Byspeed 3015 BA V010 en

Byspeed
Operating Manual
Edition: 10.2004
Byspeed_BA_V10_en.fm © Bystronic Laser AG, 2004 0-1

Byspeed
0-2 © Bystronic Laser AG, 2004 Byspeed_BA_V10_en.fm

Byspeed
Product identification
These operating instructions apply to:
Byspeed
Document identification
Operating instructions: Byspeed_BA_V10_en.fm
When reordering please give the document identification and the issuing
date.
Purpose of the operating instructions

These operating instructions form part of the overall documentation. It in-
structs on the safe and intended use of the product.
Other documents
The overall documentation contains the following documents:
Operating instructions
Spare parts catalog
Diagrams
Supplier documentation
Machine documentation
Machine logbook

Byspeed
Target group
The operating instructions are aimed at the user, the operator and the
maintenance and repair personnel.
Storage
The operating instructions must be freely accessible to the target group at
all times.
Copyright
It is not permitted to pass on and duplicate this document, or to exploit
and disseminate the contents, unless expressly permitted by the owner.
Breaches will lead to compensation claims. All rights reserved.

Byspeed
Argentina Australia
BEHRENDT MAQUINARIAS S.A. LMC LASER SERVICE PTY. LTD
Lima 355 - Piso 8 1/8 Kylie Place
AG-1073 Buenos Aires AUS-3192 Cheltenham, Victoria
Tel.: +54 11 5031 5312 Tel.: +61 3 9555 5525
Fax: +54 11 5031 5303 Fax: +61 3 9555 2970
Austria Brazil
BYSTRONIC AUSTRIA GmbH BYSTRONIC DO BRASIL Ltda.
Wienerstrasse 131 Rua Arapongas, 285
A-4020 Linz BR-83040 200 São Cristóvão
Tel.: +43 732 341 377 São José dos Pinhais - Paraná
Fax: +43 732 341 153 Tel.: +55 41 398 2000
Fax: +55 41 398 1789
Email: [email protected]
China Czech Republic

BYSTRONIC CO LTD CANMET s.r.o.
Waigaoqiao FTZ Pudong Karlova 37
CN-200131 Shanghai CZ-61400 Brno
Tel.: +86 21 5868 0478 Tel.: +420 5 4542 4566
Fax: +86 21 5868 0481 Fax: +420 5 4542 4545/43
England France
PULLMAX LIMITED BYSTRONIC FRANCE SA
Lowfields Avenue 2, Burospace
Leeds LS12 6HH F- 91571 Bievres Cedex
Tel.: +44 113 277 8112 Tel.: +33 1 6941 9984
Fax: +44 113 271 9862 Fax: +33 1 6941 9951
Email: [email protected] Email: [email protected]
Germany Greece
BYSTRONIC LASER GmbH ADECA LTD
Mollenbachstrasse 33-35 Ave. Alexandras 56
D-71229 Leonberg GR-11473 Athens
Tel.: +49 (0)7152 6090 0 Tel.: +302 10 822 8503
Fax: +49 (0)7152 6090 20 Fax: +302 10 821 6746
Hungary Israel
AUTOREL Kft. KATZENSTEIN MACHINE TOOLS
Attila ut 131 / III. 12. 6 Meitav St.
HU-1537 Budapest IL-67898 Tel Aviv
Tel.: +36 1 212 7270 Tel.: 972 3 562 6266
Fax: +36 1 212 7271 Fax: 972 3 562 6299
Italy Netherlands
BYSTRONIC ITALIA SRL BYSTRONIC BENELUX BV
Via del Lavoro 30 Stek 8
I-20030 Bovisio Masciago / MI NL-3371 Hardinxveld-Giessendam
Tel.: +39 0362 5710 46/47 Tel.: +31 (181) 611 020
Fax: +39 0362 5941 35 Fax: +31 (184) 617 774

Byspeed
Poland Russia
ABPLANALP CONSULTING Sp.z o.o. L-SERVICE
Ul. Marconich 11/10 S. Laso, 25-A, 106
PL-02954 Warschau RU-443112 Samara
Tel.: +48 22 858 9478 Tel.: +7 846 279 5403
Fax: +48 22 642 5077 Fax: +7 846 242 6194
Singapore South Africa

BYSTRONIC PTE. LTD FOREST ENGINEERING
61 Alexandra Terrace PF169
#06-11 Harbour Link ZA-1600 Isando
SG-119936 Singapore Tel.: +27 11 397 4050
Tel.: +65 278 6678 Fax: +27 11 397 4210
Fax: +65 272 5978 Email: [email protected]
South Korea Spain

HAN KWANG CO. LTD. BYSTRONIC IBERICA, S.A.
Yanggam-Myun Avenida de los Pirineos, 9
KR-445932 Hwasung-Si / Kyonggi-Do E-28700 San Sebastian de los Reyes
Tel.: +82 313 50 2900 Tel.: +34 91 654 4496
Fax: +82 313 50 2992 Fax: +34 91 652 4983
Sweden Switzerland
BYSTRONIC AB BYSTRONIC LASER AG
Östra Bangatan 18 Industriestrasse 21
SE-19560 Arlandastad CH-3362 Niederönz
Tel.: +46 (0)8 5944 1550 Tel.: +41 (0)62 956 3333
Fax: +46 (0)8 5944 1555 Fax: +41 (0)62 956 3386
Taiwan Turkey
CHASER C.D. ENTERPRISE CO.LTD LASERPRESS MAKINA VE CELIK
22F, No. 639, Chung Cheng Rd. SAN.TIC. LTD. STI
TW-238 Shuh Lin City - Taipei Hsien Dedeoglu Cad. Kiremitdere Sok.
Tel.: +886 22 689 7988 NO:60 Çubuklu / Beykoz
Fax: +886 22 689 7986 TR-34805 Istanbul / Turkiye
Email: [email protected] Tel.: +90 216 413 7677
Fax: +90 216 425 2341
USA
BYSTRONIC INC.
185 Commerce Drive
NY-11788 Hauppauge
Tel.: +1 631 231 1212
Fax: +1 631 231 1040

Byspeed
Table of contents
1 Product description
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

1.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1.1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.1.3 Precautionary measures . . . . . . . . . . . . . . . . . . . . . 1–4
1.1.4 Work stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1.1.5 Product markings . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
1.2 Operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.2.1 Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.2.1.1 Max. cuttable thickness . . . . . . . . . . . . . . . . . . . . 1–8
1.2.1.2 Dust collector system . . . . . . . . . . . . . . . . . . . . . 1–8
1.2.2 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . 1–9
1.2.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.2.3.1 Laser cutting machine and chiller connection . . . . . 1–9
1.2.3.2 Laser power requirement . . . . . . . . . . . . . . . . . . . 1 – 10
1.2.3.3 Dust collector system connection . . . . . . . . . . . . . 1 – 11
1.2.4 Cutting gas supply . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 11
1.2.5 Compressed air supply . . . . . . . . . . . . . . . . . . . . . . 1 – 12
1.2.5.1 Laser cutting machine connection . . . . . . . . . . . . . 1 – 12
1.2.5.2 Dust collector system connection . . . . . . . . . . . . . 1 – 13
1.2.6 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 14
1.3 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 15
1.3.1 Design variants . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 15
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Table of contents
2 Safety regulations
2.1 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . 2–3

2.2 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.2.1 Safety and monitoring devices . . . . . . . . . . . . . . . . . 2–5
2.2.2 Safety-conscious working . . . . . . . . . . . . . . . . . . . . 2–5
2.3 Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.3.1 Warning and information signs. . . . . . . . . . . . . . . . . 2–7
2.4 Product specific hazards . . . . . . . . . . . . . . . . . . . . . 2–8
2.4.1 Hazard from laser beam . . . . . . . . . . . . . . . . . . . . . 2–8
2.4.1.1 Normal operating mode . . . . . . . . . . . . . . . . . . . . 2–8
2.4.1.2 Special operating mode . . . . . . . . . . . . . . . . . . . . 2–8
2.4.1.3 Direct laser beam . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.4.1.4 Reflected and scattered radiation . . . . . . . . . . . . . 2–9
2.4.2 Hazard from high voltage . . . . . . . . . . . . . . . . . . . . 2 – 10
2.4.3 Hazard from electricity . . . . . . . . . . . . . . . . . . . . . . 2 – 11
2.4.4 Pneumatic hazard. . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 12
2.4.5 Hazards from gas, dust, steam, smoke . . . . . . . . . . . 2 – 12
2.4.5.1 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 12
2.4.5.2 Extraction system . . . . . . . . . . . . . . . . . . . . . . . . 2 – 13
2.4.6 Optics handling hazards . . . . . . . . . . . . . . . . . . . . . 2 – 14
2.4.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 14
2.4.6.2 Notes on fire and damage . . . . . . . . . . . . . . . . . . 2 – 14
2.4.6.3 Health notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 14
2.4.7 Lubricants, coolants and cleaning agents. . . . . . . . . . 2 – 15
2.5 Personnel requirements . . . . . . . . . . . . . . . . . . . . . 2 – 16
2.5.1 User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 16
2.5.1.1 User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 16
2.5.1.2 Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 16
2.5.1.3 Works mechanic . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 16
2.5.2 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 17
2.5.3 Responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 17
2.6 Additional hazards . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 18
2.7 In an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 19
0-8 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

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Table of contents
3 Design and operation
3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

3.2 Safety and monitoring devices . . . . . . . . . . . . . . . . 3–4
3.2.1 Protective devices. . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.2.2 Emergency off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.2.3 Light barrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
3.2.4 Safety door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
3.3 Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.4 Mechanical structure. . . . . . . . . . . . . . . . . . . . . . . . 3–9
3.5 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 10
3.5.1 Control cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 10
3.5.1.1 CNC cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 10
3.5.1.2 LSM cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 11
3.5.1.3 STL cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 11
3.5.2 Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 12
3.5.3 Operating terminal . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 13
3.5.4 Handheld controller . . . . . . . . . . . . . . . . . . . . . . . . 3 – 14
3.5.5 Tool cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 15
3.5.6 Netbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 16
3.5.7 Pneumatic valves . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 17
3.5.8 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 18
3.5.9 Central lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 20
3.5.9.1 Lubrication cycle . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 21
3.5.9.2 Level monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 21
3.5.10 Sheet clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 22
3.6 Base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 23
3.6.1 Extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 23
3.6.2 Small parts trays . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 24
3.7 Bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 25
3.7.1 Cutting bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 25
3.7.2 Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 26
3.7.2.1 Connector box . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 26
3.7.3 Z-axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 27
3.7.4 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 29
3.7.4.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 29
3.7.4.2 Cutting head applications . . . . . . . . . . . . . . . . . . . 3 – 30
3.7.4.3 Influence of focal length on cutting . . . . . . . . . . . . 3 – 31
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Table of contents
3.7.5 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 32
3.7.5.1 Nozzle selection . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 33
3.7.5.2 Nozzle designations . . . . . . . . . . . . . . . . . . . . . . . 3 – 34
3.7.6 Nozzle cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 35
3.7.6.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 35
3.7.6.2 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 36
3.7.7 CutControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 37
3.7.7.1 Design and operation. . . . . . . . . . . . . . . . . . . . . . 3 – 37
3.7.7.2 CutControl with Bylaser 5200 ARC. . . . . . . . . . . . . 3 – 38
3.7.8 Crossjet (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 39
3.7.8.1 Oil mist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 40
3.7.8.2 Cross blowing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 40
3.7.9 Sensing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 41
3.7.9.1 Capacitive sensing. . . . . . . . . . . . . . . . . . . . . . . . 3 – 41
3.7.9.2 Tactile sensing (optional) . . . . . . . . . . . . . . . . . . . 3 – 42
3.8 End plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 44
3.8.1 Flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 44
3.8.2 Shuttle table console . . . . . . . . . . . . . . . . . . . . . . . 3 – 45
3.9 Beam guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 46
3.9.1 Beam protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 47
3.9.2 Deflecting mirror . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 48
3.9.3 Adaptive optics . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 50
3.9.3.1 Focal position with flat mirror . . . . . . . . . . . . . . . . 3 – 51
3.9.3.2 Focus correction with adaptive optics. . . . . . . . . . . 3 – 52
3.9.3.3 Focal position . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 53
3.10 Shuttle table system . . . . . . . . . . . . . . . . . . . . . . . . 3 – 54
3.10.1 Shuttle table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 54
3.10.2 Support grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 55
3.11 General assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 56
3.11.1 Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 56
3.11.2 Axes drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 57
3.11.3 Linear measuring systems . . . . . . . . . . . . . . . . . . . . 3 – 58
3.12 Cutting gasses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 59
3.12.1 Cutting gas quality . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 59
3.12.2 Cutting gas consumption . . . . . . . . . . . . . . . . . . . . . 3 – 60
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Table of contents
4 Operating elements
4.1 Warning signals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

4.1.1 Warning and information lamp . . . . . . . . . . . . . . . . . 4–3
4.1.2 Fault displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.2 Operating and display elements . . . . . . . . . . . . . . . 4–5
4.2.1 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
4.2.2 Emergency off switch . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.2.2.1 Operating terminal . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.2.2.2 Handheld controller . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.2.2.3 Shuttle table console . . . . . . . . . . . . . . . . . . . . . . 4–7
4.2.2.4 Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4.2.3 Operating terminal . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
4.2.3.1 State of illuminated function keys . . . . . . . . . . . . . 4–9
4.2.3.2 Activating the function keys . . . . . . . . . . . . . . . . . 4–9
4.2.3.3 Description of the function keys . . . . . . . . . . . . . . 4–9
4.2.4 Handheld controller . . . . . . . . . . . . . . . . . . . . . . . . 4 – 10
4.2.4.1 Activate handheld device . . . . . . . . . . . . . . . . . . . 4 – 10
4.2.4.2 Hand wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 11
4.2.4.3 Handheld controller keys . . . . . . . . . . . . . . . . . . . 4 – 11
4.2.5 Shuttle table console . . . . . . . . . . . . . . . . . . . . . . . 4 – 13
4.2.5.1 Shuttle table console keys . . . . . . . . . . . . . . . . . . 4 – 13
4.3 Laser cutting machine operating modes. . . . . . . . . 4 – 15
4.3.1 Normal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 15
4.3.2 Special mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 15
4.4 Operating modes adaptive optics 1 . . . . . . . . . . . . 4 – 16
4.4.1 Operating mode 0 (Service mode) . . . . . . . . . . . . . . 4 – 16
4.4.1.1 Fixed mirror adjustment height for operating mode 0
(setup value) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 16
4.4.1.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 17
4.4.2 Operating mode 1 (standard mode) . . . . . . . . . . . . . 4 – 18
4.4.2.1 Focus correction . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 18
4.4.2.2 Focus location to cutting parameter values . . . . . . . 4 – 18
4.4.2.3 Result of focus correction and focus location. . . . . . 4 – 18
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5 Commissioning

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Table of contents
6 Operating
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

6.1.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.1.2 Personnel requirements. . . . . . . . . . . . . . . . . . . . . . 6–3
6.2 Operating the machine . . . . . . . . . . . . . . . . . . . . . . 6–4
6.2.1 Pre-startup checks . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.2.2 Switching on the laser cutting machine in normal mode 6–5
6.2.3 Switching off the laser cutting machine in normal mode 6–6
6.2.4 Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.2.5 Restarting after an emergency off . . . . . . . . . . . . . . 6–7
6.3 ByVision user interface . . . . . . . . . . . . . . . . . . . . . . 6–8
6.3.1 General structure . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.3.2 User log on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.3.2.1 User rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 10
6.3.2.2 Access to individual views . . . . . . . . . . . . . . . . . . 6 – 11
6.3.3 Structure of the views. . . . . . . . . . . . . . . . . . . . . . . 6 – 13
6.3.4 MAIN view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 14
6.3.4.1 Administration . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 15
6.3.4.2 Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 16
6.3.4.3 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 17
6.3.5 HAND view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 18
6.3.6 WORK view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 19
6.3.7 TOOLS view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 20
6.3.8 System, status and error messages . . . . . . . . . . . . . 6 – 21
6.3.8.1 Message list . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 22
6.3.8.2 Quick help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 22
6.3.9 Switch appearance . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 23
6.3.10 Function keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 23
6.3.11 Online help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 24
6.3.11.1 Search functions . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 25
6.3.11.2 Print output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 25
6.4 Handling operation user interface . . . . . . . . . . . . . 6 – 26
6.4.1 Starting the application . . . . . . . . . . . . . . . . . . . . . . 6 – 26
6.4.2 General structure . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 27
6.4.2.1 Navigation switches . . . . . . . . . . . . . . . . . . . . . . . 6 – 28
6.4.2.2 Function switches . . . . . . . . . . . . . . . . . . . . . . . . 6 – 30
6.4.3 Start page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 31
6.4.4 Log on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 32

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6.4.5 Alarm messages. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 33

6.4.5.1 Alarm list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 34
6.4.5.2 Acknowledge alarm messages . . . . . . . . . . . . . . . 6 – 35
6.4.5.3 Alarm history . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 35
6.4.6 Info view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 36
6.4.6.1 Change dialog language . . . . . . . . . . . . . . . . . . . . 6 – 37
6.4.7 Operating the shuttle table system . . . . . . . . . . . . . . 6 – 38
6.4.7.1 Simple table change . . . . . . . . . . . . . . . . . . . . . . 6 – 38
6.4.7.2 Reset job data . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 39
6.4.7.3 Extended operating . . . . . . . . . . . . . . . . . . . . . . . 6 – 40
6.4.7.4 Material status in the cutting and loading positions . 6 – 41
6.4.8 Setup functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 42
6.4.8.1 Machine-specific settings . . . . . . . . . . . . . . . . . . . 6 – 42
6.4.9 Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 44
6.4.9.1 Move shuttle tables manually . . . . . . . . . . . . . . . . 6 – 44
6.5 Setup and adjustment. . . . . . . . . . . . . . . . . . . . . . . 6 – 46
6.5.1 Initiate axis movement . . . . . . . . . . . . . . . . . . . . . . 6 – 46
6.5.2 Changing the cutting head. . . . . . . . . . . . . . . . . . . . 6 – 46
6.5.3 Changing the nozzle . . . . . . . . . . . . . . . . . . . . . . . . 6 – 47
6.5.4 Centering the laser beam in the nozzle . . . . . . . . . . . 6 – 48
6.5.5 Tactile sensing (optional) . . . . . . . . . . . . . . . . . . . . 6 – 51
6.5.5.1 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 51
6.5.5.2 Calibrating the sensor . . . . . . . . . . . . . . . . . . . . . 6 – 52
6.6 Manual mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 53
6.6.1 Separating cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 53
6.6.1.1 Fine positioning using the hand wheel . . . . . . . . . . 6 – 54
6.6.2 Cutting plan origin offset . . . . . . . . . . . . . . . . . . . . . 6 – 55
6.7 The cutting process. . . . . . . . . . . . . . . . . . . . . . . . . 6 – 56
6.7.1 The manual cutting process . . . . . . . . . . . . . . . . . . . 6 – 56
6.7.1.1 Creating a cutting job . . . . . . . . . . . . . . . . . . . . . 6 – 56
6.7.1.2 Import cutting plan . . . . . . . . . . . . . . . . . . . . . . . 6 – 59
6.7.1.3 Assign cutting parameters . . . . . . . . . . . . . . . . . . 6 – 60
6.7.1.4 Starting a cutting process . . . . . . . . . . . . . . . . . . 6 – 62
6.7.2 Automatic mode (loading and unloading manually). . . 6 – 63
6.7.2.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 63
6.7.2.2 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 63
6.7.2.3 Starting a cutting process . . . . . . . . . . . . . . . . . . 6 – 66

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6.8 Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 67

6.8.1 Travel to service position. . . . . . . . . . . . . . . . . . . . . 6 – 67
6.8.2 Travel to park position . . . . . . . . . . . . . . . . . . . . . . 6 – 67
6.8.3 Calibrating the nozzle . . . . . . . . . . . . . . . . . . . . . . . 6 – 67
6.8.4 Cleaning the nozzle . . . . . . . . . . . . . . . . . . . . . . . . 6 – 67
6.8.5 Displacing the origin . . . . . . . . . . . . . . . . . . . . . . . . 6 – 68
6.9 Special functions. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 69
6.9.1 Crossjet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 69
6.9.1.1 Crossjet log on . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 69
6.9.2 Sheet clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 70
6.9.3 Edge detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 71
6.9.3.1 Edge detection with active sheet clamping . . . . . . . 6 – 71
6.9.3.2 Edge detection with CutControl . . . . . . . . . . . . . . . 6 – 71
6.9.4 CutControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 72
6.9.4.1 Working with CutControl . . . . . . . . . . . . . . . . . . . 6 – 72
6.9.4.2 Determining the calibration threshold . . . . . . . . . . 6 – 73
6.9.4.3 CutControl functional checks. . . . . . . . . . . . . . . . . 6 – 76
6.9.5 Microwebs / welding webs . . . . . . . . . . . . . . . . . . . . 6 – 77
6.9.5.1 Automatic microwebs. . . . . . . . . . . . . . . . . . . . . . 6 – 78
6.9.5.2 Programmed microwebs. . . . . . . . . . . . . . . . . . . . 6 – 79
6.9.5.3 Welding webs . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 80

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7 Maintenance
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

7.1.1.1 Working on live components. . . . . . . . . . . . . . . . . 7–3
7.1.1.2 Working on gearboxes . . . . . . . . . . . . . . . . . . . . . 7–3
7.1.1.3 Lingering within the danger zone . . . . . . . . . . . . . 7–4
7.1.1.4 Operating resources . . . . . . . . . . . . . . . . . . . . . . 7–4
7.1.1.5 Third-party assemblies . . . . . . . . . . . . . . . . . . . . 7–4
7.1.1.6 Tools, testing equipment and spare parts . . . . . . . . 7–4
7.1.2 Personnel requirements . . . . . . . . . . . . . . . . . . . . . 7–5
7.2 Customer service information. . . . . . . . . . . . . . . . . 7–6
7.3 Operating resources . . . . . . . . . . . . . . . . . . . . . . . . 7–7
7.4 Operating hours display . . . . . . . . . . . . . . . . . . . . . 7–8
7.5 Maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . 7–9
7.6 Maintenance record . . . . . . . . . . . . . . . . . . . . . . . . 7 – 19

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8 Repairs
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

8.1.1.1 Working on live components . . . . . . . . . . . . . . . . . 8–3
8.1.1.2 Working on gearboxes . . . . . . . . . . . . . . . . . . . . . 8–3
8.1.1.3 Lingering within the danger zone . . . . . . . . . . . . . 8–4
8.1.1.4 Operating resources . . . . . . . . . . . . . . . . . . . . . . 8–4
8.1.1.5 Third-party assemblies. . . . . . . . . . . . . . . . . . . . . 8–4
8.1.1.6 Tools, testing equipment and spare parts . . . . . . . . 8–4
8.1.2 Personnel requirements. . . . . . . . . . . . . . . . . . . . . . 8–5
8.2 Fault finding and remedy . . . . . . . . . . . . . . . . . . . . 8–6
8.3 Safety checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
8.4 Lubricants, care and cleaning tasks . . . . . . . . . . . . 8–9
8.4.1 Operating terminal . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
8.4.1.1 Cleaning the screen . . . . . . . . . . . . . . . . . . . . . . . 8–9
8.4.1.2 Clean keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
8.4.2 Central lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 10
8.4.2.1 Top up lubricant . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 10
8.4.3 Sheet clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 12
8.4.3.1 Replacing a clamping lever . . . . . . . . . . . . . . . . . . 8 – 13
8.4.4 Shuttle table system . . . . . . . . . . . . . . . . . . . . . . . . 8 – 14
8.4.4.1 Roller chain tension . . . . . . . . . . . . . . . . . . . . . . . 8 – 14
8.4.4.2 Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 16
8.4.4.3 Drives and gearbox, lifting unit . . . . . . . . . . . . . . . 8 – 16
8.4.5 Base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 18
8.4.5.1 Extraction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 18
8.4.5.2 Small parts trays. . . . . . . . . . . . . . . . . . . . . . . . . 8 – 18
8.4.6 Cutting bridge and carriage (x- and y-axis) . . . . . . . . 8 – 19
8.4.6.1 DHM drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 19
8.4.6.2 Motor bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 20
8.4.6.3 Changing the nozzle body . . . . . . . . . . . . . . . . . . 8 – 21
8.4.6.4 Fitting the nozzle body. . . . . . . . . . . . . . . . . . . . . 8 – 22
8.4.7 Linear guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 23
8.4.8 Linear measurement system . . . . . . . . . . . . . . . . . . 8 – 23
8.4.8.1 Measurement tapes . . . . . . . . . . . . . . . . . . . . . . . 8 – 23
8.4.8.2 Reading head . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 25

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8.4.9 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 26

8.4.9.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 28
8.4.9.2 Reset switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 29
8.4.9.3 Crossjet oil tank, top up oil. . . . . . . . . . . . . . . . . . 8 – 30
8.4.9.4 Bleed Crossjet . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 32
8.4.10 Cutting gas, changing the gas bottles . . . . . . . . . . . . 8 – 33
8.4.10.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 34
8.4.10.2 Cutting gas regulators . . . . . . . . . . . . . . . . . . . . . 8 – 35
8.4.10.3 Replacing gas bottles during operating . . . . . . . . . 8 – 36
8.5 Beam guidance – optics . . . . . . . . . . . . . . . . . . . . . 8 – 37
8.5.1 Optics components . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 37
8.5.1.1 Deflecting mirror . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 37
8.5.1.2 Adaptive optics . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 37
8.5.1.3 Cleaning the deflective mirror and lens in the
cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 38
8.5.2 Cleaning / replacing the deflecting mirror . . . . . . . . . 8 – 39
8.5.3 Adaptive optics . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 43
8.5.3.1 Cleaning / replacing. . . . . . . . . . . . . . . . . . . . . . . 8 – 43
8.5.3.2 Determining the characteristic curve . . . . . . . . . . . 8 – 45
8.5.4 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 48
8.5.4.1 Replace lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 48
8.5.4.2 Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 49
8.5.4.3 Construction of cutting heads . . . . . . . . . . . . . . . . 8 – 50
8.5.4.4 Removing the lens. . . . . . . . . . . . . . . . . . . . . . . . 8 – 51
8.5.4.5 Cleaning the lens and mirror. . . . . . . . . . . . . . . . . 8 – 54
8.5.4.6 Cleaning when slightly soiled . . . . . . . . . . . . . . . . 8 – 55
8.5.4.7 Cleaning with cotton buds for heavier soiling . . . . . 8 – 56
8.5.4.8 Cleaning when heavily soiled . . . . . . . . . . . . . . . . 8 – 57
8.5.4.9 Refitting the lens. . . . . . . . . . . . . . . . . . . . . . . . . 8 – 58
8.6 Adjusting the beam guidance . . . . . . . . . . . . . . . . . 8 – 61
8.6.1 Aim of adjustments . . . . . . . . . . . . . . . . . . . . . . . . 8 – 61
8.6.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 61
8.6.3 Complete readjustment of the optics . . . . . . . . . . . . 8 – 61
8.6.3.1 Adjustment options on the deflecting mirror . . . . . . 8 – 62
8.6.3.2 Adjustable deflecting mirror . . . . . . . . . . . . . . . . . 8 – 63
8.6.4 Position of the laser beam . . . . . . . . . . . . . . . . . . . . 8 – 64
8.6.5 Protective and auxiliary devices . . . . . . . . . . . . . . . . 8 – 65
8.6.6 Preparing for adjustment of the machine optics . . . . . 8 – 67

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8.6.7 Removing the alignment devices . . . . . . . . . . . . . . . 8 – 67

8.6.7.1 Deflecting mirror telescope position . . . . . . . . . . . . 8 – 68
8.6.7.2 Deflecting mirror bridge position . . . . . . . . . . . . . . 8 – 69
8.6.7.3 Deflecting mirror z-axis position . . . . . . . . . . . . . . 8 – 70
8.6.7.4 Cutting head position. . . . . . . . . . . . . . . . . . . . . . 8 – 71
8.6.8 Single pulse procedure . . . . . . . . . . . . . . . . . . . . . . 8 – 72
8.6.9 Adjusting the machine optics . . . . . . . . . . . . . . . . . . 8 – 74
8.6.9.1 Adjusting the deflecting mirror telescope . . . . . . . . 8 – 75
8.6.9.2 Adjusting the bridge deflecting mirror . . . . . . . . . . 8 – 75
8.6.9.3 Adjusting deflecting mirror z-axis . . . . . . . . . . . . . 8 – 76
8.6.9.4 Centering the laser beam in the nozzle . . . . . . . . . 8 – 77
8.7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 78
8.7.1 Tactile sensing (optional) . . . . . . . . . . . . . . . . . . . . 8 – 78
8.7.1.1 Tactile sensing sensor breakage . . . . . . . . . . . . . . 8 – 78
8.7.1.2 Remedying sensor breakage . . . . . . . . . . . . . . . . . 8 – 79
8.8 Circuit diagrams, drawings . . . . . . . . . . . . . . . . . . . 8 – 82
8.9 Customer service information. . . . . . . . . . . . . . . . . 8 – 83

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9 Decommissioning

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10 Packing and transport

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11 Disposal
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 3
11.1.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 3
11.1.2 Personnel requirements . . . . . . . . . . . . . . . . . . . . . 11 – 3
11.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 4
11.2.1 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 4
11.2.2 Operating resources . . . . . . . . . . . . . . . . . . . . . . . . 11 – 4
11.3 Assemblies suitable for disposal. . . . . . . . . . . . . . . 11 – 5
11.3.1 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 5
11.4 Disposal centers, govt. agencies. . . . . . . . . . . . . . . 11 – 6
11.4.1 Return to manufacturer. . . . . . . . . . . . . . . . . . . . . . 11 – 6
11.4.2 Notification of govt. agencies and manufacturer . . . . . 11 – 6

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12 Cutting technology
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 3
12.1.1 Material specification . . . . . . . . . . . . . . . . . . . . . . . 12 – 4
12.2 Design guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 5
12.2.1 Sheet formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 5
12.2.2 Cutting gap clearance for laser cutting . . . . . . . . . . . 12 – 5
12.2.3 Rectangularity of the cut edges . . . . . . . . . . . . . . . . 12 – 6
12.2.4 Roughness of the cut edges . . . . . . . . . . . . . . . . . . . 12 – 7
12.2.5 Contour radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 9
12.2.6 Sheet thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 10
12.2.7 Common separating cut . . . . . . . . . . . . . . . . . . . . . 12 – 11
12.2.8 Hanging hole for the paint shop . . . . . . . . . . . . . . . . 12 – 12
12.2.9 Edge deformation . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 12
12.2.10 Cut-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 13
12.2.11 Brackets (bended parts only) . . . . . . . . . . . . . . . . . . 12 – 13
12.2.12 Relief cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 14
12.2.13 Intermittent limb . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 14
12.2.14 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 15
12.2.15 Marking similar parts . . . . . . . . . . . . . . . . . . . . . . . 12 – 16
12.3 Definitions and limitations . . . . . . . . . . . . . . . . . . . 12 – 17
12.3.1 Definition of limit thickness / normal thickness. . . . . . 12 – 17
12.3.2 Definition of part area . . . . . . . . . . . . . . . . . . . . . . . 12 – 19
12.3.3 Definition of part size . . . . . . . . . . . . . . . . . . . . . . . 12 – 20
12.3.4 Definition of web width / minimum web width . . . . . . 12 – 21
12.3.5 Part separation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 22
12.3.6 Hole templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 23
12.3.7 Achievable part precision. . . . . . . . . . . . . . . . . . . . . 12 – 24
12.4 The laser cutting process . . . . . . . . . . . . . . . . . . . . 12 – 26
12.4.1 Laser fusion cutting . . . . . . . . . . . . . . . . . . . . . . . . 12 – 26
12.4.2 Plasma cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 27
12.4.3 Laser flame cutting . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 28
12.4.4 Laser sublimation cutting . . . . . . . . . . . . . . . . . . . . 12 – 29
12.4.5 The cutting process . . . . . . . . . . . . . . . . . . . . . . . . 12 – 30
12.4.6 Gas parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 31

Byspeed
Table of contents
12.5 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 32
12.5.1 Technology wizard . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 32
12.5.1.1 Functionality examples . . . . . . . . . . . . . . . . . . . . 12 – 33
12.5.1.2 Adaptations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 35
12.5.1.3 Peculiarities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 35
12.5.1.4 Guidelines for initial cut types . . . . . . . . . . . . . . . . 12 – 36
12.5.2 Piercing and initial cuts . . . . . . . . . . . . . . . . . . . . . . 12 – 40
12.5.2.1 Outer contour . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 41
12.5.2.2 Inner contour (cut-outs) . . . . . . . . . . . . . . . . . . . 12 – 42
12.5.3 Programming process macros . . . . . . . . . . . . . . . . . 12 – 43
12.5.4 Radii on inner and outer contours. . . . . . . . . . . . . . . 12 – 44
12.6 Cutting parameters . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 45
12.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 45
12.6.2 Adapt cutting parameters . . . . . . . . . . . . . . . . . . . . 12 – 47
12.6.2.1 Reasons for parameter adaptations . . . . . . . . . . . . 12 – 48
12.6.2.2 Requirements for parameter adaptations . . . . . . . . 12 – 48
12.6.3 Procedure for optimizing the cutting parameters . . . . 12 – 49
12.6.3.1 Cutting focal position . . . . . . . . . . . . . . . . . . . . . . 12 – 51
12.6.3.2 Laser power cutting . . . . . . . . . . . . . . . . . . . . . . . 12 – 53
12.6.3.3 Gas cutting pressure . . . . . . . . . . . . . . . . . . . . . . 12 – 54
12.6.3.4 Cutting feed rate . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 55
12.6.3.5 Nozzle distance, cutting . . . . . . . . . . . . . . . . . . . . 12 – 56
12.6.4 Cutting laser 5200 ARC . . . . . . . . . . . . . . . . . . . . . . 12 – 57
12.6.4.1 Focal position and beam diameter . . . . . . . . . . . . . 12 – 57
12.7 Machining process. . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 59
12.7.1 Summary of the various technologies . . . . . . . . . . . . 12 – 59
12.7.2 Cutting structural steel . . . . . . . . . . . . . . . . . . . . . . 12 – 60
12.7.2.1 Machining thick sheets . . . . . . . . . . . . . . . . . . . . . 12 – 62
12.7.2.2 Piercing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 62
12.7.2.3 Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 62
12.7.2.4 Normal sheet thickness . . . . . . . . . . . . . . . . . . . . 12 – 63
12.7.2.5 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 64
12.7.2.6 Sheet thicknesses at the limit range . . . . . . . . . . . 12 – 67
12.7.2.7 Unsuitable parts for production . . . . . . . . . . . . . . . 12 – 69
12.7.2.8 Cutting with nitrogen (N2) . . . . . . . . . . . . . . . . . . 12 – 70
12.7.3 Pulsed cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 71
12.7.3.1 Pulsed cutting (application examples) . . . . . . . . . . 12 – 71
12.7.3.2 Pulsed piercing (application examples). . . . . . . . . . 12 – 71
12.7.3.3 Guide values. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 73
12.7.3.4 Parameter adaptations for complex contours . . . . . 12 – 75

Byspeed
Table of contents
12.7.3.5 Adapting the cutting mode pulse parameters . . . . . 12 – 76

12.7.3.6 Adapting the piercing mode pulse parameters . . . . 12 – 78
12.7.3.7 Influencing factors in pulse mode . . . . . . . . . . . . . 12 – 78
12.7.3.8 Alternatives to pulsed cutting . . . . . . . . . . . . . . . . 12 – 78
12.7.3.9 Programming for pulsed contours . . . . . . . . . . . . . 12 – 79
12.7.3.10 Background information . . . . . . . . . . . . . . . . . . . . 12 – 81
12.7.4 Oxide-free cutting in stainless steel . . . . . . . . . . . . . 12 – 82
12.7.4.1 Cutting parameters for stainless steels . . . . . . . . . 12 – 83
12.7.5 Oxide-free cutting of aluminum alloys . . . . . . . . . . . . 12 – 84
12.7.6 Machining diverse materials. . . . . . . . . . . . . . . . . . . 12 – 85
12.7.7 Plasma cut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 88
12.7.7.1 Practical applications . . . . . . . . . . . . . . . . . . . . . . 12 – 89
12.7.7.2 Stored cutting parameters . . . . . . . . . . . . . . . . . . 12 – 90
12.7.7.3 Cutting parameters for custom sheets . . . . . . . . . . 12 – 91
12.7.7.4 Initial cut type in stainless steel, 15/20 mm . . . . . . 12 – 93
12.7.7.5 Partial plasma cut for sheet thicknesses up to 1.5 mm 12 – 94
12.7.7.6 Time comparison between normal and plasma cut. . 12 – 95
12.7.8 Engraving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 97
12.7.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 97
12.7.8.2 Assessing the quality of an engraving . . . . . . . . . . 12 – 98
12.7.9 Machining with process macros . . . . . . . . . . . . . . . . 12 – 99
12.7.9.1 Process macro 1 . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 99
12.7.9.2 Process macro 2 . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 99
12.7.9.3 Process macro 2 for the initial cut . . . . . . . . . . . . . 12 – 100
12.7.9.4 Example with process macros . . . . . . . . . . . . . . . . 12 – 101
12.7.10 Various piercing methods . . . . . . . . . . . . . . . . . . . . 12 – 102
12.7.10.1 Conventional, pulsed piercing (without monitoring) . 12 – 104
12.7.10.2 CPP (Controlled Pulsed Piercing) . . . . . . . . . . . . . . 12 – 105
12.7.10.3 Normal CW piercing . . . . . . . . . . . . . . . . . . . . . . . 12 – 108
12.7.10.4 Lead in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 108
12.7.10.5 Lead in with piercing time . . . . . . . . . . . . . . . . . . 12 – 109
12.7.10.6 Lead in without piercing time . . . . . . . . . . . . . . . . 12 – 110
12.7.10.7 Pre-cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 112
12.7.10.8 Special piercing in thick sheets . . . . . . . . . . . . . . . 12 – 113
12.7.10.9 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 114
12.7.10.10 Cutting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 115

Byspeed
Table of contents
12.7.11 Microwebs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 116

12.7.11.1 Define microwebs . . . . . . . . . . . . . . . . . . . . . . . . 12 – 118
12.7.11.2 Alternatives to microwebs . . . . . . . . . . . . . . . . . . 12 – 118
12.7.12 Machining corners . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 119
12.7.12.1 Machining corners with corner tolerance . . . . . . . . 12 – 119
12.7.12.2 Pointed corners in thick sheets (with dwell time
parameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 120
12.7.13 Support grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 121
12.7.13.1 Standard support grid . . . . . . . . . . . . . . . . . . . . . 12 – 121
12.7.13.2 Support grid for thin sheets . . . . . . . . . . . . . . . . . 12 – 122
12.7.13.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 123
12.8 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 124
12.8.1 Material properties . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 124
12.8.2 Alloy components . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 124
12.8.3 Microstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 125
12.8.4 Material surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 125
12.8.4.1 Bad influences . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 125
12.8.4.2 Good influences . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 125
12.8.5 Surface treatment . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 126
12.8.5.1 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 126
12.8.6 Beam reflectance . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 127
12.8.7 Thermal conductivity . . . . . . . . . . . . . . . . . . . . . . . 12 – 127
12.8.8 Heat-affected zone . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 128
12.8.9 Stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 129
12.9 Low-staff production. . . . . . . . . . . . . . . . . . . . . . . . 12 – 130
12.9.1 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 130
12.10 High-dynamic cutting . . . . . . . . . . . . . . . . . . . . . . . 12 – 131
12.10.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 131
12.10.2 Part programming . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 131
12.10.3 Machine dynamics . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 132
12.10.3.1 Guide values for radial acceleration (dynamics) . . . 12 – 132
12.10.3.2 Blunt corners (with the corner tolerance parameter),
quality cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 132
12.11 Hints for optimum part programming. . . . . . . . . . . 12 – 133
12.11.1 Initial cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 133
12.11.1.1 Machining without initial cuts . . . . . . . . . . . . . . . . 12 – 133
12.11.1.2 Machining with initial cut . . . . . . . . . . . . . . . . . . . 12 – 133
12.11.1.3 Initial cut type . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 134
12.11.1.4 Initial cut point . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 135

Byspeed
Table of contents
12.11.2 Direction of rotation and cutting sequence in the part . 12 – 136

12.11.3 Positioning in Bysoft . . . . . . . . . . . . . . . . . . . . . . . . 12 – 137
12.11.4 Positioning the machine axes . . . . . . . . . . . . . . . . . . 12 – 138
12.11.5 Hole templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 138
12.11.6 Thin sheet machining using scanning . . . . . . . . . . . . 12 – 139
12.11.6.1 Schematic representation of the machining sequence 12 – 139
12.11.6.2 Machining characteristics for scanning . . . . . . . . . . 12 – 140
12.11.6.3 Machining examples . . . . . . . . . . . . . . . . . . . . . . 12 – 141
12.11.7 Erect parts after machining . . . . . . . . . . . . . . . . . . . 12 – 142
12.11.8 Thin sheet grids . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 143
12.11.9 Part machining sequence. . . . . . . . . . . . . . . . . . . . . 12 – 143
12.11.10 Warping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 144
12.11.11 Pointed corners in thick sheets with loops . . . . . . . . . 12 – 144
12.11.12 Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 145
12.11.13 Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 145
12.12 Cut assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 146
12.12.1 Cutting with oxygen (O2). . . . . . . . . . . . . . . . . . . . . 12 – 146
12.12.1.1 Steel 235, 4 mm thick . . . . . . . . . . . . . . . . . . . . . 12 – 146
12.12.1.2 Steel 235, 10 mm thick . . . . . . . . . . . . . . . . . . . . 12 – 148
12.12.1.3 Steel, 15 mm thick . . . . . . . . . . . . . . . . . . . . . . . 12 – 151
12.12.1.4 Steel RAEX 420 Laser, 20 mm thick. . . . . . . . . . . . 12 – 152
12.12.1.5 Stainless steel, 1.4301, 6 mm thick. . . . . . . . . . . . 12 – 154
12.12.2 Cutting with nitrogen (N2) . . . . . . . . . . . . . . . . . . . . 12 – 155
12.12.2.1 Steel, hot galvanized, 2 mm thick . . . . . . . . . . . . . 12 – 155
12.12.2.2 Steel 235, 6 mm thick . . . . . . . . . . . . . . . . . . . . . 12 – 156
12.12.2.4 Stainless steel, 1.4301, 10 mm thick . . . . . . . . . . . 12 – 159
12.12.2.6 Aluminum AlMg3, 3 mm thick . . . . . . . . . . . . . . . . 12 – 165
12.12.2.7 Aluminum AlMg3, 12 mm thick . . . . . . . . . . . . . . . 12 – 167
12.12.2.8 Brass, 5 mm thick . . . . . . . . . . . . . . . . . . . . . . . . 12 – 169
12.12.2.9 Wodd, 24 mm thick . . . . . . . . . . . . . . . . . . . . . . . 12 – 170
12.12.2.10 Copper, 3 mm thick . . . . . . . . . . . . . . . . . . . . . . . 12 – 171
12.12.2.11 Titanium, 3 mm thick. . . . . . . . . . . . . . . . . . . . . . 12 – 171
12.12.3 Cutting with argon (Ar) . . . . . . . . . . . . . . . . . . . . . . 12 – 172
12.12.3.1 Titanium, 3 mm thick. . . . . . . . . . . . . . . . . . . . . . 12 – 172
12.12.4 Piercing with oxygen (O2) . . . . . . . . . . . . . . . . . . . . 12 – 173
12.12.4.1 Steel 235, 6 mm thick . . . . . . . . . . . . . . . . . . . . . 12 – 173

Byspeed
Table of contents
12.12.5 Piercing with nitrogen (N2) . . . . . . . . . . . . . . . . . . . 12 – 175

12.12.5.3 Aluminum AlMg3, 12 mm thick . . . . . . . . . . . . . . . 12 – 177
12.13 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 178
12.13.1 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 178
12.13.2 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 179
12.13.3 Beam guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 179
12.13.4 Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 179

Byspeed
Chapter 1
1 Product description
This chapter contains general information, operating data and equipment

notes. Further information can be found in the order confirmation.
Byspeed_Kap01_V10_en.fm © Bystronic Laser AG, 2004 1-1

Product description Byspeed
1-2 © Bystronic Laser AG, 2004 Byspeed_Kap01_V10_en.fm

Byspeed Product description
1.1 Introduction
1.1.1 Overview
Fig. 1.1-1 Overview of the laser cutting machine
E D A C
A Laser machine
B Laser
C Shuttle table system
D Exhaust air filter
E Cooling unit

1.1.2 Intended use
The laser cutting machine is for industrial cutting and engraving of sheets
made from non-flammable, metal materials and sheets with a protective
film, in the stipulated range.
Processing of materials that produce toxic gases on evapora-

tion, or of flammable materials, requires additional filters or
special extraction systems.
Further information can be obtained from the manufacturer of
the material concerned.
Any change in the agreed intended use or the agreed basic

conditions without written approval from the manufacturer is
at your own risk!
1.1.3 Precautionary measures
Only materials approved for the laser cutting machine may be processed.
This information can be taken from the order confirmation and must be
made available to the operating personnel by the user.

1.1.4 Work stations
Fig. 1.1-2 Laser cutting machine with Bylaser 4400 or Bylaser 5200 ARC
A H E
G
B D
C
A Control cabinets
B Laser
C Operating terminal
D Shuttle table console
E Shuttle table system
F Material carriage and rotating loader (optional)
G Tool cabinet
H Machining area

1.1.5 Product markings
Fig. 1.1-3 Type plate on the machine frame and on the cutting bridge
Type plate Positioning
Machine frame
Cutting bridge
A D
B E
F
C
G H
A System name
B Job number
C Total weight of machine in kg
D Date of manufacture
E Machine number
F Equipment number (technical identification number of the com-
plete laser cutting machine)
G Max. weight of a sheet in kg/m2
H CE conformity certification

Fig. 1.1-4 Type plate on control cabinet
Type plate Positioning
Control cabinet
A D
B E
C F
G H I J
K
L
A System name
B Job number
C Total weight of machine in kg
D Date of manufacture
E Machine number
F Equipment number (technical identification number of the com-
plete laser cutting machine)
G Mains voltage
H Mains frequency
I Electrical power
J Peak current
K Rated current
L CE conformity certification

1.2 Operating data
1.2.1 Capabilities
Machine tolerance to VDI 3441 ±0.1 mm/m
Repetition tolerance ±0.05 mm
Positioning speed X-/Y-axes simultaneously 169 m/min
Max. axis acceleration 30 m/s2
Max. radial acceleration 10 m/s2
Max. cutting rate 50 m/min
Max. laser power 5,200 W
Cutting area X = 3,000 mm
Y = 1,500 mm
Cutting head stroke Z = 100 mm
Max. shuttle table bearing capacity 890 kg
1.2.1.1 Max. cuttable thickness
Steela) 0.8…25.0 mm
Stainless steela) 0.8…20.0 mm
Aluminuma) 0.8…12.0 mm
a) depending on material and surface quality
1.2.1.2 Dust collector system
Extraction capacity 2,200 m3/h
Residual pressure 240 dPa
Clean air dust content <0.5 mg/m3

1.2.2 Dimensions and weights
Overall systema) 12,580 x 5,550 mm
Weight of laser cutting machinea) approx. 17,000 kg
Total weight including peripheralsa) approx. 20,000 kg
a) see installation drawing
1.2.3 Power supply
The power supply may not be subject to frequent voltage

fluctuations or spikes/dips across the overall mains tolerance
range, such as those generated by spot welding units, for ex-
ample.
Equipment and machines operating on the same grid must
comply with the relevant standards.
1.2.3.1 Laser cutting machine and chiller connection
Connection 3 phase & PE
Mains frequency 50 Hz / 60 Hz
Supply voltage 3 x 400 V / 3 x 480 V
Voltage tolerance +6% / -10%
Back-up fuse 125 AT
Connected load 68 kVA

1.2.3.2 Laser power requirement
4400 W P S I cos (ϕ)

[kW] [kVA] [A]
P Laser 100% 51.2 56.2 81 0.91
P Laser Standby 36.4 43.6 63 0.83
P Laser 0% 33.3 39.3 56.7 0.85
Shutdown 4.5 5.3 7.5 0.86
5200 W P S I cos (ϕ)

[kW] [kVA] [A]
P Laser 100% 56.4 61.9 89 0.91
P Laser Standby 38 45 65 0.84
P Laser 0% 35 42 61 0.83
Shutdown 4.4 5.1 7 0.86
1 - 10 © Bystronic Laser AG, 2004 Byspeed_Kap01_V10_en.fm

1.2.3.3 Dust collector system connection
Connection 3 phase & PE
Voltage tolerance +6% / -10%
Back-up fuse 25 AT
Mains frequency 50 Hz 60 Hz
Supply voltage 3 x 400 V 3 x 480 V
Connected load 4.6 kVA 4.4 kVA
cos (ϕ) 0.87 0.91
1.2.4 Cutting gas supply
The oxygen (O2) and nitrogen (N2) consumption can deviate

from the average values given here, depending on the mate-
rial and use. They are measured at the respective machine
connector.
Non-oxidized and cleaned copper or stainless steel pipes must
be used for the supply lines.
N2 Dynamic primary pressure 25 bar
N2 Dynamic flow 1,600 l/min
N2 Static primary pressure 30 bar
O2 Dynamic high pressure 18 bar
O2 Dynamic high pressure flow 500 l/min
O2 Static primary pressure 20 bar
O2 Dynamic low pressure 10 bar
O2 Dynamic low pressure flow 300 l/min
O2 Static low pressure 20 bar
Machine connection (Ø) 12 mm
Cutting gas pressures at the nozzle (adjustable) 0.1…20 bar
Byspeed_Kap01_V10_en.fm © Bystronic Laser AG, 2004 1 - 11

1.2.5 Compressed air supply
The air drawn by the compressor must be free from solvent

vapors and aerosolsa). To avoid the risk of contamination by
the compressor an oil-free screw compressor with down-
stream compressed air treatment (air drier) is required. The
air distribution network must be free from soiling and may not
contain oil.
If the above requirements are not fulfilled, a compressed air
or nitrogen bottle or tank must be connected for the output
coupler and beam path ventilation. A separate screw com-
pressor with compressed air treatment (air drier) can also be
used for ventilation.
a) Aerosols are gaseous, liquid or solid (powder) components dissolved in the air.
1.2.5.1 Laser cutting machine connection
Minimum supply pressure 6 bar
Connection dimension ½ inch
Maximum consumption 50 Nm3/h
Minimum compressed air quality at machine inlet ISO 8573-1
Maximum particle diameter (Class 4 or better) 15 µm
Maximum particle density (Class 4 or better) 8 mg/m3
Maximum residual oil content (Class 3 or better) 1 mg/m3
Dew point 5°C
Max. compressed air temperature on entering mainte- 40°C

nance unit

1.2.5.2 Dust collector system connection
The compressed air supply must be clean and dry with low oil
content. If necessary, oil and water traps must be installed as
close as possible to the filtering system.
Minimum supply pressure 6 bar
Connection dimension ½ inch
Maximum consumption 16.2 Nm3/h
Maximum particle diameter (Class 4 or better) 15 µm
Maximum particle density (Class 4 or better) 8 mg/m3
Maximum residual oil content (Class 3 or better) 1 mg/m3
Dew point 5°C

1.2.6 Environment
The temperature in the workshop must be between 15° and 35°C. Direct
sunlight on the machine components is prohibited.
In tropical climates or workshop temperatures above 35°C, an air-condi-
tioned room is needed.
The dew point of the ambient air must be below 10°C in order tom avoid
condensation on cooled components.
For a constantly good-quality cutting result it is necessary to place the
machine on a vibration-free footing.
Vapors, for example from spraying equipment or solvents, can absorb the
laser light and thus impair the performance of the machine. In addition,
the vapors represent a substantial explosion hazard in conjunction with
the laser beam.

1.3 Equipment
1.3.1 Design variants
The laser cutting machine is available in the 3015 format

(3,000 mm x 1,500 mm) with optional accessories.
Only material to a maximum size of 3,000 mm x 1,500 mm

may be processed on the laser cutting machine.


Byspeed
Chapter 2
2 Safety regulations
This chapter describes the safety measures for protection of people and
machine. The symbols and warnings used in these operating instructions
are explained below.
Despite all safety precautions a risk remains when using this product.
These must be taken into consideration at all times. Before work may be
started with this product, the safety regulations must be read and under-
stood.

Safety regulations Byspeed

Byspeed Safety regulations
2.1 Warnings and symbols
DANGER
Immediate danger, leading to severe injuries or death!
WARNING
Dangerous situation, possibly leading to severe injuries
or death!
CAUTION
Dangerous situation, possibly leading to minor injuries
or damage to property!

Indicates special technical features, which must be observed

by the operating and maintenance personnel.
Indicates useful tips on specific topics
1. Describes a handling sequence or the steps involved in an activity.
2.
3.

2.2 Product safety
Safe working is guaranteed if:

the operating instructions are observed
the operating, maintenance and repair personnel are trained on the
machine
the responsibilities for differing operating personnel are clearly defined
and adhered to
unauthorized personnel are kept away from the working area
all working practices which are detrimental to safety are avoided
faults that impair safety are immediately rectified
maintenance intervals are adhered to
2.2.1 Safety and monitoring devices
The safety and monitoring devices serve to protect personnel and may not
be removed, bridged or bypassed.
The system components are automatically controlled by electric and pneu-
matic drives. Remaining within the safety devices during operating can be
dangerous.
2.2.2 Safety-conscious working
Work on mechanical, electrical and gas equipment may only be carried out
by qualified personnel or under their supervision!
Improper use and operating can lead to hazards and to damage to the
machine!
For this reason it is forbidden:
to transport persons
to process prohibited materials
to remain within the danger zone. The operator is obliged to ensure
that no unauthorized persons remain within the danger zone.

2.3 Danger zones
DANGER
Lingering within a danger zone
While the laser cutting machine is operating it is forbid-
den to linger within the machining area!
Keep unauthorized personnel away from the working
area
Access to the emergency stop buttons on the operating terminal and the
shuttle table console may not be blocked by obstacles.
Hazards can arise during loading and unloading in particular, as well as
when moving the shuttle table or the material carriage in and out.
CAUTION
Crushing hazard when loading and unloading the
shuttle table or the material carriage
Wear protective gloves and steel-capped boots!
The clear space around the laser cutting machine must be designed so
that the supply and removal of material at the shuttle table is not im-
paired.
WARNING
Crushing hazard when moving the shuttle table or
the material carriage in and out
When traversing the shuttle table or the material car-
riage take care that no persons are in the path.

2.3.1 Warning and information signs
The signs must be permanently fixed and be easily visible. If signs are
badly aged or illegible, they must be replaced.
The locations of the signs may not be altered during replacement.
The positioning of the individual signs can be taken from Chapter
6 ›Operating‹ and Chapter 8 ›Repairs‹.
Fig. 2.3-1 Warning and information plates used
Symbol Description Positioning
High voltage warning see laser module operat-

ing instructions
Laser beam warning Cutting head

Laser (see laser module
operating instructions)
Focal length of cutting Cutting head

head in inches
Voltage warning Control cabinets
Use light breathing Dust collector system

equipment
Warning notice Dust collector system
Hand injuries warning Sheet clamp

2.4 Product specific hazards
2.4.1 Hazard from laser beam
A detailed description of the operating modes is can be found in Chapter

4.3 ›Laser cutting machine operating modes‹.
2.4.1.1 Normal operating mode
The laser cutting machine corresponds to Laser class 1 in normal operat-

ing mode (i.e. completely screened laser beam). All covers must be fitted.
The safety door protects against reflected and scattered radiation. It is not
necessary to wear protective goggles against reflected and scattered radi-
ation.
If persons are exposed to the cutting beam for prolonged pe-

riods, it is recommended to wear goggles with anti-glare fil-
ters.
2.4.1.2 Special operating mode
WARNING
The laser cutting machine corresponds to Laser
class 4 in special operating mode (i.e. not com-
pletely screened laser beam).
The direct laser beam, as well as reflected and scattered
radiation, are present a hazard to the eyes and skin.
Limit access to laser area
Cover or remove reflective objects
Remove flammable objects
Avoid generation of explosive solvent vapors
Wear laser safety goggles

2.4.1.3 Direct laser beam
WARNING
Direct laser beam.
In special operating mode the laser cutting machine cor-
responds to Laser class 4.
The direct laser beam can cause life-threatening injuries
on the whole of the body!
The following points must be observed when using the laser cutting ma-
chine:
Never expose yourself to direct laser beams!
Do not make any changes to the mountings of optical components!
Observe the operating instructions!
2.4.1.4 Reflected and scattered radiation
Avoid irradiating the eyes and skin with reflected and scattered radiation.
Laser safety goggles must be worn for the special operating mode. These
laser safety goggles are sufficient protection against reflected and scat-
tered radiation.
Laser safety goggles to DIN 58215 with Protection class L5A must be
used. These protective goggles are available at trade outlets or from the
manufacturer of the laser cutting machine.
Fig. 2.4-1 Laser safety goggles, protection class L5A (to DIN 58215)
Standard modela) Spectacle wearer's modela)
a) Not included in the delivery

2.4.2 Hazard from high voltage
A high voltage of 25,000 volt is generated in the laser module. In addition,

components that store electrical energy, such as capacitors, can carry
high charges. These can lead to dangerous electrical shocks.
WARNING
High voltage, 25,000 v DC
Voltages above 50 v and currents greater than 20 mA
are dangerous and can be lethal.
Work on high voltage components may only be carried
out by the manufacturer's servicing personnel.

2.4.3 Hazard from electricity
WARNING
Dangerous electrical voltage
Improper or negligent handling of electrical systems or
operating resources can lead to severe injuries or death.
Work on electrical systems or operating resources may
only be carried out by qualified personnel or under their
supervision.
The following points must be observed when dealing with electrical sys-
tems or operating resources:
Use only original fuses with the specified amperage!
In the event of a fault in the electrical supply, switch the machine off
immediately!
Electrical components on which maintenance work is being carried out
must be isolated unless otherwise specified.
First check that isolated components are voltage-free, earth and short-
circuit, and isolate adjacent live components!
Inspect the electrical equipment regularly. Rectify faults such as loose
connections or charred cables immediately.
When working on live parts get a second person to assist who can oper-
ate the Emergency stop or main switch in an emergency. Close off
the working area with a red and white safety chain and warning sign.
Use insulated tools only!

2.4.4 Pneumatic hazard
Check all loads, valves and hoses regularly for leaks!
WARNING
Danger of injury by ejected parts and leaking com-
pressed air
Do not perform any assembly or dismantling work, or
unscrew or tighten any screw connections, while the
system is under pressure.
Depressurize all subsystems which require opening be-
fore commencing maintenance and repair work.
2.4.5 Hazards from gas, dust, steam, smoke
2.4.5.1 Gas supply
In combination with oxygen and an open flame, leaks in the gas supply
can lead to explosions. Check that the gas supply is connected correctly.
WARNING
Explosion hazard
Do not oil or grease oxygen connections.
This can lead to explosion as the result of a chemical re-
action.
Further information on the gas supply and its dangers can be found in the
laser module operating instructions.

2.4.5.2 Extraction system
The vapors occurring during cutting are filtered by an extraction system.

If conspicuous smells occur during cutting, the correct functioning of the
extraction system should be examined.
WARNING
Fire hazard
There is a danger that the gases and cutting residues
are insufficiently extracted by the extraction system and
can ignite.
The extraction system capacity must correspond to the
specifications at all times. Adhere to maintenance inter-
vals in accordance with the maintenance schedule.
When processing flammable materials (e.g. aluminum),
suitable extraction and filter systems must be installed.
Ensure that there is sufficient ventilation when working in confined spac-

es! Observe local regulations!

2.4.6 Optics handling hazards
2.4.6.1 General
The laser output coupler and the lens in the cutting head are made of zinc
selenide. These components present no hazard in an undamaged condi-
tion.
If a lens is thermally damaged, toxic vapors are produced. In addition,
damage to the coating releases thorium fluoride, which is slightly radioac-
tive.
2.4.6.2 Notes on fire and damage
Zinc selenide is non-flammable. However, at temperatures above 400°C

thermal decomposition takes place, releasing toxic vapors and dust parti-
cles.
The dust must be allowed to settle before cleaning work can commence.
Avoid stirring up dust!
CAUTION
Toxic vapors and dust particles
Wear breathing equipment and protective gloves.
Return defective lenses to the cutting machine manufac-
turer in a sealed container.
Ventilate the working area well after a damage incident.
2.4.6.3 Health notes
Detailed information on first-aid measures can be taken from the zinc

selenide and thorium safety data sheets in the supplier documentation
folder.

2.4.7 Lubricants, coolants and cleaning agents
Always observe the manufacturer’s safety instructions for the respective

product when handling operating resources, particularly oil and grease
and other chemical substances. Further information can be found in the
folder Supplier documentation.
Avoid prolonged, intensive skin contact with these substances
If necessary, wear protective gloves, goggles and apron
Apply a suitable barrier cream before starting work
Change oil-soaked clothing immediately
Do not carry oily rags around in your pockets
CAUTION
Poisoning
Inhalation of oil mist or oil vapors can lead to nausea
and sickness.
Avoid contact with oil mist and oil vapor. Ensure ventila-
tion is sufficient.
WARNING
Explosion hazard
Do not bring aerosols and aerosol cans into contact with
not objects, machine components, gases or vapors.
Place work equipment on suitable surfaces (e.g. tool
cabinet).
The user is responsible for the correct disposal of lubricants,

coolants and cleansing agents, and of substances contaminat-
ed by these.

2.5 Personnel requirements
After commissioning the machine an operators training course is provided

by the manufacturer's service personnel. Further information can be taken
from the order confirmation.
The user is responsible for the ensuring that operating personnel are
properly trained.
A variety of machine training courses are offered as options. Detailed in-
formation can be requested from the Customer Training Center.
2.5.1 User
All persons working with or on the machine are referred to as Users in

these operating instructions.
The requirements placed on the users vary according to the activity that
they must perform. We therefore differentiate the following users:
2.5.1.1 User
The contractual partner of the manufacturer or his representative is re-

ferred to as the user. The user is entitled to sign legally binding contracts.
He purchases the machine and ensures that it is put to its intended use.
2.5.1.2 Operator
A person instructed in the operation of the machine is referred to as the
operator. The operator operates and supervises the use of the machine
during normal operating.
The operator's training includes participation in a course held by the man-
ufacturer.
2.5.1.3 Works mechanic
A tradesperson with mechanical or electrical basic training is refereed to

as the works mechanic. The works mechanic maintains the machine and
carries out minor repairs if necessary.

2.5.2 Qualifications
Only persons instructed and trained by the user may work on the ma-
chine. The personnel is responsible for third parties within the working ar-
ea.
Personnel being trained, instructed or taught are only allowed to operate
the machine under constant supervision by an experienced person!
2.5.3 Responsibility
The responsibilities for the various activities (operating, setting-up, main-

tenance, repair) on the machine must be clearly defined and adhered to.
Ambiguous responsibilities are a safety risk!
The user must provide the operator and the mechanic with access to the
operating instructions and ensure that they have been read and under-
stood.

2.6 Additional hazards
Unauthorized modifications or alterations to the machine are forbidden for

safety reasons!
No changes may be made to the programmable controls.
Machines may not be integrated into existing systems without the manu-
facturer's permission.

2.7 In an emergency
Personal injury
Carry out first aid measures
Call a doctor
Inform direct supervisors
Observe country-specific and company regulations


Byspeed
Chapter 3
3 Design and operation
This chapter describes the location and function of the various assemblies.
Furthermore, it contains information on the safety and monitoring devic-
es, which the product is equipped with.

Design and operation Byspeed

Byspeed Design and operation
3.1 Overview
Fig. 3.1-1 Laser cutting machine
A B C D E F G H I J K L
A Laser G Exhaust air filter

B Control cabinets H Protective fence
C Operating terminal I Rotating loader (optional)
D Tool cabinet J Shuttle table system
E Cooling unit K Material carriage (optional)
F Laser machine L Light barrier

3.2 Safety and monitoring devices
The machine is equipped with various safety devices, which may only be
activated in emergency situations.
Notes on safety devices allocated to a certain automation mod-

ule or storage system, but which operate in conjunction with
the laser cutting machine, can be taken from the corresponding
operating instructions.
3.2.1 Protective devices
Protective measures have been put in place at hazard spots in accordance

with the safety regulations that apply to the machine.
It is the user’s responsibility to install the appropriate barriers and to
check them regularly for effective functioning.
Protective and safety devices may only be removed, altered or taken out
of service if this is absolutely essential for transportation and repair work.
Before work commences, appropriate measures must be taken to protect
persons, and to prevent damage and breakage to structural parts.
Ensure that all protective devices are in place and that all hazard zones
are protected according to local safety regulations before commissioning
the machine.
The laser cutting machine's protective devices include

Emergency off switches
Safety light barrier
Safety door

3.2.2 Emergency off
An emergency off situation can be initiated by activating an emergency

off switch on the laser cutting machine or by an internal emergency off
from the laser controls.
The following emergency off switches are available

On the operating terminal
On the handheld controller
On the shuttle table console
On the front of the laser
If an emergency off switch is activated, all electrical loads are discon-

nected from supply.
However, this does not apply to the controller and the vacuum pump of
the charging system (if these are fitted to the laser cutting machine).
The laser cutting machine may only be restarted after the emergency sit-
uation, together with faults and damage, has been rectified (see Chapter
6.2.5 ›Restarting after an emergency off‹).

3.2.3 Light barrier
The light barrier monitors the hazard areas around the shuttle table and
the rotating loader. As soon as the light beam is interrupted, the drives for
the respective handling systems are switched off. The controls store the
last program step.
Fig. 3.2-1 Monitoring of hazards areas by the light barrier
A B
A Laser machine
B Shuttle table system
C Safety light barrier
D Rotating loader (optional)
The control states of the light barrier are visualized at the shuttle table
console using the reset button.
Reset button Control state
Button flashes The light barrier safety circuit is interrupted. Prompt in

the status bar of the user interface to activate the reset
button
Button lights The light barrier safety circuit is working and activated

3.2.4 Safety door
The entire machining area is enclosed by covers and a laterally moveable

protective door at the front. This protects the machining area during pro-
cessing. The view of the workpiece is guaranteed by large windows in the
protective door and illumination of the interior.
The protective door is monitored by a safety switch.
DANGER
Lingering within the danger zone
Moving parts such as the cutting bridge, carriage or the
z-axis, present a crushing hazard which can cause life
threatening injuries.
Nobody may remain within the machining area when the
protective door is closed.
Fig. 3.2-2 Laser cutting machine safety door
The safety door must be locked before a work process can be started on
the laser cutting machine.
The safety door protects against

Reflected laser radiation
Material splashes when cutting
Crushing by moving parts
Crushing by the sheet clamp

3.3 Laser
The laser beam is generated in the upper section of the laser. The turbine,
the vacuum pump, the gas treatment, the water distributor for the cooling
unit and part of the controls are located in the lower section.
Fig. 3.3-1 Laser
Further details on the laser can be found in the operating instruction for
the corresponding type.

3.4 Mechanical structure
Fig. 3.4-1 Main machine assemblies (without protective covers)
C D
A B
A Frame with integrated control cabinets

B Base frame
C Bridge with cutting bridge and carriage
D End plate

3.5 Frame
3.5.1 Control cabinets
The CNC, LSM and STL cabinets are fitted to the frame. The three control
cabinets are connected to each other and equipped with ventilators for air
circulation.
Air conditioning units are fitted in the doors of the CNC and the STL cabi-
nets in order to keep the temperature inside the cabinets at the optimum.
Fig. 3.5-1 CNC, LSM and STL cabinets
A B C
A CNC cabinet
B LSM cabinet
C STL cabinet
3.5.1.1 CNC cabinet
The CNC controls (Computer Numeric Control) are located in the CNC cab-
inet. The cabinet door is equipped with an air conditioning unit.
The CNC controls convert plans and process parameters into axis move-
ments. They control the course of the laser beam across the workpiece by
a combination of movements of the cutting bridge, carriage and z-axis.
They automatically adjust the travel speed and the laser power to the con-
tours of the parts geometry.
The machine executes the plans independently of program input. The
computer therefore remains available for creating and editing geometries,
while the machine processes the cutting plans.

3.5.1.2 LSM cabinet
The supply and the power distribution are located in the LSM
(Laser Supply Module) cabinet. The main switch for the laser cutting ma-
chine is fitted on the outside of the door. When switched off the main
switch can be secured with a padlock.
3.5.1.3 STL cabinet
The controller for the table change and the safety functions are located in
the STL (Table Laser Control) cabinet. The cabinet door is equipped with
an air conditioning unit.
The laser cutting machine operating computer is also located in this cabi-
net (see Chapter 3.5.2 ›Computer‹).

3.5.2 Computer
The computer is located in the STL cabinet. The drives are accessible from
behind a flap in the side wall of the STL cabinet.
Visualization is by means of the user interface on the operating terminal.
Fig. 3.5-2 Computer drives
A CD-RW drive
B ZIP drive
C 3½inch disk drive

3.5.3 Operating terminal
The operating terminal is attached to the frame by a swivel arm. It can be

moved horizontally around two axes and be fixed by means of fixing
clamps.
An emergency off switch is located on the operating terminal, together
with the reset button for enabling the safety circuit.
Fig. 3.5-3 Operating terminal
The machine can be operated either by means of the keyboard, the mouse
or the TFT touch screen.
A description of the operating terminal can be found in Chapter
4.2.3 ›Operating terminal‹.

3.5.4 Handheld controller
The handheld controller is located in a mounting beside the operating ter-

minal.
The handheld controller is provided with an emergency off switch. A de-
scription of the operating elements can be found in Chapter
4.2.4 ›Handheld controller‹.
Fig. 3.5-4 Handheld controller
Use of the handheld controller is required for the following operations:

Setup tasks
Operating the laser cutting machine in normal mode
Separating remaining sheets (separating cuts)
Trial cutting for parameter determination
Adjusting the laser beam

3.5.5 Tool cabinet
A lockable tool cabinet with six drawers is built into the frame.
Fig. 3.5-5 Tool cabinet
From top to bottom the following items can be found in the drawers:
Tools and replacement nozzles
Cutting heads and alignment tools for beam adjustment
Cleaning material for lenses and mirror
Protective goggles
Material for laser cutting machine maintenance

3.5.6 Netbox
The netbox (B) is located behind the covering on the frame (A). It is
equipped with a router and a hub.
Fig. 3.5-6 Netbox with open cover
A Cover
B Netbox with router and hub
The netbox is used to:

create a clear interface between the machine and the customer network
create a self-contained, permanent network, which can be handled by
the service engineer

3.5.7 Pneumatic valves
The valve island (B) with the pneumatic valves is located behind the cov-
ering on the frame (A). The valves are mounted on a plate which can be
pulled out at the front.
Fig. 3.5-7 Valve island with open cover
The valve controls the following elements:

Extraction system sector flaps
Shuttle table fixing device
Sheet clamp
Cutting head locking device
Shuttle table opening flap
The precise function of the individual pneumatic valves can be

taken from the appropriate diagram (see Diagrams folder).

3.5.8 Supply unit
The supply unit is fitted to the rear part of the frame. It supplies the laser
cutting machine with compressed air and clean air. The clean air is treated
in am air filter1).
The Crossjet oil tank is also located on the supply unit, together with the
pressure regulator and cutting gas pressure indicator.
Fig. 3.5-8 Location of supply unit
1) The air filter contains two adsorber units. These operate cyclically, i.e. in one element
the air is filtered and dried, whilst the second regenerates.

Fig. 3.5-9 View X: Supply unit
B A
C
D
H
G
K
J
A Pressostat
B Beam path ventilation pressure reduction 2 bar
C Activated charcoal filter
D Compressed air connection
E Water trap / prefilter
F Filter
G Main air pressure reduction 6 bar
H Air filter fault indicator
I Electrical connection
J Crossjet oil tank
K Cutting gas indicator (N2 / O2)
L Clean air filter

3.5.9 Central lubrication
All lubrication points of the laser cutting machine are supplied with lubri-
cant by the central lubrication unit. An exception to this are the motor
bearings of the x- and y-axes (which are lubricated manually using a
grease gun).
To access the central lubrication unit the cover at the left of the CNC cabi-
net must be removed.
Fig. 3.5-10 Location of central lubrication unit
Fig. 3.5-11 View X: Central lubrication
The central lubrication system allows the time spent on lubrication point
maintenance to be reduced to a minimum. Each lubrication point is also
provided with the optimum lubricant quantity.

3.5.9.1 Lubrication cycle
The lubrication cycles is initiated automatically by the movement times of

the axes. If a lubrication cycle is imminent, the current cutting plan is first
completed. When the reference position is next reached the lubrication cy-
cle is started.
During the lubrication cycle the x- and y-axes move across the
entire working area at 5 m/min. This guarantees optimum dis-
tribution of lubricant.
At the end of the lubrication cycle the axes travel to the refer-
ence position.
If the error message Lubrication cycle timeout appear on the operating

terminal after the lubrication cycle is complete, the manufacturer's cus-
tomer service department must be contacted.
3.5.9.2 Level monitoring
The level in the lubricant container is monitored. If the level is too low, an
error message, Lubricant container empty is issued at the operating
terminal.
Lubricant refilling for the central lubrication is described in Chapter
8.4.2 ›Central lubrication‹.

3.5.10 Sheet clamp
The sheet clamping serves to fix the sheet to be machined onto the shut-
tle table, thus ensuring cutting quality during highly dynamic cutting.
Fig. 3.5-12 Sheet clamp
The operation of the sheet clamp can be activated or deactivated in the

Handling Operation application, Main view, by using the Clamp but-
ton.
The Clamp collet chuck and Release collet chuck operations are ini-
tiated by pressing the CLAMP button on the operating terminal.

3.6 Base frame
3.6.1 Extraction
The machine is designed so that the machining area is completely encap-

sulated. This guarantees safety and optimum extraction of cutting emis-
sions.
WARNING
Fire hazard
Generation of flammable or explosive mixtures.
When changing material from steel to aluminum or vice
versa, the dust funnel must be emptied!
The cutting area is divided into eight extraction chambers. The appropri-
ate extraction flaps are opened depending on the position of the cutting
head.
Fig. 3.6-1 Exhaust air sectors
The extracted air is passed across an exhaust air filter and cleansed of
emissions.
WARNING
Toxic vapors when cutting plastics
The vapors given off during combustion are highly toxic.
They cannot be completely removed by the extraction
system.
Plastics may not be cut on laser cutting machines (with-
out special extraction systems)!

3.6.2 Small parts trays
Small parts falling through the support grid are lead to the small parts
trays by special guides. These can be pulled out for emptying by pulling
the handle.
Five small parts trays are located below the base frame of the laser cut-
ting machine and, optionally, four below the shuttle table.
Fig. 3.6-2 Small parts trays

3.7 Bridges
3.7.1 Cutting bridge
The cutting bridge travels along the x-axis. It carries the carriage, which
travels along the y-axis.
The laser beam is deflected from the x- to the y-axis by the deflecting mir-
ror fitted to the rear of the bridge.
Fig. 3.7-1 Cutting bridge
X-
X+
Y+
Y-
A Cutting bridge
B Carriage

3.7.2 Carriage
The carriage carries the z-axis, the connector box with all supply lines,
and the Crossjet.
Fig. 3.7-2 Carriage (without protective cover)
B C
A Carriage
B Z-axis
C Crossjet
3.7.2.1 Connector box

All supply lines and connections (electrical, pneumatic, cutting gas, etc.)
are located in the connector box (A).
Fig. 3.7-3 Connector box

3.7.3 Z-axis
The z-axis represents the final beam guidance element. The laser beam is
focused in the cutting head and receives the required power density on
the workpiece for cutting.
The z-axis moves the cutting head vertically. It raises the cutting head for
positioning between different figures on the workpiece and ensures that
the nozzle distance remains constant even if the workpiece is uneven. The
z-axis is driven by a ball screw drive.
Fig. 3.7-4 Z-axis structure
C
Z+
Z- E
A Cutting head
B Cover for tactile sensor connection (optional)
C Focal length of cutting head in inches
D Z-axis
E Nozzle
The beam is deflected from the y- to the z-axis by the adaptive mirror fit-
ted above the bridge.
The nozzle and the complete cutting head electronics are fitted into the z-
axis. The focal length is altered using various sizes of cutting head.

The cutting gas is supplied by the cutting head. During cutting, this drives
molten material away from the cut and thus protects the focusing lens
from splashing slag. The stream of cutting gas is shaped by the nozzle
such that the greatest possible amount of gas flows through the cut.

3.7.4 Cutting head
3.7.4.1 Structure
The lens built into the cutting head bundles the laser beam. The cutting
gas supplied through the z-axis is targeted by the nozzle on to the work-
piece. Using the two knurled screws on the cutting head, the lens is dis-
placed within the cutting head in order to center the laser beam in the
nozzle.
Fig. 3.7-5 Cutting head 7.5" (removed)
A A
A Lens adjustment screws for centering the laser beam in the cutting
nozzle
The various cutting heads vary in the focal length of the lens. The focal
length influences the applicability of the cutting head.
The following focal lengths are available:
Lens focal length Part no.
5,0" 1-10241
7,5" 1-10242
All lenses have the same diameter (1.5" = 38 mm).

3.7.4.2 Cutting head applications
A number of cutting heads with varying focal lengths are available in order
to provide optimum cutting results for the material concerned. The follow-
ing table shows their applications.
Tab. 3.7-1 Cutting head applications
Focal Focus Material Application

length
Ø Length Thick- Gas Gas
ness pres-
sure
[inch] [µm] [mm] [mm] [bar]
5.0" 130 0.6 Structural steel (S ≤3 O2 ≤5

235)
Galvanized structur- ≤4 N2 ≤ 12
al steel
Stainless steel ≤3 N2 8…16

(1.4301)
Alloyed aluminum ≤4 N2 8…16
7.5" 190 1.4 Structural steel (S ≤ 20 O2 ≤5

235)
Stainless steel ≤ 15 N2 8…20

(1.4301)
Alloyed aluminum ≤8 N2 8…20
Changing the cutting head is described in Chapter

6.5.2 ›Changing the cutting head‹.

3.7.4.3 Influence of focal length on cutting
The focal length influences cutting in the following way:
Fig. 3.7-6 Comparison of focal lengths: 5.0" and 7.5"
Lens
0.6 mm
5.0"
7.5"
1.4 mm
ø 130 µm
ø 190 µm
Small focal length Large focal length

Small focus diameter Larger focus diameter
Greater intensity at the focal Lesser intensity at the focal
point point
Higher cutting speed for thin Slower cutting speed for thin
sheets sheets
Thick sheets cannot be cut Higher cutting speed for thick
sheets
Small depth of focus
Greater focal depth
Sensitive to focal position
Insensitive to focal position
Narrow cut
Wider cut
Lens closer to workpiece (soil-
ing) Lens is further away from the
workpiece
Finer cut
Rough cut

3.7.5 Nozzles
The shape and diameter of the nozzle depends upon:

Focal length
Focal position
Gas pressure
Volumetric flow
Gas jet shape
Type of sensing
Scope of application
Fig. 3.7-7 Nozzle mounting on z-axis
A Nozzle body
B Nozzle
The most effective nozzle to use can be taken from the appro-
priate parameter set.
Nozzle changing and centering are described in Chapter

6.5.3 ›Changing the nozzle‹ and Chapter 6.5.4 ›Centering the
laser beam in the nozzle‹.
The available selection of nozzles is a result of the optimization of the

above named factors.

3.7.5.1 Nozzle selection

Tab. 3.7-2 Nozzle shapes and areas of application
Nozzle Area of application Designa- Part

shape tion no.
High pressure H08 3-04275

Tactile sensing H10 3-01899
Capacitive sensing
H12 3-01900
All applications for laser fusion cut-
ting (N2) H15 3-01901
Aluminum and chrome steel H17 3-01902
plates up to 10 mm thick
H20 3-01903
H25 3-04276
High pressure HK08 3-04277

Capacitive sensing HK10 3-01910
Universal nozzles for all applica-
tions HK12 3-01911
Steel to 25 mm (O2 and N2) HK15 3-01912

Stainless steel to 12 mm (N2) HK17 3-01913
Aluminum to 8 mm (N2)
HK20 3-01914
Diverse materials (O2 and N2)
HK25 3-03584
HK30 3-06112
Double nozzlea)
Capacitive sensing
Structural steel plate 4 - 5 mm NK10-15 3-16058

(O2)
Structural steel plate 6 -8 mm (O2) NK12-15 3-16059
Structural steel plate 10 -12 mm NK15-15 3-16060

(O2)
Structural steel plate 15 mm (O2) NK17-15 3-14317
Structural steel plate 16 -18 mm NK20-15 3-14318

(O2)
Aluminum to 5 - 8 mm (N2) NK25-20 3-16256
Aluminum to 10 -12 mm (N2) NK30-20 3-16257
a) Not suitable for cutting in conjunction with CutControl

3.7.5.2 Nozzle designations
H High pressure (up to 20 bar)

N Double nozzles
K Capacitive sensing
08 Nozzle diameter 0.8 mm

High pressure (tactile and capacitive sensing)
High pressure
H 20 Nozzle diameter 2.0 mm
High pressure (capacitive sensing)
High pressure
H K 17 Nozzle diameter 1.7 mm
Capacitive sensing
Double nozzles (capacitive sensing)
Double nozzle
Capacitive sensing
N K 15-10 Nozzle diameter 1.0 mm (inner)
Nozzle diameter 1.5 mm (outer)

3.7.6 Nozzle cleaning
The nozzle cleaner consists of a brass brush mounted on the base frame.
It is an important tool for ensuring problem-free work.
Fig. 3.7-8 Cleaning brush
3.7.6.1 Application
The nozzle head is soiled by splashes during operations. Material residues
are removed by traveling across the brush with the nozzle head.
The nozzle cleaner is suitable for the following materials:
Structural steel (all thicknesses)
Stainless steel (all thicknesses), in particular for stainless steels with
protective film
Aluminum to 3 mm
When cutting thick aluminum plates the droplets cling heavily to the noz-
zle. These can subsequently only be removed with a brush or by hand.
CAUTION
Burns hazard
There is a danger of burns when cleaning the nozzle by
hand.
Wear protective gloves.
Nozzle cleaning can be initiated automatically after a work sequence, or

manually by means of the service functions on the user interface.

3.7.6.2 Replacement
When the brush is full of splashed metal it loses ist effectiveness and must
be replaced.

3.7.7 CutControl
3.7.7.1 Design and operation
CutControl monitors the cutting process during fusion cutting of stainless

steel. The process monitoring system uses light reflected from the work-
piece to regulate the feed or interrupt the cutting process.
Fig. 3.7-9 Cross-section of cutting head with CutControl
A B
A Photodiode
B Deflecting mirror
C Cutting head
D Light reflected from the workpiece
E Workpiece
The light reflected during the continuous wave cutting of steel is deflected
via a concentric reflecting condenser and measured by silicon photo-
diodes. Mirror and photodiodes are integrated in the z-axis. The measure-
ment signals from the photodiodes are converted by the SENSOS-Print
(integrated in the z-axis) and transmitted to the PROMON card in the CNC
control cabinet. The CNC controls process this signal and monitor the cut-
ting process.

Piercing, pulsing and engraving are not monitored. CutControl is not acti-
vated until after the initial cut acceleration. A deteriorating cutting process
is recognized by the signal change and influenced by the subsequent con-
trol functions.
Control function Description
Feed rate reduction If the signal reaches the alarm or plasma threshold
the feed rate is reduced in stages to a predefined per-
centage. This reduction continues until the signal falls
below the alarm or plasma threshold or until the max-
imum reduction is reached. The reduced feed then re-
mains constant during the Reduced feed rate
period.
If the alarm ceases or the plasma extinguishes, cut-
ting is accelerated again to the original target feed
rate (value in cutting parameters).
Stop feed rate If the signal value does not fall back below the alarm
or the plasma threshold, or the stop threshold is ex-
ceeded, cutting is stopped and the head raised. After
cutting has stopped and the beam withdrawn, the
process is reset by a specific distance (but no further
than the last piercing) and the cut repeated.
The number of resets is limited to a maximum value
per contour section, after which a normal STOP func-
tion is triggered. This prevents uncontrolled endless
repetition under faulty cutting conditions.
3.7.7.2 CutControl with Bylaser 5200 ARC
When using the Bylaser 5200 ARC, steel piercing (cutting gas: oxygen) is
programmed by default as pulsed piercing (CPP). Piercing is monitored
by CutControl. Immediately after piercing the contour is cut.
For steel (cutting gas: oxygen), this procedure offers the following advan-
tages:
High process reliability
Short piercing time
See Chapter 12 ›Cutting technology‹ for further information.

3.7.8 Crossjet (optional)
The Crossjet is located beside the cutting head. It prevents melted materi-
al from sticking to the material surface by spraying an oil / air mix.
A weld shielding agent is used for the oil (see Tab. 7.3-2).
Fig. 3.7-10 Crossjet on z-axis
E
D
G B
F
H C
A Height adjustment screws

B Crossjet
C Crossjet fixing screw
D Air connection for valve controls
E Air connection for oil atomization
F Knurled screw for setting spray force
G Air connection for cross blowing
H Crossjet oil connection
Oil refilling is described in Chapter 8.4.9.3 ›Crossjet oil tank,

top up oil‹.

3.7.8.1 Oil mist
Oil is sprayed onto the surface of the workpiece before piercing. This oil
film reduces the adhesion of the slag that escapes upwards during pierc-
ing. The extent of the oil film depends on the flow rate, the nozzle diame-
ter and the duration of the spraying process.
3.7.8.2 Cross blowing
After piercing, compressed air blows the material escaping upwards away
to the side. This reduces the material adhering to the workpiece and the
nozzle.

3.7.9 Sensing
The optimum machining quality depends on the constant distance of the

nozzle to the workpiece. The nozzle distance is determined with the aid of
the cutting parameters.
Two options are available for measuring the distance between the nozzle
and the workpiece:
Capacitive sensing
Tactile sensing (optional)
The distance of the nozzle to the workpiece is controlled by moving the z-

axis to the predefined value.
Both sensing methods cannot be employed simultaneously.

Tactile sensing must be removed after used.
3.7.9.1 Capacitive sensing
Using capacitive sensing, the electrical capacitance between the nozzle

and the workpiece is measured. It can therefore only be employed for
electrically conductive materials.
The capacitive sensing is integrated in the z-axis.
Nozzle and workpiece together form the two plates of a variable capacitor.
This capacitor is connected to the controller. The controller compares the
capacitive charge with the target value that corresponds to the selected
nozzle distance.

3.7.9.2 Tactile sensing (optional)
The tactile (mechanical) sensor allows the distance to be senses for all
materials. However, it is primarily utilized for electric non-conductive ma-
terials. The tactile sensing is mounted on the side of the z-axis.
The tactile sensor is lowered onto the work piece. The distance from the
workpiece to the cutting head is determined by means of a linear potenti-
ometer. The nozzle distance is then adjusted relative to the sensor.
Fig. 3.7-11 Tactile sensing
A Fixing screws
B Casing
C Sensing ring

Fig. 3.7-12 Tactile sensor mounting on the z-axis
A Serial port for data transfer

B Pneumatic connections
C Centering hole
D Mounting plate for tactile sensor
Fitting and calibration of the tactile sensor are described in

Chapter 6.5.5 ›Tactile sensing (optional)‹.

3.8 End plate
The end plate closes the end of the machining area. The bridge and the
base frame are attached to the end plate.
Fig. 3.8-1 Laser cutting machine end plate (without shuttle table)
3.8.1 Flap
A flap (A) is fitted above the table change opening, which opens automat-
ically for a table change. It closes the machining area off during machin-
ing. This ensures that no outside air is taken in.
Material splashes and small parts are cleared from the grate by the brush
(B) at each table change.
Fig. 3.8-2 Shutter flap for table change
A Flap B Brush

3.8.2 Shuttle table console
The shuttle table system and the rotating loader (optional) can be operat-
ed manually by means of the shuttle table console. It is equipped with the
necessary buttons and an emergency off button.
Fig. 3.8-3 Shuttle table / rotating loader console
The function of the individual buttons are described in Chapter

4.2.5 ›Shuttle table console‹.

3.9 Beam guidance
The laser beam is directed from the resonator to the output coupler and
via the polarization mirror, deflecting mirror and focusing lens to the
workpiece.
The route of the laser beam, between the laser beam's exit from the laser
and the mounting of the cutting head on the z-axis, is known as the beam
path.
The bridge and carriage move during operating, together with the deflect-
ing mirrors mounted on them. This alters the length of the beam path.
This laser beam guidance principle is known as Flying optics.
WARNING
Fire and explosion hazard
The laser beam can ignite flammable and explosive liq-
uids and vapors. Conversely, foreign bodies, fluids and
gases can have an adverse effect on the beam quality.
Cleansing agents and solvents and their vapors must be
kept away from the beam path!
Fig. 3.9-1 Schematic diagram of beam guidance
D C B A
H G F E

A Laser beam deflection

B Beam protection tube
C Laser beam
D Beam deflection adaptive mirror
E Z-axis / cutting head
F Carriage
G Beam deflection carriage
H Cutting bridge
3.9.1 Beam protection
DANGER
Invisible laser beams
The protective beam path covers may not be removed
or modified!
The beam protection tune between the laser and the
machine may not be subject to mechanical loads!
The laser beam can exit unprotected or damage the
tube if the beam protection tube is bent.
The beam path is totally closed off by structural components, bellows and
protective covers.
Bellows and protective covers protect persons from stray radiation and
from contact with the laser beam. They also protect the optics from exter-
nal influence.

3.9.2 Deflecting mirror
Deflecting mirrors are used along the machine axes to deflect the laser
beam. The mirrors are flat mirrors. The beam quality (the parallelism, for
example) is maintained with flat mirrors.
Fig. 3.9-2 Deflecting mirror
D
B
E
F
G H
A Cover for coarse adjustment

B Cover fixing screw
C Coolant connection
D Mirror mounting
E Mirror fixing screw
F Fine adjustment screw
G Mirror retention plate
H Deflecting prism

The angle of incidence and the angle of reflection are measured against
the axis of incidence. The angle of incidence and the angle of reflection are
equal.
If the deflecting mirror is rotated by a given angle, the direction of the re-
flected beam alters by twice that angle.
Fig. 3.9-3 Reflection angle of a deflecting mirror
A B
C
D
A Angle of incidence α D Coating

B Angle of reflection β E Substrate
C Laser beam F Axis of incidence
Always observe the exact mirror designations when replacing

the deflecting mirrors.
In particular, the differences between bending, deflection,
telescopic and polarization mirrors must be observed (see
Spare parts catalog)!
The deflecting mirrors are held in a mirror mounting by a clamping ring.

The mirror mounting can be adjusted by rotating it horizontally and verti-
cally using adjusting screws.
The beam path adjusting screws are set at commissioning and do not re-
quire any further adjustment.

3.9.3 Adaptive optics
A deformable mirror is employed as an adaptive optic. This is designed to

ensure that the surface of the mirror maintains constant optical properties
in prolonged use.
The deformable mirror serves as a 90° deflector in the z-axis. The mirror
surface is deformed by the pressure of the coolant. A pressure booster
station fitted into the cooling circuit increases the water pressure. The
working pressure of the adaptive optic is between 3 and 11 bar.
The electronic controls monitor the pressure of the coolant flowing in the
mirror via a proportional or solenoid control valve and a pressure sensor
on the mirror.
Fig. 3.9-4 Adaptive mirror with mounting
D E
A Aperture
B Pressure sensor
C Water circulation
D Deformation of the mirror
E Adaptive mirror

3.9.3.1 Focal position with flat mirror
On machine using flying optics, the focal position changes within the
working area of the laser cutting machine. The greater the distance be-
tween the laser's output coupler and the lens in the cutting head, the low-
er the focal point. The reason for this lies in the natural divergence of the
laser beam. This results in different qualities of cut across large working
areas.
Fig. 3.9-5 Focal behavior with flat mirror
B C D E
A G I
A Laser
B Deflecting mirror
C Curved wave front
D Flat mirror
E Beam
F Lens
G Workpiece
H Cutting area
I Focus behavior over the entire cutting range

3.9.3.2 Focus correction with adaptive optics
By using the adaptive optics it is possible to keep the focal point constant,
independent of the distance from the focusing lens to the laser, controlling
it to suit to the process and workpiece.
Fig. 3.9-6 Focus behavior with adaptive optics
B C D E
K
+40 µm I
A 0
-40 µm
A Laser
B Deflecting mirror
C Curved wave front
D Beam
E Adaptive mirror
F Plane wavefront
G Lens
H Cutting area
I Workpiece
J Focus behavior over the entire cutting range
K Focal position

3.9.3.3 Focal position
In addition to the focus correction, the focal position can be adapted to the
material to be cut. The setting for the focal position can be taken from the
cutting parameters.

3.10 Shuttle table system
The shuttle table system consists of a shuttle table drive and two shuttle
tables with support grids.
Fig. 3.10-1 Shuttle table system
By changing tables it is possible to dispatch cut parts and to prepare the

next sheet ready for machining while the laser cutting machine processes
the current cutting plan.
The table change can be fully automatic, or be controlled manually by
means of the Handling Operation application. It is also possible to
change a table manually by pressing the Table change button on the
shuttle table console.
Information on operating the shuttle table system can be found in Chapter
4.2.5 ›Shuttle table console‹.
3.10.1 Shuttle table
The shuttle table serves to charge and unload the laser cutting machine.
The nozzle cleaning brush and the sensing calibration plate are also fitted
onto the shuttle table.

3.10.2 Support grid
The support grid serves as a workpiece support. The support grids can be
manufactured by the user. The necessary drawings are stored on the
computer as DXF files.
The bars can be manufactured from a number of metals. Copper bars
have the best endurance. The slag can be easily removed. The reflectance
of copper can have a negative influence in the thin sheet range, for small
holes (holes become imprecise) or for oxide-free cutting (plasma forma-
tion, beam break).
Bars of steel and stainless steel impair the cutting process least. The dura-
bility of these bars depends on the laser power used for cutting.
Fig. 3.10-2 Support grids
Support grid for thin sheet Support grid for thick sheet
Tab. 3.10-1 Material comparison
Material
Steel Stainless steel Copper
Economical, low reflec- Splashes from this grid High reflectance, high
tance, low durability cannot oxidize on stain- durability
less materials
Costs can be saved if oxygen is used as cutting gas for the bars.

3.11 General assemblies
3.11.1 Illumination
The machining area is illuminated by two fluorescent lamps.

One lamp is located near the operating terminal and is arranged so that
adequate lighting is available for setting up the machining head.
The second lamp is mounted on the end plate. It illuminates the ma-
chining area behind the cutting bridge.
Fig. 3.11-1 Interior lighting near the operating terminal

3.11.2 Axes drive
The cutting bridge (x-axis) and the carriage (y-axis) are moved by a DHM
drive (Direct Helical Motor Drive). This drive concept makes the extreme
dynamics of the laser cutting machine possible.
Fig. 3.11-2 Cutting bridge DHM drive
The DHM drive is a fixed ball spindle with a spindle nut built directly into
the motor.
Both axes are thermally monitored and have no additional cooling. The
drive units have dust-proof seals guaranteeing high durability.
The z-axis is driven by a conventional ball screw spindle.

3.11.3 Linear measuring systems
The movements of the x- and y-axes are read off directly by a non-con-
tacting optical linear measurement system. This allows the position of the
cutting head to be precisely determined.
Fig. 3.11-3 Measurement tape x-axis (bellows removed)
A
X-axis
Fig. 3.11-4 Measurement tape y-axis (bellows removed)
A
Y-axis
The linear measurement system consists of a fixed measurement tape

(A), which is fixed to the bridge (x-axis) and the carriage (y-axis).
A reading head is mounted on both the moveable cutting bridge and the
carriage respectively, and passes the measurement signal to the control-
ler.

3.12 Cutting gasses
Nitrogen (N2) and oxygen (O2) are used for laser cutting.
3.12.1 Cutting gas quality
The gas quality has a decisive influence on cutting quality. Nitrogen influ-
ences the quality of the cut surfaces. The following tables show the corre-
lation between the quality grade and oxide formation on the cut surface.
Tab. 3.12-1 Quality grade and oxide formation using oxygen as cutting gas
Gas Quality Purity Proportion Proportion Cut surface

type Nitrogen of water
+ Argon
[Vol. %] N2 + Ar / [ppm] H2O / [ppm]
Oxygen 3.5a) ≥ 99.95 ≤ 500 ≤5 Oxide formation

O2
Tab. 3.12-2 Quality grade and oxide formation using nitrogen as cutting gas
Gas Quality Purity Proportion Proportion Cut surface

type Oxygen of water
[Vol. %] O2 / [ppm] H2O / [ppm]
Nitrogen 2.8 ≥ 99.8 ≤ 500 ≤ 20 Oxide-free, pale

N2 yellow
Nitrogen 3,5a) ≥ 99.95 ≤ 100 ≤ 10 Oxide-free, not

N2 guaranteed
bright
Nitrogen 4,5 ≥ 99.995 ≤ 10 ≤5 Oxide-free, guar-

N2 anteed bright
Nitrogen 5,0 ≥ 99.995 ≤3 ≤5 Oxide-free, guar-

N2 anteed bright
a) Recommendation

3.12.2 Cutting gas consumption
Cutting gas consumption depends on the pressure and the nozzle used.
The following diagrams show guide values for cutting in the low and high
pressure ranges.
Fig. 3.12-1 Low pressure to 6 bar
Gas consumption
Gas pressure
Fig. 3.12-2 High pressure to 20 bar
Gas consumption
Gas pressure

Byspeed
Chapter 4
4 Operating elements
This chapter describes the warning signals issued by the machine. In addi-
tion, the operating and display elements located on the product are de-
scribed. The individual operating modes are described below.

Operating elements Byspeed

Byspeed Operating elements
4.1 Warning signals
4.1.1 Warning and information lamp
The warning and information lamp is located on the laser. The various col-
ors indicate the operating status of the laser.
Fig. 4.1-1 Warning and information lamp
The lamps are allocated the following meanings:
A Red warning lamp

If the red warning lamp lights up, the shutter is open and the laser
beam is being emitted from the laser. If the lamp is dark, the shut-
ter is closed.
If the red warning lamp flashes, the laser is in special mode (laser
class 4). The laser is in special mode is when the cover is open.
Working in special mode is described in Chapter 4.3.2 ›Special
mode‹.
B Orange warning lamp
If the orange warning lamp lights up the high voltage to the laser
is switched on. The laser is operating.
C White information lamp
The white lamp indicates low pressure in the gas supply. This indi-
cator enables the gas supply to be swapped to the reserve bottle
before machining is stopped automatically by the controls because
of insufficient gas supply.
The gas with insufficient pressure is given in the laser control soft-
ware, LaserView.

4.1.2 Fault displays
Machine messages are displayed in the status and error bars in ByVision
and Handling Operation. Explanations of the messages can be found in
the Online help.

4.2 Operating and display elements
4.2.1 Main switch
The main switch is located on the LSM cabinet. After the power is switched
on (ON position), all the units and controls (gas control, extraction, cool-
ing, PC, etc.) required for operation of the laser cutting machine are auto-
matically started.
Fig. 4.2-1 Main switch on LSM cabinet
A LSM cabinet
B Main switch

4.2.2 Emergency off switch
There are four emergency off buttons on the laser cutting machine, al-
lowing the machine and its components to be switched off in the event of
danger.
4.2.2.1 Operating terminal

Fig. 4.2-2 Emergency off on the operating terminal
Emergency off
4.2.2.2 Handheld controller

Fig. 4.2-3 Emergency off on the handheld controller
Emergency off

4.2.2.3 Shuttle table console

Fig. 4.2-4 Emergency off on the shuttle table console
Emergency off
4.2.2.4 Laser
Fig. 4.2-5 Emergency off button on the laser
Emergency off

The operating terminal is equipped with a touch screen. This means that
the user interface can be operated by touching the appropriate switches or
keys.
Fig. 4.2-6 Elements of the operating terminal
B A
A Emergency off button

B Screen with touch screen functions
C Keyboard
D Function keys on the membrane keyboard
E Mouse (optional)

4.2.3.1 State of illuminated function keys
If the key lamp is lit, the key function is active

If the key lamp is extinguished, the key function is inactive
4.2.3.2 Activating the function keys
When the user interface is started, the relevant function keys are activat-
ed depending on the configuration of the laser cutting machine.
4.2.3.3 Description of the function keys
Key Description
Enable safety circuit
Unlock safety door
Stop automation (e.g. table change)
Unlock cutting head
Clamp / release collet chuck
Reserve
Reserve
Reserve

4.2.4 Handheld controller
The handheld controller is used for setup and adjustment tasks, for sepa-
rating remaining sheets and for test cuts to determine parameters.
Fig. 4.2-7 Handheld controller

B Hand wheel
C Keypad
4.2.4.1 Activate handheld device
To activate the handheld controller the HAND view must be selected on

the user interface.
The emergency off key and the STOP and CONT keys are al-
ways active (regardless of whether the HAND view is selected).

4.2.4.2 Hand wheel
Fine positioning of axes when simultaneously holding the JOG key.
4.2.4.3 Handheld controller keys
Key Description
Software stop. Stops all axis drives.

Not an emergency off
Fine positioning with hand wheel active as long as key is held
Function activated (LED lit)

The capacitive sensing is switched on (default)
Function activated (LED lit)
The capacitive sensing is switched off
Move x-axis in positive direction, manual mode feed
Move x-axis in negative direction, manual mode feed
Move y-axis in positive direction, manual mode feed
Move y-axis in negative direction, manual mode feed
Raise cutting head (sensing depends on function of the TOOL)

key
Lower cutting head (sensing depends on function of the TOOL)

key
Rotary axis turns counter-clockwise (ccw), manual mode feed

Key Description
Rotary axis turns clockwise (cw), manual mode feed
Crossjet functions
Single pulse. Open the shutter for the predefined duration. This
function is used to adjust the laser beam and for nozzle center-
ing.
Open shutter. The shutter remains open as long as the key is

pressed.
Confirm key (continue)

4.2.5 Shuttle table console
The shuttle table system and the rotating loader (optional) can be operat-
ed manually by means of the shuttle table console.
Fig. 4.2-8 Shuttle table / rotating loader console

B Shuttle table keypad
C Handling keypad (only assigned if an optional handling system is
used)
4.2.5.1 Shuttle table console keys
Key Description
PLC stop
If this key is pressed, all automatic table change and loading se-
quences are stopped.
Not an emergency off
Reset light barrier

If the light barrier is interrupted, the table change operation and
the loading and unloading are stopped. The key lamp flashes.
The light barrier is reactivated by pressing the key. At each re-
start of the laser cutting machine, the key must be pressed again
in order to enable the safety circuit.
Table change
An automatic table change is performed if this key is pressed (if
the light barrier is not interrupted).

Key Description
Material positioned
This key must be pressed when raw material has been positioned
on the shuttle table in the loading position, and is to be cleared
for further machining. This notifies the CNC that additional raw
material is available for the next cutting plan when the current
cutting plan has been completed.
Once the current cutting plan has been completed, a table
change is automatically executed and the next cutting plan is cut
in automatic mode.
The following states are indicated by this key:
Key lit: The raw material on the loading table is ready
Key flashes: Waiting for raw material
Key dark: Function not active
Load raw material

If the key is pressed, raw material is transported to the shuttle
table by a handling system.
Unload raw material

If the key is pressed, the raw material is transported from the
shuttle table to a material carriage by a handling system.
Unload cut material

If the key is pressed, the cut material is transported from the
shuttle table to a disposal position by a handling system.
This key is only active if a double fork system is used in the han-
dling system.

4.3 Laser cutting machine operating modes
4.3.1 Normal mode
The laser cutting machine is in normal mode if:

All components are correctly fitted and set up
All covers and protective fences are correctly fitted
The laser cutting machine is switched on
All safety devices are cleared
Cutting plans and parameters have been read in
The machining process has started
4.3.2 Special mode
The laser cutting machine is in special mode if normal mode has been in-
terrupted. It makes no difference whether the interruption serves adjust-
ment and inspection tasks, loading and unloading, or is to enable cleaning
and maintenance work to be carried out.
The machine enters special mode at the moment when non-contacting
safety devices (e.g. light barriers) are crossed, the safety door(s) are
opened or permanent safety devices are dismantled.
Normal mode is restored when the laser cutting machine is once more
ready for use, the safety devices are reset and the process is started up
again.

4.4 Operating modes adaptive optics 1
4.4.1 Operating mode 0 (Service mode)
No cutting can be carried out in operating mode 0!
Fig. 4.4-1 Operating mode 0
+40 µm (11 bar) A
0 µm (7 bar) B
-40 µm (3 bar)
C
A Mirror deformation
B Constant
C Beam length
4.4.1.1 Fixed mirror adjustment height for operating mode 0 (setup

value)
The defined mirror adjustment height remains constant over the entire
cutting area, regardless of the beam length. The focal position is not auto-
matically corrected in this mode.
In operating mode 0, adaptive optics 11) and adaptive optics 22) behave
like a flat mirror, if the setup value Fixed mirror pressure 1 is set to
7 bar for operating mode 0.
The technically feasible adjustment range lies between –40 - +40 µm (3 -
11 bar).
1) Adaptive optics 1 = Bypos

2) Adaptive optics 2 = ARC (Adaptive Radius Control)

4.4.1.2 Application
The Fixed mirror pressure 1 setup value must be set to 7 bar for the
following activities in operating mode 0:
Checking the beam shape (mode cube)
Determine performance characteristic for adaptive optics 2

4.4.2 Operating mode 1 (standard mode)
4.4.2.1 Focus correction
The focus displacement is corrected as a function of beam length, which is

acquired from the divergence (see Chapter 3.9.3.1 ›Focal position with
flat mirror‹) of the laser beam.
Fig. 4.4-2 Operating mode 1
A
B
A Mirror deformation
B Performance characteristic
C Beam length
4.4.2.2 Focus location to cutting parameter values
In addition, in operating mode 1, the focus location and the nozzle dis-
tance are taken from the parameters.
4.4.2.3 Result of focus correction and focus location

The total deformation is automatically calculated from the position-depen-
dent focus correction value (performance characteristic) and a character-
istics-dependent offset1).
1) Function of focal length, focus location and the nozzle distance. These values are taken
from the respective cutting parameters.

Byspeed
Chapter 5
5 Commissioning
Installation and commissioning are of the product are performed by the

manufacturer's personnel or under their supervision.
For this reason, the operating instructions do not contain this chapter.

Commissioning Byspeed

Byspeed
Chapter 6
6 Operating
This chapter instructs on safe operating, as well as providing information

on setting up and adjusting, and on the various product functions.

Operating Byspeed

Byspeed Operating
6.1 Introduction
6.1.1 Safety regulations
In order to prevent injuries and damage to property during work on the

laser cutting machine, it is essential to observe the safety regulations. In
particular, all persons working with the machine must have read and un-
derstood Chapter 2 ›Safety regulations‹.
The machine hazard areas, which may not be entered while the machine is
operating, can be found in Chapter 2.3 ›Danger zones‹.
The machine may only be utilized for the intended uses described in Chap-
ter 1.1.2 ›Intended use‹.
6.1.2 Personnel requirements
The operating personnel must understand the software and have technical
experience. Operating personnel must be capable of performing the fol-
lowing tasks:
Switch the machine or system on and off
Operate the machine controls
Start and use the operating software
Create a cutting plan and start the cutting process
Perform dimensional corrections
Convert the machine for a change in production
Clean the machine or system
Carry out maintenance work which is necessary during normal operat-
ing

Operating Byspeed
6.2 Operating the machine
The laser cutting machine is operated from the operating terminal, the
handheld controller and the shuttle table console.
6.2.1 Pre-startup checks
Before switching the machine on, the following points must be checked:
All safety devices, emergency off devices and sound proofing are
present and in working order!
All emergency off buttons must be reset.
The laser machine and its components show no signs of external dam-
age or faults!
Compressed air is connected, pressure and quality in accordance with
Chapter 1.2.5 ›Compressed air supply‹.
Laser gas bottles are connected and the pressure reducing valves open.
Gas quality for laser gas in accordance with the Bylaser operating in-
structions
Cutting gas bottle is connected, the pressure reducing valves open, and
the pressure and quality is in accordance with Chapter 1.2.4 ›Cutting
gas supply‹.
The shutter remains locked as long as there is no cutting gas at the gas
controls.
The main switch from the chiller and the extraction unit must be
switched on.
There should be no 3½ inch disk in the computer's floppy drive. The
computer cannot be booted automatically if there is a disk in the drive.

Byspeed Operating
6.2.2 Switching on the laser cutting machine in normal mode
The following sequence must be adhered to in order to start the laser cut-
ting machine in normal mode.
1. Main switch on (ON position).
2. Press the reset key on the operating terminal. The safety circuit is
enabled by the reset key.
3. If necessary, log on to the operating system.

z The operating system is started.
z The ByVision user interface, the Handling Operation applica-
tion and the LaserView laser control software are started.
4. The error message Drives locked in issued in the status bar.
5. Log on user (see Chapter 6.3.2 ›User log on‹).
6. Press the OPEN DOOR key on the operating terminal. Open the
safety door and close again.
If the safety door is open it must be closed.
7. Select the HAND view on the user interface by means of the Menu
switch (see Chapter 6.3.3 ›Structure of the views‹).
8. Press the Reference switch.
9. Press the CONT key on the handheld controller. The axes travel to
the reference positions.
10. Wait till the laser ready message appears in the user interface status
bar.
The laser readiness is also indicated by the orange information lamp
on the laser.
11. The machine is ready to operate.

Operating Byspeed
6.2.3 Switching off the laser cutting machine in normal mode
Before the laser cutting machine can be switched off, the active cutting
and handling processes must be complete.
1. Switch the LaserView laser control software to CNC operating

mode.
2. Close the Handling Operation application.
3. Select the MAIN view on the ByVision user interface and press the
Exit switch.
4. Select Shutdown machine and confirm with OK.
5. As soon as the laser is flooded, all applications are automatically

closed. The computer is shutdown.
6. Main switch off (OFF position). All laser cutting machine modules are
isolated.
7. Close the laser gas supply stop valves, and the compressed air.

Byspeed Operating
6.2.4 Emergency shutdown
The laser cutting machine can be switched off in an emergency by press-

ing one of the emergency off buttons. All movements and processes are
immediately interrupted. Further information can be found in the
3.2.2 ›Emergency off‹ Chapter.
If persons are injured the appropriate measures must be initiated. The
appropriate regulations must be observed.
If damage is caused to the machine the supervisor and the manufactur-
er must be informed.
6.2.5 Restarting after an emergency off
The laser cutting machine may only be restarted after the emergency sit-
uation, together with all faults and damage, has been rectified.
1. Release the activated emergency off button by pulling or turning

clockwise (cw).
2. Press the reset key on the operating terminal. This enables the safe-
ty circuit.
3. Start the LaserView laser control software.
4. Select the Operate laser view.
5. Acknowledge any faults by pressing the Fault reset key.

If the Automatic laser status is set, the laser starts automatically.
6. Wait until the orange message lamp on the laser lights. Cutting can
then be continued.

Operating Byspeed
6.3 ByVision user interface
The laser cutting machine's cutting process is controlled by means of the

ByVision user interface. All operating elements are designed to be oper-
ated from the touch screen.
6.3.1 General structure
The user interface is divided into fixed areas for navigation (J) and func-
tion (H). These divisions are the same for all views.
Fig. 6.3-1 Structure of the ByVision user interface
A B C D E F
A Title of active view

B Select operating mode (Operating mode switch)
C Selected operating mode display, Man. mode, Automatic mode
or DNC mode
D Function keys (CNC, Service, Stop and Help functions)

Byspeed Operating
E Date (set in the computer's control panel)

F Time (set in the computer's control panel)
G Displays the current cutting plan, material designation and dimen-
sions, and process parameters
H Function bar (changes with active view)
I Status bar (system, status and error messages)
J Navigation bar (changes with active view)
6.3.2 User log on
Before the laser cutting machine can produce, parameters be altered or

cutting plans read in, a user must be logged in with a user name (A) and
password (B).
Access to the individual views is controlled by the user rights. Further in-
formation on the user list and user rights can be found in the online help.
Fig. 6.3-2 Log on / off dialog
The following are the default users:

Operator
Expert
Manager
See 6.3.2.1 ›User rights‹ for user rights and 6.3.2.2 ›Access to individual
views‹ for access rights to the individual views.
User administration can only be carried out by the manager.

Operating Byspeed
6.3.2.1 User rights
Activity User
Operator Expert Manager
Read in a cutting plan
Assign cutting parameters
Start a cutting job
Edit cutting parameter values
Display and hide the WORK and

HAND parameter views
Display and hide the machine setup

values views
Display and hide the hardware config-

uration views
Edit the machine setup values
Access to the administration area
Integration of add-on applications
Access
No access

Byspeed Operating
6.3.2.2 Access to individual views
View of user interface User
MAIN view
Administration
User interface configuration
Hardware configuration
Manage users
Views
WORK view
Hardware configuration
Setup values, machine
WORK parameters
HAND parameters
Diagnosis
User interface
Machine service
CNC
Clean screen
Information
Close user interface
HAND view
Setup values, machine
Manual cut parameters
Access
No access

Operating Byspeed
View of user interface User
WORK view
Job list
Cutting parameters
Pots
TOOLS view
Access
No access

Byspeed Operating
6.3.3 Structure of the views
The user interface is divided into different views. They can be selected by
using the Menu switch in the navigation bar or the function keys [F5] to
[F8] on the keyboard.
Fig. 6.3-3 Main areas of the user interface
[F5]
[F6]
[F7]
[F8]
A MAIN view. Logging in or off of users and administration sub-ar-

eas, defining user-specific views and system diagnosis (see Chap-
ter 6.3.4 ›MAIN view‹).
B HAND view. Defining machine setup values and parameters for
manual operating (see Chapter 6.3.5 ›HAND view‹).
C WORK view. Load cutting plans, edit current cutting parameters
and start the cutting process (see Chapter 6.3.6 ›WORK view‹).
D TOOLS view. Starting add-on applications (see Chapter
6.3.7 ›TOOLS view‹).

Operating Byspeed
6.3.4 MAIN view
When the application is started the MAIN view is always active. It con-
tains administration sub-areas, areas for defining user-specific views and
for system diagnosis.
Before the functions on the user interface can be used, a user must be
logged in (see 6.3.2 ›User log on‹).
Fig. 6.3-4 Functions in the MAIN view
MAIN
A B C
A Administration functions (MAIN – Administration)

B Define user-specific views (MAIN – Views)
C Diagnosis functions (MAIN – Diagnosis)

Byspeed Operating
6.3.4.1 Administration
Within these views, configuration settings for the user interface and the
CNC can be defined, users be managed and their access rights altered.
Fig. 6.3-5 Administration functions
MAIN – Administration
A B C
A Configuration settings for the user interface. Integration of add-in

applications, which can be started or brought into the foreground
from the user interface.
(MAIN – Administration — Configuration, ByVision)
B Configuration settings for the CNC.
(MAIN – Administration — Configuration, hardware)
C Manage users and alter access rights
(MAIN – Administration — Users)

Operating Byspeed
6.3.4.2 Views
Each user can individually adapt the views cleared for personal use. These
settings are saved in the respective profile and loaded again at the next
log on.
Fig. 6.3-6 Defining views
MAIN – Views
A B C D E
A Define work views (MAIN – Views — Work)

B Display or hide parameters for the CNCa)
(MAIN – Views — Configuration, hardware)
C Display and hide the machine setup values viewsa)
(MAIN – Views – Setup values, machine)
D Display and hide the work parametersa)
(MAIN – Views – Work parameters)
E Display or hide parameters for manual operatinga)
(MAIN – Views – Manual parameters)
a) Requires user rights at the Manager or Service level

Byspeed Operating
6.3.4.3 Diagnosis
In this view, the connection to the CNC, any existing storage system, and
the directory paths can be displayed and controlled.
CNC diagnosis and machine service data can also be displayed.
Fig. 6.3-7 Diagnosis functions
MAIN – Diagnosis
A B C
A Display connection and directory data

(MAIN – Diagnosis — ByVision)
B Machine service diagnosis data
(MAIN – Diagnosis – Machine service)
C CNC diagnosis data
(MAIN – Diagnosis – CNC)

Operating Byspeed
6.3.5 HAND view
In this view, machine setup values and parameters for manual operating
can be defined.
The parameters edited in manual mode are not reset when

leaving manual mode.
Fig. 6.3-8 Functions in the HAND view
HAND
A B
A Define machine setup valuesa)

(HAND – Setup values, machine)
B Define parameters for operating in manual mode
(HAND – Parameters)
a) Requires user rights at the Expert or Manager level

Byspeed Operating
6.3.6 WORK view
These views provide the functions for loading cutting plans, editing pa-
rameters and starting the cutting process. In addition, information on the
current cutting plan can be displayed.
During the visualization of a cutting plan the processed contours are
shown in gray and the unprocessed contours in blue.
Fig. 6.3-9 Functions in the WORK view
WORK
A B C
A Manage the list of prepared cutting jobs

(WORK – Job list)
B Editing the current cutting parameters whilst processing a cutting
plan
(WORK – Parameters)
C Dynamic editing of certain cutting parameters (e.g. Cutting pres-
sure, gas type 2 or Feed rate, cutting) whilst processing a cut-
ting plan
(WORK – Pots)

Operating Byspeed
6.3.7 TOOLS view
In the TOOLS view, user-selectable add-in applications can be started or

brought into the foreground from the user interface. These add-in applica-
tions can be integrated in the Administration area.
A maximum of seven add-in applications can be integrated.
Fig. 6.3-10 Functions in the TOOLS view
TOOLS
e.g.
e.g.
Handling
LaserView
operation
A B C
A Application 1 (e.g. LaserView)

B Application 2 (e.g. Handling operation)
C Further applications
The key combination [Alt + Tab] allows movement between the individu-
al applications.

Byspeed Operating
6.3.8 System, status and error messages
All system, status and error messages are shown in the status bar (A). If
further messages are waiting to be displayed, three dots (…) are visible at
the end of the text.
The message list can be opened by pressing the (B) switch.
Fig. 6.3-11 System, status and error message display
The individual messages are differentiated by color:
Color Class Description
Error The started processes are inter-

rupted (e.g. stopped by emer-
red gency off).
The cause must be completely
rectified before restarting.
Warning A safety-relevant element has ac-

tivated (e.g. safety door open or
orange light barrier interrupted).
Operation request The message requires operator

intervention (e.g. to press the
yellow CONT or STOP buttons).
Information Information on the active process

(e.g. reading the cutting plan).
pale blue
A description of the cause of the error and the remedy is con-

tained in the ByVision operating instructions.

Operating Byspeed
6.3.8.1 Message list
All pending messages are listed in the message list. The most recent mes-
sage is at the top.
Fig. 6.3-12 Message list
6.3.8.2 Quick help
The Quick help can be opened by pressing switch (A). This function shows
an explanation of the selected message in the lower area (B).
Fig. 6.3-13 Show Quick help
The Quick help is hidden again by pressing the switch (A) once more.

Byspeed Operating
6.3.9 Switch appearance
Appearance Status Description
active Access permitted
inactive Access not permitted due to user rights

or an impermissible machine function
6.3.10 Function keys
Key Description
Opens a menu, which allows CNC functions to be selected (e.g.

program reference, sensor button or switch test on / off).
Opens a menu, which allows service functions to be selected

(e.g. travel to service position, travel to park position, clean noz-
zle, etc.).
Interrupt before and after processing a cutting plan.
Interrupt at the cutting plan origin and at the origin of the indi-
vidual parts.
Interrupt before and after a contour (before and after piercing).
Programmed interrupt in machining.
Start online help (see Chapter 6.3.11 ›Online help‹). The Help
can also be started by pressing F1.

Operating Byspeed
6.3.11 Online help
The user interface has an integrated online help. It contains information

on various topics, such as functions, views, cutting parameters, setup val-
ues, etc. The Help can also be started by pressing HELP or F1.
The online help is available in the user interface langauges.
Fig. 6.3-14 Online help
B C D E F G H
I
A
A Navigation window
B Show table of contents in navigation window
C Hide navigation window
D Show keyword search in navigation window
E Show full text search in navigation window
F Show term definitions in navigation window
G Print current contents of display window
H Input box for search functions
I Display window
J Close online help

Byspeed Operating
6.3.11.1 Search functions
The online help provides the following functions for searching for the re-
quired information:
Contents When searching for content the entire table of contents

is listed in the navigation window. The table of contents
displays a directory structure which can be navigated by
means of main- and sub-topics until the required infor-
mation has been found.
Keyword Search for keyword. Enter keyword and start the search
function with Enter. The search results are listed in the
navigation window.
Full text Search for words, word combinations or terms. Enter
search term and start the search function with Enter.
The search results are listed in the navigation window.
6.3.11.2 Print output
All the information in the online help is provided as a printed document in

the shape of the ByVision operating instructions.

Operating Byspeed
6.4 Handling operation user interface
The Handling Operation application is used for operating the shuttle ta-
ble system and for optional handling systems. The application allows use
of either the touch screen, keyboard or, optionally, a mouse.
Below, the views for the shuttle table system operating and service func-
tions are described. Depending on the system configuration, some func-
tions remain unavailable.
If a handling system is integrated, the functions are explained

in the respective operating instructions.
6.4.1 Starting the application
The Handling Operation application is started automatically when the

laser cutting machine is started.
The key combination [Alt + Tab] allows movement between the individu-
al applications.

Byspeed Operating
6.4.2 General structure
Fig. 6.4-1 Structure of the Handling Operation user interface
A B C D
I J
G
E
A Title of active view

B Alarm field If an alarm message is pending the field
flashes red.
C Communication sta- Field green: Connection to PLC exists
tus field Field red: Connection to PLC interrupted
D Title bar Manufacturer and software information
E Alarm message The alarm bar is only visible if an alarm is
pending
F Status messages Current process stage of shuttle table sys-
tem and operation requests
G Navigation switches Switches for selecting individual views.
The switch assignments change with the
active view.
H Function switches The switch assignments change with the
active view.

Operating Byspeed
I Date Set in the computer's control panel

J Time Set in the computer's control panel
K Visualization window The visualization changes with the active
view
6.4.2.1 Navigation switches
Tab. 6.4-1 Handling operation navigation switches
Switch Description
In these views, the shuttle table system can be operated

manually (table change, defining materials).
In these views, settings relating to a handling system can

be edited and machine-specific preferences be defined.
In these views, the job data can be reset and the shuttle
tables be moved manually for servicing.
The complete system is configured in these views. These

settings are performed exclusively by the manufacturer's
personnel.
Change to ByVision application.
Select Main – Home start page.
These views contain functions and settings which relate to

handling systems.
In the absence of an integrated handling system, all func-
tions with the exception of the dialog language are inactive
and may thus not be selected.
These views contain machine-specific functions and set-

tings.
Information relating to software versions and IP addresses

used by the PLC (see Chapter 6.4.6 ›Info view‹).
Change dialog language.
Log on user (log on setup and log on service)
User log off
Change to the previous page of the same view. The switch

is only visible if a view has several pages.

Byspeed Operating
Switch Description
Change to the next page of the same view. The switch is

only visible if a view has several pages.
Display alarm messages. If an alarm message is pending

the switch flashes red.
Acknowledge an alarm, see Chapter 6.4.5 ›Alarm messag-
es‹.
Return to previous view
Exit the Handling Operation application.

Operating Byspeed
6.4.2.2 Function switches
Tab. 6.4-2 Handling operation function switches
Switch Description
Travel to shuttle table park position. If the shuttle tables

are not at the end position (e.g. after interrupted light bar-
rier), they can be moved to the end position (park position)
by pressing the Park switch.
Switch automatic mode on or off.
Remote diagnostics function (optional). See Chapter

6.4.6 ›Info view‹).
Delete shuttle table material status (see Chapter

6.4.7.2 ›Reset job data‹).
Activate sheet clamp. This is active if the switch is green.

Byspeed Operating
6.4.3 Start page
The Main – Home start page is automatically displayed on start up. When
navigating within the user interface, the start page can always be reached
by pressing the Home switch.
Fig. 6.4-2 Main – Home view

Operating Byspeed
6.4.4 Log on
From the Main – Home start page, the views Manual, Setup, Service or
Config can be selected. The log on controls the access options.
The views Service and Setup allow the same access and require a pass-
word to open. The Manual view can be activated without a log on.
The system is configured in the Config view. Access here is only possible
with a special password (only for the manufacturer's service engineers).
The current clearances are displayed on the start page by icons.
Fig. 6.4-3 Access icons
The password for these views is valid, access is possible.
No valid password has been entered for this view, no ac-

cess possible.

Byspeed Operating
6.4.5 Alarm messages
If an alarm message is pending due to a fault, the switch (A) and the
alarm field (B) flash red alternately.
In addition, the current alarm message is displayed in the alarm bar (C).
Fig. 6.4-4 Start page – alarm message pending
C A

Operating Byspeed
6.4.5.1 Alarm list
The alarm list is selected by pressing the ALARM switch. All alarm mes-
sages (including follow-up errors) are listed. The most recent message is
always at the top.
Fig. 6.4-5 Alarm list
Tab. 6.4-3 Active switches in the alarm list
Switch Description
Close alarm history
Display alarm history (see Chapter 6.4.5.3 ›Alarm histo-

ry‹).
Acknowledge current alarm message
Display help text for selected alarm message

Byspeed Operating
6.4.5.2 Acknowledge alarm messages
When the fault has been rectified, the corresponding alarm message must
be acknowledged by pressing the ACK ALARMS switch. If several mes-
sages are pending, each one must be individually remedied and acknowl-
edged.
Different alarm stages are indicated by a corresponding message color.
Tab. 6.4-4 Alarm message colors
Color Meaning
Currently pending alarm message that shuts down the sys-

tem.
red
The alarm message was acknowledged, but the fault still

exists.
violet
The fault is rectified and the alarm message acknowledged.

By pressing the ACK ALARMS switch again the alarm mes-
blue sage is deleted.
6.4.5.3 Alarm history
By pressing the HISTORY switch, all alarms recorded in the course of the
day can be listed in a separate window.
Fig. 6.4-6 Alarm history

Operating Byspeed
6.4.6 Info view
The view shows information relating to software versions and the IP ad-
dresses used by the PLC1).
Fig. 6.4-7 Information on handling operations
Handling operation Software version Handling operation

Machine PLC PLC software version
Machine PLC IP PLC IP address
1) Programmable logic controller

Byspeed Operating
Tab. 6.4-5 Active switches in the Info view
Switch Description
Remote diagnostics function (optional)
Switch on system bar (only for development)
Switch off system bar
6.4.6.1 Change dialog language
Select the desired dialog language by pressing the Panel language

switch.
Fig. 6.4-8 Switch for changing dialog language
The following languages are available:
German [DE]
English [EN]
French [FR]
Italian [IT]
Spanish [SP]
After changing the dialog language close the application and

start again.

Operating Byspeed
6.4.7 Operating the shuttle table system
6.4.7.1 Simple table change
In the Manual – General view, a manual table change can be performed

by pressing the switch (A).
Fig. 6.4-9 Manual – General view
The following conditions must be fulfilled:

The laser cutting machine axes are in the reference positions.
The safety door is closed
The light barrier in the loading area is activated

Byspeed Operating
6.4.7.2 Reset job data
The Reset job data function deletes the material status of both shuttle
tables. This is utilized in conjunction with a storage system or before
switching to automatic mode.
Fig. 6.4-10 Confirm or cancel reset

Operating Byspeed
6.4.7.3 Extended operating
In the Manual – Machine view, the material status on the shuttle tables
can be defined (cutting and loading position).
For service work or special functions both shuttle tables can be moved to
the loading position.
Fig. 6.4-11 Manual – Machine view
A B
C D
A Define the material status on the shuttle table in the cutting posi-
tion.
B Define the material status on the shuttle table in the loading posi-
tion.
C Carry out manual table change (see Chapter
6.4.7.1 ›Simple table change‹).
D Move shuttle table to maintenance position. Both shuttle tables are
then located above each other in the loading position.

Byspeed Operating
6.4.7.4 Material status in the cutting and loading positions
After pressing the Mat Pos. switch, a dialog window opens, allowing defi-
nition of the material status on the shuttle tables (cutting or loading posi-
tion).
Fig. 6.4-12 Dialog window for defining the material on the shuttle tables
A B C D
A The shuttle table is filled with raw material

B The shuttle table is filled with cut material
C The shuttle table is filled with material which was not completely
cut. The cutting job was aborted.
D The shuttle table is empty

Operating Byspeed
6.4.8 Setup functions
Access to the setup functions requires a valid password.
Fig. 6.4-13 Main – Setup view
6.4.8.1 Machine-specific settings
The Setup – Machine view contains machine-specific settings. Depend-

ing on the laser cutting machine configuration, some functions remain un-
available.

Byspeed Operating
Fig. 6.4-14 Setup – Machine view
A B
C D
A If the axes remain in the reference position for a prolonged period,

or a CNC error is pending, automatic shutdown is initiated after
1 hr. if the function is active.
Laser is shutdown and flooded
Chiller is switched off
Compressed air valve is closed
Cutting gas valves are closed
B When function is active the table change is locked. This function
can be activated for special applications.
C This function allows the extraction flaps to be opened when all cut-
ting plans are processed and closed again after the defined period.
D If a raw sheet is at the cutting and loading position with activated
automatic mode, the lifting unit is raised or lowered to the change
position.

Operating Byspeed
6.4.9 Service functions
Access to the setup functions requires a valid password.
Fig. 6.4-15 Main – Service view
6.4.9.1 Move shuttle tables manually
The Service – Machine (1/3) view contains the functions for manually
moving the shuttle tables. The shuttle table or lifting unit is moved until
the appropriate switch is pressed or until the end position is reached. The
following must be observed:
The safety door must be closed
The light barrier in the loading area must be acknowledged

Byspeed Operating
Fig. 6.4-16 Service – Machine (1/3) view
A B
C D
A Move shuttle table towards cutting position

B Move shuttle table towards loading position
C Raise lifting unit
D Lower lifting unit
The views Service – Machine (2/3) and Service – Machine

(3/3) are inactive with a laser cutting machine without han-
dling systems.

Operating Byspeed
6.5 Setup and adjustment
6.5.1 Initiate axis movement
In general, every axis movement is initiated by pressing the CONT key on

the handheld controller.
A started function can be stopped or aborted at any time using the STOP
key on the handheld controller.
1. Preselect the desired function on the user interface (e.g. Reference)
2. The corresponding message is issued in the status bar (e.g. CNC:

Reference run, continue with CONT, cancel with STOP)
3. Press the CONT key on the handheld controller. The preselected

function is confirmed and simultaneously initiates the axis move-
ment.
6.5.2 Changing the cutting head
1. Close safety door and travel to service position.
2. Press the OPEN DOOR (on the operating terminal) key.
3. Open safety door.
4. Unlock the cutting head by pressing the HEAD key (on the operating
terminal) and then remove.
5. Place the new cutting head in the guide on the z-axis until it reaches
the stop. The cutting head is automatically locked when the safety
door is closed.
6. Close safety door.

Byspeed Operating
6.5.3 Changing the nozzle
The nozzle must be replaced under the following circumstances:

If the selected cutting parameter requires a different nozzle
If the machining quality declines and damage is determined upon ex-
amining the nozzle
Fig. 6.5-1 Nozzle mounting on z-axis
1. Clean the outside of the nozzle (B) and the nozzle body (A).
2. Unscrew the nozzle by hand. If it is tight, a ring spanner may be used

with the necessary caution.
3. Screw the new nozzle in tightly by hand.
Each time a nozzle is replaced, the centering of the laser

beam in the nozzle must be examined and corrected if neces-
sary.
Where tactile sensing is used (optional), it must be calibrated

after replacing a nozzle (see Chapter 6.5.5.2 ›Calibrating the
sensor‹).

Operating Byspeed
6.5.4 Centering the laser beam in the nozzle
Optimum machining quality depends greatly on a good centering lens. A

poorly centered lens can cause the laser beam to touch the nozzle, leading
to beam deformation. It is therefore vital that the lens is precisely cen-
tered.
Fig. 6.5-2 Laser beam not centered
A B
Fig. 6.5-3 Laser beam correctly centered
A B
A Nozzle bore
B Laser burn on the adhesive strip
C Adhesive strip

Byspeed Operating
The two centering screws (D) on the cutting head have right-hand
threads.
Fig. 6.5-4 Cutting head 7.5" (removed)
D D
Turning in a clockwise direction (cw) causes a displacement of the laser

beam towards the centering screw.
Turning in a counter-clockwise direction (ccw) causes a displacement of
the laser beam away from the centering screw.
1. Fix the transparent adhesive strip to the nozzle in the cutting head.
2. Select the HAND – Setup machine view on the user interface.
3. In the Laser power single pulse parameter, enter a value of ap-

prox. 10 W (guide value).
4. In the Pulse width, single pulse parameter, enter a value of ap-

prox. 50 ms (guide value).
5. Close the HAND – Setup values, machine view. The HAND view is
active on the screen.
6. Activate the handheld controller by pressing the Manual mode

switch.
8. Press the PULS key on the handheld controller.
9. Unlock and open safety door.
10. Check, with the help of a mirror, whether the hole burned in the ad-
hesive strip by the laser is exactly central with the nozzle bore (see
Fig. 6.5-3).

Operating Byspeed
11. If necessary, correct the laser beam in the required direction by

means of the centering screws on the cutting head.
12. step 1 to step 11 may be repeated until the laser beam passes di-
rectly through the center of the nozzle.

Byspeed Operating
6.5.5 Tactile sensing (optional)
Tactile sensing is primarily utilized for electrically non-conductive materi-

als. It is fitted to the side of the z-axis.
Fig. 6.5-5 Tactile sensing
Without tactile sensing Tactile sensing fitted
A
C
A Cover
B Fixing screws
C Knurled screws
D Tactile sensing
E Sensing ring
6.5.5.1 Fitting
1. Unscrew the two fixing screws (B) and remove the covering (A).
2. Carefully place the tactile sensor (D) over the two centering bolts in
the mounting provided.
3. Fix the sensor to the mounting plate with the two knurled screws (C).
4. The controls automatically recognize the presence of the tactile sen-

sor.

Operating Byspeed
6.5.5.2 Calibrating the sensor
The sensor must be recalibrated after the following activiaties.

After replacing the nozzle or the nozzle body
After replacing the ring sensor
1. Preselect the Calibrate nozzle service function. The following mes-

sage is shown in the status bar: Calibration, continue with CONT,
cancel with STOP
2. Press the CONT key on the handheld controller.
3. Calibration is now performed automatically. The nozzle is lowered to

the calibration plate and contacts. The sensor follows this movement
and is also lowered to the calibration plate.
The z-axis then travels up until the nozzle distance specified in the
parameters is reached. This position is stored.

Byspeed Operating
6.6 Manual mode
The handheld controller is a flexible extension of the operating terminal. It

is connected to the CNC controls by a cable.
The two most common applications for the handheld controller are de-
scribe below.
Separating cuts
Cutting plan origin offset
6.6.1 Separating cuts
This function allows the separation of waste or reducing the size of re-
maining sheets.
CAUTION
Execute separating cuts
The cutting head must always be lowered for cutting.
Otherwise, strong reflections and stray radiation may
result.
After confirming with the BURN key, immediately move
the cutting head, otherwise the laser beam may damage
the sheet off-cut guides under the shuttle table or the
support grid.
Separating cuts should always be performed using the pa-

rameters assigned to the material to be cut.
1. Select the HAND view on the user interface.
2. Preselect the Calibrate nozzle service function and start the pro-
cess by pressing the CONT key.
3. Activate the handheld controller by pressing the Manual mode

switch (the Tool key on the handheld controller lights up).

Operating Byspeed
4. Move the cutting head to the desired start position using the keys for
the x- and y-axes. The separating cut is started from this position.
5. Press the Z- key on the handheld controller and hold until the cutting
head has been lowered to the appropriate nozzle distance. Then re-
lease the key.
A slower cutting spped is active when the cutting head is lowered.
This allows precise travel to the start position.
6. Travel approx. 1 mm past the the sheet edge with the cutting head.
7. Open the shutter by pressing the BURN key. It remains open as long
as the key is pressed.
Immediately move in the desired direction for cutting the sheet using
the keys for the x- and y-axes.
8. Release the BURN key immediately after the separating cut. The
shutter is closed
9. Press the Z+ key on the handheld controller. The cutting head trav-
els up.
6.6.1.1 Fine positioning using the hand wheel
The fine positioning of the cutting head is ideally carried out in the lowered
position.
1. Hold the JOG key on the handheld controller.
2. Select the desired axis (the travel direction is irrelevant).
3. Move the selected axis by rotating the hand wheel in positive or neg-
ative direction.

Byspeed Operating
6.6.2 Cutting plan origin offset
The origin displacement of the cutting plan is used to enable parts to be

cut at any position on the shuttle table. The principal applications are:
Use of remaining sheets
Cutting without edge detection
Material is not located at the machine origin
Use the origin displacement only for cutting individual parts

(not for large-format cutting plans).
If the cutting plan projects past the edge of the sheet due to
the origin displacement, there is a hazard that the cutting
head will run past the edge of the existing sheet or the axes
run into the stops.
The cutting plan origin is displaced as follows:
1. Select the WORK view on the user interface and start a cutting job.
The following message is shown in the status bar: CNC: Process the
cutting plan, continue with CONT, cancel with STOP
2. Activate the STOP ZERO stop function. The switch lights yellow.
3. Press the CONT key on the handheld controller. The cutting head
travels to the machine origin.
4. Preselect the Displace origin service function. The following mes-

sage is shown in the status bar: CNC: Displace origin, continue
with CONT, cancel with STOP
5. Move the cutting head to the desired start position using the keys for
the x- and y-axes on the handheld controller.
6. Press the CONT key on the handheld controller. The new origin is
confirmed.
7. Press the CONT key on the handheld controller. Cutting plan pro-
cessing now begins at the newly defined origin.

Operating Byspeed
6.7 The cutting process
The laser cutting machine's cutting process is controlled by means of the

ByVision user interface.
Operating is done from within the individual views, which can be selected
via the Menu switch in the navigation bar or the function keys F5 to F8
on the keyboard (see Chapter 6.3 ›ByVision user interface‹).
6.7.1 The manual cutting process
The manual cutting process is the simplest way to start a cutting process
on the laser cutting machine.
This process may differ from that described here depending on the con-
nection of the laser cutting machine to other automation systems.
During the manual cutting process, the creation of a cutting job (reading
cutting plan and assigning cutting parameters) is described up to the start
of the cutting process.
6.7.1.1 Creating a cutting job
A cutting job consists of the following information:

Cutting plan
Cutting parameters
Number of passes
Cutting plan
A cutting plan describes the contours of the parts to be cut. In addition,
the individual contours can be assigned a variety of technologies. Cutting
plans are saved with the file extensions .lcc or .ncp.
Cutting parameters
The cutting parameters are material- and thickness-dependent. The speed
and power adjustments necessary for the respective cutting process are
carried out with these parameters. Cutting parameters are saved with the
file extension .par.

Byspeed Operating
Number of passes
The number of passes defines how often the cutting plan is processed.
Each pass requires a sheet of raw material in a format corresponding to
the cutting plan.
1. Select the WORK view on the user interface.
2. Select the list of cutting jobs by pressing the Job list switch.
3. Press the Add switch in the job list. The Add job dialog window is
opened.
4. Select the top-level folder in which the cutting plans are stored. Con-
firm the selected folder with OK.
Fig. 6.7-1 Select top-level folder
Cutting plans can also be imported from other drives (floppy

disk, CD, ZIP or network drive). See Chapter 6.7.1.2 ›Import
cutting plan‹

Operating Byspeed
5. Select cutting plan. If the Plan preview check box is activated, the
selected cutting plan is displayed in the preview window.
Fig. 6.7-2 Select cutting plan
Upon confirming with OK, the selected cutting plan is placed at the
end of the job list. The Default value has been automatically as-
signed for the cutting parameters. This must be reassigned on the
basis of the material to be cut.
See Chapter 6.7.1.3 ›Assign cutting parameters‹
6. If there is more than one job in the list, the sequence can be altered
using the functions Prioritize, Move forward and Move back.
All cutting jobs containing Default in the Parameter column

use the cutting parameters of the previously processed cutting
job.
Further information on creating cutting jobs is contained in the

online help or in the ByVision operating instructions.

Byspeed Operating
6.7.1.2 Import cutting plan
A cutting plan can be imported from any drive (floppy disk, CD, ZIP or
network drive) and saved in the defined target folder.
1. Select the WORK view on the user interface.
2. Press the Import / Export switch. The individual import and export
functions are available.
3. Press the Import job switch. The Import job(s) dialog window
opens.
4. Select the source folder and the cutting plan for import. A number of
cutting plans can be selected.
5. Select target folder.
Fig. 6.7-3 Import cutting plan
6. Press the OK switch. The selected cutting plan is imported to the tar-
get folder. If the Add imported job(s) to the job list check box is
activated, the cutting plan is placed at the end of the job list.

Operating Byspeed
6.7.1.3 Assign cutting parameters
Every cutting job must be assigned cutting parameters appropriate for the
material to be cut.
In the selector list, the cutting parameters suited to the configuration (la-
ser machine, laser source, etc.) are listed.
1. Select the WORK – Job list view on the user interface.
2. Select the job in the Prepared cutting jobs list to which cutting pa-
rameters are to be assigned.
3. Press the Edit switch. The Edit job dialog window opens.
4. Press the Select switch. The Parameter selection list dialog win-
dow opens.
Fig. 6.7-4 Parameter selection list
5. It is easiest to search for the desired cutting parameter based on fil-

ter criteria (material, thickness, cutting gas, cutting head and addi-
tional information).
The cutting parameter can also be selected directly from the selec-
tion list. In This case, however, it is recommended to deactivate all
active filters.
If the cutting parameters are structured into sub-folders (e.g. steel,
inox, aluminum, etc.), they can be selected by pressing (A).

Byspeed Operating
6. Upon confirming with OK, the selected cutting parameter is assigned

to the cutting job.
All cutting jobs containing Default in the Parameter column

use the cutting parameters of the previously processed cutting
job.

Operating Byspeed
6.7.1.4 Starting a cutting process
Before the cutting process is started, the material to be cut with the cut-
ting job must be placed at the shuttle table loading position. The axes
must be in the reference position and the safety door closed.
If the Table change key on the shuttle table console is pressed (see
Chapter 4.2.5 ›Shuttle table console‹), the shuttle table and the material
travel from the loading position to the machining area (ensure light barrier
is enabled).
A table change can also be initiated from within the Handling

Operation application (see Chapter 6.4.7 ›Operating the shut-
tle table system‹).
The cutting head and the nozzle must correspond to the selected cutting
parameters. Moreover, the laser beam must be centered in the nozzle
(see Chapter 6.5.4 ›Centering the laser beam in the nozzle‹).
To check the correctness of the cutting data, such as focal

length of cutting head, nozzle type, material thickness, etc., an
information window can be opened in the WORK view by press-
ing Info.
1. In the WORK view, press the Start switch. The current job and the
assigned parameters is read.
2. Depending on the selected stop keys (STOP CYCL, STOP ZERO,

STOP WORK or STOP SEL), a confirmation consisting of CONT or
STOP is requested in the status bar in order to advance to the next
step of the program.
The stop keys allow the cutting process to be checked (before or af-
ter certain program steps). See Chapter 6.3.10 ›Function keys‹ for
descriptions of the individual stop functions.
3. Select special functions (nozzle cleaning, Crossjet, edge detection,

microwebs).
4. Press the CONT key on the handheld controller. The cutting process
is started

Byspeed Operating
6.7.2 Automatic mode (loading and unloading manually)
By automatic mode with manual loading and unloading cutting with auto-
matic table change is understood.
The cutting process is carried on until
no material is ready at the loading position and the Mat Pos key is no
longer acknowledged
all active jobs in the job list are processed
The ways and means of material loading and unloading on the shuttle ta-
ble is not taken into consideration.
6.7.2.1 Requirements
The system is switched on and started correctly

The axes remain in the reference position
The system is in automatic mode
There is at least one job in the job list. The correct parameters are as-
signed (see Chapter 6.7.1 ›The manual cutting process‹).
Raw material for cutting is situated on a shuttle table
The STOP CYCL, STOP ZERO, STOP WORK and STOP SEL keys
must be deactivated during the cutting process.
6.7.2.2 Preparation
Before the cutting process can be started, the material status on the shut-
tle table in both the loading and in the cutting positions must be defined.
This is done by means of the Handling Operation application.
No stop keys may be activated when processing several cut-

ting jobs.
If one of the keys is active, the cutting process is interrupted
at the corresponding location. A message appears in the sta-
tus bar, which must be confirmed with CONT or STOP.
The operator is responsible for the correct raw material (ma-

terial, format and thickness) being loaded.

Operating Byspeed
1. Change to the Handling Operation application.
2. Select the Manual – Machine view. In this view the material status
of both shuttle tables is displayed.
Fig. 6.7-5 Manual – Machine view
B A
3. Define material status:

z Switch (A) for the material status on the shuttle table in the load-
ing position
z Switch (B) for the material status on the shuttle table in the cut-
ting position
The automatic mode must be switched on (switch (D) is green).

Byspeed Operating
4. If the Mat Pos. switch is pressed the following dialog window is

opened
Fig. 6.7-6 Dialog window for defining the material on the shuttle tables
A B C D
A The shuttle table is filled with raw material

B The shuttle table is filled with cut material
C The shuttle table is filled with material which was not com-
pletely cut. The cutting job was aborted.
D The shuttle table is empty
An automatic table change is performed if:

z the shuttle table in the cutting position is full or devoid of cut ma-
terial
z the shuttle table in the loading position is filled with raw material

Operating Byspeed
6.7.2.3 Starting a cutting process
1. In the WORK view, press the Start switch. The current job and the
assigned parameters is read.
2. Select special functions (nozzle cleaning, Crossjet, edge detection,

microwebs).
3. Press the CONT key on the handheld controller.
4. The cutting process is started if the shuttle table is filled with raw
material (loading or cutting position).
After the cutting plan is processed, the shuttle table is changed auto-
matically.
5. Remove cut material from the loading position and fill the shuttle ta-
ble with new raw material.
6. If new raw material is on the shuttle table (in the loading position),
press the Mat Pos key on the shuttle table console (see Chapter
4.2.5 ›Shuttle table console‹).
This tells the controls that new material is at the loading position and
therefore an automatic table change can be carried out.
7. The shuttle table travels to the waiting position.

Byspeed Operating
6.8 Service functions
The service functions can be selected in every view.
6.8.1 Travel to service position
The service point is used for cutting head replacement, nozzle replace-
ment and nozzle centering.
This function allows the cutting head to travel to a defined location within
the machining area. The location of the service point can be defined in the
HAND – Setup machine view.
6.8.2 Travel to park position
This function allows the cutting head to travel to the extreme right corner
of the machining area. This provides free access to the machining area
(e.g. for repair and maintenance work).
The location of the park position can be defined in the HAND – Setup
machine view.
6.8.3 Calibrating the nozzle
This function allows the cutting head to travel across the calibration plate
and the calibration process to be carried out automatically. During calibra-
tion, the nozzle is lowered to the calibration plate until contact is made.
The z-axis then travels upwards and checks a variety of nozzle distances.
This function can be used for both tactile and capacitive sensing.
6.8.4 Cleaning the nozzle
This function allows the nozzle head to travel across the brass brush on
the shuttle table. The nozzle cleaner removes soiling, deposits and metal
splashes, which have adhered to the nozzle during cutting. The number of
cleaning passes can be defined in the HAND – Setup machine view.
Furthermore, it is possible to define whether automatic nozzle cleaning is
performed after a given number of piercings or at the end of a cutting
plan. After each cleaning the sensor is automatically calibrated.

Operating Byspeed
6.8.5 Displacing the origin
The origin displacement of the cutting plan is used to enable parts to be

cut at any position on the shuttle table (see Chapter 6.6.2 ›Cutting plan
origin offset‹).
Use the origin displacement only for cutting individual parts

(not for large-format cutting plans).
If the cutting plan projects past the edge of the sheet due to
the origin displacement, there is a hazard that the cutting
head will run past the edge of the existing sheet or the axes
run into the stops.

Byspeed Operating
6.9 Special functions
6.9.1 Crossjet
The Crossjet effectively prevents slag adhering to the surface of the work-
piece during piercing. The structure and modus operandi of the Crossjets
is described in Chapter 3.7.8 ›Crossjet (optional)‹.
The Crossjet has the following operating modes:
Oil mist
Cross blowing
6.9.1.1 Crossjet log on
If the Crossjet is mounted on the z-axis, it must be activated (WORK

view, Special functions).
The Crossjet can only be activated if the Oil mist time prior to
piercing cutting parameter is defined with a value greater than
zero, or the Cross blowing after piercing function is switched
on.

Operating Byspeed
6.9.2 Sheet clamp
The sheet clamp prevents the sheet being moved on the shuttle table sup-
port grid when cutting at high speeds. If the sheet clamp is activated, the
sheet is automatically clamped after every table change.
The sheet clamp is activated in the Handling Operation application,
Main view, by pressing the switch (A). The sheet clamp is active if the
switch is green.
Fig. 6.9-1 Main – Home view, activate sheet clamp
By pressing the CLAMP key on the operating terminal , the clamp can be
released or clamped. During the cutting process the clamp can only be re-
leased, but not clamped again. Only after the cutting process is aborted
can the sheet be clamped once more.
When cutting with the sheet clamp, the area clamped must be
taken into consideration in the cutting plan. The area clamped
can be defined in the cutting plan in Bysoft by defining the left
sheet edge.
It must be noted that the cutting sequence of the parts must be
from right to left (X+ to X-) in order to ensure the stability of
the sheet at the end of the cutting plan.

Byspeed Operating
6.9.3 Edge detection
The origin and the location-angle of the sheet are detected by the edge
detection. This allows better exploitation of the raw material. It also in-
creases the process reliability.
The edge detection can be switched on or off in the WORK view, Special
functions.
Detection type 3 (X / Y / Angle) is recommended. The sheet is

to be placed on the shuttle table in loading position 1 (front
left).
Further information on edge detection is contained in the online
help or in the ByVision operating instructions.
6.9.3.1 Edge detection with active sheet clamping

When the sheet clamping is used the sheet must be correctly position in
the x-direction. During detection the sheet is only scanned in the y-direc-
tion.
In order to prevent a collision with the collet chuck, the detection in x-di-
rection is automatically blocked.
6.9.3.2 Edge detection with CutControl
Scanning is more precise when using the edge detection in conjunction

with CutControl.
The normal capacitive edge detection is extended in conjunction with Cut-
Control using the following steps:
1. After the capacitive edge detection the edge is passed by approx.

5 mm.
2. The laser beam is switched on using Laser power detection and

Gas pressure detection.
3. The cutting head travels towards the sheet edge until it is recognized
by CutControl.
4. The axes stop and the determined detection value is stored.
5. Travel to the next scanning section and repeat sequence.

Operating Byspeed
6.9.4 CutControl
The structure and function of the CutControl is described in Chapter

3.7.7 ›CutControl‹.
6.9.4.1 Working with CutControl
Before CutControl can be employed the system must be operating in per-

fect condition. The cut quality and the cutting parameters must be correct
(see Chapter 6 ›Cutting technology‹).
To check this, the CutControl must be deactivated (HAND – Setup ma-
chine view).
Input value: 0 = off

1 = on
1. Activate CutControl (HAND – Setup Machine view).
2. The calibration threshold for the material to be cut is stored in the

cutting parameters. Using these values cutting can commence imme-
diately, without manual determination.
During production the calibration threshold should be determined
and, if necessary, edited in the cutting parameters (see Chapter
6.9.4.2 ›Determining the calibration threshold‹).
3. CutControl can now be used and the cutting plan can be started.
4. CutControl is active until the function is deactivated or until the cali-

bration value is set to 0 in the cutting parameters.
CutControl can remain constantly active. When cutting mate-

rial types that cannot be monitored by CutControl, the func-
tion must be deactivated.

Byspeed Operating
6.9.4.2 Determining the calibration threshold
The calibration threshold is determined during a good cut in cutting or

manual mode. In cutting mode the calibration threshold can be deter-
mined with the Cutcontr.lcc cutting plan. This cutting plan is stored on
the computer.
The calibration threshold is determined as follows:
1. Load and start the Cutcontr.lcc cutting plan
2. Whilst cutting contour elements 1 to 5 the Calibrate while cutting

function must be activated by entering 1. This initiates the calibra-
tion process.
The values determined is displayed after approx. 2 sec. This is the
calibration threshold.
Fig. 6.9-2 Cutcontr.lcc cutting plan
C
B
X
A
A Contour element 1 D Contour element 4

B Contour element 2 E Contour element 5
C Contour element 3
During calibration the values are always determined on a

straight cut (both axes in positive and negative direction).

Operating Byspeed
Tab. 6.9-1 Cutting sequence of contour elements
Contour ele- Cutting direction Determined value

ment (example)
1 X+ 315
2 X+ 232
3 X- 212
4 Y+ 232
5 Y- 233
Average value: 245
The calibration thresholds are different for each cut direction (see Table
6.9-2 ›Guide values and tolerances for the calibration thresholds‹).
The average is formed from the contour elements 1…5. This takes the
anisotropy into consideration. The average must be entered in the Gas
type calibration threshold 2 cutting parameter and saved. This deter-
mined value generally does not fluctuate strongly and must therefore only
be occasionally checked during production.
The calibration threshold can vary strongly if the cutting parameters are
changed, the lens has been covered with splashes or the mirror is soiled.
The tolerance limit for correct functioning of CutControl is, however, very
large (see Table 6.9-2 ›Guide values and tolerances for the calibration
thresholds‹).
If a different material or a known material with a different

surface finish is cut, a new calibration value must be deter-
mined.
After calibration, or after the cut is prematurely cancelled, the
setup value is automatically reset.

Byspeed Operating
Tab. 6.9-2 Guide values and tolerances for the calibration thresholds
Material thickness Stainless steel Structural steel
1 mm 350 ±150 350 ±150
2 mm 350 ±150 350 ±150
3 mm 350 ±150 350 ±150
4 mm 300 ±150 350 ±150
5 mm 300 ±150 400 ±150
6 mm 350 ±150 450 ±150
8 mm 450 ±150 —
10 mm 480 ±150 —
12 mm 550 ±150 —

Operating Byspeed
6.9.4.3 CutControl functional checks
The functioning of CutControl is checked on the basis of the Cutcontr.lcc

cutting plan. This cutting plan is stored on the computer. Proceed as fol-
lows to check CutControl:
1. Load shuttle table with stainless steel
2. Ensure that CutControl is switched on.
3. Load the Cutcontr.lcc cutting plan.
4. Allocate cutting parameters.
5. Test cut in manual mode or with a rectangular test piece (cut quality
check).
6. Start the Cutcontr.lcc cutting plan.
7. The calibration threshold can be checked by means of the first five

contour elements (see Chapter 6.9.4.2 ›Determining the calibration
threshold‹).
8. When cutting the star-shaped geometries, CutControl functioning can

be checked. If all is functioning correctly, the system reacts as fol-
lows in the star points:
z If the laser beam breaks off (welding), the cutting process stops
and the axes travel back to the position previous to the beam
break. It then cuts slowly over the welding bead and accelerates
again to its original speed.
z If only the blue plasma flame results (it still cuts through), the ma-
chine slows down the cutting speed until the plasma flame extin-
guishes and then accelerates to normal cutting speed again.
Both types can occur separately or in combination. A burr is pro-
duced in contours cut slowly.
If the machine does not react after plasma formation or laser

beam break, CutControl is not functioning correctly. There is an
error.

Byspeed Operating
6.9.5 Microwebs / welding webs
Microwebs prevent cut parts from tilting or falling off (see Chapter
12.7.11 ›Microwebs‹).
There are the following types of microwebs:
Automatic microwebs: These are activated on the laser cutting

machine.
Programmed microwebs: These are programmed in Bysoft and ac-
tivated on the laser cutting machine.
Welding webs: These are programmed in Bysoft and ac-
tivated on the laser cutting machine.
Microwebs and welding webs cannot be combined within the same cutting
plan.
Microwebs are used on thin sheets
Welding webs are used on thicker sheets

Operating Byspeed
6.9.5.1 Automatic microwebs
Automatic microwebs are specified in a cutting plan as follows:
1. Select the HAND – Setup machine view on the user interface. In

Setup values, microwebs, select the appropriate function.

1 = on
2 = automatic
3 = Welding web
2. The minimum and maximum part dimensions for which an automatic

microweb can be specified can be defined with the values for Critical
parts (HAND – Setup values, machine view). The parameters are
only active if the automatic microwebs are selected.
The width of the microwebs is defined in the Width of microweb
cutting parameter. The microwebs programmed in Bysoft are also
taken into consideration. Further information can be found in the on-
line help.
3. Activate the function in the WORK view, Special functions by

pressing the Microwebs switch.

Byspeed Operating
6.9.5.2 Programmed microwebs
Programmed microwebs are programmed in Bysoft as Microweb and are

already included in the cutting plan.
The microwebs are activated as follows:


1 = on
2 = automatic
3 = Welding web
All microwebs programmed in Bysoft are specified. Further informa-

tion on programming microwebs can be found in the Bysoft online
help.
2. Activate the function in the WORK view, Special functions by


Operating Byspeed
6.9.5.3 Welding webs
The welding webs are programmed in Bysoft as Microweb and are al-
ready included in the cutting plan.
In contrast to the microweb, the welding web must be programmed as
centrally as possible to the contour, because the welding web is set on the
cut joint of a previously cut contour. Welding webs are used primarily in
the thick sheet range above 4 mm, if the material thickness makes it diffi-
cult or impossible to break out the part.
The welding webs are activated as follows:


1 = on
2 = automatic
3 = Welding web
Further information on programming microwebs can be found in the

Bysoft online help.
2. The setup values for the welding webs are defined in the HAND –
Setup machine view.
3. Activate the function in the WORK view, Special functions , by


Byspeed
Chapter 7
7 Maintenance
This chapter contains the maintenance schedule and tables for the main-
tenance record. Moreover, it lists all operating resources required for
maintenance work.

Maintenance Byspeed

Byspeed Maintenance
7.1 Introduction
The maintenance personnel must be familiar with the technical details of

the laser cutting machine. All operating and safety-relevant instructions in
these operating instructions must be read and understood.
The machine must be isolated for all maintenance and repair work. The
main switch must be secured by a padlock and the key be kept out of the
reach of third parties.
7.1.1.1 Working on live components
WARNING
Electric shock
When working on live components there is a danger of
electric shock.
Electrical components on which maintenance work is be-
ing carried out must be isolated unless otherwise speci-
fied.
Check that isolated components are voltage-free
Isolate neighboring, live components
7.1.1.2 Working on gearboxes
CAUTION
Burns hazard
When carrying out maintenance and repair work on
gearboxes there is a danger of burns.
Allow gearboxes to cool.

Maintenance Byspeed
7.1.1.3 Lingering within the danger zone
No unauthorized personnel may linger in the laser cutting machine danger

zone when carrying out maintenance and repair work. Close off the dan-
ger zone.
7.1.1.4 Operating resources
The safety regulations of the respective manufacturer must be observed

when handling operating resources, in particular gearbox oil, solvents and
greases.
7.1.1.5 Third-party assemblies
The Supplier documentation for all installed third-party assemblies

must be observed (e.g. extraction system, chiller, etc.).
7.1.1.6 Tools, testing equipment and spare parts
Only use specified tools and testing equipment.

Only use the manufacturer's original spare parts (see Spare parts cat-
alog).

Byspeed Maintenance
Maintenance personnel must be capable of performing the following tasks:

Operating the machine controls
Repair work on pneumatic and hydraulic systems
Replace, repair and adjust mechanical components
Carry out mechanical and electric adjustments on the machine

Maintenance Byspeed
7.2 Customer service information
The manufacturer's customer service is available if problems should arise.

In order to allows problems or queries to be rapidly processed, the follow-
ing information should be available before a call:
Company / address
Contact person
Job and equipment number (see type plate)
The contact address is given at the front of the operating instructions.

Byspeed Maintenance
7.3 Operating resources
The use of aids, lubricants and cleaning materials is described in Chapter

8 ›Repairs‹.
Tab. 7.3-1 Aids and cleaning materials
Designation Application Part number
Lubrication set 4-10845

(in tool cabinet)
Cleaning set Lens cleaner (acetone) 4-10846

(in tool cabinet) Lens polisher
Lens cleaning paper
Cotton buds and cotton wool
pads
Chapter 8.5.4.5 / 8.5.4.6 /
8.5.4.7 / 8.5.4.8
Filter replacement pack Filter system Ultrapac 2000 502819

Chapter 8.4.9
Cleaning cloths Cleaning the measurement 505951

(in tool cabinet) tapes on the linear measuring
system
Chapter 8.4.7
Tab. 7.3-2 Lubricants
Designation Application Part number
Motorex 190 EP Grease for guides, Spindle 1971661

bearings and DHM drive
Chapter 8.4.2 / 8.4.6.2
Chain spray WKS Chain lubricant 1972800
Molykote DX paste Grease for shuttle table drive 1973609

Chapter 8.4.4.3
Motorex Gearsynth 220 Gearbox oil 1974002

(VG220) Chapter 8.4.4.3
Motorex Proweld 264 Oil for Crossjet 8861850

Chapter 8.4.9.3

Maintenance Byspeed
7.4 Operating hours display
The critical operating hours for the respective maintenance tasks are
shown on the laser's operating hours counter.
Fig. 7.4-1 Location of operating hours counter
A Laser
B Operating hours counter

Byspeed Maintenance
7.5 Maintenance schedule
The following maintenance schedule serves as a reference for the planning

and execution of maintenance tasks on the laser cutting machine.
The maintenance tasks on the laser are described in the respec-

tive operating instructions for that type.

Byspeed Maintenance
Maintenance tasks Interval
Object Note Activity Operating re-
when required
source
Aid
1,000 hrs.
3,000 hrs.
8,000 hrs.
annually
500 hrs.
monthly
weekly
daily
Laser cutting ma- — Check for external damage X
chine
— Complete cleaning X
Safety devices Chapter 8.3 Check emergency off buttons und X

light barrier for correct functioning and
effectiveness
Operating termi- Chapter 8.4.1.1 Clean screen X

nal
Chapter 8.4.1.2 Clean keyboard X
Base frame Chapter 8.4.5 Check functioning of exhaust air sector X

flaps
Extraction cham- Chapter 8.4.5.1 Empty chambers X X

bers
Small parts trays Chapter 8.4.5.2 Empty trays X
Chapter 8.4.5.2 Clean wheels X

Byspeed Maintenance
when required
source
Aid
1,000 hrs.
3,000 hrs.
8,000 hrs.
annually
500 hrs.
monthly
weekly
daily
Extraction system Functional check of the filter controller X
documentation
and pre-coating unit

see supplier
Model: Acoustic and optical check of cleaning X

Keller pulses
Check filter elements and casing walls X

for wear. Replace if necessary
Extraction system Dust extraction system, empty dust X

funnel when ¾ full
documentation
see supplier
Model: When changing material from steel to X

Torit aluminum or vice versa, empty dust
funnel
Clean oil / water trap X
Doors, visual inspection of seals. Re- X

place if necessary

Byspeed Maintenance
when required
source
Aid
1,000 hrs.
3,000 hrs.
8,000 hrs.
annually
500 hrs.
monthly
weekly
daily
Extraction system Check connecting lines for leaks. Re- X
See supplier documentation
pair if necessary
Model: Check extraction capacity X

Torit Check filter resistance X
Filter elements, visual inspection for X

caking. Replace if necessary
Check dust remover and platform for X

damage, stability and corrosion. Re-
pair or replace if necessary
Replace all filter elements X

Byspeed Maintenance
when required
source
Aid
1,000 hrs.
3,000 hrs.
8,000 hrs.
annually
500 hrs.
monthly
weekly
daily
Shuttle table sys- Chapter 8.4.4.2 Clean guide of cutting residues and lu- Brush, cloth X X
tem bricate
Chapter 8.4.4.1 Check roller chain tension X X
— Clean and lubricate roller chain Chain spray WKS X X
Chapter 8.4.4.3 Clean and lubricate toothed gears Molykote X

(drive and lifting unit) DX paste
Chapter 8.4.4.3 Geared motors (drive and lifting unit), MOTOREX X

check gearbox oil for soiling. Replace Gearsynth 220
oil if necessary (VG220 or in ac-
cordance with
Chapter 8.4.4.3 Geared motors (drive and lifting unit), type plate) X
replace oil

Byspeed Maintenance
when required
source
Aid
1,000 hrs.
3,000 hrs.
8,000 hrs.
annually
500 hrs.
monthly
weekly
daily
Supply unit Chapter 8.4.9.1 Adsorption drier (air filter), check LED X
display
Chapter 8.4.9.1 Adsorption drier (air filter), replace Filter replace- X X

drying agent cartridge. LED display ment pack
502819
Chapter 8.4.9.1 Adsorption drier (air filter), replace X X

pre- and post-filter. LED display
Chapter 8.4.9.1 Replace activated charcoal filter X
Chapter 8.4.9.1 Replace filter and pre-filter X
Chapter 8.4.9.3 Crossjet, check oil level and top up if MOTOREX X

necessary. Lightly oil the lid seal Proweld 264
Chapter 8.4.9.3 Crossjet, check functioning of safety X

valve

Byspeed Maintenance
when required
source
Aid
1,000 hrs.
3,000 hrs.
8,000 hrs.
annually
500 hrs.
monthly
weekly
daily
Bridges — Check limit switch functioning X X
Cutting bridge Chapter 8.4.6 Cutting bridge drive, x-axis, check X
Carriage that surfaces of spindle and guides are
Z-axis greased
Chapter 8.4.6 Carriage drive, y-axis, check that sur- X

faces of spindle and guides are
greased
Chapter 8.4.6.2 Motor bearing, x- and y-axis, lubricate Universal grease X

at provided grease nipple Motorex 190 EP
Chapter 6.5.3 Check nozzle condition. Replace if nec- X

essary
— Check bellows for damage. Replace if X X

necessary

Byspeed Maintenance
when required
source
Aid
1,000 hrs.
3,000 hrs.
8,000 hrs.
annually
500 hrs.
monthly
weekly
daily
Cutting head Chapter 8.5.4 Check lens for soiling, metal splashes X X
or scratched surface. Clean or replace
if necessary
— Clean exterior of cutting head X X
Chapter 6.5.5 Tactile sensing, check functioning X
Beam guidance Chapter 8.6 Check optics. Clean and adjust if nec- Cleaning set X
essary
— Check bellows and seals for damage. X

Replace if necessary
Chapter 8.5.3 Check adaptive optics mirror for soil- X

ing. Clean if necessary
Pneumatics — Check all loads, valves and hoses for X

leaks

Byspeed Maintenance
when required
source
Aid
1,000 hrs.
3,000 hrs.
8,000 hrs.
annually
500 hrs.
monthly
weekly
daily
Central lubrica- Chapter 8.4.2 Check level. Top up lubricant Universal grease X X
tion Motorex 190 EP
— Visual inspection for leaks X X
Sheet clamp Chapter 8.4.3 Clean guides, lubricate and check for X X
damage
Linear guide Chapter 8.4.7 Guide rails, check for soiling and dam- X X
age. Clean if necessary
Linear measure- Chapter 8.4.8 Measurement tapes, x- and y-axis, X X

ment system check for soiling and damage. Clean if
necessary
Safety door — Check and clean guides X
Cutting gas sup- Chapter 8.4.10 Replace gas bottles X

ply
— Check supply lines for leaks X

Byspeed Maintenance
when required
source
Aid
1,000 hrs.
3,000 hrs.
8,000 hrs.
annually
500 hrs.
monthly
weekly
daily
Cooling unit Check coolant temperature X
See supplier documentation
Check coolant level in tank X

Model:
Replace coolant X
Furrer
Re-dose cooling liquid X
Check air filter. Clean or replace if X X

necessary
Clean air-cooled condenser X X
Cooling circuit Clean secondary flow filter X

Byspeed Maintenance
7.6 Maintenance record
The following tables can be copied and used as a record of maintenance

work carried out. This record must be kept in the machine logbook.
Maintenance and repair work must be recorded with the date and signa-
ture of the person carrying out the maintenance tasks.
The maintenance record forms the basis for any warranty claims.
Warranty is only valid in its entirety if a correctly maintained

logbook is produced.

Byspeed Maintenance
Maintenance record according to operating hours
Operating hours Maintenance interval Date Signed Remarks
500 500
1,000 500 / 1,000
1,500 500
2,000 500 / 1,000
2,500 500
3,000 500 / 1,000 / 3,000
3,500 500
4,000 500 / 1,000
4,500 500
5,000 500 / 1,000
5,500 500
6,000 500 / 1,000 / 3,000
6,500 500
7,000 500 / 1,000
7,500 500
8,000 500 / 1,000 / 8,000
8,500 500

Byspeed Maintenance
9,000 500 / 1,000 / 3,000
9,500 500
10,000 500 / 1,000
10,500 500
11,000 500 / 1,000
11,500 500
12,000 500 / 1,000 / 3,000
12,500 500
13,000 500 / 1,000
13,500 500
14,000 500 / 1,000
14,500 500
15,000 500 / 1,000 / 3,000
15,500 500
16,000 500 / 1,000 / 8,000
16,500 500
17,000 500 / 1,000
17,500 500

Byspeed Maintenance
18,000 500 / 1,000 / 3,000
18,500 500
19,000 500 / 1,000
19,500 500
20,000 500 / 1,000
20,500 500
21,000 500 / 1,000 / 3,000
21,500 500
22,000 500 / 1,000
22,500 500
23,000 500 / 1,000
23,500 500
24,000 500 / 1,000 / 3,000 / 8,000

Byspeed Maintenance
Maintenance record according to calendar
Year:
w = weekly m = monthly a = annually
Calendar week Maintenance in- Date Signed Remarks

terval
01 w
02 w
03 w
04 w/m
05 w
06 w
07 w
08 w/m
09 w
10 w
11 w
12 w/m
13 w

Byspeed Maintenance
Year:

terval
14 w
15 w
16 w/m
17 w
18 w
19 w
20 w/m
21 w
22 w
23 w
24 w/m
25 w
26 w

Byspeed Maintenance
Year:

terval
27 w
28 w/m
29 w
30 w
31 w
32 w/m
33 w
34 w
35 w
36 w/m
37 w
38 w
39 w

Byspeed Maintenance
Year:

terval
40 w/m
41 w
42 w
43 w
44 w/m
45 w
46 w
47 w
48 w/m
49 w
50 w
51 w
52 w/m/a

Byspeed
Chapter 8
8 Repairs
This chapter forms the basis for all maintenance work in accordance with
the maintenance schedule.
It provides support in fault finding and remedy. It also contains instruc-
tions for executing lubrication, care and cleaning tasks, as well as repairs
and adjustments.

Repairs Byspeed

Byspeed Repairs
8.1 Introduction
The maintenance personnel must be familiar with the technical details of

the laser cutting machine. All operating and safety-relevant instructions in
these operating instructions must be read and understood.
The machine must be isolated for all maintenance and repair work. The
main switch must be secured by a padlock and the key be kept out of the
reach of third parties.
8.1.1.1 Working on live components
WARNING
Electric shock
When working on live components there is a danger of
electric shock.
Electrical components on which maintenance work is be-
ing carried out must be isolated unless otherwise speci-
fied.
Check that isolated components are voltage-free
Isolate neighboring, live components
8.1.1.2 Working on gearboxes
CAUTION
Burns hazard
When carrying out maintenance and repair work on
gearboxes there is a danger of burns.
Allow gearboxes to cool.

Repairs Byspeed
8.1.1.3 Lingering within the danger zone
No unauthorized personnel may linger in the laser cutting machine danger

zone when carrying out maintenance and repair work. Close off the dan-
ger zone.
8.1.1.4 Operating resources
The safety regulations of the respective manufacturer must be observed

when handling operating resources, in particular gearbox oil, solvents and
greases.
8.1.1.5 Third-party assemblies
The Supplier documentation for all installed third-party assemblies

must be observed (e.g. extraction system, chiller, etc.).
8.1.1.6 Tools, testing equipment and spare parts
Only use specified tools and testing equipment.

Only use the manufacturer's original spare parts (see Spare parts cat-
alog).

Byspeed Repairs
Maintenance personnel must be capable of performing the following tasks:

Operating the machine controls
Repair work on pneumatic and hydraulic systems
Replace, repair and adjust mechanical components
Carry out mechanical and electric adjustments on the machine

Repairs Byspeed
8.2 Fault finding and remedy
The following fault finding chart describes the general procedure for find-
ing operating faults.
If a fault occurs for an unknown reason during operating, the following
fault finding sequence must be adhered to:
1. Observe machine messages.

Fault messages and their remedy are described in the online help
and in the ByVision operating instructions.
2. Localizing faults.
Is it a mechanical or electrical fault? Is it a hardware or software fault
(error message MMC / CNC / SPS)?
3. Determine cause of fault.

Faults often give rise to follow-up faults.
4. Fault frequency
Does the fault occur constantly, or do certain actions lead to the
fault?
5. Ambient conditions
Checking the laser cutting machine:
z Obstruction due to soiling, foreign objects, damage?
z Power supply (supply voltage, compressed air) present?
z Ambient conditions, climatic influence (e.g. heat, thunderstorm,
etc.)?
6. Interference from other devices and loads (voltage peaks)?
7. Check sensors and switches:

z Operating terminal illuminated key and emergency off reset
keys.
z Sensors, limit switches, safety limit switches.
z LEDs on the input and output modules.

Byspeed Repairs
8. Wiring and terminals

Check installations for loose connections and wiring breaks.
9. Switches and settings

Has an object been replaced and now has incorrect settings?
10. Initialization
Switch the complete system off and start up again.
11. Supplier documentation

It is possible that notes on faults and their remedy are available in
other operating instructions.
12. Telephone
Call the manufacturer's customer service (see Chapter
8.9 ›Customer service information‹).

Repairs Byspeed
8.3 Safety checks
Check the emergency off keys, the light barrier, and all other safety de-
vices and controls for correct functioning and effectiveness at regular in-
tervals.
Information on safety devices can be found in Chapter 3.2 ›Safety and
monitoring devices‹.

Byspeed Repairs
8.4 Lubricants, care and cleaning tasks
Never use cleaning agents containing solvents. The screen and keyboard
can be damaged by solvents and aggressive cleaning agents.
8.4.1.1 Cleaning the screen
Before cleaning the screen it must be locked by activating the Clean

screen function (user interface, MAIN view).
The screen is cleaned using a soft cloth, slightly moistened with water.
Fig. 8.4-1 Operating terminal
8.4.1.2 Clean keyboard
Before cleaning the keyboard, shut down the computer and switch of the
controls.
The keyboard is cleaned using a soft cloth, slightly moistened with soapy
water.

Repairs Byspeed
8.4.2 Central lubrication
8.4.2.1 Top up lubricant
If the lubricant container is empty (lower level reached) the message Lu-
bricant container empty is issued at the operating terminal. The axes
can then only be moved to the reference position.
In order to allow further machine operation, the central lubrication lubri-
cant container must be refilled using a grease gun (in the tool cabinet).
Lubricant: Motorex 190 EP
At the next approach to the reference position the lubrication cycle is au-
tomatically repeated and the machine can continue.
Fig. 8.4-2 Pump unit
max. A
min.

Byspeed Repairs
The following points must be observed with regard to the central lubrica-
tion:
Never completely empty the container
The lubricant must be clean and suitable for use in the central lubrica-
tion system.
Fill the lubricant without air using a grease gun at the grease nipple. Do
not overfill the lubricant container (no lubricant should escape from the
overflow bore (A))
Fig. 8.4-3 Central lubrication grease nipple
Never close the outlet of a distributor intended for supply of a lubrica-

tion point or a sub-distributor. The distributor will block the whole sys-
tem.
Fig. 8.4-4 Distributor in carriage connector box
Check all connections and pipe unions on the pump, distributor and lu-
brication points for leaks.

Repairs Byspeed
8.4.3 Sheet clamp
If the teeth (A) on one of the clamping levers is worn, it must be replaced.
WARNING
Crushing hazard
When carrying out maintenance and repair work on the
sheet clamp, there is a danger that body parts can be
crushed by the sheet clamp.
Ensure that the system is switched of and the cylinder is
pressureless.
Fig. 8.4-5 Clamping lever on sheet clamp (without protective cover)
Guide lubrication is carried out at the grease nipples (B). There are two
grease nipples per guide.
Lubricant: Motorex 190 EP

Byspeed Repairs
8.4.3.1 Replacing a clamping lever
1. Clamp the collet chuck (CLAMP key on operating terminal).
2. Switch off the laser cutting machine and safeguard against switching
on. Ensure that the clamping cylinders are not pressurized!
3. Remove the sheet clamp cover.
4. Replace defective parts.
5. Check clearance between clamp jaws. It should be 0.1 mm.

The clearance can be adjusted by turning the piston rods of the
short-stroke cylinder forwards or backwards.
6. If the limit switch was removed it must be readjusted.
7. Refit the sheet clamp cover.
8. Switch the machine on and carry out a functional check.

Repairs Byspeed
8.4.4 Shuttle table system
8.4.4.1 Roller chain tension
The chain tensioner is in the machine frame.

Too tightly tensioned chain exert unnecessary stress on the drive and
wear faster. Too loose chains tend to jump out of the teeth.
Fig. 8.4-6 Horizontal chain tensioner
A B C
A Tensioning screw with nut and locknut

B Chain wheel
C Roller chain
The slack (D) on the unloaded roller chain should be approx. 1% of the
axle centers (E) (axle centers: 4,867 mm).
Fig. 8.4-7 Roller chain slack
E
D
Slack = axle center · 0.01

Byspeed Repairs
1. Move shuttle tables to loading position.
2. Switch off the laser cutting machine and safeguard against switching
on.
3. Remove rear cover plate.
4. Loosen locknut.
5. Tighten roller chain.
6. Tighten locknut.
7. Check roller chain slack.
8. Replace rear cover plate.

Repairs Byspeed
8.4.4.2 Guides
Free hexagonal guide of cutting residue weekly using a cloth or wire

brush, spray lightly with a lubricant spray and rub off.
Fig. 8.4-8 Shuttle table hexagonal guide
8.4.4.3 Drives and gearbox, lifting unit
Check the gearbox oil every 3,000 h. Take an oil sample and examine for
soiling.
Gearbox oil: MOTOREX Gearsynth 220 (VG 220)
Fig. 8.4-9 Lifting unit toothed gear

Byspeed Repairs
Fig. 8.4-10 Geared motor (cover removed)
A Bleed screw
B Sealing plug
Synthetic oil may not be mixed with mineral oil!

Repairs Byspeed
8.4.5 Base frame
8.4.5.1 Extraction
Check functioning of exhaust air sector flaps. If the cutting head is located
over a sector, the corresponding exhaust air sector flap below must be
open.
Fig. 8.4-11 Exhaust air sector flaps
8.4.5.2 Small parts trays
Empty the small parts trays daily and clean the wheels weekly.
Fig. 8.4-12 Small parts trays
Five small parts trays are located below the base frame of the laser cut-
ting machine and, optionally, four below the shuttle table.

Byspeed Repairs
8.4.6 Cutting bridge and carriage (x- and y-axis)
8.4.6.1 DHM drive
The DHM drive is automatically provided with the required amount of lu-
bricant by the central lubrication system.
Lubricant: Universal grease Motorex 190 EP
When the interval (150 h) is reached a special lubrication program is
started at the next approach to the reference position. Both axes travel at
5 m/min so that the lubricant can be evenly distributed.
The lubrication program is ended by the signal from the limit switch, or
aborted after the Time Out.
If the lubrication program is aborted by the Time Out, the lu-

brication program was not correctly ended.
The laser cutting machine can continue to operate for 50 h af-
ter a Time Out. The current cutting plan is subsequently
completed. No more cutting jobs can then be started.
Get in touch with the manufacturer's customer service de-
partment.

Repairs Byspeed
8.4.6.2 Motor bearing
Lubricate the motor bearing annually or after 3,000 h using a grease gun
(in the tool cabinet).
Fig. 8.4-13 Grease nipple x- and y-axis
A
B
A Grease nipple, motor bearing, x-axis

B Grease nipple, motor bearing, y-axis
Adhere to the required amount of lubricant:
Lubricating point Amount
Motor bearing, x-axis 5 cm³
Motor bearing, y-axis 2.5 cm³

Byspeed Repairs
8.4.6.3 Changing the nozzle body
The nozzle body is provided with a rupture joint (A). In a collision with the
support grid or the sheet being cut, the nozzle body can break at the rup-
ture joint. This must then be replaced.
Fig. 8.4-14 Nozzle body
1. Move the axes to the service position.
2. Unlock the cutting head and remove it.
3. Hold the nozzle body from above (through the opening) with one fin-
ger.
Fig. 8.4-15 Nozzle body in z-axis
4. Loosen and remove nut (B).

Repairs Byspeed
5. Remove nozzle body (C) including ceramic rings (D and E). The ce-
ramic ring (D) may be held in the casing by the contact pin (F) (see
Fig. 8.4-17).
Fig. 8.4-16 Nozzle body removed
B D C E
6. Examine the ceramic rings (D and E) for damage and replace if nec-
essary.
8.4.6.4 Fitting the nozzle body
When fitting the new nozzle body ensure that the ceramic ring (E) is posi-
tioned correctly in the casing (note position of contact pin (F)).
Fig. 8.4-17 Nozzle body fitted
After fitting the nozzle body the laser beam must be centered
in the nozzle (see Chapter 6.5.4 ›Centering the laser beam in
the nozzle‹).

Byspeed Repairs
8.4.7 Linear guide
Examine the guide rails monthly for damage and soiling. Clean with a dry
cloth if necessary.
The guide carriages are automatically provided with the re-

quired amount of lubricant by the central lubrication system.
8.4.8 Linear measurement system
The linear measurement system consists primarily of a measurement tape

and a reading head. If one, or both, of the components soiled, this can
lead to positioning errors.
8.4.8.1 Measurement tapes
If the measurement tapes (A) in x- and y-direction are soiled, they must
be cleaned using the cleaning cloths in the cleaning set (in the tool cabi-
net).
CAUTION
Cleaning the measurement tapes
Under no circumstances may the acetone intended
for lens cleaning be used to clean the measurement
tapes. Acetone can damage the measurement tapes.
Clean the measurement tapes with the cleaning cloths in
the cleaning set only.

Repairs Byspeed
Fig. 8.4-18 Measurement tape x-axis (bellows removed)
A
X-axis
Fig. 8.4-19 Measurement tape y-axis (bellows removed)
A
Y-axis

Byspeed Repairs
8.4.8.2 Reading head
Check the signal from the reading head optically. The intensity of the sig-
nal is indicated by a LED in various colors.
The reading head may only be removed, cleaned and adjust-

ed by the manufacturer's customer service.
Fig. 8.4-20 Reading head x- and y-axis
A Reading head x-axis

B Reading head y-axis
C LED
Tab. 8.4-1 LED colors and their meanings
LED color Meaning
red The reading head must be cleaned and adjusted (only

by the manufacturer's customer service).
orange The reading head signal strength is acceptable.

Cleaning is not yet required.
green The reading head signal strength is optimal.

Repairs Byspeed
8.4.9 Supply unit
WARNING
Danger of injury by ejected parts and leaking com-
pressed air
Do not perform any assembly or dismantling work, or
unscrew or tighten any screw connections, while the
system is under pressure.
Before commencing maintenance and repair work on the
supply unit, switch off the laser cutting machine and
safeguard against switching on.
Pressure drops in the main air or the air of the beam path are monitored
by pressostats and error signals are issued via the PLC.
Fig. 8.4-21 Supply unit

Byspeed Repairs
A Pressostat
B Activated charcoal filter
C Water trap / prefilter
D Filter
E Clean air filter
F Air filter fault indicator

Repairs Byspeed
8.4.9.1 Air filter
The air filter issues an error message when a filter change is due (mes-
sage: Insufficient clean air). The fault activates the stop function STOP
WORK.
To be certain that a filter change really is due, check the LED display on
the air filter.
Fig. 8.4-22 Air filter Ultrapac 2000
The LEDs (B, C or D) indicate the element to be replaced. If necessary,

the pre-filter, post-filter or drying agent cartridges must be replaced.
Fig. 8.4-23 LED display on the air filter
A Operating display
B Replace drying agent cartridge
C Replace post-filter
D Replace pre-filter
The exact procedure can be taken from the Ultrapac 2000 operating in-
structions in the supplier documentation folder. The filter replacement
pack is available from the laser cutting machine manufacturer.

Byspeed Repairs
8.4.9.2 Reset switch
After the drying agent cartridge has been replaced, the reset switch must
be flipped with the machine switched off (reset load cycle counter). The
reset switch is located below the LED display cover.
Fig. 8.4-24 Reset switch on the control circuit board
Press the reset switch once only after cartridge replacement.

The load cycle counter reset only works with the machine
switched off.

Repairs Byspeed
8.4.9.3 Crossjet oil tank, top up oil
The Crossjet oil tank is located on the supply unit. Top up the container
when necessary.
Lubricant: MOTOREX PROWELD 264
This oil is flame retardant and therefore suitable for oil mist.
CAUTION
Fire hazard
Oil vapors can spontaneously combust in the laser beam
or on the hot surface of the workpiece.
Use only the specified oil in the correct dosage.
Further information can be taken from the safety data
sheet (see folder supplier documentation).
Fig. 8.4-25 Crossjet oil tank
A
B

Byspeed Repairs
CAUTION
Oil tank safety valve
The safety valve is correctly adjusted during assembly.
Changing the setting is detrimental to functioning.
Do not damage or remove the seal from the safety
valve.
Don not alter the safety valve setting.
1. Separate the compressed air connector at the coupling (C)
2. Separate the oil connector at the coupling (B)
3. Open the safety valve (A) by pulling in the direction of the arrow,
and release the compressed air.
Ensure at all costs that the oil tank is depressurized (check at the
pressure gauge).
Fig. 8.4-26 Bleed valve
4. Remove the oil tank cover.
5. Fill tank with oil (observe max. filling level).

Lubricant: Motorex Proweld 264
6. Lightly oil the lid seal. Replace cover.
7. Connect compressed air and oil lines.

Repairs Byspeed
8.4.9.4 Bleed Crossjet
If the oil was completely used, the line must be bled after filling.
1. Select the HAND view on the user interface
2. Activate the Oil mist special function
3. Press the JET key on the handheld controller until oil escapes from
the Crossjet

Byspeed Repairs
8.4.10 Cutting gas, changing the gas bottles
The cutting gas bottles can be replaced while the machine is operating
(see Chapter 8.4.10.3 ›Replacing gas bottles during operating‹).
CAUTION
Handling cutting gas bottles
Take care to work carefully and cleanly to avoid dirt en-
tering the gas line.
Secure gas bottles into position!
Always store disconnected gas bottles with the protec-
tive cap on!
WARNING
Explosion hazard
Do not oil or grease oxygen connections.
This can lead to explosion as the result of a chemical re-
action.

Repairs Byspeed
8.4.10.1 General notes
Never completely empty gas bottles. The bottles should always be re-
turned with a residual positive pressure of 1 atmosphere.
The correct gas quality must be adhered to when replacing cutting gas
bottles. Under no circumstances may the quality be lower than speci-
fied. See Chapter 3.12.1 ›Cutting gas quality‹).
The cutting process is stopped if the cutting gas runs out. The error
message GAS JET ERROR is issued on the screen.
The cutting process is stopped if the laser gas runs out, and the laser
excitation is switched off. The error message GAS ERROR is issued on
the screen.
Once the cause of the laser gas shortage is rectified, the pending error
message must be reset at the laser controls or on the user interface
(see Chapter 6.3.8 ›System, status and error messages‹).

Byspeed Repairs
8.4.10.2 Cutting gas regulators

Fig. 8.4-27 Cutting gas connection regulator
A B
D D
F
E E
A Pressure gauge (high pressure)

B Pressure gauge (reduced pressure)
C Reduction valve
D Stop valves (high pressure)
E Bottle connection
F Laser cutting machine supply

Repairs Byspeed
8.4.10.3 Replacing gas bottles during operating
CAUTION
Eye injuries from flying
dirt particles
The cutting gas bottles are pressurized (200 bar).
Always wear goggles when blowing off a valve.
1. Check that the stop valve (D) of the full bottle is closed.
2. Close the reduction valve (C) by turning counter-clockwise (ccw)

(pressure 0 bar).
3. Slowly open the bottle valve on the full bottle.
4. Close the stop valve (D) on the empty bottle.
5. Open the stop valve (D) on the full bottle.
6. Set the reduction valve (C) to 15 bar (oxygen) or 25 bar (oxide-free

cutting) (max. 28 bar).
7. Close the bottle valve on the empty bottle.
8. Remove the empty bottle from the cabinet and fit the protective cap.
Place the new bottle and secure.
9. Open the bottle valve on the new bottle briefly to blow out dirt from
the valve.
10. Connect the bottle.
If the machine is taken out of service for a prolonged period

(more than 8 hours), the bottle valves must be closed.
Otherwise, a pressure increase can result from leaky valves.
This can destroy the pressure regulator valve in the carriage.

Byspeed Repairs
8.5 Beam guidance – optics
Check the deflecting mirror monthly, or as required, for soiling and dam-
age. Clean or replace if necessary.
CAUTION
Damage to optical components and assemblies
Optical components and assemblies are soiled or dam-
aged by improper handling.
Wear disposable gloves when cleaning, replacing or ex-
amining the optics. Keep the workplace clean.
8.5.1 Optics components
8.5.1.1 Deflecting mirror
Various mirrors, which may appear the same upon inspection, are em-
ployed on the laser cutting machine. The type and properties of the mir-
rors can only be recognized by the part number on the optical element. A
directly or indirectly cooled mirror is fitted according to design.
Fig. 8.5-1 Directly cooled deflecting mirror
Fig. 8.5-2 Indirectly cooled deflecting mirror
8.5.1.2 Adaptive optics

Repairs Byspeed
The adaptive optics consist primarily of the mirror and casing. These op-
tics form a unit that may only be removed complete.
Fig. 8.5-3 Adaptive optics
8.5.1.3 Cleaning the deflective mirror and lens in the cutting head
The lens and mirror surfaces have a special coating. If this coating is dam-
aged the beam quality is reduced. Special attention must therefore be
paid to the optics when storing, cleaning and fitting.
Damage can occur when:

Dirt particles are burned onto the optics by the laser beam
Dirt particles leave scratches on the surface during cleaning
The coating on the mirror or lens surface is worn

Byspeed Repairs
8.5.2 Cleaning / replacing the deflecting mirror
Observe the following points:

Only remove the coolant hoses when replacing a directly cooled deflect-
ing mirror.
Do not disturb the adjusting screws (B).
Fig. 8.5-4 Directly cooled deflecting mirror
A
D
C G
Fig. 8.5-5 Indirectly cooled deflecting mirror
D
B
C G

Repairs Byspeed
A Mirror holder
B Adjusting screw (do not adjust).
C Deflecting mirror
D Coolant connection
E Cooler (indirectly cooled deflecting mirror only)
F Mirror mounting fixing screws (4).
G Mirror mounting
H Retention spring
I O-ring
J Deflecting prism
Repair work on the deflecting mirror, which exceed the scope

of the tasks described, may only be carried out by personnel
specially trained by the manufacturer.
Contact the manufacturer's customer service (see Chapter
8.9 ›Customer service information‹).
When replacing a machine mirror, note the position, date and

number of operating hours on the rear of the mirror.
1. Switch off the machine and safeguard against switching on.
2. Remove the beam path covers.
3. Unscrew the fixing screws (F) on the mirror mounting (4).
4. When a directly cooled deflecting mirror needs replacing: Remove

coolant hoses.
5. Remove the mirror mounting (G) from the prism and position it so
that the mirror points upwards.

Byspeed Repairs
6. Push the mirror from its mounting and the o-ring by pressing the
cooler (E).
7. The exposed mirror can now be gripped at the edges and removed
from the mounting.
8. Fitting a new or cleaned mirror.

Grip the mirror around the edges (without soiling it with the fingers).
Press the mirror into the o-ring using Kodak paper.
9. Before the mirror mounting is refitted, check that the mirror holder is
absolutely clean.
10. Fit the mirror mounting in the correct position in the mirror holder
and tightly the four fixing screws uniformly.
11. When a directly cooled deflecting mirror has been replaced: Connect
coolant hoses.
12. Fit all covers and switch the machine on again.
13. Before the machine can begin cutting again, a test shot must be car-
ried out. This determines whether the beam deflection has been dis-
turbed.
14. Fit the z-axis alignment gauge and shoot at a cardboard piece whilst
in the adjustment position 4.
Fig. 8.5-6 Location of the adjustment position
Cutting table
15. Centricity of the burn-in mark.

Repairs Byspeed
16. If the centricity is correct, cutting can begin. If this is not the case
the individual beam paths must be examined.
17. After replacing or cleaning deflecting mirrors, the laser beam must
be recentered in the nozzle (see Chapter 6.5.4 ›Centering the laser
beam in the nozzle‹).

Byspeed Repairs
8.5.3 Adaptive optics
8.5.3.1 Cleaning / replacing
Always remove or refit the adaptive optics as one unit.
Fig. 8.5-7 Deflecting mirror z-axis (adaptive optics)
D C A
1. Switch off the machine and safeguard against switching on.
2. Remove the beam path covers.
3. Unscrew the fixing screws (A) on the mirror mounting (4).
4. If the adaptive optics need replacing: Remove the feed (B) and re-
turn (C) water hoses and the pressure sensor (D).
5. Remove the adaptive optics from the prism and position so that the
mirror points upwards.
6. Clean the mirror or replace the adaptive optics.
7. Before the new, or cleaned, optics are refitted, check that the mirror
holder is absolutely clean.
8. Fit the mirror mounting in the correct position in the mirror holder
and tightly the four fixing screws uniformly.

Repairs Byspeed
9. If the adaptive optics have been replaced: Refit the feed (B) and re-
turn (C) water hoses and the pressure sensor (D). Note feed and re-
turn.
10. Fit all covers and switch the machine on again.
11. Before the machine can begin cutting again, a test shot must be car-
ried out. This determines whether the beam deflection has been dis-
turbed.
12. Fit the z-axis alignment gauge and shoot at a cardboard piece whilst
in the adjustment position 4 (see Chapter 8.6 ›Adjusting the beam
guidance‹).
Fig. 8.5-8 Location of the adjustment position
Cutting table
13. Centricity of the burn-in mark.
14. If the centricity is correct, cutting can begin. If this is not the case
the individual beam paths must be examined (see Chapter
8.6 ›Adjusting the beam guidance‹).
15. After replacing or cleaning deflecting mirrors, the laser beam must
be recentered in the nozzle (see Chapter 6.5.4 ›Centering the laser
beam in the nozzle‹).

Byspeed Repairs
8.5.3.2 Determining the characteristic curve
The characteristic curves are used to compensate for focal length varia-
tions (as a function of the beam properties) within the complete cutting
range.
The following are prerequisites for determining the characteristic curves:
The optical components and beam guidance system must be in perfect
condition
Material: Stainless steel, thickness: 3 mm
Cutting head 5"
Test part bypos_t.lcc (see Fig. 8.5-11 for workpiece drawing). The cut-
ting plan is stored on the computer.
1. Select the HAND – setup machine view on the user interface.
2. Setup values, adaptive optics 1, select operating mode 1 and specify

characteristic curve pressure correction 1…5 at 0 bar.
3. Read in a cutting plan.
4. Travel to reference position.
5. Characteristic curve beam length 1 (travel to minimum beam length,

approx. 600 mm). See following table.
Fig. 8.5-9 Characteristic curve points, beam input left
Characteristic 1 2 3 4 5
curve points
Beam length [mm] 600 1,600 2,600 3,600 4,600
Pressure correction 0 bar 0 bar 0 bar 0 bar 0 bar

Repairs Byspeed
6. Cut test part at characteristic curve point 1. Correct focal position in

cutting parameters until an optimum cut is obtained.
7. Move to curve point 5 (maximum beam length).
8. Cut the same test part at characteristic curve point 5. Make any nec-
essary correction to the focus position by altering the pressure in the
characteristic curve pressure correction 5 (e.g. –0.4 bar).
A higher pressure results in a lower focus position, and vice versa.
Adjust the parameters until an optimum cut is achieved.
9. Joining these two corner points gives a straight line as the character-
istic curve. The correction values for intermediate points 2…4 are cal-
culated by interpolation and stored in the characteristic curve
pressure correction 2…4.
Fig. 8.5-10 Performance characteristic
Characteristic 1 2 3 4 5
curve points
Beam length [mm]a) 600 1,600 2,600 3,600 4,600
Pressure correction 0 bar - - - -0.4 bar

0.1 bar 0.2 bar 0.3 bar
a) The beam length defines the position at which the test cut must be made.
10. By making test cuts at the intermediate points, the characteristic

curve can be checked and corrected if necessary

Byspeed Repairs
Fig. 8.5-11 Test part ›bypos_t‹
Measurement unit: mm
Material: Stainless steel X5CrNi 18 9
DIN 1.4301
Thickness: 8 mm

Repairs Byspeed
8.5.4 Cutting head
8.5.4.1 Replace lens
WARNING
Destruction of a lens
Great care is required if a lens is destroyed as they con-
tain zinc selenide and thorium. No radiation can escape
from undamaged lenses. However, if a lens is heavily
scratched or thermally damaged, radioactive material
can escape into the environment. These materials can
lead to damage to health if inhaled!
Wear breathing equipment and gloves!
Avoid stirring up dust!
Materials that have been in contact with broken lens-
es or lens dust must be thoroughly cleaned with water
or disposed of as hazardous waste!
Return destroyed lenses to the laser cutting machine
manufacturer!
After cleaning, wash the hands thoroughly in running
water!
Advanced measures and safety information can be taken
from the safety data sheets in the supplier docu-
mentation!
The lens holder and the clamping ring are adapted to the lens
focal length. Take note of the engraving (5" or 7.5") when fit-
ting.

Byspeed Repairs
8.5.4.2 Aids
The following aids are required to remove and refit a lens:

Tool set (in tool cabinet)
– Lens wrench
Lubrication set (in tool cabinet)
Cleaning set (in tool cabinet)
Fig. 8.5-12 Lens wrench
A Locknut for handle extension

B Rod for handle extension
C Larger diameter of lens wrench for pressing out the lens holder
D Smaller diameter of the lens wrench with pin for undoing the lens
nut

Repairs Byspeed
8.5.4.3 Construction of cutting heads

Fig. 8.5-13 Cutting head 5" and 7.5" (without lens adjustment)
Cutting head 5" Cutting head 7.5"
H
K
G J
L F
E
K D
C
A J I B B A
A Cover G O-ring, lens holder

B Fixing screws H Lens holder 7.5"
C O-ring, lens holder I Nut
D O-ring, inside pipe 7.5" J Clamping ring
E Lens holder 5" K O-ring
F Inside pipe 7.5" L Lens

Byspeed Repairs
8.5.4.4 Removing the lens
1. Place the cutting head on a clean surface (the white splash guard up-
wards).
2. Loosen the four fixing screws and remove the cover.
3. Adjust the lens holder to the center of the cutting head using the
centering screws.
4. Remove the inside pipe on the 7.5" cutting head.
5. Press out the lens holder (do not hit) in the direction of the arrows
using the large diameter of the lens wrench.
Fig. 8.5-14 Remove the lens holder

Repairs Byspeed
6. Remove the lens holder from the cutting head with the help of the
lens wrench. Place the lens holder on a clean surface (the clamping
ring upwards).
Fig. 8.5-15 Removed lens holder
7. Examine the lens holder o-ring for damage.
If the o-ring is damaged it must be replaced. The o-ring must be

greased lightly before fitting.
Lubricant: Syntheso Proba 270
No grease residue may be visible.
Fig. 8.5-16 Lens holder o-ring
8. Clean lens wrench.

Byspeed Repairs
9. Remove the nut from the lens holder using the lens wrench.
Fig. 8.5-17 Lens holder with nut removed
10. Carefully rotate the lens holder through 180°. If the lens is not re-
leased from the lens holder press lightly on the lens in the direction
of the arrows from above using a cotton bud.
Fig. 8.5-18 Remove the lens

Repairs Byspeed
8.5.4.5 Cleaning the lens and mirror
The cleaning aids required can be found in the laser cutting machine's tool
cabinet.
The cleaning set consists of:
Article Amount
Lens cleaner (acetone) 100 ml
Lens polisher 50 ml
Lens cleaning paper 4 sets of 50 sheets
Cotton buds 1 bag
Cotton wool pads 1 bag
Disposable gloves
Never clean the surface of the mirrors and lenses dry.

Never treat the mirrors and lenses with compressed air. Soil-
ing in the compressed air can impregnate the surface.
Store cleaning paper and cotton buds in a dust-free environ-
ment. Use once only.
Keep acetone bottles clean. Close the bottle.
Wear disposable gloves. Finger prints reduce the life of the
mirrors and lenses.
Set up work place away from the laser. Solvent vapors must
not get into the laser guidance.
Examine labeling of mirrors and lenses. Replace detached
designations.
Refit cleaned mirrors immediately. Observe fitting direction!

Byspeed Repairs
8.5.4.6 Cleaning when slightly soiled
1. Remove dirt particles by blowing or using a bellows. A clean, soft

brush may also be used.
2. Place lens cleaning paper on the optics and drip 2 - 3 drops of ace-
tone on it.
Fig. 8.5-19 Lens cleaning paper with 2 - 3 drops of acetone
3. Pull the lens cleaning paper slowly and horizontally over the mirror or
lens to avoid streaks, leaving behind a dry, clean surface.
Streaks lead to unequal adsorption of the laser beam.
Fig. 8.5-20 Pull lens cleaning paper over the mirror or lens

Repairs Byspeed
8.5.4.7 Cleaning with cotton buds for heavier soiling
Be particularly careful when using this cleaning method!

Press only lightly.
Avoid scratching the surface with dirt particles adhering to the
cotton buds.
1. Remove dirt particles by blowing or using a bellows. A clean, soft

brush may also be used.
2. Ensure that all dirt particles are removed in order to avoid scratching
the surface.
3. Using a new soaked (in lens cleaner) cotton bud, perform a spiral
movement from the inside to the outside. Rotate the cotton bud
slowly and evenly
Only use light pressure and, if necessary, repeat procedure with a
new cotton bud.
Fig. 8.5-21 Lens cleaning with a cotton bud
A Cotton bud, direction of rotation

B Circular cleaning of mirror
4. Finally, clean the lens again with lens cleaning paper to remove any
streaks.

Byspeed Repairs
8.5.4.8 Cleaning when heavily soiled
If cleaning with lens cleaning paper and acetone or cotton buds does not
produce a satisfactory result, lens polisher may be used.
1. Place some polisher on a cotton wool pad and clean the lens from the
inside to the outside using a spiral motion.
2. Leave the polisher to dry.
3. Remove polisher residue with a new cotton wool pad.
4. Clean the lens with lens cleaning paper and acetone. No residue
should be visible.
5. If this cleaning method does not lead to success, or if burns or dam-

age to the coating is discovered, the lens must be replaced.
The lens polisher is abrasive. If polishing is carried out too of-

ten or too long at high pressure, the coating is worn away.

Repairs Byspeed
8.5.4.9 Refitting the lens
1. Examine the o-ring (A) for damage and replace if necessary.
The o-ring should not be greased.
Place the clamping ring (B) with the o-ring (A) the correct way up on
a clean surface.
Fig. 8.5-22 Clamping ring with o-ring fitted
B
A
2. Place the lens (C) with the convex side up on the o-ring.
Fig. 8.5-23 Lens positioned on the clamping ring
3. Position the clamping ring (B) with the lens (C) on the large diameter
(D) of the lens wrench.
Fig. 8.5-24 Clamping ring and lens positioned on the lens wrench

Byspeed Repairs
4. Place the lens holder (E) over the prepared pack and press to the
stop. Then rotate the lens holder through 180° and remove the lens
wrench.
Fig. 8.5-25 Clamping ring and lens positioned in the lens holder
5. Hold the lens holder (E) with one hand. Using the other hand, screw
in the nut (F) and tighten evenly with the lens wrench.
Do not tighten the nut by jolting. Jolts cause blows to

the lens. This can destroy the lens.
The clamping ring must be compressed, otherwise it will

move under a thermal load.
If the clamping ring is compressed too strongly the lens
may be damaged. Do not use excessive force to tighten
the clamping ring.

Repairs Byspeed
Fig. 8.5-26 Nut screwed into lens holder
With the correct prestressing of the clamping ring the four slits in the
center are closed.
6. Using the lens wrench, fit the finished lens holder into the cutting
head.
Observe fitting direction.
7. Refit the inside pipe on the 7.5" cutting head. Examine the two o-
rings for damage and replace if necessary.
The following points must be observed:
z The lower o-ring must be correctly positioned in the groove
z The inside pipe must be flush with the casing
z The pin in the inside pipe must fit into the hole provided in the
cover
8. Lay the cover on the cutting head and secure with the four fixing
screws.
9. Fit the cutting head into the z-axis and center the laser beam in the
cutting nozzle (see Chapter 6.5.4 ›Centering the laser beam in the
nozzle‹).

Byspeed Repairs
8.6 Adjusting the beam guidance
The laser cutting machine's beam guidance is based on the principle of

flying optics. The distance from the laser source to the cutting head var-
ies as a function of the cutting head position.
The number of deflecting mirrors used depends on the number of CNC
axes used, the design and the installation configuration. These mirrors are
given an initial adjustment during assembly and commissioning.
8.6.1 Aim of adjustments
In the cutting head, the beam must be central and exit perpendicular to
the nozzle aperture at every point of the machining area.
The tolerance for the deviation of the image from the crosshairs or the
center of the cardboard or plaster plate is ±0.5 mm.
8.6.2 Scope
The optics can be adjusted using the following instructions.

The angular and linear settings are differentiated. The linear setting is
carried out initially by the manufacturer's service personnel.
The correction of the angular settings of the individual mirrors can become
necessary after replacement or cleaning, for example. When changing the
angle of a mirror it should be noted that this results in a change in all sub-
sequent mirrors.
The correction of the angle settings may only be carried out

by personnel trained for the task by the laser cutting machine
manufacturer.
8.6.3 Complete readjustment of the optics
The complete readjustment of the optics (angular and linear adjustment)

may only be carried out by personnel trained in mechanics for the task
by the laser cutting machine manufacturer.

Repairs Byspeed
8.6.3.1 Adjustment options on the deflecting mirror
The adjustment options are the same for all deflecting mirrors (flat mirror
or adaptive optics).
By turning the adjusting screw (C) or (D) clockwise (cw), the mirror is
displaced towards the deflecting prism.
By turning the adjusting screw (C) or (D) counter-clockwise (cw), the
mirror is displaced away from the deflecting prism.
Fig. 8.6-1 Adjusting screws on the deflecting mirror
D
B
A
A
A The four screws serve to loosen or tighten the clamping ring, which
fixes the mirror in the prism.
B Pivot point when adjusting by means of the adjusting screws (C)
and (D). Do not disturb the screw (B)!
C Adjusting screw for adjusting the laser beam in the vertical plane.
Screws (B) and (D) form the axis of rotation here and may not be
disturbed.
D Adjusting screw for adjusting the laser beam in the horizontal
plane. Screws (B) and (C) form the axis of rotation here and may
not be disturbed.

Byspeed Repairs
8.6.3.2 Adjustable deflecting mirror
Using these instructions, the following deflecting mirrors on the laser cut-
ting machine can be adjusted.
Fig. 8.6-2 Deflecting mirror on the laser cutting machine
A Mirror 1 Deflecting mirror telescope (flat mirror or adaptive

optics)
B Mirror 2 Deflecting mirror bridge
C Mirror 3 Deflecting mirror z-axis (adaptive optics)

Repairs Byspeed
8.6.4 Position of the laser beam
Using the alignment gauge, check that the laser beam impinges on the
center of the mirror surface. One mirror at a time is replaced by the align-
ment gauge respectively.
The previous mirror angle is adjusted in the horizontal or vertical direction
by means of the adjusting screw. A cardboard piece is pushed into the
alignment gauge and a single pulse initiated using the handheld controller.
The laser beam is visible as a burn in the cardboard piece. A cross-hair is
visible on the burn, showing the position of the laser beam.
Fig. 8.6-3 Position of the laser beam not central
Fig. 8.6-4 Correct position of laser beam
CAUTION
Fire hazard
If the burn is more than 2 mm from the center, there is
a hazard of fire in the bellows.
Precise and careful working is a fundamental requirement for

problem-free adjustment.
If the mirror is skewed on insertion, or if soiling enters the
mirror seating, it will result in unwanted deflection of the
beam, which will degrade the cutting result or cause damage
along the beam path.
Only tighten the screws of the clamping ring with sufficient
force that they cannot loosen again.

Byspeed Repairs
8.6.5 Protective and auxiliary devices
The following protective and auxiliary devices are utilized for adjustment.
Object Description
Laser safety goggles (standard model)

Protection class L5A (to DIN 58215)
Not included in the delivery
Laser safety goggles for spectacle wearers

Protection class L5A (to DIN 58215)
Not included in the delivery
Alignment gauge
Adapter ring
Bracket
Protective cap

Repairs Byspeed
Object Description
Alignment gauge z-axis
Cardboard pieces

Byspeed Repairs
8.6.6 Preparing for adjustment of the machine optics
Generally, the following points must be observed:

The optics may only be adjusted at operating temperature. Before re-
adjusting the optics, the laser must be loaded at 50% of the rated pow-
er for 30 minutes.
Protect the deflecting mirror from soiling during adjustment by means
of a cap and masking tape.
Before refitting the deflecting mirror must be checked for soiling and
cleaned if necessary.
It is easier to compare with existing burn patterns acquired dur-

ing commissioning or the previous maintenance session. In case
of doubt, contact the manufacturer's customer service.
8.6.7 Removing the alignment devices
DANGER
Invisible laser beams (laser class 4)
Manipulation by third-parties can open the shutter, al-
lowing the laser beam to escape.
before the alignment gauge is installed the shutter must
be locked.
Open safety door
Turn the key-operated switch on the laser to the
LOCK position
Remove the key

Repairs Byspeed
8.6.7.1 Deflecting mirror telescope position
Fig. 8.6-5 Deflecting mirror telescope (laser)
A B
1. Remove the mirror holder and pull out of the mirror mounting. Check
mirror for soiling and clean if necessary. Let the removed mirror
hang down.
2. Place the protective cap on the mirror.
3. Fix the alignment gauge (A) with two screws (B) to the mirror
mounting (without adapter).

Byspeed Repairs
8.6.7.2 Deflecting mirror bridge position
Fig. 8.6-6 Deflecting mirror bridge
G H
A D B F
1. Unscrew and remove the screws (A) on the mirror mounting (4).
2. Fix the mirror mounting (A) with the screw (B) to the bracket (C).
3. Fix the bracket (C) with the two knurled screws (E) to the cutting
bridge.
4. Place the protective cap (D) on the mirror.
5. Fix the alignment gauge (G) with the three screws (H) to the mirror
holder (F).

Repairs Byspeed
8.6.7.3 Deflecting mirror z-axis position
Fig. 8.6-7 Deflecting mirror z-axis
E
B
A D
1. Unscrew and remove the screws (A) on the mirror mounting (4).
2. Place the protective cap (D) on the mirror.
3. Fix the mirror mounting (A) with the screw (B) to the bracket (C).
4. Fix the alignment gauge (F) to the mirror holder (E) with the three
screws (G).

Byspeed Repairs
8.6.7.4 Cutting head position
Remove the cutting head and install the z-axis alignment gauge.
Fig. 8.6-8 Alignment gauge z-axis

Repairs Byspeed
8.6.8 Single pulse procedure
The optics may only be adjusted at operating temperature (see Chapter

8.6.6 ›Preparing for adjustment of the machine optics‹).
1. The laser cutting machine is started and ready to operate.
2. Select the HAND – setup machine view on the user interface.
Setup values, adaptive optics 1

Operating mode 0
Fixed pressure mirror 1 for operating mode = 0 7 bar
Setup laser Plaster piece Cardboard piece

Single pulse width approx. 200 ms approx. 130 ms
Single pulse laser power approx. 3,000 W approx. 400 W
3. Open safety door
4. Turn the key-operated switch on the laser to the LOCK position. Re-
move the key.
5. Install the alignment gauge in place of the deflecting mirror tele-

scope.
6. Position the cardboard piece in the alignment gauge.
7. Turn the key-operated switch on the laser to the UNLOCK position.
9. Select the HAND view on the user interface.
10. Press the PULSE key on the handheld controller for 2 secs.
11. Open safety door
12. Turn the key-operated switch on the laser to the LOCK position. Re-
move the key.
13. Remove the cardboard piece from the alignment gauge.

Byspeed Repairs
14. Check the burn. If the cardboard piece is penetrated, reduce the val-
ues for Pulse width, single pulse and Laser power single pulse
slightly.
The burn is optimal if it can be easily felt with a finger.
15. The laser beam must enter the center of the crossed hairs in the
alignment gauge with a tolerance of ±0.5 mm.
If the position of the laser beam lies outside of the permissible toler-
ance, the optics must be readjusted.
16. Checking the beam quality. The burn must be round, without shadow
and in focus.

Repairs Byspeed
8.6.9 Adjusting the machine optics
Positive results can only be achieved by adhering strictly to the respective

specified cutting head positions.
Before adjusting the optics, the laser must be loaded at 50%

of the rated power for 30 minutes.
Fig. 8.6-9 Cutting head positions
Cutting table
No. Coordinate
1 Cutting head position 1 X- Y+
2 Cutting head position 2 X- Y-
3 Cutting head position 3 X+ Y+
4 Cutting head position 4 X+ Y-
The specified cutting head positions can be quickly and precisely

traveled to using the setup (HAND view) function.

Byspeed Repairs
8.6.9.1 Adjusting the deflecting mirror telescope
1. Install the alignment gauge in place of the deflecting mirror bridge.
2. Travel to cutting head position 1 (coordinates: X-, Y+).

approx. 100 mm before end position.
3. Adjust the telescope deflecting mirror until the laser beam is in the
center of the cross-hairs.
4. Travel to cutting head position 3 (coordinates: X+, Y+) and check

the adjustment.
The deflecting mirror has been successfully adjusted when the laser
beam at points 1 and 3 is a maximum of ±0.5 mm out of the center
of the cross-hairs.
5. Replace the cleaned bridge deflecting mirror.
8.6.9.2 Adjusting the bridge deflecting mirror
1. Install the alignment gauge in place of the deflecting mirror z-axis.
2. Travel to cutting head position 3 (coordinates: X+, Y+).

3. Adjust the bridge deflecting mirror until the laser beam is in the cen-
ter of the cross-hairs.
4. Travel to cutting head position 4 (coordinates: X+, Y-).

5. Adjust the bridge deflecting mirror until the laser beam is in the cen-
6. Move to the following four cutting head positions and check the re-
spective position of the laser beam on the cardboard piece.

Repairs Byspeed
7. Write the adjustment position on the respective cardboard piece!
Cutting head position 1 X- / Y+

Cutting head position 2 X- / Y-
Cutting head position 3 X+ / Y+
Cutting head position 4 X+ / Y-
If the laser beam is more than ±0.5 mm from the center of the
cross-hairs at one or more points, all mirrors must be readjusted.
In case of problems, contact the manufacturer's customer ser-

vice.
8. If the laser beam is within the tolerance in all four points, the cleaned
z-axis deflecting mirror can be fitted.
8.6.9.3 Adjusting deflecting mirror z-axis
1. Install the z-axis alignment gauge in place of the cutting head.
2. Switch off the TOOL key on the handheld controller (LED goes out).
The capacitive sensing is switched off.
3. Carefully move to position Z-, until the alignment gauge is positioned

10 mm above the grate.
4. Adjust the z-axis deflecting mirror until the laser beam is in the cen-
5. Remove alignment gauge and replace all covers.

Byspeed Repairs
8.6.9.4 Centering the laser beam in the nozzle
After adjusting the optics the laser beam must be centered in the nozzle
(see Chapter 6.5.4 ›Centering the laser beam in the nozzle‹).

Repairs Byspeed
8.7 Repair
8.7.1 Tactile sensing (optional)
8.7.1.1 Tactile sensing sensor breakage
The sensor is positioned by the pin (A) and fixed by the fixing screw (C).
If the sensor breaks the pin, the fixing screw or both are broken.
Fig. 8.7-1 Sensing ring with fixing screw
C B
A Pin
B Sensing ring
C Fixing screw with rupture joint

Byspeed Repairs
8.7.1.2 Remedying sensor breakage
1. Using the STOP key on the handheld controller, interrupt the current
sequence.
2. Raise the cutting head using the handheld controller and move it to
the service position.
3. Open the safety door and remove the tactile sensing.
4. Place the sensor and spare parts ready on a clean table surface.
5. Loosen screws (D) and remove cover (E).
D D
D E D
6. Pull the carriage (F) completely forwards and depressurize the pneu-
matic cylinder by pressing on the valves (G) and (H).
This is most simply done by pressing briefly with an allen key on the
tip of the coupling.
G H

Repairs Byspeed
7. Unscrew the screw of the spherical head (I) from the potentiometer
and push this right back.
8. Unscrew the four screws (J) holding the head on the carriage.
I J
9. Unscrew the four countersunk screws for the cover plate (K).
10. The broken section of the pin or the fixing screw can now be pushed
or screwed out.
11. Replace the head on the carriage and fix with the screws. Then re-
place the spherical head and the head covers.

Byspeed Repairs
12. Once the covers are fitted, the sensor can be tightened and the tac-
tile sensing ne mounted on the z-axis again.
14. Reference the axes. Select the HAND view on the user interface,
press the Reference switch and start the function by pressing the
CONT key on the handheld controller.
15. Reference the tactile sensing See Chapter 6.5.5 ›Tactile sensing (op-
tional)‹).

Repairs Byspeed
8.8 Circuit diagrams, drawings
Circuit diagrams can be found in the Equipment diagram folder and

drawing in the Spare parts catalog folder.

Byspeed Repairs
8.9 Customer service information
The manufacturer's customer service is available if problems should arise.

In order to allows problems or queries to be rapidly processed, the follow-
ing information should be available before a call:
Company / address
Contact person
Job and equipment number (see type plate)
The contact address is given at the front of the operating instructions.

Repairs Byspeed

Byspeed
Chapter 9
9 Decommissioning
This chapter is not yet available in the operating instructions.

Decommissioning Byspeed

Byspeed
Chapter 10
10 Packing and transport
This chapter is not in the operating instructions. All tasks concerning the
packing and transport of the product are carried out by the manufacturer's
personnel.

Packing and transport Byspeed

Byspeed
Chapter 11
11 Disposal
This chapter describes the environmentally friendly disposal of the product

and its operating resources. It also contains notes on handling replace-
ment assemblies (e.g. replacement parts).

Disposal Byspeed

Byspeed Disposal
11.1 Introduction
The country-specific regulations and standards must be observed for all

components requiring disposal.
Also observe the respective manufacturer's instructions for operating re-
sources and cleaning agents.
Use specially trained personnel for proper disposal.

Disposal Byspeed
11.2 Disposal
11.2.1 Packing
Packing material accrued on delivery must be disposed of according to

country-specific regulations and standards.
11.2.2 Operating resources
Lubricants must be subjected to treatment or be disposed of a hazardous

waste.
The manufacturer's instructions must be observed for all operating re-
sources. Further information can be found in the safety data sheets in the
Supplier documentation folder.
Dispose of all operating resources in accordance with country-

specific regulations and standards!

Byspeed Disposal
11.3 Assemblies suitable for disposal
11.3.1 Material groups
Separate metals and plastics and send for recycling or disposal.

The system and the electrical controls must be dismantled and properly
disposed of.
The machine consists of the following materials:

Cast steel components
Steel
Non-ferrous metals (aluminum, copper)
Rubber
Plastics
The electrical controls consist of the following materials and parts:

Steel
Plastics
Non-ferrous metals (aluminum, copper)
Protective varnish on circuit boards
Electrical and electronic components
Batteries
Dispose of all materials in accordance with country-specific

regulations and standards!

Disposal Byspeed
11.4 Disposal centers, govt. agencies
11.4.1 Return to manufacturer
Various components are accepted back by the manufacturer. This particu-

larly concerns components which are replaced by repaired units within the
lifetime of the product.
11.4.2 Notification of govt. agencies and manufacturer
The manufacturer should be informed in case of decommissioning.

Byspeed
Chapter 12
12 Cutting technology
This chapter informs about the fundamentals of cutting with the laser cut-
ting machine. Furthermore, it contains information on special applications,
material coatings and alloys.

Cutting technology Byspeed

Byspeed Cutting technology
12.1 General
This chapter describes the laser cutting technology and numerous further
influence factors which play a role in the manufacturing process. These in-
clude:
The design options and limits
The influence of work methods and procedures
The effects of influence factors and parameters on the cutting result
The influence of programming
Regulations, advantages and hints
An optimum cutting result is already determined in the design process It is

important that the designer is aware of the possibilities available in laser
cutting machine design. Only then can a component be designed for the
envisaged function and optimum production.
The person responsible for creating the cutting plans must also have de-
tailed knowledge of the laser cutting machine. Ideally, this will include
long-term experience with the laser cutting machine. Only thus can cut-
ting plans be optimally adapted to the laser cutting machine and its se-
quences.
In addition, practice has demonstrated that the programming station is
ideally located close to the laser cutting machine. This guarantees a con-
stant knowledge between the operator and the programmer.
This chapter builds upon the basic knowledge of machine oper-

ating and programming. None of the basic functions are de-
scribed here.
Most descriptions are not restricted to individual laser types, but
are valid in general (for all laser and machine types). In special
cases, the laser or machine type is mentioned.

12.1.1 Material specification
If nothing to the contrary is noted, the information in this chapter refers to

the following materials:
Structural steel Thickness: 1 - 15 mm S 235

Thickness: 16 - 25 mm RAEX 420MC
Stainless steel DIN 1.4301
Aluminum AlMg3

12.2 Design guidelines
When designing the parts to be cut the following guidelines should be ob-
served. This contributes to a substantial simplification of the manufactur-
ing process.
12.2.1 Sheet formats
The principal sheet formats are:

3,000 x 1,500 mm
4,000 x 2,000 mm
2,000 x 1,000 mm
2,500 x 1,250 mm
4,000 x 1,500 mm
12.2.2 Cutting gap clearance for laser cutting
The width of the cutting gap is a function of the focal length and the sheet
thickness. The width cannot be altered. However, using the tool radius
cutting parameter, it can be compensated (to guarantee dimensional ac-
curacy).
Tab. 12.2-1 Guide values for cutting gap
Sheet thickness 1 3 5 8 12 15 20
in [mm]
Cutting gap 0.15 0.20 0.25 0.40 0.50 0.50 0.60

in [mm]
It is possible to make a cut at the width of the cutting gap only.

This is used for relief cuts in the region of bends, for example.

12.2.3 Rectangularity of the cut edges
The cutting gap is always slightly conical in laser cutting, wider at the top
than at the bottom. Per 10 mm of sheet thickness, the cut edges are
approx. 0.1 mm conical.
Fig. 12.2-1 Rectangularity for sheet thickness 10 mm
The rectangularity is always the same and cannot be influenced.

12.2.4 Roughness of the cut edges
The roughness of the cut edges increases with increasing material thick-
ness.
Generally, the roughness values of the ISO tolerance class 2 are
reached for laser cutting.
An exception to this is the plasma cut in stainless steel (thickness 15 -
20 mm). See Chapter 12.7.7 ›Plasma cut‹).
The roughness and the visual impression of the cut edges can easily be
altered in the cutting parameters.
The following diagrams (Fig. 12.2-2, Fig. 12.2-3 and Fig. 12.2-4) show
a simple summary, which can also be transferred, with limitations, to
other laser tasks. For more precise information, measurements must be
carried out on the respective workpiece.
Fig. 12.2-2 Guide values for stainless steel with Laser 4400
B 3
Roughness Rz in [µm]
Material thickness in [mm]
A Stainless steel, quality cut

B Stainless steel, plasma cut

Fig. 12.2-3 Guide values for steel with Laser 4400
3
B
2
A Steel, cutting gas nitrogen, N2

B Steel, cutting gas oxygen, O2
Fig. 12.2-4 Guide values for aluminum with Laser 4400
3

12.2.5 Contour radii
Contours and corners should be rounded on all sheet types. This offers the
following advantages:
Shorter production times
Higher process reliability
Lower injury hazard
Optically better
Tab. 12.2-2 Guide values for minimum radii at corners
Material Sheet thickness

in [mm]
-4 5-8 10 - 12 15 - 18 20 25
Structural steela) 0.8 1.0 1.5 2.0 3.0 4.0
Stainless steelb) 0.8 1.2 2.0 3.0 4.0 —
Aluminumb) 0.8 1.5 2.5 — — —
Structural steelb) 0.8 1.5 — — — —
a) Cutting gas: Oxygen (O2)

b) Cutting gas: Nitrogen (N2)
The radii can be much greater than the minimum values in the table. If
the design does not allow for a radius, the corner can remain pointed. Ra-
dii smaller than 0.8 mm are more difficult to manufacture than pointed
corners. Bysoft supports the rounding of corners very simply.

12.2.6 Sheet thickness
Select small sheet thicknesses

As far as the stability allows, the most effective material saving is
achieved by reducing the sheet thickness. This leads not only to less
weight, cutting times and handling are also shortened drastically.
However, the reduction in material thickness is only justified if it is not
achieved by additional manufacturing effort, such as welded reinforce-
ments.
Use the same sheet thickness

For single piece production it is expedient to fabricate all sheet compo-
nents of an assembly from as few different sheet thicknesses as possible.
The production times can be vastly reduced in this manner.

12.2.7 Common separating cut
If a part is designed so that two neighboring edges can be processed with

a single cut, production time can be heavily shortened.
Fig. 12.2-5 Single piece production (each piece is cut separately)
Fig. 12.2-6 Production with common cut edges
Production with common cut edges is primarily suitable for all strip-
shaped parts from 500 mm long upwards. This can, in some cases, drasti-
cally reduce manufacturing time and minimize sheet waste.
Various parts can be nested within each other so that they can all be man-
ufactured with common separating cuts.
Bysoft supports this procedure with simple functions.

12.2.8 Hanging hole for the paint shop
A hole for hanging the workpiece can be of great assistance when paint-
ing. Care should taken these holes are made at the edge of the workpiece,
so that hooks can be easily used.
Min. hole diameter for lightweight parts: ø 4 mm

Min. hole diameter for heavy parts: ø 6 mm
12.2.9 Edge deformation
On the faces of sheets, deformation of the edges can occur due to com-
pression of the material during bending. A corner relief must therefore be
manufactured when:
The face needs to lie flat
A sheet is placed in a slot which is bent
Fig. 12.2-7 Corner reliefs

r
t
t
Sheet thickness Radius and corner relief

in [mm] in [mm]
r t
up to 3.0 8.0 1.0
3.0 - 8.0 15.0 2.0
8.0 - 15.0 20.0 4.0
15.0 - 20.0 25.0 5.0

12.2.10 Cut-outs
For opposing limbs, a relief is used in the corner. Radius r = sheet thick-
ness
Fig. 12.2-8 Corner relief for opposing limbs
r
For offset limbs, a relief is used in the corner. Radius r = sheet thickness
Fig. 12.2-9 Corner relief for offset limbs

r
Bysoft supports the use of cut-outs very simply.
12.2.11 Brackets (bended parts only)
Incisions for brackets are drawn as continuous lines with the correspond-
ing gap width. This ensures simple manufacture.
The bracket width should not be less than 50 mm. Gap width x = sheet
thickness
Fig. 12.2-10 Incisions for brackets
50 x
Poor design Good design

12.2.12 Relief cuts
Holes and slots located too close to the bent edge are deformed during
bending. If the minimum limb length cannot be achieved even with a
smaller matrix, a relief cut must be made.
Fig. 12.2-11 Relief cut
a Relief cut
b Bend edge
12.2.13 Intermittent limb
In profiles with an intermittent limb, the edges must be retarded by at

least 1.5 x sheet thickness s.
Fig. 12.2-12 Retarded edge in profiles with intermittent limbs
Correct Incorrect
1.5 x s

12.2.14 Connectors
Aligning, centering and tacking can be saved during welding by using con-
nectors. A welding gauge can also be dispensed with.
Ensure that the connector is manufactured with approx. 0.5 mm play, so
that individual parts can be easily fitted together.
Examples
Fig. 12.2-13 Straight connector
Fig. 12.2-14 Right-angled connector
Fig. 12.2-15 Multipart holder

12.2.15 Marking similar parts
Marking is carried out using the engrave function. This is a simple way to
add part numbers, positioning aids and the such like to the parts in the
same work sequence as the laser cutting (also see Chapter
12.7.8 ›Engraving‹).
Examples
Fig. 12.2-16 Engraved part number
Laser engraved
Fig. 12.2-17 Engraved positioning aid
Laser engraved
The manufacturing process is prolonged by engraving markings.

12.3 Definitions and limitations
When cutting steel very high temperatures occur in the cut sheet. This is
caused by
the laser beam
The carbon (C) in the material, which supports the melting process
The cutting gas (O2), which supports melting
Further alloy constituents in the sheet
The heat input and heat development are thus physical processes.
The heat input can become so large that the cutting quality deteriorates
until the weld metal is no longer blown out. The cut parts are then use-
less.
These problems arise with various material thicknesses, part sizes, tem-
plates and laser types.
These cutting instructions are intended to indicate possible cutting prob-
lems in advance, and to demonstrate the possibilities and impossibilities.
This requires the following definitions.
12.3.1 Definition of limit thickness / normal thickness
When cutting materials in the limit thickness range, the following points
are decisive in achieving results at a constant quality:
Material and gas quality
Condition of the optics and the machine
Overall constancy of the laser system
Limit thicknesses are material thicknesses which approach the limits that
the laser can cut. All values below the limit thickness are normal thick-
nesses.
Taking the information in this chapter into consideration, the following
maximum limit thicknesses can be cut on the laser cutting machine in ac-
cordance with Tab. 12.3-1 and Tab. 12.3-2.

Tab. 12.3-1 Max. sheet thickness with regard to material and laser employed
Material Laser
2,200 3,000 4,000 4,400 5,200 ARC
Structural steel 15 mm 20 mm 20 mm 25 mm 25 mm
Stainless steel 8 mm 10 mm 12 mm 20 mm 20 mm
Aluminum 6 mm 8 mm 10 mm 12 mm 12 mm
Tab. 12.3-2 Smallest cuttable bore with regard to material and laser employed
Material Laser
2,200 3,000 4,000 4,400 5,200 ARC
Structural steel - 10 mm: - 10 mm: - 15 mm: - 15 mm: - 15 mm:

with pulsed pierc-
ing 0.8 - 1 x T 0.8 - 1 x T 0.6 - 1 x T 0.6 - 1 x T 0.6 - 1 x T
Structural steel - 10 mm: - 10 mm: - 15 mm: - 15 mm: - 20 mm:

with pulsed pierc-
ing and pulsed 0.5 - 0.5 - 0.5 - 0.5 - 0.5 - 0.8 x T
cutting 0.8 x T 0.8 x T 0.8 x T 0.8 x T
Stainless steel 0.5 - 2 x T 0.5 - 2 x T 0.5 - 2 x T 0.5 - 2 x T 0.5 - 2 x T

with process mac-
ro
Aluminum with 0.5 - 2 x T 0.5 - 2 x T 0.5 - 2 x T 0.5 - 2 x T 0.5 - 2 x T

process macro
Diverse materials 0.5 - 2 x T 0.5 - 2 x T 0.5 - 2 x T 0.5 - 2 x T 0.5 - 2 x T

with process mac-
ro
Stainless steel >2 x T >2 x T >2 x T >2 x T >2 x T

with CW
Aluminum with CW >2 x T >2 x T >2 x T >2 x T >2 x T
Diverse materials >2 x T >2 x T >2 x T >2 x T >2 x T

with CW
T = sheet thickness

12.3.2 Definition of part area
The area of a geometric part is defined on the basis of the following crite-
ria:
Part area A = Area within a closed outer contour. Bores, slots and
opening are subtracted.
Fig. 12.3-1 Example of a part area
Square = 100 cm2

2 bores = -6.3 cm2
1 slot = -22 cm2
Part area = 71.7 cm2
A A

12.3.3 Definition of part size
The greatest heat development (build-up) takes place primarily at limit

thicknesses and in small parts. Allocation of part size depends on sheet
thickness. The table is valid for the complete Laser series.
Tab. 12.3-3 Definition of part size as a function of sheet thickness
Sheet thick- Small parts Medium parts Large parts

ness Part area equal or Part area be- Part area equal or
in [mm] smaller tween greater
15.0 - 20.0 150 cm2 150 – 1,350 cm2 1,350 cm
12.0 - 14.9 100 cm2 100 - 900 cm2 900 cm
8.0 - 11.9 75 cm2 75 - 675 cm2 675 cm
4.0 - 7.9 40 cm2 40 - 360 cm2 360 cm
2.0 - 3.9 20 cm2 20 - 180 cm2 180 cm
0.5 - 1.9 10 cm2 10 - 90 cm2 90 cm
If heat problems occur in small part sizes up to max. 4 mm

sheet thickness, nitrogen (N2) can be used for cutting instead of
oxygen (O2). This offers the following advantages:
Nitrogen greatly cools the cut edge and the part being pro-
cessed
Metallic bright finish
Very small heat-affected zone
For further information on the reduction of heat development in the sheet

see Chapter 12.7.2.1 ›Machining thick sheets‹.

12.3.4 Definition of web width / minimum web width
Hole distances, opening-outer contour distance and distances between

contours are generally known as web width. The smallest distance within a
part is known as the minimum web width.
Fig. 12.3-2 Web width examples
A
A
A Web width
B Minimum web width
In order to facilitate optimum production, the minimum web widths should

be adhered to.
Tab. 12.3-4 Minimum web width with regard to sheet thickness
Sheet thickness - Sheet thickness

3 mm from 4 mm
Minimum web width 3 mm min. sheet thickness

12.3.5 Part separation
The minimum distance between two parts is known as the part separation.
Initial cuts outside of the contour are integral to the part.
Fig. 12.3-3 Part separation examples
Y
X
X Part separation in x-direction

Y Part separation in y-direction

In order to facilitate optimum production, the minimum part separations

should be adhered to.
Tab. 12.3-5 Minimum part separation with regard to sheet thickness
Material Sheet thickness - Sheet thickness from

10 mm 10 mm
Structural steela) min. 10 mm min. sheet thickness
Stainless steelb) min. 10 mm min. 10 mm
Aluminumb) min. 10 mm min. 10 mm
Structural steelb) min. 10 mm Not possible

12.3.6 Hole templates
Large parts can also be partially overheated if tightly-spaced templates

are cut. Templates are allocated the same rules and definitions as individ-
ual parts.
Fig. 12.3-4 Example of a template
The same rules and definitions apply for this field as for the corresponding
individual part.

12.3.7 Achievable part precision
The tables are based on DIN 2310 Thermal cutting and have been sup-
plemented for laser cutting machines.
The given tolerances are empirical values for laser flame cutting and laser
fusion cutting.
Tab. 12.3-6 Part precision
Material Part length

thickness L in [mm]
T in [mm]
0 < L < 10 10 < L < 100 100 < L < 300
0.5 < T < 3 ±0.10 ±0.10 ±0.20
3<T<6 ±0.20 ±0.20 ±0.20
6 < T < 10 ±0.20 ±0.20 ±0.20
10 < T < 15 ±0.25 ±0.25 ±0.30
15 < T < 20 ±0.30 ±0.30 ±0.30
Material Part length

thickness L in [mm]
T in [mm]
300 < L < 1000 1000 < L < 2000 2000 < L < 3000
0.5 < T < 3 ±0.25 ±0.30 ±0.40
3<T<6 ±0.25 ±0.40 ±0.50
6 < T < 10 ±0.30 ±0.40 ±0.50
10 < T < 15 ±0.30 ±0.40 ±0.60
15 < T < 20 ±0.30 ±0.50 ±0.60
The following conditions must be met in order to achieve the above toler-
ances for all parts:
Optimized cutting results, in particular tool compensation (generally the
default parameters)
When measuring parts, the evenness must be identical to the cutting
situation.
The residual stress of the sheet is not taken into consideration in the ta-
bles. Warping has a negative effect on the results.
The roughness must not influence the measurement.

Measurements may not be performed at the starting point of the con-

tour.
The relevant measurements may only be performed on parts with bare
edges.
Good system condition including all optical elements
Measurement and analysis procedure to VDI/DGQ 3441
Strong heating of the sheet during cutting has a negative effect on pre-
cision.
The mechanical precision of the laser cutting machine is much

greater than the precision of the parts (see Chapter 1 ›Product
description‹).

12.4 The laser cutting process
In principle, laser cutting can be divided into three areas.
Fig. 12.4-1 The laser cutting process
Laser cutting
Laser Laser Laser

fusion cutting flame cutting sublimation cutting
Laser
plasma cutting
12.4.1 Laser fusion cutting
During fusion cutting the workpiece is melted locally and the smelt ejected
by means of gas flow (nitrogen, N2). Material transport takes place exclu-
sively in the liquid phase; this why it is known as laser fusion cutting.
Fig. 12.4-2 Fusion cutting
Approximate location of the focal point
Characteristics:
Cutting gas: Nitrogen (N2) or argon

Laser power: 80 - 100% of maximum power
Gas pressure: 5 - 20 bar
Focal position: Approximately at the underside of the sheet

A very pure, inert cutting gas is supplied to the laser beam, which ejects
the melted material from the cutting gap, but does not itself participate in
the cutting process.
Laser fusion cutting is suitable for manufacturing oxide-free cuts in fer-
rous materials.
12.4.2 Plasma cutting
Plasma cutting falls into the laser fusion cutting category. By altering the
cutting parameters, a bright light (similar to an arc) can be generated.
Using this method it is possible to cut faster up to sheet thicknesses of
1.5 mm and to cut sheet thicknesses which would not otherwise be possi-
ble (stainless steel, 15 - 20 mm thick).
Fig. 12.4-3 Plasma cutting

Stainless steel Sheet thickness to 1.5 mm
Thickness 15 - 20 mm
Characteristics:
Bright light in the cutting gap during cutting.
Cutting gas: Nitrogen N2

Feed rate: Up to 40% faster than for normal laser fusion
cutting
Laser power: Mostly maximum power
Cut quality: Increased roughness (plasma cut)
Cut monitoring with CutControl not possible.

An oxide-free cut edge is generated using plasma cutting.

12.4.3 Laser flame cutting
Laser flame cutting is differentiated from laser fusion cutting by the use of
oxygen as cutting gas. The interaction of the oxygen with the warmed
metal causes a reaction which results in a further warming of the material.
Because of this effect speeds can be achieved when cutting structural
steel which are much greater than for fusion cutting in sheet thicknesses
up to approx. 6 mm.
Fig. 12.4-4 Flame cutting
Characteristics:
Cutting gas: Oxygen O2

Laser power: 25 - 80% of maximum power
Gas pressure: 0.5 - 5 bar
Focal position: Approximately at the top face of the sheet
However, this procedure can lead to a reduction in the cut quality com-
pared to fusion cutting. The results can be wider cuts, increased rough-
ness, deeper heat-affected zones and lower quality of the cut edges. The
cut edge oxidizes heavily.
Flame cutting is critical when cutting fine contours and acute angled ge-
ometries (burn-off hazard). However, in pulse mode, the heat input can
be limited.

12.4.4 Laser sublimation cutting
Using laser sublimation cutting, the material is vaporized directly at the

cut, without a liquid phase.
Laser sublimations cutting is not used in Bystronic laser cutting

machines and is therefore only mentioned here for the sake of
comprehensiveness.

12.4.5 The cutting process
By machining process is meant the interaction between the laser beam,

cutting gas and workpiece.
Fig. 12.4-5 Process parameters
Process parame-
ters of
Material Laser Cutting gas Axis movement
The zone in which this process occurs is known as the cutting front or cut
front. The laser power acting at the cutting front must heat the material to
the temperature required for phase transition of the material to smelt and
vapor.
The cutting front is an almost vertical face, which warmed and melted by
the absorbed laser beam.
During laser flame cutting, this smelt zone is further heated by the oxy-
gen entering the cut and reaches temperatures approaching the boiling
point of the materials. This causes strong vaporization, leading to abla-
tion of the material. Simultaneously, the cutting gas ejects molten ma-
terial from the underside of the workpiece.
During laser fusion cutting, the gas ejects the molten material and pro-
tects the cut from oxidation.
The melted zone advances in the direction of the cut. This results in the
continuous cut.
Many of the processes that play an important role in laser cutting take
place in this zone. An analysis of these processes allows important state-
ments on laser cutting. The cutting speed, for instance, can be estimated
and the formation of characteristic striations be explained.

12.4.6 Gas parameters
Gas type
Gas purity
Gas pressure
Nozzle diameter
Nozzle geometry
The gas pressure and the nozzle geometry influence the cut edge rough-
ness and the beading.
Cutting gas consumption depends on the nozzle diameter and the gas
pressure.
The gas pressure for cutting applications in the low pressure range is up
to 5 bar and up to 20 bar in the high pressure range.
The conventional cutting nozzle has a circular, conical orifice.
The distance between the nozzle orifice and the workpiece surface must
be as small as possible. The smaller this distance, the greater is the
proportion of the gas flow that actually enters the cut. Usual are dis-
tances of 0.5 - 1.5 mm.

12.5 Programming
Optimal programming substantially simplifies the cutting process and re-

duces manufacturing times, retaining an optimum part quality. It is there-
fore important that the programmer is familiar with the laser cutting
machine and exchanges experiences with the operating personnel.
12.5.1 Technology wizard
The technology wizard provides support when programming parts. This

means that the programmer requires less knowledge of the technology.
An optimum cutting result is achieved substantially faster.
The following technologies are set up automatically for each laser type,
sheet type, sheet thickness and geometry:
Initial cut type (straight / straight with arc)
Initial cut length
Piercing type (CW / pulse)
Cutting type (CW / pulse / process macro 1 / process macro 2) as a
function of the sheet type, thickness and the area to be cut
The cutting parameters of the laser cutting machine are opti-

mized for the wizard technologies. In general, the technology
wizard should always be used. This allows optimum exploitation
of the various options.
Fig. 12.5-1 Specify technology (in Bypart)
Steel : Material
O2 : Cutting gas (oxygen)
(52) : Laser power (5,200 W)

12.5.1.1 Functionality examples
The following tables (Tab. 12.5-1 - Tab. 12.5-3) demonstrate how the
optimum initial cuts and technologies are automatically selected by the
technology wizard for the same part, but with a different material and
sheet thickness.
Fig. 12.5-2 Part to be cut

25
8
ø14 8
60
Tab. 12.5-1 Technology for cutting structural steel, 12 mm thick
Example 1 Automatically selected technology

for Bylaser 5200ARC, cutting gas O2
Material: Structural steel Hole ø14 mm
Sheet thickness: 12 mm Initial cut type Straight with arc
Initial cut length Start in center
Piercing Pulsed (CPP)
Cutting Process macro 1
Hole 8 mm
Initial cut type Straight
Cutting Pulsed
Outer contour
Initial cut type Straight with arc
Initial cut length 12 mm
Cutting CW

Tab. 12.5-2 Technology for cutting structural steel, 6 mm thick

for Bylaser 5200ARC, cutting gas O2
Material: Structural steel Hole ø14 mm
Sheet thickness: 6 mm Initial cut type Straight
Cutting CW
Hole 8 mm
Cutting Process macro 1
Outer contour
Cutting CW

Tab. 12.5-3 Technology for cutting stainless steel, 4 mm thick

for Bylaser 5200ARC, cutting gas N2
Material: Stainless steel Hole ø14 mm
Sheet thickness: 4 mm Initial cut type Straight with arc
Piercing CW
Cutting CW
Hole 8 mm
Piercing CW
Cutting CW
Outer contour
Piercing CW
Cutting CW
12.5.1.2 Adaptations
For special applications it is possible to adapt the existing technology wiz-

ard or to program a new one. The Bypart online help describes the proce-
dure in detail.
12.5.1.3 Peculiarities
When using the process macro Scanning, the technology wizard must re-
main inactivated.
For structural steel (cut using oxygen, O2), the CPP piercing type is gen-
erally programmed for the Bylaser 5200. If Lead in is to be used, the
technology wizard must remain inactivated or be adapted.

12.5.1.4 Guidelines for initial cut types
If Bysoft is not employed for programming, the initial cuts must be ac-
cordingly defined. The following table contains base values from which
Bysoft selects the initial cuts. However, the technology wizard specifies
and optimizes the initial cuts much more precisely.
Tab. 12.5-4 Various initial cut types and their applications
Material Initial cut type
Cutting gas
Piercing
Directly Initial cut Length Radius

on length
Contour
1.0 - 1.5 mm O Possible 3 mm

2
2.0 - 3.0 mm O 5 mm
2
4.0 - 8.0 mm O 8 mm
CW
Steel
10.0 - 15.0 mm O 12 mm 1 mm
2
16.0 - 20.0 mm O 20 mm 1.5 mm

2
21.0 - 25.0 mm O 25 mm 3 mm
2
1.0 - 1.5 mm O 3 mm
2
2.0 - 3.0 mm O 3 mm
2
Pulsed
Steel
4.0 - 8.0 mm O 4 mm
2
10.0 - 15.0 mm O 5 mm
2
16.0 - 20.0 mm O 8 mm
2
1.0 - 1.5 mm N2 Possible 3 mm

Steel
2.0 - 3.0 mm N2 5 mm 1 mm
4.0 - 8.0 mm N2 8 mm 1.5 mm

Material Initial cut type
Cutting gas
Piercing
Directly Initial cut Length Radius
on length
Contour
1.0 - 1.5 mm Possible 3 mm

Stainless
2.0 - 3.0 mm 5 mm
steel
4.0 - 8.0 mm 8 mm 1.5 mm
10.0 - 12.0 mm 12 mm 2 mm
1.0 - 1.5 mm N2 Possible 3 mm

Aluminum
2.0 - 3.0 mm N2 5 mm
4.0 - 6.0 mm N2 8 mm 1.5 mm
8.0 - 12.0 mm N2 10 mm
Fig. 12.5-3 Initial cut technology
A Piercing technology. This is usually the same as the initial cut tech-
nology. If the initial cut is pulsed, piercing is also pulsed.
B Technology on the initial cut. This is not programmed in Bysoft but
is determined by the cutting parameters.
In many cases the technology is the same as the subsequent tech-
nology on the contour. But it can also be consciously different,
such as for lead in.
C Technology on the contour. This depends on the are of the part to
be cut (see Tab. 12.5-5).

Tab. 12.5-5 Technology on the contour, cutting gas oxygen
Material
1.5 x T < D ≤ 3 x T
Thickness T in
0.8 x T < D ≤ T
T < D ≤ 1.5 x T
[mm]
Cutting gas
D ≤ 0.8 x T
D>3xT
1.0 - 1.5 O2 Pulsed Pulsed Pulsed CW CW
2.0 - 3.0 O2 Pulsed Pulsed CW CW CW
4.0 - 8.0 O2 Pulsed Pulsed Process CW CW

macro 1
Steel
10.0 - 15.0 O2 Pulsed Process Process Process CW

macro 1 macro 1 macro 1


D = hole diameter
T
T = sheet thickness

Tab. 12.5-6 Technology on the contour, cutting gas nitrogen
Material
1.5 x T < D ≤ 3 x T
Thickness T in
T < D ≤ 1.5 x T
[mm]
Cutting gas
D > 3xT
D≤T
1.0 - 3.0 N2 CW CW CW CW
Steel
4.0 - 8.0 N2 Process CW CW CW

macro 1
1.0 - 3.0 N2 CW CW CW CW
Stainless

steel
macro 1
10.0 - 12.0 N2 Process Process CW CW

macro 1 macro 1
1.0 - 3.0 N2 CW CW CW CW
Aluminum

macro 1
10.0 - 12.0 N2 Process Process CW CW

macro 1 macro 1
D = hole diameter
T
T = sheet thickness
The Bysoft technology wizard optimizes the piercing, initial cut

and contour technology substantially finer than given in
Tab. 12.5-4 - Tab. 12.5-6.
Bysoft also differentiates between the various machine and
sheet types.

12.5.2 Piercing and initial cuts
The initial cuts should always achieve the length envisaged for them and
must be correspondingly placed.
The sheet is very strongly heated during piercing. Careful positioning of
piercing points and adequate length of initial cuts can help prevent heat
build-up.
If using the Laser 4400 or 5200 ARC, there is an additional function avail-
able, the CPP (Controlled Pulsed Piercing). This reduces the heat input
greatly when piercing. See Chapter 12.7.10.2 ›CPP (Controlled Pulsed
Piercing)‹).
At the limit thickness a radius initial cut is unavoidable for a uniform cut-
ting process.
Poorly selected initial cuts Well selected initial cuts with

additional radius initial cut

12.5.2.1 Outer contour
The pierce hole is generally located outside of the contour (see Fig. 2 and
Fig. 3). The connecting line between the pierce and the contour is known
as the initial cutting pane or initial cut for short.
A change in direction of the laser beam between the end of the initial cut
and the contour, and the end of a cut, are recognized on the workpiece as
an irregularity in the cut edge.
Fig. 12.5-4 The initial cut is recognizable as an irregularity in the cut
The initial cut in the outer contour should therefore be programmed as an

extension of a geometry elements (see Fig. 3).
Tab. 12.5-7 CW pierce hole
Parts with post- Normal case Thick sheet option

processing
Fig. 1 Fig. 2 Fig. 3
CW pierce hole in con- CW pierce hole outside CW pierce hole outside

tour contour contour
Corner damaged Moving in contour in a
line.
Minor markings on
part

Various initial cut types can be employed within a part. This allows an
acute corner (A), for example, to be cut optimally.
Fig. 12.5-5 Various initial cuts
12.5.2.2 Inner contour (cut-outs)
For small inner contours it is important that the heat input from piercing
can flow away before continuing. The initial cutting pane may not be pro-
grammed in tight corners and should be designed with the largest possible
angle to the contour. The allows heat to flow away better.
Fig. 12.5-6 Small inner contours
unsuitable suitable

12.5.3 Programming process macros
Contours assigned a process macro during programming with Bysoft can

be cut with other cutting parameters. This has the advantage that difficult
parts or sections of contour (e.g. gear teeth) can be better optimized.
Fig. 12.5-7 Gear teeth cut with process macro
Two process macros are available (macro 1 and macro 2):

The Bysoft technology wizard automatically assigns process macro 1
small contours (based on the rules in Tab. 12.5-5 and Tab. 12.5-6).
The cutting parameters are adapted correspondingly.
Process macro 2 is available for individual customer applications. The
cutting parameters in process macro 2 correspond to the normal CW
parameters and can be adapted individually.

12.5.4 Radii on inner and outer contours
Acute-angled contours should be avoided when working with lasers. It is

far simpler to cut a radius of 1 - 2 mm, for example, for all direction
changes. This has the following advantages:
No burning at corners
Time gain due to continuous process
Clean lasered part
Hazard of injury on part is smaller
Tab. 12.5-8 Minimum radii for outer and inner contours in [mm]
Material Sheet thickness

in [mm]
-4 5-8 10 - 12 15 - 18 20 25
Structural steela) 0.8 1.0 1.5 2.0 3.0 4.0
Stainless steelb) 0.8 1.2 2.0 3.0 4.0 —
Aluminumb) 0.8 1.5 2.5 — — —
Structural steelb) 0.8 1.5 — — — —


12.6 Cutting parameters
12.6.1 General
In order to edit the cutting parameters in a targeted manner, it is vital to

know how a part is programmed and where which technology is em-
ployed. The example below shows a part for which technologies automati-
cally selected by the technology wizard can be seen.
Fig. 12.6-1 Example: Structural steel, 8 mm thick
A Text Engraving
B Bore ø 4 mm Piercing pulsed, cutting pulsed
C Banana hole Piercing CW, cutting with process macro 1
D Gear teeth Piercing CW, cutting with process macro 1
E Outer contour Piercing CW, cutting CW
It is important that precise note is made during cutting of the operations

for which a parameter needs to be edited. Normally, only very few param-

eters should need editing. Below are some examples of how to quickly and
purposefully achieve the optimum results.
Tab. 12.6-1 Cutting operations with the corresponding parameters
Cutting operation Parameter concerned
CW piercing CW piercing type
Piercing time cont. operating
Laser power piercing
Gas pressure CW piercing
Nozzle distance, piercing
Initial cut Acceleration factor, initial cut
Gas ramp, CW piercing / cutting
Possibly all CW parameters of process macro 2

when using lead in
Outer contour Feed rate cont. operating
Laser power cutting
Gas pressure CW cutting
Nozzle type
Nozzle distance, cutting

12.6.2 Adapt cutting parameters
Cutting parameters are parameters which have a direct influence on the

cutting process. This parameters are not optimized for maximum cutting
speed, but for process reliability.
A set of cutting parameters is supplied with every laser cutting machine.
They are optimized to cut certain materials. Nevertheless, it is possible
that the parameters deliver unsatisfactory cutting results. Below, the re-
quirements and the procedure for obtaining better cutting results are de-
scribed.
For laser cutting there are numerous parameter that in part also exert a
mutual influence. Here, the five principal parameters with which the cut
quality can be optimized are listed:
Focal position
Laser power
Gas pressure
Feed rate
Nozzle distance
The adaptations are only valid for simple contours such as straight lines.
The cutting quality in a straight line cut-out only is evaluated

(directions x+, x-, y+ and y-). Interpolated cutting directions,
such as radii, diagonal cuts or initial cuts, for example, are not
taken into consideration.
The cutting parameter adaptations for complex contours such
as acute-angled corners, radii, small contours, initial and end
cuts, as well as holes are contained in this chapter.

12.6.2.1 Reasons for parameter adaptations
Alloy differences
Tolerance deviations in sheet thickness
Varying surface finish qualities
Varying material composition
Large temperature differences of the materials used
(reference temperature = +20°C)
12.6.2.2 Requirements for parameter adaptations
The following requirements must be fulfilled in order to achieve good cut

quality by adapting the principal parameters:
The laser cutting machine and the laser must be in perfect condition
The lens in the cutting head must be in perfect condition (see Chapter 8
›Repairs‹).
The cutting head and the nozzle must correspond to the data in the re-
spective cutting parameters.
Avoid overwriting the original cutting parameters!

The edited parameters can be saved respectively with a new
material designation or new supplementary information.
After adapting a parameter it is recommended to print it and

store it in a folder using the Paramview application in the
Bysoft 6 Toolbox.
It is also recommended to keep the test part.

12.6.3 Procedure for optimizing the cutting parameters
Before a new material is cut, a cutting test must be carried out. If prob-
lems with the cutting quality occur in this test, they can be rectified by
adapting the original cutting parameter.
To facilitate the adaptation of cutting plans, cutting plans are stored on
the computer in the Acceptance folder, for the respective laser type. Use
the Ab_gross.lcc cutting plan for the test. This takes all four cuts in x-
and y-direction into consideration.
The following sequence for optimizing the cutting quality should be ad-
hered to:
1. Load the shuttle table with the material for cutting and move it to the
machining position.
2. Select the WORK – Job list view on the user interface, create the
cutting job and assign the desired cutting parameters (see Chapter 6
›Operating‹).
z Cutting plan Ab_gross.lcc or Ab_klein.lcc
z Cutting parameters based on the material for cutting
3. Assess cutting quality on the basis of the part with insufficient cut
quality. The assessment is based on the information given in this
chapter.
The further procedure for cutting optimization can be derived from
the possible causes and their remedies listed here. If a number of
options are given, the following sequence should be adhered to.
Sequence when specifying cutting parameters

Step Cutting with O2 Cutting with N2
1. Focal position Focal position
2. Laser power Feed rate ±10% OK
3. Gas pressure Laser power
4. Feed rate ±10% OK Gas pressure
5. Nozzle distance Nozzle distance
The parameter values can be edited in the WORK – Parameters

view. Edit only one cutting parameter at a time and then observe the
effects (also see Chapter 12.12 ›Cut assessment‹).

4. Activate the STOP ZERO stop button before cutting. Machining is

stopped at the origin of the cutting plan or at the origin of each indi-
vidual part.
A message appears in the status bar each time, which must be con-
firmed with CONT or STOP.
5. Repeat the cutting test with the edited parameters until a good cut
result is achieved.
6. Save the edited cutting parameters under a new file name (function:
Save as).
The edited parameters can be saved respectively with a new material
designation or new supplementary information.

12.6.3.1 Cutting focal position
The focal position is the position of the point where the laser beam reach-
es its smallest diameter and thus its highest power density.
The laser beam is focused by the lens in the cutting head. Depending on
the material being cut, the focal point is located:
On the workpiece (A)
In the workpiece (B)
Below the workpiece (C)
Fig. 12.6-2 Focal position of the laser beam
Focal position A Focal position B Focal position C
The focal position depends greatly on the cutting gas used.
Gas type Laser cutting meth- Focal position

oda)
O2 Flame cutting Focal position in the upper region of

the material to be cut.
Focal position A
N2 Fusion cutting Focal position in the lower region of

the material to be cut.
Focal position C
Com- Flame and fusion cutting Focal position in the center of the
pressed air material to be cut.
Focal position B
a) Information on the laser cutting methods can be found in Chapter 12.4 ›The laser cut-
ting process‹.

Altering the focal position

The focal position is altered as follows:
1. Select the WORK – Parameter view on the user interface.
2. Select the Cutting focal position parameter and enter a new value.
Input is in [mm].
A higher value displaces the focal position downwards. A lower value
displaces the focal position upwards. The value 0 corresponds to the
material surface (A).
Fig. 12.6-3 Alteration in the focal position
3. Confirm the input with OK.
The focal position alters with the condition of the lens. Soiling or an old
lens displace the focal position upwards. This displacement can be up to
several millimeters, depending on the age or the degree of soiling. It is
therefore important to clean the lens regularly.
For the influence of focal position on various materials, see

Chapter 12.12 ›Cut assessment‹).

12.6.3.2 Laser power cutting
This parameter defines the laser power during cutting in continuous oper-
ation (CW).
The Laser power cutting can be altered as follows:
2. Select the Laser power cutting parameter and enter a new value.
Input is in [W].
For the influence of laser power on various materials, see Chap-

ter 12.12 ›Cut assessment‹).

12.6.3.3 Gas cutting pressure
The gas pressure depends on the cutting gas used.
Parameter Use
Gas cutting pressure gas Cutting with O2. Maximum gas pressure to
type 1 10 bar.
Gas cutting pressure gas Cutting with N2. Maximum gas pressure to
type 2 24 bar.
The gas pressure is altered as follows:
2. Select the appropriate parameter for the gas pressure (gas type 1 or
gas type 2) and enter a new value. Input is in [bar].
For oxygen (O2), a higher value produces a higher cutting tempera-
ture and a rougher cut surface. For nitrogen (N2), the material is
ejected better and cooled more.
For the influence of gas pressure on various materials, see

Chapter 12.12 ›Cut assessment‹).

12.6.3.4 Cutting feed rate
This parameter defines the feed rate during cutting in continuous opera-
tion (CW).
The cutting feed rate is not a fixed quantity, but should be seen as a
range. The Feed cutting saved in the cutting parameter corresponds to
approx. 90% of the maximum cutting speed.
Example:
Maximum cutting feed rate 6.0 m/min Corresponds to 100%

(at reduced quality)
Saved original parameter 5.4 m/min Corresponds to approx.
Cutting feed rate 90%
Minimum cutting speed 4.2 m/min Corresponds to approx.
70%
The cutting feed rate can be altered as follows:
2. Select the cutting feed rate parameter and enter a new value. In-
put is in [mm/min].
By reducing the feed rate by 10 - 20% the quality or process reliability can
be greatly improved in almost all cases.
For the influence of the cutting feed rate on various materials,

see Chapter 12.12 ›Cut assessment‹).

12.6.3.5 Nozzle distance, cutting
This parameter defines the distance of the nozzle from the surface of the
workpiece during cutting.
The Nozzle distance, cutting can be altered as follows:
2. Select the Nozzle distance, cutting parameter and enter a new

value. Input is in [mm].
Nozzle distance Effect

< 1 mm Wear and soiling of the nozzle increase
> 1 mm Cutting quality decreases
Lower nozzle heating for plasma cutting

12.6.4 Cutting laser 5200 ARC
12.6.4.1 Focal position and beam diameter
When altering the Beam diameter cutting parameter, the focal position
is also altered. The interaction of beam diameter and focal position can
lead to the focal positions no longer taking up their previous positions.
When determining the cutting parameters, they were based on an as-
sumed focal position for steel of 0 (focal point on the material surface).
The other focal positions are acquired from the optimum beam diameter
and the thickness.
Fig. 12.6-4 Beam diameter 20 mm (cutting head 7.5")

1. Alter beam diameter from 20 mm to 21 mm.
Fig. 12.6-5 Beam diameter 21 mm (cutting head 7.5")
2. Displacement of focal position 1 mm downwards.
3. The focal position in the cutting parameter stays the same.
4. Focal position required to position the focal point on the material sur-
face again for the altered beam diameter:
Focal position: -1 mm
Beam Displacement of fo- Displacement of fo-

diameter cal position for focal cal position for fo-
length 5.0" cal length 7.5"
Before After
20 mm 19 mm approx. 0.5 mm upwards approx. 1 mm upwards
20 mm 21 mm approx. 0.5 mm down- approx. 1 mm down-

wards wards

12.7 Machining process
12.7.1 Summary of the various technologies
Tab. 12.7-1 Operating modes and applications
Operating mode Application Example
Continuous mode Low pressure cutting Structural steel with O2

(CW) Normal cutting Aluminum with N2
High pressure cutting Stainless steel with N2
A relatively fine cut results
from continuous power op-
erating
Modulation (MOD) Cutting corners With modulation activated

Accelerating and braking the laser power is automati-
cally adjusted to the axes
speed. This prevents burn-
off at corners.
Normal pulse (NP) Piercing Structural steel example:

Small contours Small piercing on contours
(after a microweb)
Small holes to a minimum
Ø ½ material thickness
Fine contours
Normal pulse (NP) CPPa) Piercing structural steel with

(Controlled Pulsed O2
Piercing) 1 - 20 mm
Piercing stainless steel
16 - 20 mm
a) Only with laser 4400 und 5200 ARC

12.7.2 Cutting structural steel
This material can be cut to good quality with oxygen. The laser is used in
CW mode.
If oxygen is used as the cutting gas the cut edge is slightly oxidized. The
high pressure cutting method can be utilized for sheet thicknesses up to
6 mm, employing nitrogen as the cutting gas. In this case, the cut edges
are oxide-free.
Complex contours and holes (diameter smaller than material thickness)
are cut in pulse mode. This prevents burn-off on acute-angled corners and
thin webs.
The greater the carbon content of the steel, the greater the hardening
of the cut edge and the more that acute-angled corners are burned off.
Sheets with higher proportions of alloy are more difficult to cut than
those with lower proportions.
An oxidized or sand-blasted surface will produce a far poorer cut quali-
ty.
Color markings on the sheet surface have a negative effect on the cut-
ting result.
Upwards of 12 mm sheet thickness, good results are achieved with la-
ser sheet (e.g. Raex) and an oiled surface. This oil film reduces the ad-
hesion of the slag on the surface and assists cooling considerably. The
oil film is not detrimental to the cutting result.
Use only fully killed steel where possible. Impurities in unskilled steel
have are highly detrimental to the cutting result. Dressing rollers and
inner stress also influence the cuttability.

For smaller contours in sheet thicknesses of 15 and 20 mm we recom-

mend fine-grain steel, e.g.: Raex-250-Laser from Rautaruukki Steelworks,
Raahe (corresponds to a QStE 420 TM in accordance with EN, DIN, SEW).
This steel is manufactured from a special smelt with a maximum silicon
content of 0.04% and a maximum carbon content of 0.012%. It has a
tensile strength of 490 - 620 N/mm2.
No slag generation during laser cutting
No warping of cut parts
Best bending behavior
Low spring-back
Good welding properties
This steel is available in thicknesses up to 30 mm
When using S235, poorer cutting results are achieved, because it tends to
sag and burr due to the viscous slag.
The following guidelines should observed for cutting structural steel with a
clean surface:
Si ≤ 0.04%: Preferred; very good laser workability

Si < 0.25%: May have slightly reduced cutting properties
Si > 0.25%: Steel of limited suitability for laser cutting and thus infe-
rior or irregular cutting results
Tolerance to DIN for steels up to S355GT is Si ≤ 0.55%. This in-

formation is not precise enough for machining with laser.

12.7.2.1 Machining thick sheets
General notes
The serrated grid must be used for thick sheets. For critical parts, it may
be possible to raise it from the support grid using supports.
Separation a of the individual parts in the cutting plan:
a = double sheet thickness
12.7.2.2 Piercing
Whenever possible CPP piercing should be used (see Chapter

12.7.10.2 ›CPP (Controlled Pulsed Piercing)‹).
Oiling the sheets is useful. Oiling prevents piercing splashes from stick-
ing to the sheet surface and does not have a negative effect on the cut-
ting process.
The Crossjet allows an oil mist to be sprayed. The oil mist is an air-oil
mixture. The oil mist cools the piercing point. Piercing splashes can be
blown away with the cross-blowing function. This prevents the splashes
from sticking to the sheet.
Use the BYSOFT programming software Bywork module to specify the se-
quence of piercing thick sheet with numerous pierces (etching):
All pierces are processed before cutting the contours. Heat input to the
workpiece is greatly reduced and distributed more evenly.
For etching, for example, a cutting head with an older lens can also be
used. It is important that a cutting head with an intact lens must be
used to cut the contours!
After completion of the etching program, clean away any splashes from
the sheet. Only then can machining be continued.
12.7.2.3 Cutting
Take care to ensure that the sheet temperature does not exceed 40° oth-
erwise the cut edges may sag away.

12.7.2.4 Normal sheet thickness
In order to cut such parts with the necessary process reliability in produc-
tion, the following guidelines must be observed:
All acute angled contours must be given a radius.
Smallest openings (holes, slots) 1.2 - 1.5 x sheet thickness.
Minimum web width 1.2 - 1.5 x sheet thickness.
Minimum part separation 1.0 - 1.5 x sheet thickness, but at least
10 mm, in order to ensure reliable capacitive sensing.
Initial cut length 1 x sheet thickness, but at least 10 mm.
Careful programming (cutting sequence in DIN part) in order to ensure
optimum heat distribution within the part.
Well considered nesting (cutting sequence of individual parts in the cut-
ting plan). This ensures good distribution of heat within the cutting
plan.
If these guidelines are not adhered to the result can be over-

heating of the sheet. The first signs of overheating are rough
cut surfaces, burnt contour cuts and melt not blown out (also
see Fig. 12.12-14).

12.7.2.5 Examples
Example 1: Cutting in one pass
Fig. 12.7-1 Individual part
Fig. 12.7-2 Cutting plan
4 2 6
1 5 3
The numbers indicate the cutting sequence.

Example 2: Cutting in two passes
Material: RAEX 250

Thickness 15 mm
Plate dimension: x = 675 mm
y = 689 mm
Part dimension: x = 100 mm
y = 80 mm
Shape spacing: x = -18 mm
y = 17 mm
The complete cutting plan is divided into two new cutting plans. In the
first plan, only every second part is cut (1st cut).
Now the cutting must be interrupted, until the temperature of the plate
has fallen below 40ºC. Then the remaining parts can be cut (2nd cut).
Fig. 12.7-4 Process cutting plan in two passes
1st step 2nd step

Example 3: Cutting in three passes
Material: RAEX 250

Thickness 12 mm
y = 485 mm
y = 30 mm
Shape spacing: x = 20 mm
y = 20 mm
Same procedure as for two passes, but now every third part is cut on the
first pass (1st cut).
Now the cutting must be interrupted, until the temperature of the plate
has fallen below 40ºC. Only then can the second group of parts be cut
(2nd cut).
The third cut is cut in analogy to the second cut.
Fig. 12.7-6 Process cutting plan in three passes
1st step 2nd step

3rd step
12.7.2.6 Sheet thicknesses at the limit range

The following guidelines must be observed:
All acute angled contours must be given a radius.
Radius initial cut, Rmin = 1.0 - 3.0 mm
Smallest openings (holes, slots) 1.5 -2.5 x sheet thickness
Minimum web width 1.5 -2.5 x sheet thickness
Minimum part separation 1.5 - 2 x sheet thickness, but at least 15 mm
Initial cut length 1 x sheet thickness, but at least 15 mm
Careful programming (cutting sequence in DIN part, see Fig. 12.7-1) in
order to ensure optimum heat distribution within the part
Well considered nesting (cutting sequence of individual parts in the cut-
ting plan, see Fig. 12.7-2) This ensures good distribution of heat within
the cutting plan
Use CPP (Controlled Pulsed Piercing) where possible
May need to etch

Example:Cutting in two passes
Material: RAEX 250

Thickness 18 mm
y = 960 mm
y = 110 mm
Shape spacing: x = -1 mm
y = 30 mm
Cuts 1 and 2 only if the temperature of the plate is below 40°C.
Fig. 12.7-8 Process cutting plan in two passes
1st step 2nd step
Despite the measures proposed here, the necessary process reliability

when cutting small parts at limit thickness may not be achieved in produc-
tion. The parts are cuttable, but only as single parts, not as a nested cut-
ting plan. This limit is subject to the experience of the operator.

12.7.2.7 Unsuitable parts for production
These are mainly small parts at the limit thickness. However, special ge-
ometries at normal thickness can also present cutting problems.
Example:
Fig. 12.7-9 Example of an unsuitable part
Material: RAEX 250

Thickness 20 mm
y = 83 mm
Figure 1 Figure 2 y = 17 mm
Figure 1 without radii cannot be cut as it is

Figure 2 with R = 2 mm can be cut as a single part with restrictions
Parts of such size at limit thickness are unsuitable for production

12.7.2.8 Cutting with nitrogen (N2)
Structural steel is also cut using nitrogen (N2) for the following reasons:
Oxide-free cut edge. This should be aimed for particularly if the parts
are to be powder coated, varnished or painted. This guarantees that the
coating adheres to the cut edge. This is not guaranteed on an oxidized
cut edge with oxygen (O2).
Problem-free cutting of high-alloy steels, which cannot be cut at good
quality using oxygen.
Higher cutting speeds. Solids can be cut faster up to a thickness of
1.5 mm (also see Chapter 12.7.7 ›Plasma cut‹).
Reducing the heat input.
Fig. 12.7-10 Example: Gear teeth in structural steel, thickness 3 mm, cut using nitrogen
Optimum cut quality due to strong cooling effect of nitrogen. The produc-
tion time is only ¼ of the pulsed time using nitrogen.
When using nitrogen (N2) gas consumtion is substantially high-

er than for oxygen (O2).

12.7.3 Pulsed cutting
During pulsed cutting the laser is switched on and off at short intervals.
The advantage of this is that, on average, there is less heat input to the
material. This allows small bores and openings, as well as complex con-
tours, to be cut with improved quality.
Because the cutting and piercing process is interrupted in the pulse pause,
the cutting and piercing speed is slower than for continuous CW cutting
and piercing.
Fig. 12.7-11 Sequence during pulsed cutting
A
B C D
A Laser power in [W]

B Period duration
C Pulse pause
D Pulse width
E Pulse frequency in [Hz]
12.7.3.1 Pulsed cutting (application examples)
Holes and openings smaller than sheet thickness, e.g. a hole with
ø5 mm in a steel sheet, thickness 10 mm
Cutting points and corners without radii
12.7.3.2 Pulsed piercing (application examples)
Piercing with less heat input

Piercing without piercing crater
Piercing on the contour, so that inner part and outer part can be used

Tab. 12.7-2 Difference between pulsed and continuous cutting
Criterion Pulsed cutting or Continuous cutting

piercing (CW)
Cutting speed Low High
Heat input to sheet Low High
Cut quality Rough, brown color Fine
Pierce Small, fine, as wide as cut Large, with crater

gap

12.7.3.3 Guide values
Tab. 12.7-3 Simple guide values for pulsed piercing
Parameter Guide value
Piercing time, pulse mode ½ sheet thickness in seconds

[s]
Nozzle distance, piercing 1 - 2 mm (for thinner material closer to 1 mm,

[mm] for thicker closer to 2 mm)
Gas pressure pulse piercing 2 bar, for nozzle diameters over 2.5 mm 1 bar
[bar] is also permissible
Initial pulse frequency pierc- Focal length 50 - 300 Hz

ing [Hz] 5.0":
Focal length 10 - 25 Hz
7.5":
Final pulse frequency pierc- Focal length 150 - 300 Hz (always higher
ing [Hz] 5.0": than the initial pulse fre-
quency)
Focal length 100 - 150 Hz (always higher

7.5": than the initial pulse fre-
quency)
Pulse width [ms] Increases with sheet thickness from 1,000 -

2,500 ms
Laser power piercing [W] Approximately the same or higher than normal
piercing power

Tab. 12.7-4 Simple guide values for pulsed cutting
Parameter Guide value
Pulse mode feed rate Normal feed rate divided by the factor 10 (limit
[mm/min] thickness 20 mm)
Nozzle distance, cutting Same as for continuous cutting (CW)

[mm]
Gas pressure pulse cutting Same as for continuous cutting (CW)

[bar]
Cutting pulse frequency Decreasing strongly with increasing sheet thick-

[Hz] ness
Focal length Between 100 - 400 Hz

5.0":
Focal length Mostly below 100 Hz

7.5":
Pulse width [ms] Increasing strongly with increasing sheet thick-

ness
Laser power cutting [W] Higher than laser power for continuous cutting
Tool radius, pulse mode [s] To start, the same as for continuous cutting,
adapt later
The default parameters for pulsed cutting are optimized for a

hole of half the sheet thickness (e.g. structural steel, thickness
10 mm, with a hole ø5 mm).

12.7.3.4 Parameter adaptations for complex contours
Beside normal pulsed applications such as small bores, there are more ex-
otic applications, for example gears or ultra-precise webs. However, these
applications are very rare in the production of laser parts and are of corre-
spondingly little importance.
Examples:
Fig. 12.7-12 Gear teeth, steel, thickness 3 mm
Fig. 12.7-13 Fine webs in thick sheet, steel, thickness 10 mm

12.7.3.5 Adapting the cutting mode pulse parameters
1. Reduction of feed rate
2. Reduction of pulse frequency
3. Varying the pulse width
All other parameters must need not normally be adapted.
Tab. 12.7-5 Example: Complex contour
Contour Parameter Parameter value
Default Edited
Feed [mm/min] 180 45
Pulse frequency [Hz] 20 5
Pulse width [ms] 11,500 14,000

Fig. 12.7-14 Cutting result with default parameters
Cut with default parameters

Steel Thickness 10 mm
Fig. 12.7-15 Cutting result with edited parameters
Cut with edited parameters

Feed rate Minus 40%
Pulse frequency ¼ of default frequency
Pulse width Default value x 2.5
Laser power From 60% to 100%

12.7.3.6 Adapting the piercing mode pulse parameters
1. Increasing piercing time
2. Reducing the initial and/or final pulse frequency (reduction of heat

input)
3. In order to stop the piercing time becoming too ling due to step 2,
the laser power can be increased at the same time.
4. Variation of pulse width.
12.7.3.7 Influencing factors in pulse mode
Sheet quality and surface

Part geometry. The hotter the plate, the more difficult it is to achieve a
good quality cut.
The following must also be mentioned, however: If a pulse parameter
functions reliably in a hot plate, it is good and has a lot of reserve.
12.7.3.8 Alternatives to pulsed cutting
Often, cutting can be done using nitrogen instead of pulsed cutting, up to

sheet thicknesses of 6 mm. See Chapter 12.7.2.8 ›Cutting with nitrogen
(N2)‹).

12.7.3.9 Programming for pulsed contours
Whether or not contours are cut pulsed or are pierced can be determined
in two ways:
Automatically with the technology wizard. This contains the two most
important rules for machine which method is used to cut contours. It
also has the advantage of shortening the programming time.
Manually, the programmer selects the individual contours based on his
own experience cutting on the machine.
If only portions of the contour are cut pulsed, e.g. the teeth in the follow-
ing figures, the programming must be carried out so that there as few
changeover points as possible (A).
Fig. 12.7-16 Poor programming (two changeover points)
A Two changeover points (A)

A
Normal — pulse — normal
Fig. 12.7-17 Good programming (one changeover point)
One changeover point

Because of the optimum positioning of the initial cut, only one changeover
point from normal to pulsed cutting is necessary. This improves the part
quality.

Part programming has a great effect on good pulse results:

Pulsing should, where possible, be switched on after CW cutting (not
the other way round). This improves the transitions on the cut edge.
Changeover points from CW to pulse should be positioned so that the
changeover takes place at a change of direction or in a corner. Do not
changeover on straights or in curves. Changing over from one mode to
another causes small sags.
Fig. 12.7-18 Cutting in CW and pulse mode
unsuitable suitable
B B
A
A A
B B
C C
A
C C
A A A A
B B B B
A Changeover point
B CW cutting
C Pulsed cutting
The cutting sequence should be selected so that the complex

contours are always cut first on one part, i.e. the smallest first
(usually the pulsed ones).

12.7.3.10 Background information
Special parameters
The modulation is switched off for pulsed cutting.
Handheld controller
At low speeds the manual cut with display differences compared to a nor-
mal pulsed cut. In manual mode only feed rates with increments of
133 mm/min are considered. This means that the smallest possible feed
rate is 133 mm/min, then 266 mm/min, etc.
Cut assessment
The second half of the cut edge often displays a brownish coloring. This
coloring is rust. The oxidation is generated in the pulse pause by the oxy-
gen cooling (see Fig. 12.12-4).
Burning
If burning occurs at the end of the cut, setting a microweb or program-
ming an end pane outside the contour may help to alleviate this.

12.7.4 Oxide-free cutting in stainless steel
Define machine setup values

Cutting with nitrogen to achieve oxide- and burr-free cut edges for
post-processing without with further treatment.
Employing high laser power and high pressure cutting in conjunction
with nitrogen, comparable or even higher cutting speeds can be
achieved than when cutting with oxygen.
In order to cut stainless steel more than 5 mm thick burr-free across
the whole sheet using nitrogen, it is necessary to adjust the focal posi-
tion. By averaging out the focal position and reducing the speed it is
possible to cut clean cuts, albeit with slight burring.
Using the Bypos option, the manual readjustment of the focal position
is not necessary.
An oiled sheet surface improves piercing without reducing the machin-
ing quality (see Fig. 12.12-53).
Whenever possible, CutControl should be employed. This increases the
process reliability and minimizes defective parts.
Substantially greater nozzle clearance height for piercing than for cut-
ting. A greater nozzle clearance height helps to prevent splashes on the
lens.
When cutting stainless steel, stainless steel support grids

must be used.
If steel grids are used, steel splashes can melt into the cut
part at the support points. These will subsequently oxidize.

12.7.4.1 Cutting parameters for stainless steels
An extremely large amount of alloyed stainless steels are available on the

market. The default parameters refer to the most common alloy (DIN
1.4301).
With the appropriate adaptation of the focal position, feed rate, laser
power and gas pressure, almost all stainless steels can be cut. To begin
with, the respective default parameters (DIN 1.4301) should be used.
Adapt the cutting parameters based on the information given in Chap-
ter 12.6.3 ›Procedure for optimizing the cutting parameters‹. Compare
the cutting results achieved with the figures in Chapter 12.12 ›Cut as-
sessment‹.

12.7.5 Oxide-free cutting of aluminum alloys
An extremely large amount of aluminum alloys are available on the mar-

ket. The default parameters refer to the most common alloy (DIN
3.2323), AlMg3. This alloy can also be bent well.
The cutting gas used is nitrogen. Oxygen is also used for piercing in
thick sheets.
With the appropriate adaptation of the focal position, feed rate, laser
power and gas pressure, almost all aluminum alloys can be cut. To be-
gin with, the respective default parameters (DIN 3.2323) should be
used.
Adapt the cutting parameters based on the information given in Chap-
ter 12.6.3 ›Procedure for optimizing the cutting parameters‹. Compare
the cutting results achieved with the figures in Chapter 12.12 ›Cut as-
sessment‹.
Aluminum is a highly reflective material. If the laser beam no longer sepa-

rates the sheet, the laser is being reflected. This can shorten the life of the
optics. It is recommended to monitor the production process when cutting
aluminum and its alloys.
The softer and purer an aluminum alloy is, the more difficult it is to cut
with laser. This can be recognized by the burrs on sheets under 3 mm
thick. In addition, the feed rate must be reduced greatly, e.g. for pure alu-
minum (Al 99.5%) up to 40% of the default parameter.

12.7.6 Machining diverse materials
Material Remark
Titanium The cutting gases nitrogen or argon are employed for

cutting titanium sheets. The cutting parameter data-
base contains the parameters for titanium.
When cutting with nitrogen the cut edge oxidizes and
takes on a brown color. In addition, a burr forms on
the underside of the sheet (see Fig. 12.12-47).
When using argon, an oxide-free, clean cut edge
without burrs is produced (see Fig. 12.12-48).
Copper Both materials possess high reflectance and high

Brass thermal conductivity.
Brass can be cut with nitrogen up to a thickness of
6 mm, depending on the laser used (also Fig. 12.12-
43 and Fig. 12.12-44).
Copper can be cut up to sheet thicknesses of 3 mm,
but oxygen must be used as cutting gas.
Brass and copper in particular are very soft materials.
The underside therefore generally has burrs.
It is not economical to cut large amounts of copper on
a laser cutting machine. Water jet cutting is more
suitable.
Copper and brass may only be cut if a suitable device for ab-
sorbing reflections is installed on the laser cutting machine.
Reflections can otherwise destroy the optical elements.

Material Remark
Hardox, Weldox, These materials can generally be cut to good quality.

Domex The steel default parameters can be used.
Austenitic manga- Can be cut in sheets up to approx. 10 mm thick, but

nese steel causes a lot of smoke. It can also be cut with nitrogen
to reduce smoke development.
Tantalum, nickel-sil- Newer materials, can be cut without problems using

ver, inconel nitrogen. The stainless steel default parameters can
be used.
The maximum cuttable thickness is usually 1 - 2 mm
less than the maximum cuttable thickness of stainless
steel.
Checker plate Can be easily cut. Checkers always down and adapt
the cutting parameters to maximum thickness.
Pure aluminum Is poorly suited to laser cutting because of the high

reflectance. The aluminum default parameters can be
used.
The maximum cuttable thickness is usually 2 - 4 mm
less than the maximum cuttable thickness of AlMg3.
The cutting speed must be reduced by up to 40%.
Plastics Plastics may not be cut on laser cutting machines.

Observe safety instructions!
WARNING
Toxic vapors
The vapors given off during combustion are highly toxic.
They cannot be completely removed by the extraction
system.
Plastics may not be cut on laser cutting machines!

Material Remark
Wood, leather, card- Wood, leather, cardboard and paper can be cut with
board, paper the laser. The cut edge is carbonized (brown color-
ing). See Fig. 12.12-46
The higher the feed rate, the lower the carbonization.
A clean cut cannot be guaranteed for glued wood as
the adhesive layer disintegrates differently depending
on the type of adhesive. Observe safety instructions!
WARNING
Fire hazard
Cutting organic material presents a fire hazard
Nitrogen must be used as cutting gas.
Material Remark
Silver Pure silver or silver-plated sheets may not be cut. The

reflectance is too great. This can destroy optical ele-
ments.
Ceramics, tiles, Ceramics or brittle materials are not suitable for cut-
glass ting with laser. The heat input bursts the material.
Other materials Information on other materials can be obtained from

the manufacturer's customer service department.

12.7.7 Plasma cut
Whenever a very bright, white-blue light is visible during cutting, it is

known as a plasma cut.
Fig. 12.7-19 Plasma cut in steel, 1 mm thick
Fig. 12.7-20 Plasma cut in stainless steel, 20 mm thick
The advantage of the plasma cut is the increased cutting speed of up to

50%.
The plasma cut is only possible at high laser power above 4000 W.
The plasma cut is generated during laser cutting solely by editing the
cutting parameters. The cutting gas employed is nitrogen.
The plasma cut can be used on very thin sheets up to 1.5 mm thick and
on stainless steel of 15 - 20 mm.
The cut quality of plasma cuts is reduced in comparison the normal cut-
ting quality.
CutControl does not function for the plasma cut and is automatically de-
activated by the cutting parameters.
In laser cutting, the so-called plasma cut should not be confused with
the plasma cutting method.

The following cutting parameters are different for the plasma cut, com-
pared to the normal cut.
Tab. 12.7-6 Cutting parameters for plasma cut compared to normal cut
Parameter Steel, 0.8 - 1.5 mm Stainless steel, 15 -

thick 20 mm thick
Feed rate Much higher (30 - 50%) Much higher (20 - 40%)
Laser power Higher (20 - 40%) —
Nozzle clearance Higher (1.5 - 2 mm instead —

height for cutting of 0.7 mm)
Nozzle type H-nozzle instead of HK-noz- —

zle
Nozzle diameter Greater (HK17/20 instead of —

HK15)
Gas pressure Lower (20 - 40%) —
Focal position Same or slightly lower (0 - Much higher, to approx.

2 mm) 60% in material
CutControl Deactivated Deactivated
12.7.7.1 Practical applications
The operator decides whether the normal cut or the plasma cut is used.
The very high cutting speeds used in the plasma cut in sheets up to
1.5 mm thick can only be properly utilized on Byspeed machines.
On Bystar machines, the cutting speed cannot be achieved on parts small-
er than 500 x 500 mm. The acceleration is too small. No parameters have
therefore been saved for plasma cutting in sheets less than 1.5 mm thick.

12.7.7.2 Stored cutting parameters
Tab. 12.7-7 Cutting parameters for plasma cutting (machine type: Byspeed)
Material Byspeed with Bylaser
4,400 5,200 ARC
Structural steel Yes Yes

1 mm / 1.5 mm
Cutting gas N2 e.g. 10332r10.E5n e.g. 10332r10.P5n
Stainless steel Yes Yes

1 mm / 1.5 mm
Aluminum Yes Yes

1 mm / 1.5 mm

15 mm
Cutting gas N2 e.g. 14301150.E7n e.g. 14301150.P7n

20 mm
Cutting gas N2 e.g. 14301200.E7n e.g. 14301200.P7n

Tab. 12.7-8 Cutting parameters for plasma cutting (machine type: Bystar)
Material Bystar with Bylaser
4,000 4,400 5,200 ARC
Structural steel No No No
1 mm / 1.5 mm
Cutting gas N2
Stainless steel No No No
1 mm / 1.5 mm
Cutting gas N2
Aluminum No No No
1 mm / 1.5 mm
Cutting gas N2
Stainless steel Yes Yes Yes

15 mm
Cutting gas N2 e.g. e.g. e.g.
14301150.X7n 14301150.G7n 14301150.Q7n
Stainless steel No, not possi- Yes Yes

20 mm ble
Cutting gas N2 e.g. e.g.

14301200.G7n 14301200.Q7n
12.7.7.3 Cutting parameters for custom sheets
The plasma cut can also be used on material thicknesses and material
types other than those in Tab. 12.7-7 and Tab. 12.7-8, e.g.:
Stainless steel, 0.8 mm thick with film
Electroplated steel plate, 0.75 mm thick,
etc.
The cutting parameters for these custom sheets must be determined by
the operator.
Cutting parameters for custom sheets can be most quickly determined if
the stored default parameters for the plasma cut are used as the basis.

Example:
For electroplated steel plate 0.75 mm thick, the cutting parameters for
steel plate 1 mm thick are used to start, (e.g. 10332r10.z5n) and the feed
rate, laser power, gas pressure, focal position, etc. are optimized.
Fig. 12.7-21 Example of cut edges, cut with Bylaser 5200 ARC
Plasma cut in stainless steel,

20 mm thick
Cutting gas N2
0.45 m/min
Gas pressure 15 bar
Focal position approx. 12
Normal cut in steel,

Thickness 1 mm
Cutting gas N2
Feed rate 11 m/min
Gas pressure 12 bar
Roughness of the cut edges ap-
prox. Ra3.2
Plasma cut in steel,

Thickness 1 mm
Cutting gas N2
Feed rate 19 m/min
Gas pressure 10 bar
Roughness of cut edge approx.
Ra12.5

12.7.7.4 Initial cut type in stainless steel, 15/20 mm
In principal, the Bysoft technology wizard selects the correct technology

for each laser type.
When plasma cutting it is important that the initial cut type is correctly se-
lected (especially for stainless steel, 15 / 20 mm).
The initial cut types differ according to sheet thickness and la-
ser power.
Tab. 12.7-9 Initial cut in stainless steel, 15 / 20 mm thick, for Bylaser 5200 ARC
Initial cut Remark
Example stainless steel, 15 mm thick, for

Bylaser 5200 ARC
Initial cut type straight, rectangular to con-
tour. This is correctly selected automatically by
the technology wizard. The plasma cut is initiat-
ed by the sharp change in direction.
Example stainless steel, 20 mm thick, for

Bylaser 5200 ARC
The technology wizard automatically selects the
initial cut type Straight with arc on the con-
tour

12.7.7.5 Partial plasma cut for sheet thicknesses up to 1.5 mm
It is possible to change between normal and plasma cut a number of times

within one part. This allows the part time to be minimized and the quality
to be partially improved.
Fig. 12.7-22 Partial plasma cut
It is possible to program into Bysoft how to cut which part sections. In the
example in Fig. 12.7-22, for example, the two long straights (A) can be
cut with the plasma cut (CW).
All other sections, including the inner contour, are cut with the normal cut
(process macro 1). These optimizations are worthwhile for high part num-
bers in particular.

12.7.7.6 Time comparison between normal and plasma cut
Steel disk, 1 mm thick, cutting gas nitrogen N2 with Bylaser 5200 ARC
Fig. 12.7-23 Steel disk, 1 mm thick
Disk ø480 mm Cutting times:

Bores ø100 mm
Normal cut:
Feed rate = 11 m/min
Cutting time = 26 s
Plasma cut:
Feed rate = 19 m/min
Cutting time = 15 s
Reduction in cutting time of more

than 40% using the plasma cut
Use of the plasma cut in the thin sheet range up to 1.5 mm is worthwhile
primarily for large contours with few changes in direction.

Fig. 12.7-24 Comparison of cutting speeds for structural steel, cutting gas nitrogen N2
(machine type: Byspeed with Bylaser 5200 ARC)
Cutting speed in [m/min]
Sheet thickness in
[mm]
A Plasma cut
B Normal cut
The diagram clearly shows that cutting is faster with the plasma cut and
up to 1.5 mm sheet thickness and production therefore more cost-effi-
cient.
The graphics also apply in principal for other materials, e.g. stainless steel
with film or galvanized sheets.

12.7.8 Engraving
12.7.8.1 General
Engraving is available as a standard function on all machines and is a sup-

port function, e.g. for the following:
Marking of parts
Engraving positions (center cross for boreholes)
Engraving fold edges
Applying optical elements and recognition marks
Prepositioning of sheets or parts
Vaporization of films, paints, varnishes or other coatings
Fig. 12.7-25 Engraving example
Engraving for measurements of angle Engraving as inscription

Cutting gas oxygen O2 Cutting gas nitrogen N2
Engraving is primarily used on inox and steel. It is possible to engrave

with nitrogen or oxygen. In principal, engraving should always be carried
out with the gas used for cutting. This eliminates purging time.
Highly reflective materials such as copper, brass or shiny surfaces are not
suitable for engraving.
The Bystronic cutting parameters contain the engraving data.
The engraving can be simply programmed in Bysoft.

12.7.8.2 Assessing the quality of an engraving
The depth and quality of the engraving is determined on the one hand by
the specified parameters and on the other hand by the sheet surface.
Moreover, each person judges the quality of an engraving differently. The
stored parameters should therefore be seen as guide values. Optimum en-
gravings can be generated with this as the basis.

12.7.9 Machining with process macros
Process macros are additional parameters to assist optimum cutting of

complex contours. The process macro is programmed in Bysoft. The cut-
ting parameters must be altered on the machine. Two process macros are
available.
Fig. 12.7-26 Example with process macros
A Small contour (bore) with process macro 1

B Initial cut with process macro 2
12.7.9.1 Process macro 1
Process macro 1 is automatically opened by the Bysoft technology wizard

according to the rules for small contours based on Tab. 12.5-5 and
Tab. 12.5-6. The cutting parameters are also determined for the small
contours (e.g. the small bore in Fig. 12.7-26).
12.7.9.2 Process macro 2
Process macro 2 is used in three applications:

Initial cut for moving in to the sheet
Scanning (see Chapter 12.11.6 ›Thin sheet machining using scan-
ning‹). This allows the necessary parameters to be optimized.
For customer-specific applications

12.7.9.3 Process macro 2 for the initial cut
Starting on the first geometry element of the initial cut (A) using the cut-
ting parameters in process macro 2 substantially improves process reli-
ability. In many cases this means that special piercing in thick sheets can
be dispensed with (see Chapter 12.7.10.8 ›Special piercing in thick
sheets‹). This simplifies programming and reduces the piercing time.
Fig. 12.7-27 Starting on the first geometry element
CPP piercing and starting with process macro 2 parameters can be

combined. This produces the best piercing and the best process reliability
when starting in thick sheets.
Tab. 12.7-10 Using process macro 2 for the initial cut
Material Laser 4000 Laser 5200 ARC
Steel 25 mm 25 mm
Stainless steel 15 - 20 mm 15 - 20 mm
Aluminum 8 - 12 mm 8 - 12 mm
The technology wizard Version 8 and the cutting parameters

from CNC Versions P6114/P6140 contain these settings.

12.7.9.4 Example with process macros
In the following example, the individual sections are cut using different
technologies (process macro 1, process macro 2 and CW).
Fig. 12.7-28 Steel, 6 mm thick, with different process macros
C A C
A A
B
C A C
A Bores, ø6.5 mm, cut with process macro 1

B Gear teeth, cut with process macro 2
C Banana holes and outer contour, cut with CW
The part can thus be cut in top quality and in a very short time.
However, such optimizations are generally only worthwhile in
series.

12.7.10 Various piercing methods
Correct piercing is very important for the subsequent cutting process.

There are therefore various piercing methods.
Tab. 12.7-11 Process reliability and piercing time
Piercing method
Without piercing time
Special piercing
Without monitoring
pulsed piercing
With piercing time

Controlled Pulsed
Conventional,
Pre-cutting
Normal CW
piercing
Lead in
Lead in
Piercing
CPP
Process reli- Very Very High Medi- High High Very

ability high high um high
Piercing Very Very Short — Short Short Long

time long short
For applications in steel up to 8 mm thick there are a number of

piercing options. The Bysoft technology wizard generally selects
the most commonly used.
The piercing type can be selected depending on whether pro-
duction is aimed at quantity or quality.

Tab. 12.7-12 Summary of the various piercing methods and applications
Laser appli- Piercing method

cations
Conventional, CPP piercing Normal CW Lead in Pre-cutting Special pierc-
pulsed piercing piercing ing
Without monitoring Controlled Pulsed
Piercing
2,200 Steel, 1 - 15 mm Not possible All materials /thick- Not possible When required No application
nesses Steel, 12 - 15 mm
3,000 Steel, 1 - 20 mm Not possible All materials /thick- Not possible When required When required
nesses Steel, 15 - 20 mm Steel, 20 mm
4000 Steel, 1 - 20 mm Not possible All materials /thick- Machine type: Bystar When required When required
Stainless steel, nesses except steel, 1 - 6 mm Steel, 15 - 20 mm Steel, 20 mm
15 mm stainless steel,
15 mm
4400 No application as Steel, 1 - 25 mm All materials /thick- Machine type: Bystar No application as When required
CPP possible Stainless steel, nesses except steel, 1 - 6 mm CPP possible Steel, 20 - 25 mm
15 - 20 mm stainless steel, Machine type: Byspeed
15 - 20 mm steel, 1 - 8 mm
Aluminum
8 - 12 mm
5200 ARC No application as Steel 1 - 25 mm All materials /thick- Machine type: Bystar No application as When required
CPP possible Stainless steel, nesses except steel, 1 - 6 mm CPP possible Steel, 20 - 25 mm
20 mm only stainless steel, Machine type: Byspeed
20 mm steel, 1 - 8 mm
Aluminum
8 - 12 mm

12.7.10.1 Conventional, pulsed piercing (without monitoring)
This piercing method is only used on the Laser 2200, 3000 and 4000 (or
when required).
Applications: Small bores

Piercing directly on the contour. Allows the inner
and outer parts to be used.
Piercing in stainless steel, 15 mm thick (Laser
4000 only)
Advantage: Small piercing hole
Disadvantage: Time-consuming piercing (with CPP, the piercing
time, pulse mode is greatly reduced)
The sheet thickness in mm corresponds approximately to the

piercing time in seconds. Using CPP (Controlled Pulsed Pierc-
ing), the piercing time for sheet thicknesses up to 15 mm is
substantially lower.
Guide values for piercing times with CPP = 0.5 - 2.5 seconds

12.7.10.2 CPP (Controlled Pulsed Piercing)
CPP (Controlled Pulsed Piercing) replaces the previous normal CW and

conventional pulsed piercing (without monitoring) in structural steel with
the existing Laser 4400 or 5200 ARC.
The parameter variants for pulsed piercing (CPP) are reduced and simpli-
fied, because the same values can be used across a range of thicknesses.
CPP is integrated in the new CNC software for laser types 4400 or
5200 ARC and therefore functions on all laser cutting machines equipped
with one of the above named lasers.
The CPP works with pulsed piercing using oxygen (O2) as cutting gas in
Material Material thickness
Structural steela) 1 - 20 mm
Stainless steel 20 mm
Aluminum 4 - 12 mm
a) Great advantages above 5 mm thick
CPP monitors the piercing process and starts to cut directly after piercing.
This produces extremely short piercing times. The start hole is consider-
ably smaller.
Fig. 12.7-29 Start hole for CPP piercing compared to normal piercing
CPP piercing Normal piercing
Only very little material is ejected during piercing.

Reducing the heat input during piercing.
Reduces the wear on nozzles and lenses

CutControl must be activated (check Setup machine and

Parameter values ).
All pierces executed using CPP must be programmed as pulse
pierces. If the laser is correctly selected, the Bysoft technolo-
gy wizard automatically selects pulsed piercing.
Sequence for CPP piercing

CPP piercing is carried out in two steps. Step 1 prepares the penetration,
step 2 completes it.
1. The starting point for CPP piercing is located approx. 8 mm above the
sheet. The first step of pulsed piercing begins from this position
(without delay).
Fig. 12.7-30 First step for CPP piercing
B
8 mm
A Lens
B Nozzle

2. CutControl monitors the pierce. Once the sheet is pierced, the laser
cutting machine immediately starts to cut.
Fig. 12.7-31 Second step for CPP piercing
A
D
C
B
0.6 - 2 mm
A Lens
B Nozzle
C Mirror
D CutControl
If the piercing is too large and the material overheats, it is recommended

to reduce the values of the following piercing parameters:
Pulse width, step 2
Initial pulse frequency, step 2
Final pulse frequency, step 2
Piercing pressure, gas type 1, step 2

12.7.10.3 Normal CW piercing
This piercing method is the most common. Especially for fusion cutting us-
ing nitrogen N2 in steel, stainless steel and aluminum.
Advantage: Fast piercing

Disadvantage: Causes a relatively large start hole
12.7.10.4 Lead in
With the Lead in function on, the initial cut is on a contour using the CW
parameter process macro 2.
Lead in is activated in the cutting parameters. In the CW parameter
process macro 2, the macro designation must contain Lead in or Initial
cut.
In theory, Lead in can be used in every parameter, with or without pierc-
ing time. Any piercing type can also be used (e.g. CPP).
Tab. 12.7-13 Lead in application summary
Lead in with piercing time Lead in without piercing time

(best process reliability for thick (minimum part time)
sheets)
Steel sheet, 25 mm thick Steel sheet up to 8 mm thick on

Stainless steel, 15 - 20 mm thick Byspeed machines
Aluminum, 8 - 12 mm thick Steel sheet up to 6 mm thick on

Bystar machines

12.7.10.5 Lead in with piercing time
The type of piercing is independent of the Lead in function. For example,

piercing can be with CPP and than started using lead in.
Fig. 12.7-32 Starting on the first geometry element
Starting on the first geometry element of the initial cut (A) using the cut-
ting parameters in process macro 2 substantially improves process reli-
ability.
CPP piercing and Lead in with piercing time can be combined. This pro-
duces the best piercing and the best process reliability when starting in
thick sheets.
The cutting parameters from version P6114/P6140 contain the settings for
Material Laser 4400 Laser 5200 ARC
Steel 25 mm 25 mm
Stainless steel 15…20 mm 15…20 mm
Aluminum 8…12 mm 8…12 mm

12.7.10.6 Lead in without piercing time
Lead in without piercing time is the fastest option for cutting steel
sheets (up to 6 mm or 8 mm thick) using oxygen O2. The machine axes
do not stop during piercing.
Fig. 12.7-33 Piercing process
A Positioning with arc (only on Byspeed machines)

B Reduction in positioning speed to piercing speed of process
macro 2
C CW macro parameter 2 engaged. The axes do not stop.
D Switch over macro parameter 2 (e.g. to CW parameters)
Lead in without piercing time is particularly suitable for Byspeed ma-

chines. The cutting head is substantially more slender and the z-axis up to
50% faster than on Bystar machines.
On Bystar machines, Lead in without piercing time can be used on
sheets up to 6 mm thick. For large formats (4020 and larger), the time
gain with Lead in without piercing time is smaller due to the lower ma-
chine dynamics.
Piercing with Lead in without piercing time chiefly offers a great reduc-
tion in manufacturing time for parts with numerous piercings. The follow-
ing part (Fig. 12.7-34) can be manufactured up to 30% faster with Lead
in without piercing time than with CW piercing.

Fig. 12.7-34 Example application for lead in without piercing time
Advantages
Reduction in manufacturing time of up to 30%
Smaller piercing holes
Less heat in sheet
No additional programming in Bysoft
Notes on lead in
The cutting parameters of structural steel with an r at the sixth position
of the file name contain the settings for Lead in without piercing
time (e.g. 10332r40.E7o)
The sheet surface must be slightly oiled
The minimum hole diameter should be greater than 1.5 x sheet thick-
ness
Automatic nozzle cleaning should preferably be active

12.7.10.7 Pre-cutting
Pre-cutting is not required for piercing with CPP. This function is therefore
only used on Laser 2200, 3000 and 4000.
Application:
Parts with numerous holes and openings, or small parts tightly nested.
Procedure:
1. Provide the cutting plan with pre-cutting functions using the Bysoft
5.3 ByADD or Bysoft 6.0 Bywork software application
2. Pre-cut whole sheet
3. Clean sheet of piercing splashes
4. Leave sheet to cool if necessary
5. Cut
Use a smaller nozzle for pre-cutting than for cutting. (e.g. K12
instead of K17). The gas pressure during piercing must be dou-
bled in order to prevent splashes on the lens. The heat input to
the sheet is reduced considerably by pre-cutting. The piercing
hole is smaller.
Once all holes are pre-cut, the axes automatically travel to the
origin. The nozzle can be easily replaced here.
The piercing gas pressure can be reset to the original value and
the piercing time reduced to 0.
Using this procedure it is possible to cut holes and openings of
0.8 - 1.0 x sheet thickness in normal thicknesses without puls-
ing.

If the sheet heats strongly during cutting, it expands. This

can cause the pre-cut holes to be displaced.
Remedy:
Reduce size of cutting area by dividing a large cutting plan (e.g. 1 x 2 m)
in two smaller ones (e.g. 1 x 1 m).
Because of the thermal expansion, single parts should only be cut in mul-
tiple cuts for no-tolerance parts.
12.7.10.8 Special piercing in thick sheets
With increasing laser power it is possible to cut ever thicker materials. In

order to achieve optimum process reliability, the piercing described below
can increase process reliability on the one hand, and on the other hand re-
duce the minimum cuttable diameter. The technology wizard from Version
6 or higher supports special piercing.
Tab. 12.7-14 Application
Material Thickness Laser

in [mm]
Steel 20 4000
Steel 20 - 25 4400a)
Stainless steel 15 4000
Stainless steel 15 - 20 4400a)
Stainless steel 20 5200 ARCa)
a) From CNC Versions P6114/P6140 or higher, the special piercing can be dispensed with
in most cases. Piercing is dome using CPP, starting uses the parameters in process
macro 2 (see Chapter 12.7.9.3 ›Process macro 2 for the initial cut‹).
Special piercing is used:

If the hole < sheet thickness
For narrow, complex inner contours
If the sheet is too hot and the cut quality is poor

12.7.10.9 Programming
1. Select the sheet thickness in the technology wizard and automatical-

ly specify the technology. Small bores or contours are assigned pro-
cess macro 1, depending on size.
2. On complex contours, define the initial cut at a point where it is as

long as possible.
3. Program a start hole at the end of an initial cut (for an inner con-
tour).
z Radius of start hole in stainless steel = 1.25 mm
z Radius of start hole in steel = 1.6 mm
4. Automatically specify the technology once again. The start hole is

pierced pulsed using process macro 2.
5. Copy the start hole with the specified technologies to all initial cut
ends where the special piercing is required.
6. Delete the cutting sequence for the whole part.
7. Select the cutting sequence manually.

Recommendation for steel: First cut all start holes, then process
the most difficult or the smallest contours (heat reduction).

12.7.10.10 Cutting
1. Load program and cutting parameters.
2. Process the cutting plan.

12.7.11 Microwebs
Without microwebs, a cut-out is cut complete, i.e. the laser meets back up
with the start of the cut gap at the end of the cut. However, separation of
the material takes place at least one cut gap d before the geometrical end
of the cut.
Fig. 12.7-35 Part cut-out microweb
A B C
A Laser beam at separation

B Initial cut
C Laser beam at start and end of cut
The cut out part begins to tilt just at this moment and the laser beam
meets it laterally and causes a burn. The laser beam is reflected in the
melt of this burn and thus causes a further burn in the cut-out.
If these burns are to be prevented, microwebs can be employed. The CNC
controls have an automatic microweb function.

Adding a microweb leads to the laser beam being switched off at a dis-
tance b before the geometrical end of the cut-out. The cut-out thus re-
mains connected to the part and does not tilt.
After the cutting plan is processed the cut-out can be pressed out of the
part by hand or by removed with a bar magnet with the safety door open.
The web width b is selected at least as large as the cut gap d. Guide value
for web width b = approx. 0.8 mm
Fig. 12.7-36 Microweb
A Workpiece
B Cut-out

12.7.11.1 Define microwebs
Microwebs can be applied in two ways:
Automatically
A The machine does not cut completely,
a web is created for each initial cut
(A).
Programmed
In addition to the automatically de-
fined microwebs, further microwebs
can be programmed with Bysoft (B).
To facilitate easy break-out of the
parts, two microwebs on one axis are
B
expedient.
12.7.11.2 Alternatives to microwebs
Instead of microwebs, the inner parts can also be cut. Bysoft provides
simple aids. This offers the advantage that manual breaking-out is not re-
quired.
Fig. 12.7-37 Cut inner part
If microwebs are employed the initial cut type straight per-

pendicular must be used.
For further information on microwebs, also see Chapter 6 ›Op-
erating‹.

12.7.12 Machining corners
12.7.12.1 Machining corners with corner tolerance
If a pointed corner is also required on the outer contour for further ma-
chining, it must be programmed without a rounding radius.
Tab. 12.7-15 Corner tolerance
Too large Correct
If the corner tolerance is too high, overshooting can occur on

the workpiece.

12.7.12.2 Pointed corners in thick sheets (with dwell time parameter)
In the thick sheet range, too much heat is input to the workpiece when
machining with loops. For this reason, the dwell time parameter should
be employed for machining pointed corners in the thick sheet range.
The axes travel to the corner and stop during the specified dwell time. Ma-
chining is then continued.
Fig. 12.7-38 Critical angle, dwell time
Change of direction
angle
If an entry is made for the dwell time parameter, the axes brake and
dwell at all change of direction angles which are greater than the defined
Critical angle dwell time parameter.
If the GO part angle is too small, a smaller radius is used auto-

matically. The dwell time is no longer active in this case.

12.7.13 Support grids
12.7.13.1 Standard support grid
Fig. 12.7-39 Standard support grid
Advantages
Stable support grid, suitable for heavy sheets
Manufacturable with CommenCut, resulting in optimum exploitation of
the sheet
Sheets on the grid can be moved by hand
Disadvantages
Spaces are quickly filled by slag
Material rear is soiled by splashes
The design of the support grid prevents small cut parts from falling.
These can remain erect and thus reduce process reliability

12.7.13.2 Support grid for thin sheets
Fig. 12.7-40 Support grid for thin sheets
Advantages
Material rear is only slightly soiled by splashes
The large spaces fill only slowly with slag
The design of the support grid allows small cut parts to fall. This in-
creases process reliability
Disadvantages
The points of the support grid can be bent if improperly loaded and un-
loaded
Sheets on the grid can only be moved by hand with difficulty

12.7.13.3 Materials
Three different 3 mm thick materials are available for manufacturing the

support grids.
Tab. 12.7-16 Material comparison
Properties Material
Steel Stainless Copper

steel
Properties of the Suitable for all Suitable for all Suitable for all
various cutting grid material types. material types. material types.
materials during With limitations Especially for With limitations
cutting for stainless machining stain- for stainless
steel because less steel. steel and alumi-
the splashes num greater
from the steel than 6 mm thick,
grid can rust on because the dan-
the stainless ger of a beam
steel surface. break is in-
creased by the
copper grid for
these materials
and thicknesses.
Manufacturing the Laser machining Laser machining Laser machining

cutting grid possible possible not possible
Price of the cutting Low Medium High

grid
Life Low Medium High
Automation Parts can weld to Parts can weld to Parts do not ad-
the grid the grid here to the grid
Inner stability Medium High Low
Possible care / Not possible Not possible Possible

cleaning
Taking both the advantages and disadvantages of the geome-

tries and material properties into consideration, it can be seen
that there is no optimum grid for all applications.
The two tables of the shuttle table system can be equipped with
different support grids. This offers the advantage that the most
suitable can be selected respectively.

12.8 Materials
12.8.1 Material properties
The cutting result on the workpiece can be a perfectly clean cut or a

ragged and burred cut edge.
The following are regarded as the principal influence factors on the cut
quality:
Alloy components
Microstructure
Material surface
Surface treatment
Beam reflectance
Thermal conductivity
Melting point
12.8.2 Alloy components
Alloy constituents have a substantial influence on the strength, specific

weight, weldability, and oxide and acid resistance of the materials. Some
principle alloy components of ferrous materials are: carbon, chromium,
nickel, magnesium and zinc.
The higher the carbon content, the more difficult is the material to cut
(critical limit at about 0.8% carbon).
The following carbon steels can be cut well with the laser:
S235, DD11, DIN 1.203
The cutting quality and cutting performance are dependent on the alloy
components. In steel, a high Si constituent results in a rough cut edge and
increases the creation of slag and burrs. Carbon content >0.16% can lead
to poor results for sharp edges and small holes.
In the limit thickness range, Bystronic recommends laser sheets with con-
trolled alloy components.
Tab. 12.8-1 C and Si content
Material C content Si content
RAEX 250 0.12% 0.01%
RAEX 420 0.13% 0.01%

12.8.3 Microstructure
The finer grained the microstructure of the material to be cut, the better
will the quality of the cut edges generally be.
12.8.4 Material surface
The material surface has a very vital effect on the cutting result and the
cutting quality.
12.8.4.1 Bad influences
Loose rolling skin

Rust
Cinders
Uneven surface with pits and irregularities
General soiling
Steel stamping, scrap marks
Color markings
Example:
Cheap S355GT sheet, exposed to weathering
12.8.4.2 Good influences
Fine, even surface with microcinders

Sheet slightly oiled
Etched sheets
Hot-rolled oiled sheets
Sandblasted and shot-peened surfaces are only suitable to a limited ex-
tent but still better than rusty surfaces
Example:
Sheets of the RAEX series, recommended by the machine manufacturer

12.8.5 Surface treatment
All of these surface treatments and similar ones usually have a negative
effect on the cutting result. Oxygen and paint, for example, react in the
cut during cutting. This produces a very rough and frayed cut. A further
problem is presented by the layer thickness differences within a sheet.
Thickness differences in the protective layers interfere with the capacitive
sensing.
Remedy:
Thickness -4 mm: Process with nitrogen
12.8.5.1 Oil
Piercing splashes adhere less well to oiled surfaces. The capacitive sensing
is thus interfered with less. Oiling can be carried out in a number of ways:
Working with Crossjet
Purchasing oiled sheets
Manually oiling dry sheets
WARNING
Fire hazard
The oil on the sheet surface can be ignited by the laser
beam.
Flammable oils should not be used.
Always use welding protection oil
(MOTOREX PROWELD 264)

12.8.6 Beam reflectance
The beam reflectance from workpiece surfaces is dependent on the base

material, surface roughness, focal position and surface treatment. High
beam reflectance occurs in alloyed aluminum, pure aluminum, silver, cop-
per, brass and stainless steel sheets. The higher the reflectance, the more
difficult to cut the material.
Fig. 12.8-1 Comparison of beam reflectance for focal position
Large area Small area
Higher beam reflectance due to Low beam reflectance due to high-

lower focal position. A focal posi- er focal position (lower output
tion which is too low can increase coupler temperature)
the output coupler temperature.
12.8.7 Thermal conductivity
Materials with low thermal conductivity require lower power to melt the
material than materials with higher thermal conductivity.
For example, the power required for stainless steel is below the values for
structural steel, despite the lower absorption at the process temperature.
On the other hand, copper, aluminum and brass, for instance, conduct a
substantial portion of the heat generated by the absorption of the laser
beam away. The heat is quickly conducted away from the point of the la-
ser beam, hindering the local melting of the material.

12.8.8 Heat-affected zone
During laser cutting, material alterations can occur at the boundaries of

the material being cut.
Tab. 12.8-2 Guide values for the extent of the heat-affected zone as a function of the base material
and the sheet thickness
Sheet thickness Heat-affected zone

in [mm] in [mm]
S 235 Stainless steel Aluminum
1 0.05 0.05 0.10
2 0.10 0.10 0.20
3 0.15 0.15 0.30
4 0.20 0.25 0.40
5 0.25 0.35 0.50
6 0.30 0.55 0.60
8 0.40 0.75 0.70
10 0.50 0.85 —
12 0.60 — —
In low-carbon and stainless steels the hardening of the heat-affected

zone is minor.
In high-carbon steels (e.g. C60E) the boundary zones are hardened.
In hard-rolled aluminum alloys, the heat-affected zone is usually slight-
ly softer than the rest of the material.

12.8.9 Stresses
Cheap sheets generally have substantially higher residual stresses and

warp accordingly during laser cutting. The stresses are created during
sheet manufacture.
Qualitatively better sheets posses lower residual stresses. Varying levels
of stress can often be observed within one sheet. The greatest stress lev-
els are at the edges because of the quicker cooling here. Additional pro-
duction reliability can be achieved by careful nesting.
Fig. 12.8-2 Stress behavior across the complete sheet
L B
Area 1: Less stress in sheet Parts that warp heavily should be

nested in this area (e.g. long, thin strips).
Area 2: More stress in sheet Uncomplicated parts, which are not
susceptible to warping, should be placed here.

12.9 Low-staff production
The most important criterion for low-staff production is safety. Procedure

and working practice can therefore be considerably different to normal
production.
12.9.1 Recommendations
Only process cutting plans optimized for safety in a manned shift. In

particular, erect or tilted parts must be prevented (see Chapter
12.11.7 ›Erect parts after machining‹). Critical part sizes range from
20 mm to approx. 150 mm.
Ensure that the long sides of parts lie perpendicular to the grid. In
many cases this can prevent tilting.
Cut only simple part geometries
Cut only simple sheet thicknesses (e.g. 3 mm)
Optimize cutting parameters. A reduction in the feed rate of approx. 10
- 20% increases the process reliability significantly
Use CPP for piercing where possible
Monitor cutting with CutControl where possible
Use the nozzle cleaner
Use suitable sheets (see Chapter 12.8 ›Materials‹)

12.10 High-dynamic cutting
Chapter 12.10 ›High-dynamic cutting‹ and Chapter 12.11 ›Hints for opti-
mum part programming‹ describe the special characteristics of the
Byspeed-type laser cutting machine.
In order to use this laser cutting machine to its optimum, the following
points must be observed for high-dynamic cutting in particular:
Part programming
Cutting parameters
Production
The programming for high-dynamic cutting requires the Bysoft

CAD/CAM application in Version 6.4 or higher
12.10.1 Application
High-dynamic cutting is used primarily for sheet thicknesses in the 0.5 –

1.5 mm range. Sheet thicknesses from 2 - 3 mm represent a transition
zone.
From a sheet thickness of 4 mm upwards, the Byspeed machines operate
the same as the other laser cutting machines (with the exception of posi-
tioning). No special measures are required above this sheet thickness.
12.10.2 Part programming
The programming of the single parts can influence the machining process
considerably. Wrongly or below optimum programming of parts increase
machining time, can cause structural damage and increase wear on the la-
ser cutting machine.

12.10.3 Machine dynamics
12.10.3.1 Guide values for radial acceleration (dynamics)
Tab. 12.10-1 Radial acceleration for various laser cutting machines
Sheet Laser cutting machine

thickness
in [mm] Bysprint Bystar Byspeed Bytube
3015 4020/25
1-3 2.2 m/s2 1.4 m/s2 0.55 m/s2 7.1 m/s2 1.4 m/s2
4 - 10 1.4 m/s2 1.4 m/s2 1.4 m/s2 5.0 m/s2 0.55 m/s2
General notes on programming the initial cuts can be found in

Chapter 12.5 ›Programming‹.
12.10.3.2 Blunt corners (with the corner tolerance parameter), quality cuts
The following table contains guide values for the Corner tolerance pa-
rameter as a function of the laser cutting machine.
Tab. 12.10-2 Guide values for the corner tolerance in [mm].
Sheet Laser cutting machine

thickness
in [mm] Bysprint Bystar Byspeed Bytube
3015 4020/25
1-2 0.15 0.10 0.05 0.25 0.10
3-4 0.10 0.10 0.07 0.25 0.10
5 - 10 0.10 0.10 0.10 0.25 0.10
General notes on machining corners can be found in Chapter

12.7.12 ›Machining corners‹.

12.11 Hints for optimum part programming
The part geometry is programmed using the Bysoft CAD/CAM application.

The machining technology is particularly important.
12.11.1 Initial cuts
Decide whether to work with or without initial cuts.
12.11.1.1 Machining without initial cuts
This is the fastest type of machining because piercing is directly on the

contour. The initial cut is dispensed with.
Disadvantage
The piercing point is visible even on the GO part. Machining without initial
cuts speeds up cutting of templates drastically, but is usually only suitable
for sheets thicknesses up to 1.5 mm due to the quality.
12.11.1.2 Machining with initial cut
A new cut type was developed for the Byspeed laser cutting machine —
so-called are initial cuts. These are supported by Bysoft Version 6.4 and
higher. The arc initial cuts allow a fine approach to the contour at high
speed and do not generate abrupt direction changes.
Fig. 12.11-1 Arc initial cuts with Byspeed
Arc initial cuts

All further initial cut options available in Bysoft can also be utilized. How-
ever, these are not optimized for high-dynamic cutting.
In particular, the initial cut perpendicular to the contour is unsuitable be-
cause the cutting dynamics are impeded by heavy braking and reaccelera-
tion.
12.11.1.3 Initial cut type
In the following table the corresponding initial cuts are optimum. Howev-
er, different initial cut types can also be used for differing quality require-
ments.
Tab. 12.11-1 Initial cut types and their applications
Initial cut type Application
Without initial cut (piercing on the High-dynamic cutting of 0.5 - 1.5 mm

contour) thick sheets
Straight perpendicular to the contour Pulsed contours, general applications
Arc initial cut High-dynamic cutting of 0.5 - 3 mm

thick sheets
Straight with arc Sheet thickness 4 - 20 mm, general

applications
Straight tangential Sheet thickness 10 - 20 mm, outer

contours

12.11.1.4 Initial cut point
Ensure that the initial cuts reach the length defined in Bysoft. If they are
automatically shortened, the initial cut point must be edited.
Tab. 12.11-2 Initial cut position
Optimum initial cut position Poor initial cut position

Length is not achieved
It is possible to use contours with and without an initial cut within one
part. For example, a template can be cut without initial cuts, all other ge-
ometries with initial cuts.
For the first initial cut in each part, it is advisable to use an ini-
tial cut as the machine always lowers normally after positioning.
The pierce is thus more visible than in flying mode.

12.11.2 Direction of rotation and cutting sequence in the part
The direction of rotation and the cutting sequence should follow a dynamic
sequence. Sharp changes of direction or reversals must be avoided.
Tab. 12.11-3 Direction of rotation and cutting sequence
Optimum direction of rotation Poor direction of rotation and

and sequence sequence
In templates with small and large contours, ensure that the

small contours are always cut first.
Never position above a contour that has already been cut.
This avoids the risk of the cutting head colliding with a tilted
part.

Tab. 12.11-4 Cutting and positioning sequence
Optimum cutting and Poor cutting sequence

positioning sequence
12.11.3 Positioning in Bysoft
The head should always be raised for each positioning. Raising increases
process reliability and is just as fast as the lowered positioning function.
In Bysoft, the machining sequence must be specified as Posi-

tioning path optimized.

12.11.4 Positioning the machine axes
In order to eliminate structural damage, the axes are not positioned in

straight lines, but use straights and arcs.
This means of positioning is applied by using the On-the-fly cutting
start and end parameter in the cutting parameters.

1 = on
2 = on + arc
Arcs should always be used for high-dynamic cutting. The cutting parame-
ters provided are accordingly defined for up to 3 mm sheet thickness.
12.11.5 Hole templates
Hole templates are ideally cut in rows. The optimum initial cut is best done
in the quadrant.
If cutting is done without an initial cut an initial cut must be defined for a
change of row (if the row spacing is less than 8 mm) in order to avoid
structural damage.
Fig. 12.11-2 Optimum programmed hole template
If the centers (A) are less than 8 mm, the initial cut must be
applied at a change of row.

12.11.6 Thin sheet machining using scanning
Scanning is the linear machining of rectangular and square holes. Linear

machining offers the advantage of requiring much fewer changes in direc-
tion. This allows a much higher cutting speed to be adopted.
Compared to conventional machining this can be up to 50% faster for
scanning.
12.11.6.1 Schematic representation of the machining sequence
Machining with scanning is in two steps.
First step
First, all lines in x-direction are processed (processing sequence 1 - 4).
Cut contour segments are highlighted.
Fig. 12.11-3 First machining step with scanning

Second step
After the x-direction the y-direction is processed (processing sequence 5 -
8). Cut contour segments are highlighted.
Fig. 12.11-4 Second machining step with scanning
12.11.6.2 Machining characteristics for scanning
Scanning can be used on all sheet types up to 1.5 mm thick.

Plasma cutting is a suitable method (see Chapter 12.7.7 ›Plasma cut‹).
Nitrogen (N2) is used as cutting gas for maximum cutting speed.
It often makes sense to use the process macro 2 cutting parameters for
the contours to be cut using scanning. This allows better optimization of
the part.
Scanning is generally only worthwhile for large series', because of the
slightly greater programming effort. Bysoft supports programming of
scanning with a macro.
Scanning increases process reliability when cutting contours which do
not always fall safely through the support grid. These contours can be
additionally cut one or more times without losing a great amount of
time.
Microwebs can thus be avoided. The inner contours are all cut so small
that they fall safely through the support grid (see Fig. 12.11-6).
Piercing is directly on the contour when scanning. If this is impermissi-
ble, scanning cannot be used.

12.11.6.3 Machining examples
Scanning is suitable primarily for repeating hole templates (e.g. for cov-
ers, cooling slots, mountings for filter pads).
Fig. 12.11-5 Cutting hole templates
Microwebs can be avoided using scanning. The rounds (A) are cut so small
that they fall safely through the support grid.
Fig. 12.11-6 Avoid microwebs
A A

12.11.7 Erect parts after machining
It must be ensured at all costs that no parts remain erect, which could
causes a collision. This can be achieved by various means.
Tab. 12.11-5 Measures for preventing erect parts
Situation Measures
Inner parts with diameters less than No measures necessary, parts always
approx. 15 mm fall through
Parts larger than 200 mm No measures necessary, parts always

remain flat
Microwebs Inner contours in danger of tilting and

the parts themselves between 15 mm
and 200 mm in x- and y-direction
must be safeguarded against tilting
Microwebs
and becoming erect by microwebs.

The best method is to program two
axis-symmetrical microwebs to facili-
tate easy break-out of the parts. The
microwebs are programmed in Bysoft.
Cutting parts with the aid of guide By cutting the inner part into several
cuts pieces it is possible to ensure the
parts fall through safety without be-
Guide cut coming erect.
Advantage over microweb:
The parts do not need breaking out.
Disadvantage:
Increased programming effort in
Bysoft. Guide cuts are supported in
Version 6.4 and higher.

12.11.8 Thin sheet grids
To improve the safe falling through of parts even further, special thin
sheet grids can be employed. See Chapter 12.7.13 ›Support grids‹ for fur-
ther information.
12.11.9 Part machining sequence
For high-dynamic cutting the sheet is automatically clamped at three

points on the left side. The cutting sequence should be selected so that
the sheet remains stable as long as possible, i.e. from right to left.
The numbers in the following cutting plan indicate the part cutting se-
quence.
Fig. 12.11-7 Part machining sequence
A B
13 12 4
3
21
20 19 14 11 10 5 2
15 6
1
22
16 7
18 9
17 8
A Clamping area on sheet

B Safety microwebs
C Machining the parts from right to left

12.11.10 Warping
Parts such as perforated sheets and ventilation grilles have a tendency to

wart during cutting. In order to guarantee reliable production these parts
should not be located directly in the sheet boundary zones, because warp-
ing is strongest here. Parts (9) and (18) in Fig. 12.11-7 are correctly posi-
tioned.
In order to stop warped parts from becoming erect, microwebs should also
be employed here. Parts (5), (7), (14) and (16) in Fig. 12.11-7 are there-
fore safeguarded with microwebs.
12.11.11 Pointed corners in thick sheets with loops
Loops are used when cutting thin sheets at high speeds. This procedure
offers the following advantages:
The axes travel around a pointed corner with a continuous direction
change
The part itself is cut at a uniform speed
Axis overshoot and additional burring are prevented
Heat input in the corner is reduced
Fig. 12.11-8 Corners with loops
A Loop
B Radius
C Part to be cut

12.11.12 Production
In order to achieve maximum production reliability it is recommended to

individually test the parts to be cut with heavily reduced cutting and posi-
tioning speed and the check the simulation in Bysoft. These points should
be observed:
Never position over a previously cut contour
Observe the direction of rotation for cutting and positioning
No erect parts
Processing the cutting plan from right to left
12.11.13 Sheets
In the 0.5 - 3 mm thickness range, special care should be taken that the
sheets are high quality and are transported with care.
The sheets should be as flat as possible and not display any warping. Dur-
ing storage, handling and transport sheets should be kept flat and not be
bent.

12.12 Cut assessment
The following images are magnified up to 10x. This is why striations and
irregularities can even be seen on the optimum cuts.
The solutions described generally apply to all laser strengths
The solutions can also be extrapolated to other sheet thicknesses
12.12.1 Cutting with oxygen (O2)
12.12.1.1 Steel 235, 4 mm thick
Fig. 12.12-1 Optimum CW cut
Cut:
Fig. 12.12-2 Nozzle diameter too large
Cut:
Situation: Very coarse cut surface in approximately the upper

third of the cut.
Remedy: Use smaller nozzle (ø1.7 mm was used instead of
ø1.2 mm).
On the user interface, WORK view, the correct nozzle
for each material can be seen by pressing the Info
switch.

Fig. 12.12-3 Laser power and gas pressure too low, nozzle diameter too small
Cut:
Situation: Cut parts do not fall out of the sheet independently. A

bead of slag is found on the underside of the sheet.
Good cut surface except the lower third.
Remedy: Increase laser power cutting. Increase gas pressure
cutting. Use larger nozzle.
Fig. 12.12-4 Optimum pulsed cut surface
Cut:
Situation: Rough, but regular cut surface (brown coloring in the

lower third). Pulsed cut.
Remedy: The figure shows an optimum pulsed cut surface. It is
always rougher than the cut surface of a CW cut.

12.12.1.2 Steel 235, 10 mm thick
Fig. 12.12-5 Optimum cut
Cut:
Fig. 12.12-6 Laser power and gas pressure too high
Cut:
Situation: Rough, regular striations across the whole cut sur-

face.
Remedy: Reduce gas pressure cutting. Reduce laser power cut-
ting.

Fig. 12.12-7 Feed rate too great
Cut:
Situation: Cut parts do not fall out of the sheet independently.

Very high drag across the cut surface, especially the
lower third.
A bead of slag is found on the underside of the sheet.
Irregular cut surface.
Remedy: Reduce feed rate.
Fig. 12.12-8 Feed rate too low, laser power too high
Cut:
Situation: Coarse, regular striations across the complete cut

surface.
Remedy: Increase feed rate greatly. The example was cut at
half of the normal feed rate.
Reduce laser power cutting.

Fig. 12.12-9 Focal position too high
Cut:
Situation: Coarse, regular striations on the upper face of the

sheet.
Irregular cut surface.
A bead of slag may be found on the underside of the
sheet.
Remedy: Bring the focal position, cutting deeper (in the figure
it is 5 mm too high).
Fig. 12.12-10 Focal position too low
Cut:
Situation: Coarse, irregular cut surface.

Remedy: Bring the focal position, cutting higher (in the figure it
is 5 mm too low).

12.12.1.3 Steel, 15 mm thick
Fig. 12.12-11 Reduce laser power and feed rate, nozzle diameter too small
Cut: Surface
Cut surface with

Cut surface with de- adapted cutting para-
fault parameters meters
Situation: Sand-blasted, heavily corroded surface.

The sheet heats up strongly during cutting.
The top of the cut surface is very rough with heavy
striations. In part very heavy burns across the whole
cut surface.
Remedy: Reduce laser power cutting (default value: 4,000 W,
adapted value: 3,300 W).
Reduce feed rate (default value: 1,300 mm/min,
adapted value: 1,100 mm/min).
Use a larger nozzle (NK 20 instead of NK 17).

12.12.1.4 Steel RAEX 420 Laser, 20 mm thick
Fig. 12.12-12 Optimum cut with NK nozzle
Cut:
Fig. 12.12-13 Wrong nozzle shape used
Cut:
Situation: Irregular, wavy cut surface in approximately the up-

per third of the cut, with burns.
Remedy: Use NK nozzle instead of HK nozzle.
switch.

Fig. 12.12-14 The heat concentration on the sheet is too high
Cut:
Situation: Cut parts do not fall out of the sheet independently

(are partially fused).
Very rough, irregular cut surface. Slag is not com-
pletely blown out.
Wide cut gap, particularly when starting and after
piercing.
Remedy: The sheet is much too hot. User laser sheet such as
RAEX.
Do not cut parts consecutively, but only every second
part.

12.12.1.5 Stainless steel, 1.4301, 6 mm thick
Fig. 12.12-15 Optimum cut with oxygen
Cut:
Situation: Optimum cut with oxygen. The cut surface is much

coarser than with nitrogen.
The cut surface is oxidized. Easily removable beads
often form on the sheet underside.
Cut:
Situation: Cur surface is concave and has a coarse structure.

Heavy bead formation on the underside of the sheet
Remedy: Raise the focal position, cutting (in the figure it is
3 mm too low).

12.12.2 Cutting with nitrogen (N2)
12.12.2.1 Steel, hot galvanized, 2 mm thick
Cut:
Situation: The cut surface is always considerably rougher than

without zinc. The cut changes with varying zinc layer
thickness. The thicker the zinc layer, the rougher is
the cut surface
There is always a very fine burr on the underside of
the sheet. Electroplated sheets produce a much finer
cut.
Cut:
Situation: Irregular, heavy tears in the cut surface.Brown color-

ing downwards of the cut center.
Remedy: Reduce feed rate.
Fig. 12.12-19 Laser power too high
Cut:
Situation: Irregular, heavy tears in the cut surface.

Remedy: Reduce laser power cutting.

12.12.2.2 Steel 235, 6 mm thick
Fig. 12.12-20 Optimum oxide-free cut
Cut:
Cut:
Situation: Hard, blue colored burr on the underside of the sheet.

Heavy drag in the lower third of the cut surface.
Cut:
Situation: Rough, somewhat irregular cut from the cut center

down. Partial bead formation on the underside of the
sheet
is 3 mm too low).

Fig. 12.12-23 Gas pressure too low
Cut:
Situation: Fine cut in the upper region of the cut surface. How-
ever, the melted material ic not completely blow out.
Hard burr on the underside of the sheet
Remedy: Increase the gas pressure, cutting (in the figure it is
5 bar too low).

Fig. 12.12-24 Optimum oxide-free cut
Cut:

Cut:
Cut:
Situation: Heavy (only removable mechanically) sharp burr on

the underside of the sheet.
Good cut, may have rougher cut surface from sheet
center.
Increase gas pressure. The increased gas pressure
ejects the molten material better.

Cut:
Situation: Bead formation on the underside of the sheet. Rough

cut surface from center of sheet. Danger of laser
beam break during cutting.
is 3 mm too low). Reduce feed rate, cutting.
Fig. 12.12-28 Focal position too low, gas pressure too high
Cut:
Situation: Laser beam no longer separates sheet, the molten

material is ejected upwards. Bright blue light and
loud noises from cutting process.
Remedy: Raise focal position, cutting. Reduce gas pressure.

Fig. 12.12-29 Gas pressure too low
Cut:
Situation: Heavy burr on the underside of the sheet. Washed

out, irregular cut surface with heavy drag from ap-
prox. center of sheet thickness.
Remedy: Increase gas pressure (in the figure it is 4 bar too
low).
Fig. 12.12-30 Gas pressure too high
Cut:
Situation: Clean cut, possibly slight bead formation on the un-

derside of the sheet.
Remedy: Reduce the gas pressure, cutting (in the figure it is
5 bar too high). If the gas pressure is too high the
quality of the cut surface is generally retained, but
the cutting costs are unnecessarily increased.
Excessive gas pressure increases the risk that the la-
ser beam will break during cutting (see Fig. 12.12-
28).

Fig. 12.12-31 Feed rate too low
Cut:
Situation: Clean cut surface in the upper two thirds of the cut
surface.
Heavy drag in the lower third of the cut surface.
Heavy (only removable mechanically) sharp burr on
Remedy: Increase the feed, cutting (in the figure it is only half
of the default value). Increase gas pressure cutting.
Cut:
Situation: Good quality in the upper half of the cut surface. In-
creasing roughness and increasing drag in lower half
of the cur surface.
Remedy: Reduce the feed, cutting (in the figure it is 20%
greater than the default value).

Fig. 12.12-33 Beam diameter too large
Cut:
Situation: Good quality in the upper half of the cut surface. In-
creasing roughness and increasing drag in lower half
of the cur surface.
Bead formation on the underside of the sheet.
Remedy: Reduce the beam diameter, cutting (in the figure it is
1.5 mm more than the default value).

Fig. 12.12-34 Optimum plasma cut
Cut:
Situation: Optimum plasma cut. Coarse, regular cut surface

with wavy drag.
Removable beads on the underside of the material.
Remedy: If the quality is insufficient, a different cutting method
must be considered (e.g. water jet cutting).

12.12.2.6 Aluminum AlMg3, 3 mm thick
Cut:
Situation: Optimum cut.
Fig. 12.12-36 Gas pressure too high
Cut:
Situation: Heavy sagging in cut. Blue flashes in cut when cut-

ting.
Remedy: Reduce the gas pressure, cutting (in the figure it is
3 bar too high).
Fig. 12.12-37 Laser power too high
Cut:
Situation: Heavy sagging in cut. Blue flashes in cut when cut-

ting.
Remedy: Reduce laser power cutting.

Cut:
Situation: Fine cut surface in the upper two thirds of the cut sur-
face.
Heavy drag in the lower third of the cut surface. Hard,
difficult to remove burr on the underside of the sheet.
Cut:
Situation: Clean cut surface. Bead formation on the underside of

the sheet.
is 2 mm too low).

Fig. 12.12-40 Optimum cut with NK nozzle
Cut:
Situation: Optimum cut with NK nozzle. Uniform cut surface,

somewhat rougher with increasing sheet thickness.
Easily removable burr on the underside of the sheet
Fig. 12.12-41 Wrong nozzle shape used
Cut:
Situation: Uniform cut surface, somewhat rougher with increas-

ing sheet thickness. Coarse tears across the complete
cut surface. Easily removable burr on the underside
of the sheet.
Remedy: Use NK nozzle instead of HK nozzle.
switch.

Fig. 12.12-42 Focal position too high, gas pressure too low
Cut:

ing sheet thickness. Hard, long burr.
it is 3 mm too high). Increase gas pressure cutting.

12.12.2.8 Brass, 5 mm thick
Cut:
Situation: Optimum cut. Uniform cut surface, somewhat rough-

er with increasing sheet thickness. Bead formation on
Cut:

ing sheet thickness. Brown-black coloring from sheet
center down.
is 2.5 mm too low).

12.12.2.9 Wodd, 24 mm thick
Cut:
Situation: Optimum cut. Heavy carbonization of cut surface.

Partially concave cur surface.

12.12.2.10 Copper, 3 mm thick
Cut:
Situation: Optimum cut. Rougher cut surface with increasing

sheet thickness. Because copper is very soft a heavy
burr forms on the underside of the sheet.
12.12.2.11 Titanium, 3 mm thick
Cut:
Situation: Optimum cut with nitrogen. Titan oxidizes when cut

with nitrogen. This causes a brown to black coloring
across the complete cut surface. Hard, removable
burr.

12.12.3 Cutting with argon (Ar)
12.12.3.1 Titanium, 3 mm thick
Cut:
Situation: Optimum cut. Fine, oxide-free cut edge. Because tita-

nium is an expensive material, the oxide-free quality
is generally demanded.

12.12.4 Piercing with oxygen (O2)
12.12.4.1 Steel 235, 6 mm thick
Fig. 12.12-49 Standard piercing in steel from 4 mm thick
CPP piercing:
Remarks: Standard piercing in steel from 4 mm thick. The

piercing hole is only slightly larger than the cut. Only
a small amount of material is warmed and ejected.
Both criteria increase process reliability.
Very well suited to small bores.
Fig. 12.12-50 Fastest variant for piercing
Lead in piercing:
(piercing time = 0)
Remarks: Fastest variant for piercing. The axes continue to

travel during piercing (plunge into the material).
The size of the piercing hole is between that of CPP
and CW piercing.

Fig. 12.12-51 Uncontrolled piercing at high power
CW piercing:
Remarks: Uncontrolled piercing at high power creates a large

piercing hole.
Is now only used if CPP or lead in piercing are not
possible.

12.12.5 Piercing with nitrogen (N2)
Fig. 12.12-52 Piercing on dry sheets
CW piercing:
Remarks: The melt ejected upwards during piercing is ejected

on to the surface in a star shape. This can adhere
very strongly.
Small bores can interfere with capacitive sensing.
This reduces the quality.
Fig. 12.12-53 Piercing on oiled sheets
CW piercing:
Remarks: Practically no splash on the sheet. The upwardly

ejected melt cannot adhere due to the oil film and
runs off.
High process reliability and quality even for small
bores. The oil film can be applied either using Cross-
jet or manually.

Fig. 12.12-54 Small piercing
CW piercing:
Remarks: Small piercing. The melt can fill the piercing after
starting. This can cause the laser beam to break.
Highly suitable for piercing directly on the contour.
Fig. 12.12-55 Large piercing
CW circular pierc-
ing:
Remarks: Large piercing. High process reliability for sheet thick-

nesses above 6 mm.
The melt cannot fill the piercing after starting.

Fig. 12.12-56 Large piercing
CW circular pierc-
ing:
Remarks: Large piercing using circular piercing. Excessive

ejected melt can influence the capacitive sensing
when cutting small holes.
Heavy soiling of the nozzle when piercing. This re-
quires regular nozzle cleaning.
Fig. 12.12-57 Minimum piercing size
CPP piercing:
Remarks: Minimum piercing size. Only little ejected melt. Small

bores can be cut with high process reliability. High
process reliability when starting with the lead in pa-
rameter.
Minimum soiling of nozzle, therefore regular nozzle
cleaning unnecessary. Long nozzle service life.

12.13 Fault finding
Optimum machining quality can only be achieved under the following con-
ditions:
Precise adjustment of the laser cutting machine
Maintenance in accordance with the maintenance schedule
Operating resources in accordance with requirements
Workpiece surface is rust and cinder-free (etched, pickled or polished)
Suitable parameters for the material and sheet thickness at hand
Parameters harmonized to each other
The following points must be examined if the machining quality falls com-
pared to previous results:
1. Parameter
2. Cutting head
3. Beam guidance
4. Laser
12.13.1 Parameter
Never overwrite the default parameters delivered with the laser cutting
machine.
A new folder must be created for the customized cutting parameters.
If cut quality deteriorates, examine whether the default parameters have
been changed substantially compared to your customized parameters.

12.13.2 Cutting head
Focal length in accordance with parameters

Nozzle shape in accordance with parameters
Lens clean
Nozzle precisely centered
Focal position
Lens correctly mounted and tightened
Check water cooling on cutting head
12.13.3 Beam guidance
Deflecting mirror (cleanliness, fit, cooling)

Cutting head positions 1 - 4 for adjusting the optics
Laser mode in Plexiglas cube
Positive pressure in the beam channel and bellows
Solvents in the ambient air
Sufficient air quality for the beam channel ventilation
12.13.4 Laser
Optical impression of gas discharge

Power check
Tube current
Positive pressure in output coupler
Polarization mirror
Divergence optics
Density of laser
Output coupler (service)
End mirror (service)
Deflecting mirror (service)


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Byspeed_BA_V10_en.fm © Bystronic Laser AG, 2004 0-1

0-2 © Bystronic Laser AG, 2004 Byspeed_BA_V10_en.fm

Operating instructions: Byspeed_BA_V10_en.fm

Purpose of the operating instructions

Byspeed_BA_V10_en.fm © Bystronic Laser AG, 2004 0-3

0-4 © Bystronic Laser AG, 2004 Byspeed_BA_V10_en.fm

China Czech Republic

Byspeed_BA_V10_en.fm © Bystronic Laser AG, 2004 0-5

Singapore South Africa

South Korea Spain

0-6 © Bystronic Laser AG, 2004 Byspeed_BA_V10_en.fm

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0-7

2.1 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . 2–3

0-8 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

3 Design and operation

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0-9

0 - 10 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

4.1 Warning signals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0 - 11

0 - 12 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0 - 13

6.4.5 Alarm messages. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 33

0 - 14 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

6.8 Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 67

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0 - 15

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

0 - 16 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0 - 17

8.4.9 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 26

0 - 18 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

8.6.7 Removing the alignment devices . . . . . . . . . . . . . . . 8 – 67

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0 - 19

0 - 20 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

10 Packing and transport

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0 - 21

0 - 22 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0 - 23

0 - 24 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

12.7.3.5 Adapting the cutting mode pulse parameters . . . . . 12 – 76

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0 - 25

12.7.11 Microwebs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 116

0 - 26 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

12.11.2 Direction of rotation and cutting sequence in the part . 12 – 136

Byspeed_BA_V10_enTOC.fm © Bystronic Laser AG, 2004 0 - 27

12.12.5 Piercing with nitrogen (N2) . . . . . . . . . . . . . . . . . . . 12 – 175

0 - 28 © Bystronic Laser AG, 2004 Byspeed_BA_V10_enTOC.fm

This chapter contains general information, operating data and equipment

Byspeed_Kap01_V10_en.fm © Bystronic Laser AG, 2004 1-1

1-2 © Bystronic Laser AG, 2004 Byspeed_Kap01_V10_en.fm

Fig. 1.1-1 Overview of the laser cutting machine

Byspeed_Kap01_V10_en.fm © Bystronic Laser AG, 2004 1-3

1.1.2 Intended use

Processing of materials that produce toxic gases on evapora-

Any change in the agreed intended use or the agreed basic