Hypertherm LH2100 User Manual

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FASTLaser®Cutting Heads

LH2125/LH2100

Instruction Manual

810250 – Revision 1

LH2125/LH2100

FASTLaser Cutting Heads

Instruction Manual

Part Number – 810250

Revision 1 – January, 2008

Hypertherm and FAST Laser are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

Hypertherm, Inc.

Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.com (Customer Service Email)

Hypertherm Automation

5 Technology Drive, Suite 300 West Lebanon, NH 03784 USA 603-298-7970 Tel 603-298-7977 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax

65 6 841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit 1308-09, Careri Building 432 West Huai Hai Road Shanghai, 200052 PR China 86-21 5258 3330/1 Tel 86-21 5258 3332 Fax

France (Representative office)

15 Impasse des Rosiers 95610 Eragny, France 00 800 3324 9737 Tel 00 800 4973 7329 Fax

Hypertherm S.r.l.

Via Torino 2 20123 Milano, Italia 39 02 725 46 312 Tel 39 02 725 46 400 Fax

39 02 725 46 314 (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service) 00 800 49 73 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

801 Samty Will Building 2-40 Miyahara 1-Chome, Yodogawa-ku, Osaka 532-0003, Japan 81 6 6170 2020 Tel 81 6 6170 2015 Fax

HYPERTHERM BRASIL LTDA.

Avenida Doutor Renato de

Andrade Maia 350 Parque Renato Maia CEP 07114-000 Guarulhos, SP Brasil 55 11 6409 2636 Tel 55 11 6408 0462 Fax

Hypertherm

Branch of Hypertherm, UK, UC PO Box 244 Wigan, Lancashire, England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax

00 800 4973 7843 (Technical Service)

1/19/07

ELECTROMAGNETIC COMPATIBILITY (EMC)

Hypertherm i

6-07

EMC Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.

The limits required by EN60974-10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be necessary to use other measures to further reduce interference.

This cutting equipment is designed for use only in an industrial environment.

Installation and use

The user is responsible for installing and using the plasma equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of Workpiece. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Assessment of area

Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a. Other supply cables, control cables, signalling and

telephone cables; above, below and adjacent to the

cutting equipment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of

industrial equipment. e. Health of the people around, for example the use of

pacemakers and hearing aids. f. Equipment used for calibration or measurement. g. Immunity of other equipment in the environment. User

shall ensure that other equipment being used in the

environment is compatible. This may require additional

protection measures.

h. Time of day that cutting or other activities are to be

carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Cutting cables

The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode (nozzle for laser heads) at the same time. The operator should be insulated from all such bonded metallic components.

ELECTROMAGNETIC COMPATIBILITY (EMC)

ii Hypertherm

8-06

Earthing of workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.

Note: the cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC/TS 62081 Arc Welding Equipment Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications.

WARRANTY

Hypertherm iii

6-07

Attention

Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty.

You are responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship, if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax Series power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to laser heads within a period of one (1) year from its date of delivery to you. This warranty shall not apply to any Product which has been incorrectly installed, modified, or otherwise damaged. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherm’s place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight prepaid. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with Hypertherm’s prior written consent. The warranty

above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty. Distributors/OEMs may

offer different or additional warranties, but Distributors/ OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.

Certification test marks

Certified products are identified by one or more certification test marks from accredited testing laboratories. The certification test marks are located on or near the data plate. Each certification test mark means that the product and its safety-critical components conform to the relevant national safety standards as reviewed by that testing laboratory. Hypertherm places a certification test mark on its products only after that product is manufactured with safety-critical components that have been authorized by the accredited testing laboratory.

Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of the following occurs:

• The product is significantly modified in a manner that creates a hazard or non-conformance.

• Safety-critical components are replaced with unauthorized spare parts.

• Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added.

• There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification.

CE marking constitutes a manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking.

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement, and Hypertherm’s

WARRANTY

iv Hypertherm

6-07

obligation to indemnify shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential, indirect, or punitive damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise and even if advised of the possibility of such damages.

Liability cap

In no event shall Hypertherm’s liability, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

Insurance

At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products.

National and Local codes

National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.

Transfer of rights

You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty.

Proper disposal of Hypertherm products

Hypertherm plasma cutting systems, like all electronic products, may contain materials or components, such as printed circuit boards, that cannot be discarded with ordinary waste. It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes.

• In the United States, check all federal, state, and local laws.

• In the European Union, check the EU directives, national, and local laws. For more information, visit www.hypertherm.com/weee.

• In other countries, check national and local laws.

LH2125/LH2100 Laser Head Instruction Manual v

Electromagnetic Compatibility (EMC) ...................................................................................................................................i

Warranty.......................................................................................................................................................................................iii

Section 1 Safety...................................................................................................................................................................1-1

Recognize safety information...................................................................................................................................................................1-2

Follow safety instructions .........................................................................................................................................................................1-2

Cutting can cause fire or explosion........................................................................................................................................................1-2

Radiation hazard.........................................................................................................................................................................................1-2

Electric shock can kill................................................................................................................................................................................1-3

Cutting can produce toxic fumes............................................................................................................................................................1-3

A laser can cause injury and burns ........................................................................................................................................................1-3

A laser can burn eyes and skin ...............................................................................................................................................................1-4

Grounding safety........................................................................................................................................................................................1-4

Pacemaker and hearing aid operation...................................................................................................................................................1-4

Section 2 Specifications....................................................................................................................................................2-1

Cutting head................................................................................................................................................................................................2-2

Requirements ..............................................................................................................................................................................................2-2

Electrical ...........................................................................................................................................................................................2-2

Purge gas...........................................................................................................................................................................................2-2

Cutting gas........................................................................................................................................................................................2-2

Coolant requirements......................................................................................................................................................................2-2

Section 3 Installation..........................................................................................................................................................3-1

Mounting dimensions ................................................................................................................................................................................3-2

Right side connections .............................................................................................................................................................................3-6

Single channel interface box installation ..............................................................................................................................................3-7

Controller cable connector information.......................................................................................................................................3-7

Connect cables ................................................................................................................................................................................3-7

Capacitive height sensor (CHS) interface box installation...............................................................................................................3-8

Controller cable connector information ......................................................................................................................................3-8

Connect cables ................................................................................................................................................................................3-8

Left side connections ................................................................................................................................................................................3-9

Lens travel..........................................................................................................................................................................................3-9

Color codes.......................................................................................................................................................................................3-9

Lens installation........................................................................................................................................................................................3-10

Alignment guides .....................................................................................................................................................................................3-11

Crosshair assembly.......................................................................................................................................................................3-11

Aperture assembly ........................................................................................................................................................................3-12

Section 4 Operation............................................................................................................................................................4-1

Operation safety .........................................................................................................................................................................................4-2

FAST Laser nozzles ....................................................................................................................................................................................4-3

Principles of operation ...................................................................................................................................................................4-3

FAST nozzle installation ..................................................................................................................................................................4-3

Inspect the baffle..............................................................................................................................................................................4-3

TABLE OF CONTENTS

vi LH2125/LH2100 Laser Head Instruction Manual

Piercing.........................................................................................................................................................................................................4-4

Mild steel............................................................................................................................................................................................4-4

Stainless steel and aluminum........................................................................................................................................................4-4

Single channel interface adjustments....................................................................................................................................................4-5

Cut-error monitor..............................................................................................................................................................................4-5

Precision adjustments.....................................................................................................................................................................4-5

Capacitive height sensing ........................................................................................................................................................................4-7

Introduction........................................................................................................................................................................................4-7

Operation...........................................................................................................................................................................................4-8

Adjustment.........................................................................................................................................................................................4-8

Cut charts..................................................................................................................................................................................................4-10

Mild steel .........................................................................................................................................................................................4-10

Stainless steel................................................................................................................................................................................4-10

Focal position locations..........................................................................................................................................................................4-11

Maintenance..............................................................................................................................................................................................4-12

Drive mechanism ...........................................................................................................................................................................4-12

Inspect nozzle.................................................................................................................................................................................4-12

Inspect lens.....................................................................................................................................................................................4-12

Clean lens .......................................................................................................................................................................................4-13

Lens mounting – standard and pre-mounted options ..................................................................................................................4-14

Standard..........................................................................................................................................................................................4-14

Premounted ....................................................................................................................................................................................4-15

Lens centering................................................................................................................................................................................4-15

Troubleshooting (O2 cutting).................................................................................................................................................................4-16

Troubleshooting (N2 cutting) .................................................................................................................................................................4-18

Section 5 Parts List .............................................................................................................................................................5-1

Outside view................................................................................................................................................................................................5-2

Consumables ..............................................................................................................................................................................................5-3

Parts and accessories kits .......................................................................................................................................................................5-4

Single channel optics and lens adjustment screws ...........................................................................................................................5-5

Capacitive height sensor..........................................................................................................................................................................5-6

Lenses...........................................................................................................................................................................................................5-7

Apperture, crosshair and receiver assemblies.....................................................................................................................................5-8

Motor and timing belt.................................................................................................................................................................................5-9

Appendix A ZnSe LENS SAFETY DATA .........................................................................................................................a-1

Section I product identification.........................................................................................................................................................a-2

Section 2 Hazardous Ingredients.....................................................................................................................................................a-2

Section 3 Physical data......................................................................................................................................................................a-2

Section 4 Fire and explosion hazard data ......................................................................................................................................a-2

Section 5 Health hazard data............................................................................................................................................................a-3

Section 6 Reactivity data....................................................................................................................................................................a-4

Section 7 Disposal information.........................................................................................................................................................a-4

Section 8 Special Protection information.......................................................................................................................................a-4

Section 9 Special precautions..........................................................................................................................................................a-5

Hypertherm 1-1

10/03

Section 1

SAFETY

In this section:

Recognize safety information...................................................................................................................................................................1-2

Follow safety instructions .........................................................................................................................................................................1-2

Cutting can cause fire or explosion........................................................................................................................................................1-2

Cutting can produce toxic fumes............................................................................................................................................................1-3

A laser can cause injury and burns ........................................................................................................................................................1-3

A laser can burn eyes and skin ...............................................................................................................................................................1-4

Pacemaker and hearing aid operation...................................................................................................................................................1-4

SAFETY

10/03

1-2 Hypertherm

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual and safety labels on your machine.

• Keep the safety labels on your machine in good

condition. Replace missing or damaged labels immediately.

• Learn how to operate the machine and how to use

the controls properly. Do not let anyone operate it without instruction.

• Keep your machine in proper working condition. Unauthorized modifications to the machine may affect safety and machine service life.

DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards.

• DANGER and WARNING safety labels are located on your machine near specific hazards.

• WARNING safety messages precede related instruc tions in this manual that may result in injury or death if not followed correctly.

• CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly.

Fire Prevention

• Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby.

• Remove all flammables within 35 feet (10 m) of the cutting area.

• Quench hot metal or allow it to cool before handling or before letting it touch combustible materials.

• Never cut containers with potentially flammable materials inside – they must be emptied and properly cleaned first.

• Ventilate potentially flammable atmospheres before cutting.

Explosion Prevention

• Do not use the laser system if explosive dust or vapors may be present.

• Do not cut pressurized cylinders, pipes, or any closed container.

• Do not cut containers that have held combustible materials.

CUTTING CAN CAUSE FIRE OR EXPLOSION

• Visible or invisible radiation (class IV) can be present when the laser head door is open.

• Avoid eye and skin exposure to direct and scattered radiation.

• Never look into the laser beam.

RADIATION HAZARD

SAFETY

10/03

Hypertherm 1-3

The laser beam will cut quickly through gloves and skin.

• Keep away from the nozzle tip.

• Do not hold metal near the cutting path.

• Never point the laser toward yourself or others.

A LASER CAN CAUSE INJURY AND BURNS

Electric Shock Prevention

• Never touch the laser head, while in operation.

• Install and ground this equipment according to the instruction manual and in accordance with national or local codes.

• Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill.

• Before checking, cleaning or changing parts, disconnect the main power or unplug the power supply.

• When making input connections, attach proper grounding conductor first.

ELECTRIC SHOCK CAN KILL

Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death.

• Keep the cutting area well ventilated or use an approved air-supplied respirator.

• Do not cut in locations near degreasing, cleaning or spraying operations. The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation.

• Do not cut metal coated or containing toxic materi als, such as zinc (galvanized), lead, cadmium or beryllium, unless the area is well ventilated and the operator

CUTTING CAN PRODUCE TOXIC FUMES

wears an air-supplied respirator. The coatings and any metals containing these elements can produce toxic fumes when cut.

• Never cut containers with potentially toxic materials inside – they must be emptied and properly cleaned first.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.

SAFETY

5/04

1-4 Hypertherm

Eye Protection Lasers produce intense visible and

invisible (ultraviolet and infrared) rays that can burn eyes and skin.

• Use eye protection in accordance with applicable national or local codes.

• Wear eye protection (safety glasses or goggles with side shields) with appropriate lens shading to protect your eyes from ultraviolet and infrared rays.

• Reference laser system manufacturer and standard BS EN 207:1999 for proper eye protection level.

A LASER CAN BURN EYES AND SKIN

Skin Protection Wear protective clothing to protect

against burns caused by ultraviolet light, sparks and hot metal.

• Gauntlet gloves, safety shoes and hat.

• Flame-retardant clothing to cover all exposed areas.

• Cuffless trousers to prevent entry of sparks and slag.

• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.

Input Power

• If installation of the laser head involves connecting the power cord to the power supply, be sure to connect the power cord ground wire properly.

• Tighten all electrical connections to avoid excessive heating.

• Follow system recommendations for grounding the workpiece.

GROUNDING SAFETY

Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. Pacemaker and hearing aid wearers should consult a doctor before going near any cutting equipment.

PACEMAKER AND HEARING AID OPERATION

DANGER

Never put fingers or hands between the lens assembly and the laser head enclosure. Moving parts can cause severe crush injuries.

LH2125/LH2100 Laser Head Instruction Manual 2-1

Section 2

SPECIFICATIONS

In this section:

Purge gas...........................................................................................................................................................................................2-2

Cutting gas........................................................................................................................................................................................2-2

Coolant requirements......................................................................................................................................................................2-2

SPECIFICATIONS

2-2 LH2125/LH2100 Laser Head Instruction Manual

Cutting head

This manual provides the information needed to install, operate, and maintain the LH2125 and LH2100 laser cutting heads. The LH2125/2100 is designed to process material with a CO2laser cutting system. Lens position is controlled by a servo motor for precise and repeatable location of the focal position, relative to the cutting nozzle. The LH2100 accepts 2" (50.8 mm) diameter optics with focal lengths of 7.5" and 10" (190.5 mm and 254 mm).The LH2125 accepts 2" (50.8 mm) diameter optics with focal lengths of 7.5", 10" and 12.5" (190.5 mm, 254 mm and 317.5 mm).

Requirements

Electrical:

Motor ..................................................................................................................System dependent

Encoder..............................................................................................................System dependent

Sensor................................................................................................................9 – 36 VDC, 2 Watts

Capacitive interface.........................................................................................9 – 36 VDC, 5 Watts

Purge gas: air or nitrogen

Gas quality ........................................................................................................Clean, dry and oil-free

Flow rate ............................................................................................................2 liters/minute

The customer must provide a regulated gas supply capable of delivering at a pressure of 1.4 bar (20 psig) to the laser head.

Cutting gas: air, oxygen, nitrogen

Maximum system pressure ............................................................................27.5 bar (400 psi)*

Coolant requirements:

Coolant type......................................................................................................Water

Water purity.......................................................................................................200 kΩ – cm

Flow rate ............................................................................................................9 liters/hour (2.4 gallons/hour)

Pressure ............................................................................................................4.8 bar (70 psi) maximum

Note: Use purified water as coolant in order to prevent corrosion in the coolant system. The hardness

of the water should be between 0.2 and 8.5 ppm. If using a conductivity meter to measure water purity, the recommended level is between 0.5 and 5 µ Siemens/cm at 25° C (77° F).

*Maximum pressure is determined by the individual lens used. Check with the lens manufacturer for pressure rating.

Hypertherm lenses are rated for 20.7 bar (300 psi).

LH2125/LH2100 Laser Head Instruction Manual 3-1

Section 3

INSTALLATION

In this section:

Mounting dimensions ................................................................................................................................................................................3-2

Right side connections .............................................................................................................................................................................3-6

Single-channel interface box installation ..............................................................................................................................................3-7

Controller cable connector information.......................................................................................................................................3-7

Connect cables ................................................................................................................................................................................3-7

Capacitive height-sensor (CHS) interface box installation...............................................................................................................3-8

Controller cable connector information ......................................................................................................................................3-8

Connect cables ................................................................................................................................................................................3-8

Color codes.......................................................................................................................................................................................3-9

Cross-hair assembly .....................................................................................................................................................................3-11

Aperture assembly ........................................................................................................................................................................3-12

INSTALLATION

3-2 LH2125/LH2100 Laser Head Instruction Manual

9.1 Kgs 20 Lbs

Mounting dimensions

Note: Customer is responsible for breakaway collision protection.

LH2125

LH2100

7.7 Kgs 17 Lbs

INSTALLATION

LH2125/LH2100 Laser Head Instruction Manual 3-3

INSTALLATION

3-4 LH2125/LH2100 Laser Head Instruction Manual

0.54 Kgs

1.2 Lbs

Capacitive height sensor – interface box

INSTALLATION

LH2125/LH2100 Laser Head Instruction Manual 3-5

0.64 Kgs

1.4 Lbs

single-channel interface box

INSTALLATION

3-6 LH2125/LH2100 Laser Head Instruction Manual

Right side connections

single-channel interface (SC): box and cable

Capacitive height-sensing amplifier

Coolant water OUT: 1/8" NPT, internal thread

Coolant water IN: 1/8" NPT, internal thread

Anti-spatter IN: 1/8" NPT, external thread

Pressure port: 1/8" NPT, external thread

Capacitive height sensing interface (CHS): box and cable

single-channel interface box installation

The single-channel interface box provides 3 independent optically isolated outputs. Outputs can be used by the controller to detect piercing and cutting operations.

Controller cable connector information (9 pin D-Sub)

J1 pin-outs (Output To Controller)

Output Circuit

+ Output

MOC8050

If = 2mA

Connect cables

Controller cable – 9 pin cable to controller

Sensor cable – interface box to laser head

Pin Wire

Number Color Description

1 Red Voltage in+ (9-36 VDC, 2 watts maximum) 2 Black Voltage in3 White Cut error + 4 Green Cut error 5 Blue Continuous wave pierce complete + 6 Brown Continuous wave Pierce complete 7 Orange Pulsed pierce complete + 8 Yellow Pulsed pierce complete 9 Shield Electromagnetic protection (earth ground)

INSTALLATION

LH2125/LH2100 Laser Head Instruction Manual 3-7

Note: Nominal voltage drop across output (+/-) is 1.2 volts. Current must be limited by input

resistance.

Connect cables

Interface box (CHS) 15-pin cable to controller

Amplifier module to interface box (CHS)

INSTALLATION

3-8 LH2125/LH2100 Laser Head Instruction Manual

Capacitive height sensor (CHS) interface box installation

The amplifier module will be mounted to the laser head if the capacitive height sensing option was ordered. Choose a suitable location for the CHS interface box.

Controller cable connector information (15 pin D-Sub)

Pin-outs (Output To Controller)

Note: Outputs are dry-contact relay outputs.

Pin Wire

Number Color Description

1 Blue Not used 2 Purple Not used 3 Brown Over-range + 4 Grey Over-range 5 Yellow Tip-touch + 6 Green Tip-touch 7 White Distance signal + 8 Orange Distance signal 9 Red + Volt input (9-36 VDC)

10 Black - Volt input

11-14 Not used

15 Shield Electromagnetic Protection (earth ground)

Power indicator

Over-range indicator

Under-range indicator (not shown)

Left side connections

Cutting gas: 1/8" NPT, internal thread

Purge gas: 1/8" NPT, external thread

INSTALLATION

LH2125/LH2100 Laser Head Instruction Manual 3-9

M12 thread

Interlock and limit switch connector

Pin 1

Pin 4 Pin 3

Pin 2

Pin # Description Wire color

1 Limit switch, home position Brown 2 Limit switch, home position White 3 Door interlock Blue 4 Door interlock Black

Lens travel

The lens travels 0.706 mm for each revolution of the motor.

Color codes

12.5" lens door and cartridge – Green* 10" lens door and cartridge – Blue

7.5" lens door and cartridge – Gold Blanks – Black

*LH2125 only

Green

Blue

Gold

INSTALLATION

3-10 LH2125/LH2100 Laser Head Instruction Manual

Lens installation

햲 Check condition of the lens seal before insertion. If there are any cuts or abrasions, replace seal. See Parts List. 햳 Orient lens tab in upward position, seal downward. Door will not close if lens is incorrectly oriented. 햴 Align lens tab with cut out in lens door to allow lens door to close. 햵 Close and latch lens door securely.

Note 1: Seal is designed to operate dry. Do not lubricate. Note 2: Only 1 lens can be used at a time for a process. Empty lens bays must have a lens blank

installed before cutting. See Parts List for part number.

Lens tab in upward position

Seal (not shown)

햲햳

Lens door

Lens tab

Cut-out

햴

햵

12.5" lens bay (LH2125 only)

10" lens bay

7.5" lens bay

Alignment guides

Two alignment guides will help align the laser beam with the mechanical axis of the cutting head.

DANGER

Visible and invisible radiation (class IV) can be present when the laser head door is open. Avoid eye and skin exposure to direct and scattered radiation. Always follow safety precautions set by the manufacturer of the laser system.

INSTALLATION

LH2125/LH2100 Laser Head Instruction Manual 3-11

Cross-hair assembly

1. Insert the crosshair assembly into the upper lens bay. Orient the tab straight out the front of the lens bay. The diameter of crosshair assembly prevents the lens bay door from closing all the way.

2. Insert a beam card or heavy paper into the lower lens bay and pulse the laser beam to form an imprint. Be careful not to ignite the card or the cavity will become dirty and reduce the life of the lens.

3. Adjust beam delivery mirrors to center the beam with the cross-hair.

INSTALLATION

3-12 LH2125/LH2100 Laser Head Instruction Manual

Nozzle Adapter

Aperture assembly

1. Insert the aperture assembly into the upper lens bay. Orient the tab straight out the front of the lens bay. The diameter of the aperture assembly prevents the lens bay door from closing all the way.

2. Remove the nozzle and place a beam card or tape over the nozzle adapter opening. Pulse the beam to cause an imprint but do not ignite the material. Check that the imprint and the nozzle adapter opening are concentric. If not, the beam axis and mechanical axis are incorrectly aligned and need to be adjusted.

3. Make necessary adjustments and repeat the procedure until the beam pattern is centered with the cross-hair and the aperture imprint is concentric with the nozzle adapter’s opening.

LH2125/LH2100 Laser Head Instruction Manual 4-1

Section 4

OPERATION AND MAINTENANCE