlling and monitoring via CHC

(Digital integration)
The following connections are required:
− Laser light cable from the laser
− Cooling water supply
− Cutting−gas supply
− Purging air supply
− Connection between the controller and CHC
− Data cable (1 piece) and sensor cables (2 pieces) from the
BIMO−FSC to the CHC
70 − Hose from the BIMO−FSC to the pressure switch (option)
− Cable from the pressure switch to the system controller (op-
tion)
Connection scheme
See the page on the right:
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compressed air hose

Laser light cable
Laser compressed air hose Cutting gas
BIMO−FSC
cooling water hose
Cooling water Purge air
cooling water hose
Cable
CHC
Cable (optional)
compressed air hose
Cable (optional) compressed air hose
compressed air hose
Pressure
switch
(optional)
Cables Cable
System controller
HIGHYAG
71

HIGHYAG
4.5.1.2 Analogue control via the system controller and monitoring via ac-

cessories (analogue integration)

The following connections are required:
− Laser light cable from the laser
− Cooling water supply
− Cutting−gas supply
− Purging air supply
− Connection between the electric drive unit and system con-
troller
− Sensor cable form the BIMO−FSC to the distance measure-
ment module FJB
− Inputs and outputs from the FJB to the system controller
− Sensor cable from the BIMO−FSC to the compact cover slide
monitor KSGM C
− Outputs from the KSGM C to the system controller
− Hose from the BIMO−FSC to the pressure switch (option)
− Cable from the pressure switch to the system controller (op-
tion)
Connection scheme
See the page on the right:
72
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Compressed air hose

Laser light cable
Laser Cutting gas
BIMO−FSC Compressed air hose
Cooling water hose
Cooling water Purge air
Cooling water hose
Cable
FJB Cable
Compressed air hose
(optional)
Cable
Compressed air hose
KSGM C
(optional) Compressed air hose
Pressure
switch
(optional)
Cables Cables Cable
System controller
HIGHYAG
73

HIGHYAG
4.5.2 Connecting the coolant supply

Note! Risk of overheating!

The BIMO−FSC laser cutting head can only be operated with the
cooling system connected.
An impaired function of the cooling system causes extremely high
temperatures and damages to the laser cutting head.
The customer/user is solely responsible for providing a cooling
system with sufficient cooling capacity.
Important!
Coolant that penetrates the laser cutting head or the laser light
cable receiver may damage the optical components.
D Lay the coolant hoses in such a manner that no leaking
coolant can enter the optics or the laser light cable receiver.
Coolant hose: external diameter = 6 mm,

hydrolysis−resistant
The BIMO−FSC comes with two connect-

ing hoses (1) and quick−action couplings
3
2 (2, 3) for the connection to the coolant
4
supply. In the as−supplied condition, the
1 quick−action couplings can be connected
via a short hose element (4).
In order to connect the coolant hoses,
proceed as follows:
74
D Pull the quick−action couplings (2,3) apart to separate.
D Remove the hose element (4).
D Fit the coolant supply hoses with the quick−action couplings
(3).
D Connect the coolant supply hoses by closing the quick−action
couplings with the BIMO−FSC.
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During subsequent disassembly of the laser cutting head, the

coolant supply can be interrupted quickly and securely by sepa-
rating the quick−action couplings.
HIGHYAG
Remove the hose element

D Press the hose into the plug−type
5 connector and at the same time press
the clamping ring down towards the
connection.
D Keep the clamping ring in the de-
pressed position and pull the hose off
the plug−type connector.
Fitting the quick−action couplings with the coolant supply

hoses
D Use a sharp knife in order to cut the hose ends at right angles,
straight and without burrs.
D Make sure that the hose ends are not damaged. The exterior
must be free from score marks or scratches.
The plug−type connectors (5) at the quick−action couplings have
2 pressure points (collect and gasket) through which the hose
must be pushed in order to ensure secure and tight seating of the
hose.
D Fully push the hose into the plug−type connector (5). Two
pressure points must be overcome.
D Slightly pull the hose in order to make sure that it is firmly se-
cured.
75
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4.5.3 Connecting the cutting−gas supply

Warning! Fire and explosion hazard!

If oxygen is used as cutting gas, there is a fire and explosion haz-
ard during the machining process, for instance, due to oil, grease
or dust in the machining environment or in the ducts.
Exploding or flying parts can cause injury.
D Please observe the safety rules when handling oxygen and
other gases.
D Make sure that the gas pipes and hoses are free from grease,
oil or dust and that no grease, oil or dust can enter these
pipes or hoses.
D Whenever changing the cutting gas, thoroughly purge the gas
hoses. The cutting gas to be used for purging depends on the
cutting gas that was used in the process and the gas that is to
be used in the forthcoming machining process.
D Use oil−free compressed air if compressed air is used to
purge the gas hoses.
Connections
1 Cutting gas
1 LEGRIS plug−type connectors
for hose
(2 pcs., external diameter = 10 mm)
3 2 Purge air
plug−type connectors for a hose
2 (2 pcs., external diameter = 6 mm)
76 3 Cutting−gas pressure monitoring
connector
(Accessories for monitoring the cut-
ting−gas pressure are not included in
the scope of delivery)
Max. permissible pressure

Refer to the data sheet.
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To achieve a uniform gas flow rate, it is recommended to use both

connectors.
If only one connector is used, the second connector should be
sealed with a sealing plug.
Connecting the hoses

D Cut off the hose ends straight.
D Insert the hose into the plug−type connection (1): When you
begin to feel resistance, fully push the hose further into the
plug−type connector.
cured.
77
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4.5.4 Connecting the cutting head controller CHC for digital inte-

gration
BIMO−FSC CHC
X13
X21 X1 X5
Cable
Z: 01−05−12−0031
MZ: 01−05−12−0035
X6 Cable 01−04−01−0190
Cable 01−04−01−0464
X10
Connecting of the electric drive unit

D Connect the connector ”X13” on the BIMO−FSC and connec-
tor ”X21” on the CHC using the supplied data cable.
The type of cable to be used depends on the configuration of
the laser cutting head:
Configuration with Z−collimation: cable 01−05−12−0031
78 Configuration with MZ−collimation: cable 01−05−12−0035
Connecting of the capacitive sensor

D Connect the connector ”X6” on the BIMO−FSC and connector
”X5” on the CHC using a triaxial cable.
Connecting of the cover slide and the cutting attachment

monitoring
D Connect the connector ”X10” on the BIMO−FSC and connec-
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tor ”X1” on the CHC using the cable 01−04−01−0464.
Connection of the CHC to the system controller

The connection of the CHC to the system controller is described
in the CHC manual.
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4.5.5 Connecting the electric drive unit for analogue integration

BIMO−FSC
X13
control cable System

(not included in the scope controller
of delivery)
CONINVERS
connection coupling
Z: 01−04−03−1207
MZ: 01−04−03−1334
Connection to the system controller

D Install the supplied CONINVERS connection coupling to the
control cable (the control cable is not included in the scope of
delivery). In doing so, note the configuration of the laser cut-
ting head:
Configuration with Z−collimation: coupling 01−04−03−1207
Configuration with MZ−collimation: coupling 01−04−03−1334
Refer to the electric circuit diagram for PIN assignment.
D Connect the connector ”X13” on the BIMO−FSC with the sys-
tem controller via the control cable.
The electrical supply data and the signals are specified in the
electric circuit diagram.
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4.5.6 Fitting the FJB distance measuring module (option)

BIMO−FSC FJB
X6
Cable
01−04−01−0190
Input Sensor
Connecting the FJB to the BIMO−FSC

D Connect the connector ”X6 on the BIMO−FSC and connector
”Input Sensor” on the FJB via triaxial cable 01−04−01−0190.
Connecting the FJB to the system controller

The connection of the FJB to the system controller is described in
the FJB manual.
4.5.7 Connecting the KSGM C compact cover slide monitor (option)
BIMO−FSC KSGM C Connector

cover slide
drawer
80
X10
Cable 01−04−01−0464
Connecting KSGM C to the BIMO−FSC

D Connect the ”X10” connector on the BIMO−FSC and the
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”Cover slide drawer connector” on the KSGM C via cable

01−04−01−0464.
Connecting the KSGM C to the system controller

The connection of the KSGM C to the system controller is de-
scribed in the KSGM C manual.
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4.5.8 Fitting the pressure switch (option)

BIMO−FSC
X16
Gas Monitoring
Cable
01−04−01−0129
Compressed air hose Pressure switch

external diameter NORGREN 18D
4 mm
Connecting the pressure switch to the BIMO−FSC

D Remove the plug from the ”Gas Monitoring” connector on the
BIMO−FSC.
D Connect with the enclosed compressed air hose (external di-
ameter 4 mm) the ”Gas Monitoring” connector on the BIMO−
FSC with the pressure switch.
Connect the compressed air hose

D Insert the hose into the plug−type connector: When you begin
to feel resistance, fully push the hose further into the plug−
type connector.
cured.
Connecting the pressure switch to the system controller 81

Connect the pressure switch with the system controller via con-
nected cable 01−04−01−0129.
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4.5.9 Connecting the laser light cable

Note! Danger of contamination

Even the slightest contamination in the laser light cable receiver
may damage the optics system.
D If possible, only connect the laser light cable in a clean, dust−
free environment.
D Before removing the sealing plug, clean the laser light cable
receiver and the surrounding area thoroughly.
D Before connecting the laser light cable, check whether the
cover slide drawer before the collimation unit is fitted with a
cover slide that is properly seated.
D Ensure that no dirt can get into the laser light cable connector
or the laser light cable receiver.
D If possible, place the laser processing optics in a horizontal
position to connect the laser light cable. This reduces the risk
of dirt falling onto the optics or the laser light cable connector.
D Remove the protective cap or sealing plug carefully and
smoothly from the laser light cable or the laser light cable re-
ceiver so that no dust is drawn in.
D Keep the protective caps and sealing plugs for the laser light
cable connectors or laser light cable receivers in a clean, seal-
able plastic bag.
D Seal the laser light cable receiver and the laser light cable
connector with the corresponding sealing plug or protective
cap, whenever the laser light cable is uninstalled.
D Never touch parts such as the glass stone or fibre
end in the laser light cable connector.
82
D After connecting the laser light cable, pull the
cover slide drawer and check it for soiling. Replace
the cover slide drawer if necessary.
Fibre end
Glass stone
Important!
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Please refer to the related information in the manual for the laser
light cable.
If the cooling water system connection is provided on a laser light
cable connector, the cooling water specifications in the respective
laser light cable manual must be obeyed.
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4.5.9.1 QBH laser light cable receiver

1 QBH laser light cable receiver
3
2 Threaded ring
1
3 Sealing plug
2
4 Laser light cable connector
5 Red dot on the laser light cable connector
6 Red dot on the QBH laser light cable receiver
7 Red dot on the threaded ring
8 Groove on the laser light cable connector
4
5 D Lay the laser light cable in accordance with the

8 manufacturer ’s instructions and and initially secure
6 in place only loosely (e. g. with cable ties).
7 D Unlocking the laser light cable receiver (1): Turn
the threaded ring (2) anti−clockwise, push down
and turn anti−clockwise until it stops.
D Remove the protective cap from the laser light cable
connector on the optics side and the sealing plug (3)
from the laser light cable receiver.
D Check the laser light cable receiver and connector to
ensure that they are clean; clean if necessary.
4 D Insert the laser light cable connector (4) into the
laser light cable receiver (1). To do this the three
red dots (5, 6, 7) on the laser light cable connec-
tor (4) and the laser light cable receiver (1) must 83
be on top of each other so that the securing pin in
the laser light cable receiver can slot into the
2 groove in the laser light cable connector (8).
Push the laser light cable connector (4) slowly
into the laser light cable receiver until it stops.
D Locking the laser light cable receiver (2): Turn the threaded
ring (2) clockwise (approx. 37 ), pull out and turn again until it
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stops (approx. 15 .

D Store the sealing plug (5) and the protective cap in a clean,
sealable plastic bag.
Sealing plugs and protective caps must be reinserted or rein-
stalled each time the laser light cable is removed.
HIGHYAG
4.5.9.2 Auto laser light cable receiver

D Lay the laser light cable in accordance with the

1 2
manufacturer ’s instructions and and initially secure
in place only loosely (e. g. with cable ties).
D Remove the protective cap (1) from the laser light
cable connector (2). To do this turn the protective
3 cap slightly so that the locking pin is released from
the groove (3) and the protective cap can be re-
4 moved. Remove the protective cap slowly from the
connector so that no dust is drawn in.
D Push the clamping ring (4) into the laser light cable
receiver in the direction of the arrow and remove
the sealing plug (5).
D Check the laser light cable receiver and connector
6 5
for soiling, and clean if necessary.
7 D Push the laser laser light cable connector into the

receiver and secure in place. The locking pin (7)
on the laser light cable connector must be seated
correctly in the slot (6) in the laser light cable re-
ceiver.
Release the clamping ring (4) on the laser light ca-
8 ble receiver so that it clicks into place in the groove
in the laser light cable connector.
D Store the sealing plug (5) and the protective cap
(1) in a clean, sealable plastic bags.
Sealing plugs and protective caps must be reinserted or rein-
stalled each time the laser light cable is removed.
84
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4.6 Assembly inspection

Warning! Risks associated with pressurized gas!
The cutting gas used for laser material processing is under high
pressure (up to 2.5 MPa).
If the maximum permissible pressure is exceeded, parts or lines
can be blown off which may cause injuries to personnel or dam-
age to property.
D The maximum permissible cutting gas pressure specified in
the data sheet must be adhered to.
Insufficiently secured parts may get loose and may cause injuries
to personnel or damage to property due to pressurisation of the
laser cutting head.
D Prior to switching on the cutting gas supply, make sure that:
− The cutting gas hoses are plugged in correctly and se-
curely fastened,
− unused connections are closed,
− the cover slide drawer in the base module is plugged in
correctly and the lock levers are engaged,
− the cover before the cover slide drawer is closed.
Cutting gas can churn up dust and dirt particles. This can lead to
eye injuries. In addition, an emission sound level of 111 dB (A) is
reached. This may damage your hearing ability.
D Wear protective goggles and suitable hearing protection when
working on the equipment with the cutting gas switched on.
The cutting gas exiting from the cutting nozzle under high pres-
sure, forms a sharp beam that may cause injuries. 85
D Never touch underneath the cutting nozzle when the cutting
gas supply is switched on.
Important!
Refer to section 5.2.2 for inspection and replacement of the cover
slide drawers.
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Assembly check list

Step Description Check

1 Check:
laser cutting head secured on the handling machine o
2 Check:
the laser light cable is correctly connected o
3 Check the cover slide drawer in front of the collimation
unit: o
Ensure that the cover slide is in place o
Cover slide and drawer are clean o
Ensure that the threaded ring has been tightened
4 Place and secure the cover slide drawer before the
collimation unit.
Check:
Cover slide drawer secured in place o
5 Pull and check the cover slide drawer in the base module:
Ensure that the cover slide is in place o
Cover slide and drawer are clean o
Cover slide cover is securely tightened o
6 Place and secure the cover slide drawer in the base mo-
dule.
Check:
Cover slide drawer is in place o
Locking lever locked o
Cover closed o
7 Check:
Compressed air hoses for purging air are connected
correctly o
Unused connections are closed o
86 8 Switch on the compressed air supply and check that:
Connections and hoses are tight o
9 Check:
Compressed air hoses for cutting gas are connected
correctly o
Unused connections are closed o
Pressure switch is correctly connected or the
pressure switch connector is closed o
10 Switch on the cutting gas supply and check that:
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Connections and hoses are tight o

11 Check that:
The cooling water hoses are correctly positioned o
12 Switch on the coolant supply and check that:
System is tight o
HIGHYAG
4.7 Setup

After assembly and installation of the BIMO−FSC some compo-
nents and the laser cutting head must be adapted to the process
conditions.
The corresponding setup procedures are described in this sec-
tion.
4.7.1 Setting up the electrical drive system
The setup procedures for electric drives of the collimation system

differ in the type of integration of the BIMO−FSC laser cutting
head into the laser cutting system.
4.7.1.1 Control via CHC for digital integration

The procedure for setting up the communication between the sys-
tem controller and the cutting head controller CHC is described in
the CHC manual.
4.7.1.2 Control via the system controller for analogue integration

D Download the formulas for focus positioning into the system
controller. In doing so, note the configuration of the laser cut-
ting head.
D Download the specific coefficients into the system controller
from the data sheet of the laser cutting head.
D Switch on the voltage for the electric motors.
Green and red LEDs on the front of the drive unit light up.
D Wait a few seconds; the electric motors perform a reference
operation. This may take about 5 seconds. 87
During initialization, the ”No Error” signal is not defined, i.e. it can
drop for a short time and the red LED may go out shortly. The
electric drive system is ready for operation, if ”No Error” signal =
24 V is emitted for all existing motors and the corresponding
LEDs light up permanently.
D Perform 3 drive runs over the entire adjusting range to lubri-
cate the bearings. For this purpose, the target values for the
positioning of the drives are given via the system controller to
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the BIMO−FSC.
The corresponding signals are shown in the electric circuit dia-
gram.
HIGHYAG
Functioning of the LEDs

Configuration with Z−collimation

Item Colour Function
1 1 red on Drive for focus posi-
tioning OK
off Position or excess
2 current fault
2 green on Operating voltage
ready
off No operating voltage
connected
Configuration with MZ−collimation

1 2 Item Colour Function
3 1 red on Drive for focus posi-
tioning OK
current fault
2 green on Operating voltage
ready
off No operating voltage
connected
3 red on Drive for focus diam-
eter adjustment OK
88 current fault
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4.7.2 Aligning the laser beam in relation to the cutting nozzle

Before the laser cutting head is set into operation for the first time,
and after modifications, the laser beam must be aligned in relation
to the cutting nozzle.
Danger! Laser!
The light in the near−infrared spectral range emitted by the laser
is invisible and can inflame clothes and objects and cause irre-
versible personal injury, in particular, damage to eyes, skin and
hair.
D Never look at the laser beam. When handling class 4 laser
equipment, wear protective goggles suitable for laser equip-
ment (BGV B2).
D When using a pilot laser, observe the safety information ac-
cording to the laser class of the pilot laser.
Caution! High cutting gas pressure!

The cutting gas pressure can be as high as 25 bar. This results in
an emission sound pressure level of up to 111 dB (A). This can
also blow up dust and dirt particles. If the laser beam is adjusted
with the cutting gas switched on, this can injure both ears and
eyes.
D Switch off the cutting gas before adjusting the laser beam.
Note!
The turn knobs for the x − and y−adjustment are provided with a
lock nut for preventing accidental calibration. Loosen the lock nuts
before calibration in order to prevent damage to the adjusting 89
mechanism.
D Loosen the lock nuts of the turn knobs before calibration.
D Retighten the lock nuts of the turn knobs once the calibration
is complete.
Important!
The turn knobs for the x − and y−adjustment are not secured
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against unscrewing.
D Unscrew the turn knobs to the extent required for calibration
only.
HIGHYAG
Important!

Shock of the laser cutting head (e.g. due to falling) can cause
maladjustment.
D In such a case, check the alignment of the laser beam in rela-
tion to the cutting nozzle and re−adjust the laser cutting head
if necessary.
Use two turn knobs to align the focusing

optics in the x− and y−directions The
laser beam is centered in relation to the
nozzle opening.
2
1 1 Turn knob for adjustment in the
x direction
2 Turn knob for adjustment in the
y direction
Marks indicating the adjusting direction are attached next to the
turn knobs.
Total adjusting distance possible = 2 mm.
Functions of the turn knobs

2 1 Lock nut for arresting the turn knob
1 3 2 Scale division for general orientation
3 Slots in two different lengths. The end
of the shorter slots indicates the 0 po-
sition. The end of the long slots indi-
cates the end of the adjustment range
in the negative x− or y−direction.
90 4 Hexagon slot for adjusting the turn

5 4 knob
5 Radial mark for orientation: Distance
between the marks ¢ 0.5 mm adjust-
ment range
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Adjustment process

A camera system or an adhesive strip (as described herein) can
be used, for instance, to check that the laser beam is correctly
aligned.
Necessary tools and materials:

− Allen key, gauge 3
− Adhesive strips, matt transparent
D Make sure that the focus position in the z−direction is at the

cutting nozzle opening level (0−position).
D Make sure that the cutting gas supply is switched off and can-
not be accidentally switched back on again.
D Switch off the laser and make sure it cannot be accidentally
switched back on again.
D Stick an adhesive strip onto the nozzle opening.
D With low laser power (depending on the laser source < 100 W)
generate a short laser pulse.
D Switch off the laser and secure it against being switched back
on.
D Hold a mirror under the cutting nozzle and check whether the
hole in the adhesive strip and the nozzle opening are concen-
tric. This means that the hole in the adhesive strip and the
nozzle opening have the same center.
If the hole in the adhesive strip and the nozzle opening are not
concentric:
D Shift or stick a new adhesive strip so that the nozzle opening
is covered again.
91
D Correct the x− and y−direction using the respective turn knob.
To do this, release the lock nut, adjust the turn knob and then
tighten the lock nut.
D Check again for correct alignment as described above.
D Repeat the adjustment procedure until the cutting nozzle and
the hole in the adhesive strip are concentric.
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4.7.3 Setting up the FJB and KSGM C accessory devices (optional)
The procedures for setting up the FJB and KSGM C attachments

are described in the manuals of the devices.
HIGHYAG
4.8 Starting up

The laser cutting process is programmed, for example, via the

handling machine controller. This work depends strongly on the
application provided by the user.
A description of the procedures for programming the handling ma-
chine itself is not included in this manual.
Prior to setting the system into operation, always remember:
D to switch on the purging−air supply
D switch on the cutting−gas supply
D switch on the cooling water supply
92
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5 Maintenance and repair

The maintenance terminology used in this section is based on
DIN 31 051 ‘Maintenance‘. According to this, maintenance in-
cludes all measures required to maintain and restore the target
state and to determine and assess the actual condition of techni-
cal system resources. These measures include maintenance, in-
spection and repairs.
Inspection includes all measures required to determine and as-
sess the actual condition of technical system resources.
Maintenance includes all measures required to maintain the target
state of technical system resources.
Repair includes all measures required to restore the target state
of technical system resources.
Inspection and maintenance intervals are specified in operating
hours. Here approx. 160 hours is equivalent to one week and 680
hours equivalent to one month with three shifts 7 days a week.
The applicable safety instructions are compiled in the “Safety in-
formation” section and must be observed.
Caution! Risk of injury due to hot surfaces!

Parts of the laser cutting headmay reach high temperatures du-
ring operation.
D Let the laser cutting head cool down before working on it.
Important!
Some components cannot be removed by the operator. Settings
may be lost. 93
D Do not remove the red marked screws under any circum-
stances!
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Caution! Danger of destruction of optical components!

Soiling of optical components such as cover slide can lead to

damage or destruction.
Therefore, opening of the optical system of the laser cutting head
is not permitted unless the necessary qualification has been ob-
tained for this purpose through the corresponding training provi-
ded by the manufacturer. When used in this manual, ”optical sys-
tem” refers to an area inside the laser cutting head between the
cover slide in the base module and the cover slide in the collima-
tion module. Exceptions to the above prohibition is the replace-
ment of the cover slide drawers and the replacement of the moni-
toring unit of tactile cover slide monitoring. Make sure you
observe the procedures described in these instructions.
No guarantee is assumed in conjunction with any work on the
opened optical system! This applies, in particular, to damage to
lenses or mirrors caused by dirt exposure or incorrect handling.
D Always perform this kind of work in a clean, dust−free environ-
ment!
D Clean the laser cutting head and the surrounding area care-
fully before you remove the laser light cable or dismantle mod-
ules.
D Position the laser cutting head so that no dirt can enter the
openings during work.
D Cover the openings on the product (for example, with an ad-
hesive tape).
D Never touch the optical components, such as cover slides,
with your hand.
D Prior to re−assembling, clean, in particular, the mounting sur-
94 faces (supports) once again.
D Before fitting individual modules, check the O−rings for dirt or
damage. Clean a soiled O−ring and/or replace a defective
O−ring.
D Store the spare parts in the appropriate transport boxes at all
times.
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5.1 Scheduling of inspection and maintenance work

The need for inspection and maintenance measures depends
heavily on the actual duty cycles and loads of the equipment dur-
ing operation. Maintenance measures and intervals are shown
below.
We recommend adapting the maintenance intervals to the operat-
ing conditions according to practical experience.
5.1.1 Daily maintenance
− Perform lubricating operations with the electric drive system

(see section 5.2.1).
Minimum requirement: Every 2 hours or 3 runs throughout
the entire adjustment range.
Recommendation: Every 30 minutes during operation
3 runs throughout the entire adjustment range
(e.g. each time the plate is changed).
− If necessary, e.g, in the event of suspected soiling, check the
cover slide and cover slide drawer in the base module. Re-
place, if necessary.
(refer to section 5.2.2.2).
5.1.2 Weekly maintenance
− Clean the laser cutting head from the outside.

− Remove and clean the cutting attachment
(refer to section 5.2.4). 95
− Check the cutting gas, compressed air and water connections.
All the connections must be correct and tight.
(see section ”Assembly”).
− Check the cable connections and make sure that they are
connected correctly and firmly (see section ”Assembly”).
− Check the correct connection of the laser light cable
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− Check that the laser cutting head is securely fastened on the

handling machine, and tighten the screws, if necessary
HIGHYAG
5.2 Maintenance work

5.2.1 Lubricating the collimation system
The drives of the collimation system include spindle bearings and

ball bearings. The bearings are lubricated by the manufacturer.
If the bearings are exposed to very small strokes or angles of ro-
tation, there is a risk that the grease film tears apart. This causes
increased wear and tear.
In order to prevent the grease film from tearing apart, regular lu-
brication operations must be performed.
Minimum requirement: 3 drive cycles over the entire adjustment
range
− whenever the collimation system is set into operation (after a
reference operation of the drives)
− after interruptions of operation and repairs (always after a ref-
erence operation of the drives)
− at least every 2 hours during operation.
Recommendation: Every 30 minutes during operation
3 runs throughout the entire adjustment range
(e.g. each time the plate is changed).
5.2.2 Checking and replacing the cover slides
Caution! Danger of contamination

The cover slides and cover slide drawers must be free of dirt. Ex-
96 posure of soiled optical elements to laser power can damage the
optics.
D Clean the cover slide module and the surrounding area care-
fully before removing the cover slide drawer.
D Handle the cover slide drawer by its handle only.
D Prevent dirt from entering the open cover slide module during
the cover slide inspection (for example, by attaching adhesive
tape on the opening the opening).
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D Store the cover slide drawers in the corresponding transport

boxes only.
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Important!

The manufacturer recommends having a second cover slide
drawer available as replacement and to always change the com-
plete cover slide drawer. The soiled cover slide and/or other parts
of the cover slide drawer can then be changed in a clean environ-
ment in order to minimize the risk of soiling.
5.2.2.1 Replacing the cover slide drawer in front of the collimation module
Necessary tool: − Torx screwdriver TX10
1 Cover slide module

2 Cover slide drawer
3 Countersunk screws
2 (2 pcs countersunk screws,
DIN 7991 T M3x10)
4 Cover slide
1
3 5 Guide pins (2 pcs)
6 Sealing
6 4 7 Guide pin holders
5
D Use an oil−free cloth and/or a hard
plastic brush in order to clean the
3 cover slide module and the surround-
ing area.
D Loosen two countersunk screws (3).
D Take the cover slide drawer (2) by the
handle and pull it out of the cover
slide module. 97
D Cover the housing openings with ad-
hesive tape.
D Check the cover slide (4) for soiling.
1 7 To do this, look through the cover
slide against the light as the first step.
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Then turn the cover slide so that the light is reflected and

check the surface of the cover slide. In doing so, check the
cover slide drawer, the sealing (6) and the guide pin (5). Re-
place the cover slide drawer.
D Before placing the drawer, ensure that it is oriented correctly
(Note ”Top” on the handle).
D Place the clean cover slide drawer carefully into the cover
slide module. In doing so, push the guide pins (5) into the ho-
les (7) in the cover slide module.
D Secure the cover slide drawer with countersunk screws (3)
(Tightening torque = 1.8 + 0.2 Nm).
98
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5.2.2.2 Replace the cover slide drawer in the base module

Warning! Risk of injury caused by parts flying around!
The cover slide drawer in the base module seals the interior of the
BIMO−FSC against cutting gas. If the cover slide drawer is incor-
rectly inserted and the cover is not closed, the drawer can be
thrown out when switching on cutting gas.
D Once the cove slide drawer has been placed, check if the
locking lever is engaged.
D Close the cover.
Caution! Risk of damage!

Ensure that an appropriate cover slide only is used for the respec-
tive model of the BIMO−FSC. If an incorrect cover slide is used,
there is a risk that the monitoring unit may get damaged when the
cover slide drawer is placed.
D Make sure there is a letter sequence ”SLT” in the serial num-
ber of the cover slide drawer.

1 2 Cover slide drawer
2
3 Cover slide
3
4 Locking lever
5 Cover
6 Sealing
4 7 Serial number
99
8 Borehole
5
D Use an oil−free cloth and/or a hard
plastic brush in order to clean the
cover slide module and the surround-
ing area.
D Fold the cover (5) down.
D Press the locking lever (4) on the
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cover slide drawer and pull it out of

6 7 8
the cover slide module.
D Attach adhesive tape on the housing opening or place a spare

drawer.
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D Check the cover slide (3) for soiling. To do this, look through

the cover slide against the light as the first step. Then turn the
cover slide so that the light is reflected and check the surface
of the cover slide. In doing so, check the cover slide drawer
and the sealing (6).
Replace the cover slide drawer.
D If a new drawer is used, check whether this is a cover slide for
tactile cover slide detection. The ”SLT” letter sequence in the
serial number of the cover slide drawer is the distinguishing
mark.
D Press the locking lever (4) down. Make sure that the drawer is
inserted in the correct direction (Note ”Top” on the handle).
D Carefully insert the cover slide drawer all the way into the
cover slide module.
D Release the locking lever and make sure that it snaps into
place in the cover slide module (1).
D Fold the cover up and close it over the cover slide drawer.
5.2.3 Replace the cover slides and elements of the cover slide
drawer

The cover slides and cover slide drawers must be free of dirt. Ex-
posure of soiled optical elements to laser power can damage the
optics.
ment!
100 D Clean the cover slide drawer thoroughly before removing its
parts.
D Wear clean protective gloves to replace the cover slide.
D Never touch the plane surfaces of the cover slide.
D Clean the cover slide drawer and the transport box again after
replacing the cover slide.
D Store the cover slide drawers in the corresponding transport
boxes only.
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5.2.3.1 Cover slide drawer in front of the collimation unit

Important!
Only the original tool (6) must be used for the work described
here.
Necessary tool: − Assembly tool for

Retaining ring

1 2 3 4
2 Cover slide
3 Cover slide screw−in ring
4 Upper sealing ring
5 Lower sealing ring
6 Screw−in tool
D Remove the cover slide drawer from

4 the cover slide module.
3 D Use the screw−in tool (6) to unscrew
and remove the screw−in ring (3).
2 D Take the cover slide (2) carefully out

of the cover slide drawer (3).
5 D Check the lower and upper sealing
ring (4, 5) of the drawer for damage or
contamination. Replace the seals, if
necessary (refer to the following sec-
tion).
1 101
D Insert a new cover slide into the cover
slide drawer.
D Screw in the cover slide screw−in ring
as far as it will go using the screw−in
6 tool.
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Replacing the upper sealing ring

Caution!
If the sealing ring is removed with a tool, it is vital to ensure that
the sealing ring base surface is not damaged.
Caution!
Always use a new sealing ring, as the old one will be damaged
during disassembly.

1 4
4 Upper sealing ring
(External diameter = 37.0 mm)
D Remove the defective sealing ring

from the cover slide drawer by lifting
the sealing ring by its inner diameter.
D Put the new sealing ring into place in
such a manner that it is fully sup-
1 4 ported by the base surface. The seal
must be flush with the rear on the
outer surface of the retaining groove.
The illustration shows a section view
of the sealing ring.
102
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5.2.3.2 Cover slide drawer in the base module

Necessary tool: − Allen key, gauge 2.5

1 2 5 4
2 Cover slide
3 Sealing ring, on the cover slide side
4 Cover
5 Sealing ring, on the housing side
6 6 Countersunk screws
(4 pcs, M4x8, DIN 7991)
7 Borehole
8 Optical fiber end
D Remove the cover slide drawer from

7 the cover slide module
D Unscrew 4 countersunk screws (6)
and remove the cover (4).
D Take the cover slide (2) carefully out
of the cover slide drawer (3).
D Check the seals (3 and 5) in the cover
for cleanliness and damage and re-
7 8 place if necessary. (Refer to the sec-
tion below)
D Check the optical fiber end (8) and
the borehole (7) for the contact pin of
the cover slide monitoring unit for
1 103
cleanliness, and clean if necessary.
The cover slide drawer monitoring unit
will not run correctly unless these
parts are clean.
2
D Carefully insert the cover slide into the
drawer.
3
D Fit the cover and tighten it with the
four countersunk screws (6).
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(Tightening torque = 3.0 Nm)

4
5
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Replace the sealing rings in the cover slide cover.

Caution!
When using a tool to remove the inner sealing ring, make sure
that the sealing ring base surface in the cover slide drawer is not
damaged.
Caution!
Always use a new sealing ring, as the old one will be damaged
during disassembly.
1 Sealing ring, on the cover slide side

2 Sealing ring, on the housing side
1 D Proceed as described above to re-

move the cover slide cover.
D Remove the defective sealing ring
from the cover slide cover by lifting
the sealing ring by its inner diameter.
D Put the new sealing ring into place in

such a manner that it is fully sup-
104 ported by the base surface. The seal
must be flush with the rear on the
outer surface of the retaining groove.
The illustration shows a section view
of the cover slide cover with the in-
serted sealing rings.
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5.2.4 Maintaining the cutting attachment

Warning! Risk of injury!
The cutting module can be fitted with a cutting nozzle adapter
with a predetermined breaking point (see arrow).
In the event of a collision in the nozzle
area, the nozzle adapter will break at the
predetermined breaking point. The result-
ing breaking edges can be extremely
sharp. Disassembly and cleaning work on
the cutting module with a broken nozzle
adapter can therefore cause severe hand
cuts.

sembly work on a cutting attachment with a broken nozzle
adapter.
The cutting attachment has minimum maintenance requirements.

Parts of the cutting attachment must be cleaned at regular inter-
vals. In doing so, inspect the parts of the cutting attachment for
faultless condition and replace if necessary.
Cutting nozzle adapter and cutting nozzles come in various ver-
sions. The images in this section are given by way of example
and may slightly differ from the delivered model.
5.2.4.1 Removing and installing the cutting attachment
Caution! Risk of damage! 105
The threaded ring (1) of the cutting attachment is tightened by

hand. Do not use tools as this can damage the threaded ring.
D Do not use tools for loosening and tightening the threaded
ring.
If the cutting attachment is installed incorrectly, the electrical con-
tacts for capacitive distance measuring (5, 9) can be damaged.
D Pull the cutting attachment straight down to remove it or push
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it on straight from below to fit it. No tilting or twisting is permit-

ted.
HIGHYAG
Necessary tools: − soft plastic brush

− clean and lint−free cloth
1 Threaded ring
3 Guide pin holder
1 4 Mounting surface
2 5 Contacts for capacitive distance mea-

suring on the base module
6 O−ring (Ø 37.82 x 1.78)
7 Guide pin
8 O−ring (Ø 4.00 x 1.5)
9 Contacts for capacitive distance mea-
3 suring in the cutting attachment
4 Dismantling
5 D Clean the cutting attachment and the
surrounding area carefully
D Loosen the threaded ring (1) and pull
the cutting attachment (2) straight
9 down.
6
Assembly
8
D Check the cutting attachment for
cleanliness and integrity of the electri-
7 cal contacts; clean if necessary
106
D Inspect the O−rings (6, 8) for cleanli-
ness, integrity and proper seating;
clean or replace if necessary.
D Carefully clean the assembly surface (4).
D Place the cutting attachment straight from below, so that the
guide pin (7) slides into the holder (3) in the base module.
D Press the cutting attachment all the way into the base module
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and tighten the threaded ring by hand.

HIGHYAG
5.2.4.2 Cleaning the outside of the cutting attachment

Necessary tools: − soft brass − or plastic brush,
clean and lint−free cloth
− pliers
3 Cutting nozzle
1 D Unscrew the cutting nozzle adapter

2 (2).
3 D Clean the cutting attachment (1).

D Screw in the cutting nozzle adapter
(tightening torque 7.5 Nm).
5.2.4.3 Cleaning the inside of the cutting attachment

After the cutting attachment has been removed, the electric con-
tacts for the distance measuring module are freely accessible.
D Do not use a wire brush and water for cleaning.
107
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Necessary tool: − soft plastic brush

− lint−free cloth
1 Threaded ring
3 Counterpiece for inductive sensor
1 4 Electrical contacts for distance mea-

suring
2 5 O−ring (Ø 37.82 x 1.78)
6 Guide pins
7 Purging air inlets with O−rings
(Ø 4.00 x 1.5)
3 4 8 Guide pin holder
9 Mounting surface
5
7 10 Inductive sensor
11 Purging air outlets
6 12 Electrical contacts for distance mea-

suring
D Clean the cutting attachment and the

surrounding area carefully
8 D Remove the cutting attachment
11 (refer to section 5.2.4.1).
9
12 D Clean the cutting attachment inside
10 and outside.
108 D Clean the electrical contacts (4, 12)
for the distance measuring module
and check whether these are in a per-
fect condition.
D Clean the inductive sensor (10) and the counterpiece (3), and
check whether these are in a perfect condition.
D Clean the purge air inlet and outlet openings (7, 11) and in-
spect for proper condition.
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D Inspect and, if necessary, replace the O−rings (7).

D Check the O−rings (5) in the cutting attachment for cleanliness
or damage. Clean or replace the O−ring as needed.
D Clean the assembly surface (9).
D Install the cutting attachment (see section 5.2.4.2).
HIGHYAG
5.3 BIMO−FSC Removing and installing

To remove the laser cutting head proceed as described below:
D Disconnect the voltage, compressed air, cutting gas and cool-
ing−water supply.
D Detach the laser light cable.
D Disconnect the cooling−water connections.
D Detach the compressed air and cutting gas hoses.
D Disconnect the signal cables.
D Detach the BIMO−FSC from the handling machine.
5.3.1 Disconnecting the laser light cable
This section describes how to remove the laser light cable.

The procedure for connecting the laser light cable is described in
the “Installation” section.
Caution! Risk of destruction!

Dust or dirt in the laser light cable connector or the laser light ca-
ble receiver may lead to the destruction of the laser light cable
and the optical system.
D Prevent dirt penetrating into the laser light cable receiver or
the laser light cable connector.
D Pull the laser light cable connector slowly and smoothly out of
the laser light cable receiver. Removing it quickly may suck in
dirt.
109
D Keep the protective covers ready for the laser light cable and
the laser light cable connector.
D Refer to the laser light cable manual.
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5.3.1.1 QBH laser light cable receiver

Tools and materials required:

− Protective cap for laser light cable connector
− Sealing plug for laser light cable receiver
D Clean the laser light cable receiver, the laser light

cable connector and the surrounding area care-
fully.
D Switch off the cooling water to the laser light cable
connector.
D Remove the cooling water hoses from the laser
light cable connector and wipe away any leaking
cooling water.
D Unlocking the laser light cable receiver: Turn the
threaded ring (1) anti−clockwise (approx. 15 ), en-
1 gage it and then turn it anti−clockwise (approx.
37 ) until it stops. The two red dots on the laser
light cable receiver must be in line on top of each
other.
D Pull the laser light cable connector out of the laser
light cable receiver without twisting it.
D Put the protective cap onto the laser light cable
connector immediately.
D Store the laser light cable in a safe place (do not
twist and do not expose to mechanical load).
D Secure the laser light cable receiver on the laser
cutting head with the sealing plug.
110
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5.3.1.2 Auto laser light cable receiver

Tools and materials required:
− Protective cap for laser light cable connector
− Sealing plugs for laser light cable receiver
D Clean the laser light cable receiver, the laser light

cable connector and the surrounding area care-
1 fully.
3 D Switch off the cooling water to the laser light cable
connector.
2
D Remove the cooling water hoses from the laser
light cable connector and wipe away any leaking
cooling water.
D Pull the clamping ring (3) on the laser light cable
receiver (2) in the direction of the laser light cable
3 receiver and hold it (see second illustration).
D Pull the laser light cable connector (1) out of the
laser light cable receiver slowly and smoothly.
D Place the protective cap (4) onto the laser light ca-
5
4 ble connector so that the guide pin (5) on the laser
light cable connector slides into the slot (6) on the
protective cap. Then turn the sealing plug (7)
clockwise to lock it.
6 D Place the laser light cable down safely (do not

turn, do not put a mechanical load on it).
111
D Insert the sealing plug (7) into the laser light cable
receiver. When doing this ensure that the guide pin
7 (8) on the sealing plug slides into the slot (9) in the
laser light cable receiver.
8
D Push the clamping ring (3) to its start position.
9
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5.3.2 Disconnecting and connecting cables and hoses

Proceed as follows in order to disconnect the hoses and cables:

D Switch the cooling water supply off.
D Switch the compressed air and cutting gas supply off.
D Disconnect the cables and hoses from the laser cutting head:
− Electric drive unit cable
− Cover slide monitor cable (option)
− Distance measuring cable (option)
− Two purging−air hoses
− Two cutting−gas hoses
− Compressed air hose for pressure monitoring (option)
− Two quick−action couplings at cooling−water hoses.
D Drain the cooling water (for instance, using compressed air)
and subsequently seal the cooling system at the BIMO−FSC,
in order to prevent residual water from leaking.
5.3.2.1 Plug−type connection for cooling water
Detaching the hose

D Pull the quick−action couplings (1)
apart to separate.
1 Connecting the hose

D Connect the quick−action couplings.
112
Draining the coolant

In order to drain the cooling water it is recommended that two
hose pieces be fitted with quick−action couplings (counterpieces
to the connectors on the laser cutting head). The cooling water
may be discharged through these hose pieces and the piping can
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be blown out with compressed air.

HIGHYAG
5.3.2.2 Plug−type connectors for purging air, cutting gas and pressure

monitoring
1 Cutting−gas connections
LEGRIS plug−type connectors
1 for hose
3 (2 pcs, external diameter = 10 mm)
2 2 Purging air connections

plug−type connectors for a
hose
(2 pcs, external diameter = 6 mm)
3 Pressure monitoring connector (op-
tional),
plug−type connector for a hose
(external diameter = 4 mm)
Detaching the hoses

D Press the hose into the plug−type connector and at the same
time press the clamping ring down towards the connection.
D Keep the clamping ring in the depressed position and pull the
hose off the plug−type connector.
Connecting the hoses

D Insert the hose into the plug−type connector: When you begin
to feel resistance, fully push the hose further into the plug−
type connector.
cured. 113
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5.3.3 BIMO−FSC removal

The BIMO−FSC can be disassembled after the laser light cable

and all the cables and hoses have been removed.
D Loosen the fastening screws (1) with

locking washers.
(4 pcs, M6x25, ISO 4762)
D Detach the BIMO−FSC from the han-
dling machine.
D If you have not yet done so:
1
Drain the coolant and blow out the
coolant pipelines with compressed air
(see section 5.3.2.1).
Installation is described in the ”Assembly”
section.
114
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5.4 Repair

5.4.1 Replacing the cutting attachment or the cutting nozzle
adapter
Warning! Risk of injury!

The cutting module can be fitted with a cutting nozzle adapter
with a predetermined breaking point (see arrow).
In the event of a collision in the nozzle
area, the nozzle adapter will break at the
predetermined breaking point. The result-
ing breaking edges can be extremely
sharp. Disassembly and cleaning work on
the cutting module with a broken nozzle
adapter can therefore cause severe hand
cuts.

sembly work on a cutting attachment with a broken nozzle
adapter.

D Observe the instructions given in section 5.2.4 regarding the
cleaning and assembly of the cutting attachment!
Important!
If another element type of is used when replacing the cutting noz- 115
zle and the cutting nozzle adapter, the capacitive distance mea-
surement should be recalibrated by means of the CHC or FJB de-
vices.
5.4.1.1 Replacing the cutting attachment and the cutting nozzle adapter
Refer to section 5.2.4.1 for details on how to replace the cutting
attachment.
The cutting nozzle adapter must also be removed when cleaning
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the cutting attachment. The procedure is described in section

5.2.4.2.
HIGHYAG
5.4.1.2 Changing a broken cutting nozzle adapter

To remove the broken cutting nozzle adapter, detach the cutting

attachment.
Necessary tool: − pliers
1 Threaded ring
1 4 Cutting nozzle
2 D Clean the cutting attachment (2) and

the surrounding area carefully
3
4 D Remove the cutting attachment
D Remove the cutting nozzle adapter (3) from inside the cutting
attachment. The exact procedure depends on the cutting noz-
zle adapter used.
D Screw in a new cutting nozzle adapter
(tightening torque: 7.5 Nm)
D Clean the cutting attachment and the base module
D Mount the cutting attachment (see section 5.2.4.1).
5.4.2 Replacing the cutting−gas guiding system
116 Caution! Danger of contamination

D Make sure you prevent the penetration of dirt into the interior
of the BIMO−FSC. Therefore, check prior to starting work
whether the cover slide drawer is fitted with an intact cover
slide correctly inserted in the base module.

D Observe the instructions given in section 5.2.4 regarding the
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cleaning and assembly of the cutting attachment!

HIGHYAG
Necessary tools: − Allen keys, gauge 2 and 4

1 Threaded ring
3 Grub screw (M4x8, ISO 4027)
1 4 O−ring (Ø 5.28 x 1.78)

5 Cover
2
6 Cutting−gas guiding system
D Clean the cutting attachment (2) and

the surrounding area carefully
D Remove the cutting attachment
D Unscrew the grub screw cover (5).
3 D Carefully remove the O−ring (4) below.

4
5 D Unscrew the grub screw (3).
6
D Pull the cutting−gas guiding system
(6) downwards from the base module
to remove it.
D Insert the new cutting−gas guiding
system into the base module. Make
sure that the boreholes in the cutting
gas guide system (8) and in the base
module (7) coincide.
7 The marking (9) at the bottom of the
cutting−gas guide system serves as
an additional orientation. 117
D Lock the cutting−gas guide system
with the grub screw (3).
(tightening torque: 3 + 0.3 Nm)
8 D Insert the O−ring (4). Make sure that
the O−ring is clean and intact. Re-
9 place the O−ring, if damaged.
D Screw in and tighten the cover (5) for the grub screw.
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D Clean the cutting attachment and the base module

D Mount the cutting attachment (see section 5.2.4.1).
HIGHYAG
5.4.3 Replacing the cover slide monitoring unit


When replacing the cover slide monitoring unit, the optics of the
BIMO−FSC are open. Therefore, there is a risk that dirt can pene-
trate inside the optics. Soiling of optical components can lead to
damage or destruction when they are exposed to laser power.
No guarantee is assumed in conjunction with any work on the
opened optical system! This applies, in particular, to damage to
lenses or mirrors caused by dirt exposure or incorrect handling.
ment!
D Clean the laser cutting head and the surrounding area care-
fully before removing the cover slide monitoring unit.
D Position the laser cutting head so that no dirt can enter the
opening during work.
D Cover the openings on the product (for example, with an ad-
hesive tape).
D Prior to re−assembling, clean, in particular, the mounting sur-
faces (supports) once again.
D Before fitting individual modules, check the O−rings for dirt or
damage. Clean a soiled O−ring and/or replace a defective
O−ring.

After loosening the screws, the cover slide monitoring unit may
still be securely seated in the base module.
118 D Do not use any tools for removing the monitoring unit. Con-
tacts can get damaged.
The contact pin (4) must not be exposed to traverse loads, as it
can get damaged.
D When dismantling or assembling, make sure that the contact
pin does not touch anything.
D Store the cover slide monitoring unit in the corresponding
transport box only.
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To ensure disassembly or assembly of the cover slide monitoring

unit, the rear side of the BIMO−FSC must be accessible.
Necessary tool: − Allen key, gauge 2.5
1 Cover slide monitoring unit

2 Countersunk screws
(2 pcs, M4x8, DIN 7991)
3 O−ring (Ø 14.0 x 1.78)
1
4 Contact pin
D Clean the cover slide module, the

monitoring unit as well as the sur-
rounding area carefully.
2 D Remove the cover slide drawer and
put aside safely protected against
contamination
4 D Close the cover at the front of the
3 cover slide module.
D Remove two countersunk screws (2)
from the monitoring unit (1).
D Remove the monitoring unit (1).
D Take the new monitoring unit out of the transportation box.
D Check whether the O−rings (3) are correctly seated. If the ring
is defective or soiled, it must be replaced.
D Carefully insert the new cover slide monitoring unit, whilst
making sure that the contact pin (4) does not touch anything.
119
D Tighten the monitoring unit with two countersunk screws (2).
Tightening torque = 3.0 Nm
D Reinsert the cover slide drawer
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5.4.4 Change the cover slide drawer cover


2 Cover
1 D Clean the cover slide module and the

surrounding area carefully.
D Open the cover (2) to an angle of 90°
and pull forward to remove from the
2 axle.
D Fit new cover at an angle of 90° and
snap on the axle.
The cover is mounted correctly, if this
folds down, but does not fall after re-
leasing.
D Close the cover.
120
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5.4.5 Changing the turn knobs for x− and y−adjustment

Important!
After replacing the knobs, check the focus position in the x− and
y−direction and readjust, if necessary.
Dirty or damaged turn knobs (1) can be easily turned out and
changed.

x direction
2 y direction
1
3 Locknut
D Clean the turn knobs (1, 2) and the

surrounding area carefully.
D Note the scale markings of the knobs.
D Loosen the locknut (3).
3
D Unscrew the turn knob together with
the locknut.
D The locknut can be finally unscrewed
from the turn knob.
D Screw in the new turn knob with the
locknut.
D Set the turn knobs to the previously
noted scale markings.
D Check the focus position in the x and 121
3 y direction and readjust if necessary.
(refer to section 4.7.2).
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122
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6 Troubleshooting

Important!
The operation of a laser processing system requires technical
knowledge and experience that go beyond the scope of this man-
ual. The information relating to troubleshooting is therefore in-
tended for people who are proficient and experienced in dealing
with laser processing systems, as well as instructed in the use of
the system to be used.
Proper integration into the system controller is vital for a trouble−

free operation of the BIMO−FSC laser cutting head.
In the subsequent treatment of possible faults, the errors caused
by other parts of the system are not covered to a full extent. De-
tecting and correcting of the faults, whose causes lie beyond the
laser cutting head and the peripherals supplied by the manufac-
turer are therefore not part of this Troubleshooting Manual.
For further details on performing individual, subsequently desig-
nated work steps, refer to the sections relating to installation or
maintenance.
If faults cannot be unambiguously defined and eliminated or the
work steps necessary for troubleshooting are unclear, contact the
Customer Service of the manufacturer for further clarification.
123
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6.1 No cutting or insufficient cutting quality

Findings Possible causes of fault Remedy

Laser power does Laser light cable broken Inspect the laser light ca-
not reach the sur- ble and replace, if neces-
face of the sary
workpiece The laser light cable Inspect the connector and
connector is not properly connect it correctly
connected
Insufficient cutting No cutting gas connected Connect the cutting gas
gas flow Cutting gas supply valve Check the control and re-
does not switch on place the valve if neces-
sary
Cutting gas hose leaking Determine the cause,
replace the hose if neces-
sary
Poor Process parameters are Check whether the
cutting quality not properly selected or process parameters are
adjusted suitable for for the planned
workflow the material pro-
cessed. The inspection
should include in particu-
lar:
− Laser power,
− Imaging ratio,
− Focus position,
− Cutting speed or feed,
− Cutting gas quality
(type and composition)
− Cutting gas pressure
− Diameter of the cutting
nozzle
− Distance between cutting
124 nozzle and workpiece
If adequate quality of the
cut cannot be achieved,
contact the Customer Ser-
vice
The wrong cutting gas se- Check the cutting gas
lected
Gas flow too low or too Adjust the gas flow
high
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Inappropriate diameter of Select the appropriate cut-

the cutting nozzle ting nozzle for the cutting
process
HIGHYAG

Poor Focus set incorrectly Check whether the focus
cutting quality position matches the re-
quired processing
Check whether the motor−
driven adjustment is ready
for operation and whether
the parameters stored in
the machine control sys-
tem are correct
Incorrect focus position, Inspect the cutting attach-
because the distance be- ment and cutting nozzle for
tween the cutting head or proper seat and damage,
the cutting nozzle and the correct the seat or replace
workpiece is incorrect due the attachment or nozzle.
to the malfunction of the Check if the correct FJB
distance sensor system of curve is used, check cali-
the FJB bration, recalibrate if nec-
essary
Focus shift Check the cover slides and
fibre tips for soiling or dam-
age and clean, or replace,
if necessary
Check the lenses for soil-
ing (visual inspection)
contact Customer Service,
if necessary
Insufficient expulsion of the Check the cutting gas
molten mass from the cut- pressure and adjust, if nec-
ting gap essary; check the nozzle
diameter and correct, if
necessary; check the dis- 125
tance between the nozzle
and the workpiece, correct,
if necessary
For MZ collimation: Check
the imaging ratio and ad-
just if necessary
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Cut is asymmetri- Position of the laser beam Check and adjust if neces-
cal in the cutting nozzle is in- sary
correct
Cutting quality de- Process parameters are Check the laser power pro-
creases with the set incorrectly vided, check the gas pres-
increasing cutting sure, check the distance
time control for correct function.
The problems persist:
Check the focus shift as a
cause, contact the Cust-
omer Service, if necessary
6.2 Laser processing head is getting hot

Coolant circuit in- Coolant hose is not prop- Check the flow direction,
terrupted erly connected check the coolant supply
and connect properly
Coolant hose defective Replace the coolant hose
Coolant supply has not Turn on or repair the
switched on or failed coolant supply
Coolant flow rate Coolant supply hose is Determine the cause and
too low clogged, kinked, etc. eliminate, increase the flow
rate if necessary
Coolant flow impeded due Contact the Customer Ser-
to deposits (no inhibitor in vice to coordinate further
the coolant) procedure
Note!
126 Cleaning can be performed
by the manufacturer only
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Laser cutting head Aperture module is over- Check the numerical aper-
overheats heated due to poor beam ture of the laser (perform
quality of the laser beam the divergence measurem-
(exceeding the maximum ent)
permitted divergence an-
gle)
A large amount of heat is Check the process param-
reflected from the cutting eters, determine and elimi-
process, for example, due nate the cause, contact the
to highly reflective material Customer Service if neces-
sary
Cutting nozzle or cutting Check the process param-
attachment have too high eters, in particular the
a temperature imaging ratio, focus posit-
ion and nozzle diameter
(beam diameter must be
smaller at the outlet than
the diameter of the cutting
nozzle)
Correct the process pa-
rameters if necessary, con-
tact the Customer Service,
if necessary
Optical elements are soiled Determine and eliminate
(warming through scatter- the cause, contact the
ing of the laser beam) Customer Service if
necessary
127
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6.3 Service life of the cover slides is insufficient


Service life of the Cutting gas flow rate is too Too low pressure regulator
cover slides is in- low setting, correct the pres-
sufficient sure regulator setting
Cutting gas supply hose is
leaking, determine and
eliminate the cause, rep-
lace the supply line if nec-
essary
Cutting nozzle clogged
(for example, due to dam-
age) Clean or replace the
nozzle
specific cause of the error Check the process param-
cannot be determined eters, contact the Cus-
tomer Service if necessary
6.4 Cover slide soiled

(message via CHC or KSGM C)

CHC Cover slide drawer or Check and clean the cover
Signal: cover slide soiled slide and the cover slide
”SGM_Status”, drawer
Bit 2 = 0 Contact pin on the monito- Clean the contacts, re-
KSGM C ring unit is soiled or defec- place the monitoring unit if
Warning at the tive necessary
output A018
Monitoring unit (sensor) Replace the monitoring
128 (voltage = 0 V)
defective unit
Cable or connection to the Check the cable and con-
KSGM C is faulty nection and repair if neces-
sary.
KSGM C faulty Replace KSGM C
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6.5 Cover slide is heavily soiled or damaged


CHC Cover slide is heavily Note!
Signal: soiled or damaged Stop the process immedi-
”SGM_Status”, ately, check the cover
Bit 1 = 0 slide, replace the cover sli-
KSGM C de if the slide is broken.
Error at the output Check the focusing unit
A018 (front lens) for soiling or
(voltage = 0 V) damage, clean the focu-
sing system, if necessary
have it replaced by the
manufacturer,
contact the Customer Ser-
vice, if necessary
KSGM C sensitivity level is Adjust the KSGM C
too high
Cable or connection to Check the cable and con-
KSGM C or cover slide nection,
drawer is faulty repair or replace as
needed
6.6 Cover slide or cutting attachment are not available or

not properly placed

CHC Cover slide drawer with the Insert the cover slide
Signal: cover slide is not inserted drawer with the cover 129
”SGM_Status”, or cutting attachment is not slide, place the cutting
Bit 3 and bit 4 = 0 placed or improperly attachment or check for
KSGM C placed proper seating
Error at the output Cable or connection to Check the cable and con-
A019 KSGM C or cover slide nection, and repair as
(voltage = 0 V) drawer is faulty needed.
Contact pin on the monito- Check the contact and the
ring unit is stuck or defec- monitoring unit and replace
tive as needed
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6.7 Pressure switch B561 is triggered


Pressure switch is Drawer is not inserted Check the drawer, ensure
triggered its correct position
Cover slide is missing or Replace the cover slide
broken
Sealing on the cover slide Inspect the seal,
drawer is missing or is de- replace as needed
fective
Cover slide is not properly Check, ensure its correct
installed (seated loosely) seat
6.8 Condensation

Condensation and Dew point temperature not Adhere to the dew point ta-
the resulting loss observed, coolant temper- ble,
of power ature is too low adjust the coolant temper-
ature
130
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HIGHYAG

BIMO−FSC laser cutting head

Document no.: 07−02−57−6001

0 Address and contact information . . . . . . . . . . . . 11

2.2.9 Risks associated with the noise level . . . . . . . . . . . 26

3.1 Principles of optics . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.6.1 Digital integration through CHC . . . . . . . . . . . . . . . . 52

3.7.2 Changing the focus diameter (adjusting the focus

4 Assembly, Installation and Setup . . . . . . . . . . . . 65

4.5.5 Connecting the electric drive unit for analogue

5 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . 93

5.2.3.1 Cover slide drawer in front of the collimation unit 101

5.3 BIMO−FSC Removing and installing . . . . . . . . . . . 109

6.6 Cover slide or cutting attachment are not available or

0 Address and contact information

The purpose of this Operator’s Manual is to provide information

All abbreviations used in this manual are explained in this section.

1.3 Other applicable documents

In addition to this User’s Manual, the following documents must

technical documentation of the product which is supplied with the

1.4 Copyright protection

1.5 Customer Service

Should you require technical assistance, please contact our cus-

1.6 Change Service

The manufacturer reserves the changes in terms of technical im- 15

1.7 Declaration of incorporation

Should a declaration of incorporation is required for the country of

vided as a separate document.

1.8 Limitation of liability

All instructions and specifications contained within this manual

2.1 Intended use

The BIMO−FSC laser cutting head is intended for installation in a

2.1.2 Operating environment

18 The BIMO−FSC laser cutting head may be operated only in a sys-

The BIMO−FSC laser cutting head must only be used together

Using a laser cutting head that is not attached to a guide machine

2.1.3 Operating conditions

The BIMO−FSC may be operated in a technically perfect condi-

cable receiver. Contamination in these areas may result in the

CHC or compact cover slide monitor KSGM C, and determining

the appropriate thresholds for the replacement of the cover slide.

2.1.4 Qualifications of personnel

All work on the laser cutting head, such as installation, connec-

2.1.5 Working close to BIMO−FSC laser cutting head

2.2 Information on special dangers

2.2.1 Exposure to laser light and reflection!

The laser emits a beam of light in an invisible wave length range

particularly the safety instructions, and can also implement

D Improper installation and integration into the system can

2.2.2 Risk of fire and explosion

Combustible materials exposed to excessive heat generated in

2.2.3 Risks associated with harmful gases, dusts and vapours

Life−threatening dust, gases, and vapours may occur when pro-

2.2.4 Risks associated with high−energy UV radiation

The formation of plasma, for example, during the laser machining

2.2.5 Risk associated with compressed air and cutting gas

D Prior to commissioning of the BIMO−FSC, make sure that the

Once loosened, pressurized lines can fly off uncontrollably and

2.2.6 Injury hazard due to moving parts!

The BIMO−FSC is installed on the handling machine. Entering the

2.2.7 Risk of injury caused by sharp edges!

The cutting nozzle adapter of the BIMO−FSC normally has a pre-

Broken cover slides may have sharp edges.