Hypertherm LR2075 User Manual

FASTLaserTMCutting Heads

LR2075

Instruction Manual

805130 – Revision 0

LR2075

FASTLaser Cutting Heads

Instruction Manual

Part Number – 805130

Revision 0 – June, 2007

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

1/19/07

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

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)

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

ELECTROMAGNETIC COMPATIBILITY (EMC)

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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

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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

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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

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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.

LR2075 Laser Head Instruction Manual v

ELECTROMAGNETIC COMPATIBILITY (EMC).....................................................................................................................i

WARRANTY..................................................................................................................................................................................ii

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

Moving parts can cause severe crush injuries.....................................................................................................................................1-4

Section 2 SPECIFICATIONS .............................................................................................................................................2-1

Retrofit 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

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

Electrical connections.....................................................................................................................................................................3-3

Capacitive height sensor calibration curve................................................................................................................................3-4

Right side connections .............................................................................................................................................................................3-5

Digital readout connection.............................................................................................................................................................3-5

Nozzle travel.................................................................................................................................................................................................3-6

Color codes.................................................................................................................................................................................................3-6

Lens installation...........................................................................................................................................................................................3-7

Alignment guides........................................................................................................................................................................................3-8

Crosshair assembly .........................................................................................................................................................................3-8

Aperture assembly...........................................................................................................................................................................3-9

Acrylic mode-burn procedure.....................................................................................................................................................3-10

Section 4 OPERATION........................................................................................................................................................4-1

Safety ............................................................................................................................................................................................................4-2

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

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

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

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

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

TABLE OF CONTENTS

vi LR2075 Laser Head Instruction Manual

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

Capacitive height sensor..........................................................................................................................................................................4-5

Mild steel nozzle selection........................................................................................................................................................................4-6

Cut charts.....................................................................................................................................................................................................4-7

Stainless steel...................................................................................................................................................................................4-7

Focal position locations ............................................................................................................................................................................4-8

Definitions..........................................................................................................................................................................................4-8

1.5" diameter lenses .......................................................................................................................................................................4-8

2.0" diameter lenses .......................................................................................................................................................................4-8

Maintenance ................................................................................................................................................................................................4-9

Nozzle inspection.............................................................................................................................................................................4-9

Lens inspection ............................................................................................................................................................................... 4-9

Clean the lens ................................................................................................................................................................................4-10

Lens mounting ..........................................................................................................................................................................................4-11

Standard..........................................................................................................................................................................................4-11

Lens centering................................................................................................................................................................................4-12

Troubleshooting (O2cutting).................................................................................................................................................................4-13

Troubleshooting (N2cutting).................................................................................................................................................................4-15

Section 5 PARTS LIST ........................................................................................................................................................5-1

Laser heads, lens adjustment screws and potentiometer cable .....................................................................................................5-2

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

Dual flow nozzle parts.....................................................................................................................................................................5-4

Parts and accessories kit for 1.5" optics..............................................................................................................................................5-5

Parts and accessories kit for 2.0" optics..............................................................................................................................................5-6

Capacitive height sensor ..........................................................................................................................................................................5-7

Lenses...........................................................................................................................................................................................................5-8

Aperture and cross-hair assemblies.......................................................................................................................................................5-9

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

Section 1 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

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Section 1

SAFETY

In this section: