ProCutter Thunder ECO

Operating Instructions

© Precitec GmbH & Co. KG EN 10/2022 D 380311

Imprint ProCutter Thunder ECO

This documentation is protected by copyright law for Precitec GmbH & Co. KG
and must not be reproduced without the prior written consent of Precitec or used
against the due interests of Precitec.
It is intended exclusively for internal use associated with setup and service work.
Any other use is not permitted. Any communication of this documentation to a
third party requires the prior express written permission of Precitec.
We reserve the right to change technical details in the descriptions, information
and illustrations in this documentation.
All in Light, Lasermatic, Laser Path Finder, LWM, the Precitec logo and precitec
are registered trademarks in Germany and/or other countries.
This product group is protected by the patents and utility models below:

DE 10108955 CN 1981976 HK 1105388

DE 102015101263 CN 204867829 KR 1465200
DE 202014105807 EP 1130361 KR 1020177023993
JP 2017539636 EP 3250958 US 6469523
Further patents pending.

Printed in the Federal Republic of Germany.

Responsible for the content

Translation of the original operating instructions

Precitec GmbH & Co. KG

Draisstraße 1
D - 76571 Gaggenau - Bad Rotenfels

Tel.: +49 (0)7225 684-0

Fax: +49 (0)7225 684-900
E-mail: [email protected]

ii © Precitec GmbH & Co. KG • EN 10/2022 D 380311

Table of Contents

Table of Contents

1 Basic safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

1.1 Warranty and liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2 Meaning of symbols and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.3 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
1.4 Basic standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
1.5 Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
1.6 Obligations of operator and personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
1.7 Normal operation safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.1 Protection against electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.2 Risk of injury from moving parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.3 Risk of injury from explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7.4 Risk of injury from laser radiation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7.5 Corrosion in the water cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7.6 Noise occurring during the laser cutting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
1.9 What to do in emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4

2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
2.1 Product view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2.2 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
2.2.1 Protective and monitoring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
2.3 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
2.4 Mechanical dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
2.4.1 Image ratio 100/150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
2.4.2 Image ratio 100/200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
2.5 Hole pattern for connecting customer accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2.6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.6.1 Analysing electronics: EG8030A/EG8040C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.6.2 Communication interface: I/O CAN adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.6.3 Optics Service Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13

3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 14
3.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
3.2 Checking package contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15
3.3 Integration into the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16
3.3.1 Fitting the ceramic part and nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16
3.3.2 Connecting the laser head to the laser fibre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17
3.3.2.1 Fitting the fibre socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17
3.3.2.2 Optimum fibre coupling sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18
3.4 Checking the protective window COL for any contamination. . . . . . . . . . . . . . . . . . . . . 3 - 19

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Table of Contents ProCutter Thunder ECO

3.5 Fixing the laser head to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 20

3.5.1 Image ratio 100/150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 20
3.5.2 Image ratio 100/200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21
3.5.3 Grounding the laser head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 22
3.6 Connecting gas and water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 23
3.6.1 Connecting the cooling water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 23
3.6.2 Connecting the cooling gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 25
3.6.3 Connecting the cutting gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27

4 Commissioning – I/O operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28

4.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28
4.2 Running cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29
4.3 Connecting the laser head to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30
4.4 Configuring the laser head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 34
4.4.1 Carrying out reference travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 34
4.4.2 Setting and approaching the focal position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 34
4.4.3 Adjusting the focal position viewing window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 36
4.5 Adjusting the laser beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 37

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39
5.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39
5.2 Maintenance work summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 40
5.3 Maintenance recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 41
5.4 Maintaining the ceramic part and nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 42
5.5 Maintaining the protective window cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 43
5.5.1 Removing and installing the cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 43
5.5.2 Maintaining the protective window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 44
5.5.3 Maintaining the axial gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 45
5.6 Maintaining the sensor insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 46

6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 47
6.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 47
6.2 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 48
6.2.1 Electrical malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 48
6.2.2 Status LED error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 48
6.2.3 Mechanical malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 49

7 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50
7.1 Basic technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50
7.1.1 Conversion of Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50
7.1.2 Gas quality (ISO 8573-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 50
7.1.3 Cooling water - Dew point temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50

iv © Precitec GmbH & Co. KG • EN 10/2022 D 380311

Table of Contents

7.2 Parts available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51

7.3 Nozzles available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51

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Table of Contents ProCutter Thunder ECO

vi © Precitec GmbH & Co. KG • EN 10/2022 D 380311

1 Basic safety notes

1 Basic safety notes

These operating instructions contain the most important notes for operating the product in compliance
with safety regulations. Observe all instructions and guidelines in this documentation.
In addition, observe the accident prevention regulations and instructions applicable to the area of use.

1.1 Warranty and liability

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

1.2 Meaning of symbols and notes

In these operating instructions the following typographical conventions are used:

Danger!
Indicates an immediate hazardous situation that, if not avoided, will result in death or very serious injuries.
• Observe the instructions to avoid hazardous situations.

Warning!
Indicates a potentially hazardous situation, that, if not avoided, could result in death or very serious
injuries.
• Observe the instructions to avoid hazardous situations.

Caution!
Indicates a potentially hazardous situation, that, if not avoided, could result in minor or moderate injuries.
• Observe the instructions to avoid hazardous situations.

Notice!
Indicates a potentially harmful situation, that, if not avoided, could result in equipment or property
damage.
• Observe the instructions to avoid hazardous situations.

Provides useful information.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 1

1.3 Intended use ProCutter Thunder ECO

Indicates that additional information is available elsewhere, either in the present document or other
documentation.

• Describes the conditions that must be fulfilled to perform the relevant action.

1. Describes the steps that the user must carry out to achieve the objective.

→ Indicates the results of successful actions.

1.3 Intended use

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

1.4 Basic standards

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

2 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

1 Basic safety notes

1.5 Electromagnetic compatibility (EMC)

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

1.6 Obligations of operator and personnel

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

1.7 Normal operation safety measures

Only use the parts supplied or original spare parts and do not connect any other units or cables.
The products must only be operated in compliance with the specifications stated in the Technical Data
sheet.
Only use the product in dry working environments.
If it has been decided that safe operation is no longer possible, the product or machine must be
switched off. The product or the machine must be protected against unintended use.

1.7.1 Protection against electric shock

For operational reasons, components of the laser head such as nozzle body, sensor body, sensor
inserts and nozzle electrodes as well as the accompanying fitting parts such as union nuts etc. cannot
all be connected to protected earth. These components may carry low voltage.
When installing the unit, make sure that the electrical equipment is designed in such a way that
individuals are protected against electric shock.
The regulations contained in EN 60204-1, especially those included in Sections 6 'Protection against
electric shock' and 6.4 'Protection by PELV' (Protective Extra Low Voltage) must be met.
Use a safety transformer in compliance with DIN EN 61588-2 (IEC 61558-2).
Earth the machine according to the regulations.

1.7.2 Risk of injury from moving parts

When lowering the linear drive or robot hand to which the laser head is fitted, there is a risk of injury or
damage to equipment.

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1.8 Storage and transport ProCutter Thunder ECO

Never put your hands or other parts of the body under the laser head.
Repair or maintenance work must only be carried out with the power supply switched off.

1.7.3 Risk of injury from explosion

Laser heads are loaded with gas under pressure depending on their intended use. The specified
maximum pressure must never be exceeded. To ensure that individuals are not harmed, the laser head
must always be kept in perfect condition.
Any connecting elements such as screws and nuts must be tightened firmly.

1.7.4 Risk of injury from laser radiation

Caution – Laser beam!

The laser head does not emit any laser radiation. However, laser radiation is guided through the laser
head. During commissioning the machine may operate in laser class 4.
• Avoid radiation to eyes or skin caused by direct or scattered radiation.
• Do not look directly at the laser beam even using optical instruments.
• Use laser goggles in compliance with DIN EN 207 and BGV B2 that are designed for the wavelength of
the connected laser.
• The machine must be switched off when carrying out any installation or maintenance work.

1.7.5 Corrosion in the water cooling circuit

To avoid any corrosion observe the instructions and maintenance intervals prescribed by the machine
manufacturer, laser source manufacturer or cooling unit manufacturer.
To protect the water cooling circuit (stainless steel) against electro-chemical corrosion, copper or brass
connections must not be used. Only stainless steel or plastic connections can be used.
For pure stainless steel circuits only use water with a conductivity value prescribed by the laser
manufacturer.

1.7.6 Noise occurring during the laser cutting process

With high cutting gas pressure the noise level is >75 dB(A). Noise emitted by the cutting gas depends
on the operating conditions.
To ensure that individuals are not harmed by noise, the manufacturer of the system / machine must
implement relevant safety measures. These measures must be observed by the machine operator.

1.8 Storage and transport

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

1.9 What to do in emergency situations

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

4 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

2 Product description

2 Product description

2.1 Product view

1 15
2
6
7

2
8
3

10
11
4
12
16 17
13
5
14

1 Fibre socket 10 Focal position (viewing window)

2 Water connections, ø6 11 Scale adjustment
3 Cooling gas connection M7x1 / 8 mm deep 12 Nut
4 Cutting gas connection G1/8 13 Ceramic part
5 Sensor insert 14 Nozzle
6 Water connections, ø6 15 19-pin connection
7 Protective window cartridge COL 16 Protective window cartridge, focusing unit
8 Collimating unit (inside) 17 BNC connection
9 Focusing unit (inside)

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2.2 Design and function ProCutter Thunder ECO

2.2 Design and function

The laser head is used for the distance-controlled laser cutting of metals using fibre-coupled lasers on
flat bed machines.
It is precisely engineered, rugged, service-friendly and can be adjusted easily.
All connections on the laser head point upwards.
Fibre plug-in connection
The fibre socket is fitted firmly to the laser head.
All water-conducting parts in the cooling system (integrated in the collimating area) are made of
stainless steel. Fittings for hoses are used for cooling water outflow and inflow.
Precitec offers fibre sockets for its laser heads for connecting conventional fibre optic cables.
Beam shaping optics
The laser head features a drive for the motor-controlled adjustment of the focal position. This can be
used to cut sheet metal of various thicknesses without having to carry out manual adjustment.
The device interface (via an analogue signal from 0.24 to 9.44 V) or the fieldbus sets the required focal
position.
Different focal position ranges can be set depending on the optics configuration (collimating lens or
focusing lens). A characteristic curve is saved for each configuration.
Protective window cartridges
Collimators are equipped with two protective windows which protect the collimating lens from dust and
dirt when the fibre is being removed. One protective window is located in a protective window cartridge
(protective window cartridge COL).
Another protective window is firmly installed in a protective window cartridge below the beam shaping
optics. The protective windows are pressure-proof and can withstand maximum laser head pressure.
Cutting gas
The laser head can be operated at a cutting gas pressure of a max. of 25 bar (2.5 MPa).
The cutting gas also cools the protective window.
Sensor insert
The sensor insert (SE) is fitted firmly to the laser head. It can be removed by undoing four screws. A
ceramic part is fitted to the integral sensor insert from below. It locks into place firmly as it can only be
fitted in one direction and is secured by a union nut (MU).
Nozzle
The nozzle (DE) is screwed into the ceramic part and can be replaced easily if worn. Precitec nozzles
and sensor inserts are very precisely engineered. Because of the minimum concentricity tolerance any
re-adjustment work can be reduced or avoided when replacing these parts.
Fixing to the machine
The laser head is fixed to the machine from the front, using the four ø6.6 mm bore holes. See Chapter
3.3.2, page 3-17. A pin hole ø5,05H7 (5.2 mm deep) and a long hole ø5,05H7 (5.2 mm deep) at the back
are used to position the unit precisely and in such a way that this position can be reproduced.

6 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

2 Product description

Distance controller
For distance-controlled cutting, the laser head is equipped with the capacitive Lasermatic® distance
sensor system. Together with the other control loop components the system guarantees a constant
standoff distance between the nozzle electrode and the workpiece during laser beam cutting if there are
no edges or large workpiece surface bulges in the sensor's scanning range.
Focal position viewing window
The focal position can be read on the scale in the viewing window. The zero mark in the viewing window
stands for the optics’ theoretical zero position with a focal point of 1 mm below the nozzle electrode. The
values shown in the focal position viewing window are not 100% correct. Any tolerances are corrected
at the factory. However,it may be necessary to readjust the display (see Chapter 4.4.3 “Adjusting the
focal position viewing window”, page 36 and Chapter 5.4.3 “Adjusting the focal position viewing
window”, page 54).

2.2.1 Protective and monitoring equipment

Cooling the collimating area
The collimator must be water-cooled. Fittings for hoses are available for cooling water outflow and
inflow. The cooling water is conveyed around the fibre socket and aperture in two stainless steel water
cooling circuits.
Cooling the nozzle
If required, a cooling gas connection with an outlet orifice enables additional nozzle cooling, e.g. when
laser cutting highly reflective materials. The cooling gas connection is located on the sensor insert. If
cooling gas is required, it must be delivered from the outlet orifice to the nozzle using relevant customer
equipment (see Chapter 3.6.2 “Connecting the cooling gas system”, page 25)
Collision detection
When Precitec analysing electronics are used, an electronic collision signal is emitted when the sensor
insert or the nozzle contacts the machine mass. The signal stops the drive or enables the laser head to
take evasive action.
Status LED
An LED on the laser head informs you about the laser head’s status. If the LED lights up red, the
machine must be stopped immediately (noting the process condition) and the cause must be checked/
removed (see Chapter 6.2.1 “Electrical malfunctions”, page 48).

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 7

2.3 Technical specifications ProCutter Thunder ECO

2.3 Technical specifications

Laser head Thunder

Laser wave length 1030– 1090 nm

Laser power max. 6,6 kW
Possible focal lengths (collimating focal length 100, 150, 100, 200 mm
(fC) / focusing focal length (fF))

NA specification 99.0% power enclosed at 120 mrad

(  beam divergence - half angle)
Average transmission > 97% @ 1030– 1090 nm
Max. external acceleration (laser head) 30 m/s2

Max. jolt 1000 m/s3

Max. focal position shift speed max. 185 mm/s
Adjustment range:
• horizontal ±1.5 mm
• vertical -22.5 / +17.5 mm (guaranteed range)
Fitting holes See Chapter 3.5 “Fixing the laser head to the machine”, page
20.
Media connections:
• Cutting gas G1/8, max. 25 bar
• Cooling gas/shielding gas (nozzle) M7, max. 5 bar (0.5 MPa)
• Water cooling circuits M5, max. 5 bar (0.5 MPa), flow rate min. 1.5 l/min
Supply lines with an external / internal diameter of ø6 / ø4 mm
Water cooling circuit (material) Stainless steel
Distance sensor system connection BNC for Lasermatic®
I/O interface operating voltage 24 V ±10%, max. 6 A
Operating temperature 5 to 55 °C
Storage temperature -25 to +55°C (+70°C for a short time)
Humidity 30–95 %, no dew
Dimensions See Chapter 2.4 “Mechanical dimensions”, page 9.
Weight:
• Image ratio 100/150 approx. 5.9 kg
• Image ratio 100/200 approx. 6 kg

8 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

2 Product description

2.4 Mechanical dimensions

2.4.1 Image ratio 100/150

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 9

2.4 Mechanical dimensions ProCutter Thunder ECO

2.4.2 Image ratio 100/200

10 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

2 Product description

2.5 Hole pattern for connecting customer accessories

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 11

2.6 Accessories ProCutter Thunder ECO

2.6 Accessories
2.6.1 Analysing electronics: EG8030A/EG8040C

The adjust box is the analysing electronics for the tried and tested Lasermatic® sensors. The adjust box
delivers either an analogue control voltage or a linear distance signal.
The adjust box also provides an analogue signal for monitoring the sensor insert temperature or plasma
activity. It also creates digital signals, e.g. if a cable is broken, the nozzle touches the workpiece or
interfering contours, the nozzle is lost, the standoff distance is too high etc.

For detailed information on the analysing electronics, please refer to the separate Adjust Box EG8030 /
EG8040C documentation.

2.6.2 Communication interface: I/O CAN adapter

The I/O CAN adapter enables the device interface to communicate (IO) with the primary controller
(digital inputs/outputs, 24 V).
The supply voltage connections are protected by fuses.
Two green LEDs indicate that the unit is supplied with power.

12 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

2 Product description

2.6.3 Optics Service Case

The optics service case is used to store replacement optics and accessories (cleaning materials,
protective covers, auxiliary tools) required for the care and maintenance of the beam shaping optics
(P0001-000-Q0002).

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 13

3.1 Safety notes ProCutter Thunder ECO

3 Installation

3.1 Safety notes

Danger – Electrical voltage!
Electrical voltage can cause life-threatening electric shocks.
• The system must be switched off and protected against being switched on again before carrying out
any installation work.

Warning – Excess pressure!

An excess pressure of up to 25 bar (2.5 MPa) can be supplied to the laser head through the relevant
connection point. The laser head's functional efficiency must always be guaranteed to avoid any
accidents.
• If damaged, the laser head must be protected against accidental use.
• Replace damaged parts.

Caution – Machine movement!

Unexpected machine movement can cause crush injuries.
• During all installation work, no hands or other body parts should be in the proximity of the linear drive or
under the laser head.

Notice – Contaminated optics!

Dust and firmly adhering dirt can lead to burn marks on the optics or damage them.
• Only touch the non-sensitive parts on the optical components.
• Only carry out any work in a clean workplace.

In addition to these specific instructions the general instructions contained in Chapter 1 “Basic safety
notes”, page 1-1 also apply.

14 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

3 Installation

3.2 Checking package contents

Check the package before installing the laser head:
• Are the parts supplied complete (see the delivery note)?
• Is there any visible damage?
Package contents
• Laser head with integrated beam shaping optics (collimating and focusing lenses, protective
window) and sensor insert SE pre-assembled (version as stated on the delivery note)
• Ceramic part (KT B) with O-ring (ø26.00x1.50 Viton) and nozzle (DE)
• Sensor cable
• Analysing electronics (version as stated on the delivery note)

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3.3 Integration into the machine ProCutter Thunder ECO

3.3 Integration into the machine

3.3.1 Fitting the ceramic part and nozzle
This step is only necessary in the case of individual parts delivery.

• The protective window cartridge is installed.

• The beam path is closed.
• The workplace is clean.

2
3
4

1 Sensor insert SE 4 Ceramic part KT B

2 Locating pin 5 Nut MU
3 O-ring 6 Nozzle DE (nozzle electrode)

1. Insert the O-ring (3) into the groove on the sensor insert (1).
2. Insert the ceramic part (4) into the sensor insert carefully.
Note the locating pin (2) on the sensor insert when doing this – it must engage into the ceramic part.
3. Screw the ceramic part to the sensor insert (1) hand-tight using the union nut (5).
The nut must only be tightened by hand. Otherwise the ceramic part could be damaged. Do not use
any tools.
4. Screw the nozzle (6) into the ceramic part hand-tight.
A tool can be used. Tighten the nozzle with a maximum torque of 3 Nm.

→ The ceramic part and nozzle are installed.

16 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

3 Installation

3.3.2 Connecting the laser head to the laser fibre

3.3.2.1 Fitting the fibre socket

• The workplace is clean.

1. Remove any dirt from the plug and the 3 bajonet contours.
2. Move the laser head to a horizontal position.
3. Remove the protective film/ protective cap from the fibre socket.
4. Insert the correctly aligned fibre plug into the unlocked fibre socket up to the stop.
Before inserting the plug make sure that its bayonet contour is aligned with the red marks on the
locking cap and socket.
5. Release the locking cap. The cap will snap into place in the direction of the fibre and lock.
Locking or unlocking the socket is not permitted when the plug is not inserted.

→ The laser head is connected to the laser fibre.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 17

3.3 Integration into the machine ProCutter Thunder ECO

3.3.2.2 Optimum fibre coupling sealing

Processes where a large amount of dust occurs may require the fibre plug/fibre socket interface to be
sealed.

• The ambient temperature is 5 to 35°C.

• The workplace and the fibre plug on the laser head are clean.

1. Cut a strip of adhesive tape. The adhesive tape is very flexible. You will only need a small strip
(about 1/2 of the fibre diameter).
2. Remove the protective film from the adhesive tape.
3. Apply the adhesive tape under the water connections in such a way that the two ends have the
same length and stretch it.

4. Firmly wrap the adhesive tape around the fibre connection. Keep it stretched while doing this.
5. Tape the two ends together.
They should overlap by about 1/3 of the diameter. A larger overlap does not provide better protection
against contamination.

→ The connection between the laser head and laser fibre is better protected against any contamination.

18 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

3 Installation

3.4 Checking the protective window COL for any contamination

We recommend that you check the protective window COL for any contamination when the fibre socket
is connected to the laser head.

Notice - Contaminated optics!

Dust and firmly adhering dirt can lead to burn marks on the optics or damage them.
• Only touch the non-sensitive parts on the optical components.
• Only carry out any work in a clean workplace.

• The workplace is clean.

• Recommendation: Clean the laser head beforehand.
• The pressurised air can is ready at hand.

1 Protective window cartridge COL 3 Screws

2 Cover

1. Loosen the screws (3).

2. Remove the cover.
3. Pull out the protective window cartridge.
4. Check the protective window cartridge for any contamination. If necessary, blow away any dirt
from the protective window with clean pressurised air until it is clean.
If the protective window can no longer be cleaned or if it is damaged, the protective window cartridge
must be replaced. Call service engineer.
5. Insert the protective window cartridge.
6. Insert the cover and screw it on.

→ The protective window COL has been checked for any contamination and has been inserted again.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 19

3.5 Fixing the laser head to the machine ProCutter Thunder ECO

3.5 Fixing the laser head to the machine

Caution - Risk of vibration!
Laser head vibration may cause minor injury.
• Take appropriate measures to prevent the laser head from vibrating.

1. Position the laser head using the pin hole (ø5,05H7, 5.2 mm deep) at the back as required.
2. Fix the laser head to the machine using the four bore holes (ø6.6).

→ The laser head is fixed to the machine and aligned.

3.5.1 Image ratio 100/150

20 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

3 Installation

3.5.2 Image ratio 100/200

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 21

3.5 Fixing the laser head to the machine ProCutter Thunder ECO

3.5.3 Grounding the laser head

Notice!
Improper earthing may cause sensor system malfunctions and damage the machine (moving parts).
• Earth the laser head and machine properly.

1. Connect the two non-anodised bore holes shown in the above figure to the machine mass (PE).

→ The laser head is earthed.

22 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

3 Installation

3.6 Connecting gas and water

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

3.6.1 Connecting the cooling water system

The maximum pressure for the cooling water is 5 bar (0.5 MPa).
The minimum cooling water flow rate is 1.5 l/min.

Notice - Unsuitable cooling water!

Unsuitable cooling water may prevent the laser head from working properly.
• For pure stainless steel circuits only use water with a conductivity value prescribed by the laser
manufacturer. If water cooling circuits consist of different metals, adhere to the laser manufacturer's
instructions.

Notice - Condensation on the optics!

With an unsuitable temperature inside the water cooling circuit condensation can form on the optics.
• The temperature inside the water cooling circuit must be set in such a way that condensation cannot
form on the optics (see dew point, Chapter 7.1.3 “Cooling water - Dew point temperature”, page 7-50).

Notice - Corrosion in the cooling circuit!

Corrosion in the water cooling circuit can prevent the laser head from working properly.
• Observe the instructions and maintenance intervals prescribed by the machine manufacturer, laser
source manufacturer and cooling unit manufacturer.

Precitec recommends that you use a suitable distributor so that the two cooling circuits can be installed in
parallel and as close as possible to the laser head.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 23

3.6 Connecting gas and water ProCutter Thunder ECO

1 Water connections (fibre socket) - ø6/4 mm 2 Water connections (collimating area) - ø6/4 mm

1. Connect the cooling water hoses to the relevant connections on the fibre socket (1).
Supply lines (inlet/outlet) with an external/internal diameter of ø6/ø4mm.
2. Connect the cooling water hoses to the relevant connections in the collimating area (2).
Supply lines (inlet/outlet) with an external/internal diameter of ø6/ø4mm.

→ The cooling water system is connected.

The water cooling circuit flow direction can be freely selected.

The order in which Precitec recommends connecting the hoses is not mandatory.

24 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

3 Installation

3.6.2 Connecting the cooling gas system

Use the optional gas connection if additional nozzle cooling is required. We recommend that you use
the additional gas nozzle cooling device when cutting highly reflective and thick materials.
When delivered, the connection is closed with a locking screw.
The maximum pressure for cooling the nozzle is 5 bar (0.5 MPa).

Remove tab
The connection is covered with a tab when delivered. This must be removed before the first connection
of cooling gas.

3
1

1 Tab 3 Spatter protection plate

2 Screws (2 x M4x6 (SW7))

1. Loosen the screws (2).

2. Remove the splash protection plate (3).
3. Break the tab (1) out of the splash protection plate with a tilting movement.
4. Reattach the splash protection plate to the laser head with the screws.

→ The cooling gas can now be connected.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 25

3.6 Connecting gas and water ProCutter Thunder ECO

Connection

Notice - Unsuitable cooling gas!

Unsuitable cooling gas can prevent the laser head from working properly.
• Only use clean, dry cooling gas (kein O2).
Gas quality in compliance with ISO 8573-1:2010; Solid particles - Class 2, Water - Class 4, Oil - Class 3
(see Chapter 7.1.2 “Gas quality (ISO 8573-1)”, page 7-50).

2
1

1 Cooling gas connection M7x1 (thread, 8 mm deep) 3 Nozzle

2 Cooling gas outlet orifice ø8 mm

1. Connect the cooling gas hose to connection (1).

The fitting must not be sealed using sealing tape or sealing material.
2. Use a tube (supplied by the customer) to supply gas from the outlet orifice (2) to the nozzle (3).
A threaded pin on the sensor is used to fix the tube.

→ The cooling gas system is connected.

The cooling gas flow rate and pressure mainly depend on the laser power used for cutting. Therefore we
cannot recommend a gas pressure value. The correct pressure must be determined by carrying out tests.
Optimum cooling can already be achieved from about 0.5 bar (0.05 MPa).

26 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

3 Installation

3.6.3 Connecting the cutting gas system

The maximum pressure on the laser head is 25 bar (2.5 MPa).
To ensure that the cutting gas pressure is high enough, check that:
• the hose diameter is large enough.
• the hose is as short as possible.
• the hose is run in a straight line (do not use any elbow pieces etc.).
• fittings to reduce the hose diameter are installed as close to the laser head connection as possible.
Notice - Unsuitable cutting gas!
Unsuitable cutting gas may prevent the laser head from working properly. The purer the cutting gas is the
longer the protective window will last.
• Only use clean, dry cutting gas.
Gas quality in compliance with ISO 8573-1:2010; Solid particles - Class 2, Water - Class 4, Oil - Class 3
(see Chapter 7.1.2 “Gas quality (ISO 8573-1)”, page 7-50).

1 Cutting gas connection G1/8, 6 mm deep (for thread)

1. Connect the gas hose to connection (1).

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

→ The cutting gas system is connected.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 27

4.1 Safety notes ProCutter Thunder ECO

4 Commissioning – I/O operation

4.1 Safety notes

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

Caution - Laser beam!

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

Caution - Machine movement!

Unexpected machine movement can cause crush injuries.
• During all commissioning work, no hands or other body parts should be in the proximity of the linear
drive or under the laser head.

Notice - Contaminated optics!

Dust and firmly adhering dirt can lead to burn marks on the optics or damage them.
• Only touch the non-sensitive parts on the optical components.
• Only carry out any work in a clean workplace.

In addition to these specific instructions the general instructions contained in Chapter 1 “Basic safety
notes”, page 1 also apply.

28 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

4 Commissioning – I/O operation

4.2 Running cables

Notice - Unsuitable cables!
Unsuitable or wrongly assembled cables can have a negative effect on sensor system functionality.
• Only use original Precitec cables.

The machine must be planned and designed to conform to applicable standards to ensure its trouble-
free, permanent operation.
• Make sure to comply with applicable DIN regulations (safety, EMC).
• Compliance with these regulations must be guaranteed: DIN EN 50173 - Generic cabling systems,
and DIN EN 50174 - Information technology - Cabling installation.
• Only use suitable cabling systems.
• To comply with EMC standards use suitable materials and carry out any work in a professional
manner.
• When creating the installation plan, please note that the EG and I/O CAN adapter must be not be
installed together with servo amplifiers.
• Run the sensor cables separately from electrically live cables.
• Run the analogue signal cables and digital signal cables separately (see the separate adjust box
documentation).
The basic rules below must be observed when fitting the cables:

When fitting cables, all movements relating to the specific application must be observed
(max. displacement, max. rotation angle).
Avoid extreme robot hand rotation when teaching a process path.

Avoid any strain on cables and plug-in connections.

Cables must not be bent below the minimum bending radius specified in the technical
data sheet.

Cables must not be twisted in such a way that the maximum angle of twist specified in
the technical data sheet is exceeded.

Cables where no angle of twist is indicated must not be twisted.

Wind cables around rotating parts in such a way that the prescribed minimum and
maximum bending radii are observed and cables are not twisted.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 29

4.3 Connecting the laser head to the machine ProCutter Thunder ECO

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

4.3 Connecting the laser head to the machine

The SE sensor insert can be used by the customer for distance measurement.
Cabling summary

3 4
2
1
6

5 - =

1 Laser head 4 Programmable logic controller (PLC)

2 Control cable (max. 20 m) 5 24V power supply unit
3 I/O CAN adapter (see paragraph “I/O CAN adapter”, page
6 I/O cable
31)

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4 Commissioning – I/O operation

I/O CAN adapter

1
2

1 PBus connector (10-pin) SV3 3 I/O connector strip

2 Control cable connector (19-pin) 4 Clips, mounting rail

The I/O CAN adapter enables the device interface to communicate (via the I/O connector strip) with the
primary controller (CNC/PLC, digital inputs/outputs (24 V)).
The supply voltage connections are protected by fuses.
Two green LEDs indicate that the unit is supplied with power.
The adapter has clips for mounting it onto a TS35 mounting rail in the control cabinet.

Notice – Unsuitable fuses!

Unsuitable fuses can prevent the device from working properly.
• If fuses must be replaced, only use fuses of the same type and rating.
-F1 – Littelfuse 02163.15MXP
-F2 – Littelfuse 0216.500MXP

Notice - Current flow too high!

The device may be damaged if the current on the switching outputs is too high.
The current at the switching outputs (PIN-9, PIN-10; optocoupler) must be limited by a suitable external
resistor circuit to a max. of 30 mA.
I/O connector strip

Input/
Output
PIN

Signal Remarks
1 I 24V POWER
Laser head / 24 VDC ±10%, max. 6 A
2 I 0V POWER
3 I 24V I/O
I/O interface / 24 VDC ±10%, max. 0.5 A
4 I 0V I/O
5 - d.n.c. do not connect
(12-pin)

6 - d.n.c. do not connect

7 I REF.TRAVEL Carry out reference travel
8 I AUTOMATIC Accept the focal position
9 A /ERROR Collective error detected
10 A POS.REACHED Position setpoint reached
11 I ANALOG-IN +
ANALOG-IN (0…10 V)
12 I ANALOG-IN –

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4.3 Connecting the laser head to the machine ProCutter Thunder ECO

1. Connect the 19-pin connector and the I/O CAN adapter using the control cable.

2. Connect the 24 V power supply unit to the I/O connector strip (I/O CAN adapter).
PIN assignment (I/O connector strip; adapter): PIN-2, PIN-4: 0 V / PIN-1, PIN-3: 24 VDC

3. Connect all the required I/Os of the laser head to the PLC (see paragraph “I/O CAN adapter
wiring diagram (PLC)”, page 33).

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4 Commissioning – I/O operation

I/O CAN adapter wiring diagram (PLC)

24 V POWER

0 V POWER 24 V / max. 4 A

REF.TRAVEL

AUTOMATIC

0 V (optocoupler)

24 V (optocoupler)

/ERROR

POS:REACHED

ANALOG IN+
ANALOG IN–

Adapter PLC

The adjust box and the laser head must be switched on at the same time to ensure that the two devices
can communicate without any errors.
For detailed information in the event of an error, please refer to Chapter 6.2.1 “Electrical malfunctions”,
page 48.

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4.4 Configuring the laser head ProCutter Thunder ECO

4.4 Configuring the laser head

4.4.1 Carrying out reference travel
Each time the system is switched on, a reference travel procedure must be carried out. This will take less
than 5 seconds.

1. Activate 'REF.TRAVEL' (PIN-7) (2) until the 'POS.REACHED' (PIN-10) (1) output is set.

REF.TRAVEL

POS.REACHED

/ERROR

→ The status LED on the front plate lights up green if reference travel has been completed successfully.
→ If the reference travel procedure has been aborted, '/ERROR' [LOW] (PIN-9) will be set and the
status LED will turn red.

4.4.2 Setting and approaching the focal position

The laser focal position is also called TCP (Tool Centre Point). Normally the TCP is located 1 mm below
the nozzle
An external analogue signal (typically -0.24 – 9.44 V) sets the focal position. Limit switches monitor the
upper and lower limit positions (which are not approached in normal operation). Refer to the
characteristic curve included in the package to determine the required voltage. The exact voltage
depends on the optics configuration. A characteristic curve is saved for each configuration.
Guaranteed range (of travel)
+17.5/-22.5 mm
Setpoint range
±0.15 mm
Calculating the required setpoint value
Setpoint voltage [V] = (focal position [mm] * (-0.213)) + 4.366
Example - required focal position: +1 mm ≈> 4,153 V (setpoint voltage)

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 4 Commissioning – I/O operation

Example - characteristic curve

The characteristic curve shown here is just for reference. The actual characteristic curve is supplied
together with the laser head.

Setting limits
Guaranteed range (of travel)
Setpoint voltage [V]

Focal position [mm]

• The laser head is not under pressure.

• The laser is switched off.
• Reference travel has been carried out.

1. Apply the required voltage to connections PIN-11 (+) and PIN-12 (-).
2. Activate ‘AUTOMATIC‘ (PIN-8) and keep for at least 5 ms.
(min. 2 ms)

ANALOG IN

AUTOMATIC
(min. 5 ms)

POS.REACHED
min. 50 ms

→ The linear drive starts moving until the status LED turns green or 'POS.REACHED' (PIN-10) has been
enabled. Then 'AUTOMATIC' (PIN-8) can be disabled.

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4.4 Configuring the laser head ProCutter Thunder ECO

Typically, focusing lenses are manufactured with a maximum nominal focal length tolerance of ± 1%. As a
result, the adjustment range can be limited and the focal position can vary depending on the lens..
Mechanical manufacturing tolerances, aspect ratios of the optics used and fibre end tolerances also
influence the actual focal position. The focal position can thus vary depending on the lens. Information
about the actual focal position determined at the factory is supplied together with each laser head and
must be observed during commissioning/adjustment.

Each time the focal position setpoint (target position) is changed, the 'POS.REACHED’ (PIN-10) digital
output will be reset for 50 ms - even if the new target position is already within the setpoint range. This
status signal can then be analysed (handshake).

The system continuously monitors the setpoint position. When the setpoint position has been reached
and is within the target value tolerance range, the ‘POS.REACHED’ message will be sent.

4.4.3 Adjusting the focal position viewing window

The values shown in the focal position viewing window are not 100% correct. Any tolerances are
corrected at the factory. However, it may be necessary to readjust the display.

1
2

1 Focal position (viewing window) 2 Extender

1. Check whether or not the value shown in the focal position viewing window (1) matches the
set focal position.
2. If necessary, use the extender (2) and turn until the focal position and the display match.

→ The set focal position and the value shown in the focal position viewing window are the same.

36 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

4 Commissioning – I/O operation

4.5 Adjusting the laser beam

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

Notice - Laser beam not adjusted correctly!

If the laser beam is not adjusted correctly, parts of the laser head can be destroyed during laser cutting.
• Care must be taken when centring the optics.

Notice - Laser beam obstructed!

Damage can occur if the laser beam is obstructed.
• When adjustment is complete, make sure that the laser beam is not obstructed in any way. The laser
beam must be in the centre of the nozzle (nozzle with the correct opening diameter for the cutting
process).

Please note the laser or machine manufacturer's adjustment instructions and use the sample
recommended by him for system setup (commissioning).

• The laser head is not under pressure.

• The distance controller is switched off.
• The laser head does not have any play.
• The laser power recommended by the laser or machine manufacturer has been set.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 37

4.5 Adjusting the laser beam ProCutter Thunder ECO

1 Adjusting screws - direction of X and Y (size 2) 2 Nozzle

1. Screw in a nozzle (2) with a large nozzle opening.

The nozzle opening should be considerably larger than the laser beam diameter at the nozzle
opening.
2. Glue the sample under the nozzle.
3. Trigger a low power laser pulse.
4. Judge the penetration in the sample.
The penetration must be round and in the centre of the nozzle opening. If not, the lens must be
centred.

good bad
5. Centre the lens using the adjusting screws (1) on the laser head.
Use an Allen key (size 2). The maximum adjustment range is ±1.5 mm.
6. Use a new sample. Trigger a low-power laser pulse and judge the penetration in the sample
again. Repeat this procedure until the penetration is good.
7. Screw in a nozzle with a smaller nozzle opening.
8. Centre the lens again as described above.

38 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

5 Maintenance

5 Maintenance

5.1 Safety notes

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

Danger - Safety equipment missing or not active!

Any protective or safety equipment removed during maintenance work will not longer function.
• Any protective or safety equipment removed during maintenance work must be fitted again - then
checked to ensure it is working properly.

Caution - Laser beam!

When carrying out any maintenance work, unexpected laser beams may cause eye damage.
• The system must be switched off and protected against being switched on again before carrying out
any maintenance work.

Caution - Machine movement!

Unexpected machine movement can cause crush injuries.
• During all maintenance work, no hands or other body parts should be in the proximity of the linear drive
or under the laser head.

Attention – Unsuitable spare parts!

Unsuitable spare parts can damage or destroy components.
• Only use the spare parts supplied by Precitec or original spare parts.

Notice - Contaminated optics!

Dust and firmly adhering dirt can lead to burn marks on the optics or damage them.
• Only touch the non-sensitive parts on the optical components.
• Only carry out any work in a clean workplace.

In addition to these specific instructions the general instructions contained in Chapter 1 “Basic safety
notes”, page 1-1 also apply.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 39

5.2 Maintenance work summary ProCutter Thunder ECO

5.2 Maintenance work summary

Precitec GmbH & Co. KG offers expert maintenance and repair services for its products.
Precitec recommends the maintenance work below:

Care/ cleaning
The following work must be carried out regularly:
• Check that the media and cable connections, the head fixing, the cartridges and the nozzle (nozzle
electrode) are connected firmly and do not have any play.
• Remove any contamination.
Wearing parts
Maintain the following parts or replace them if worn:
• nozzle
• ceramic part
• protective window
• axial gasket (protective window cartridge)
Electrical contacts
To ensure that the sensor system works reliably, the electrical contact surfaces on the parts below must
be clean:
• nozzle
• ceramic part
• sensor insert
• BNC connection
Water cooling circuit
To avoid any corrosion observe the instructions and maintenance intervals prescribed by the machine
manufacturer, laser source manufacturer or cooling unit manufacturer.
For pure stainless steel circuits only use water with a conductivity value prescribed by the laser
manufacturer.
To keep the laser head working reliably, Precitec recommends that the cooling water is checked for
microbiological contamination every 6 months (microbiological contamination <100cfu/ml, e.g. Nalco's VARIDOS
bacterial test kit, www.nalco.com).
If, as a result of such tests, test parameter limits are exceeded, the cooling water must be replaced and
the water cooling circuit cleaned or rinsed.

40 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

5 Maintenance

5.3 Maintenance recommendations

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 41

5.4 Maintaining the ceramic part and nozzle ProCutter Thunder ECO

5.4 Maintaining the ceramic part and nozzle

2
3
4

1 Sensor insert SE 4 Ceramic part KT B

2 Locating pin 5 Nut MU
3 O-ring 6 Nozzle DE (nozzle electrode)

1. Check and clean the ceramic part (4) and nozzle (6).
Replace the ceramic part/nozzle if damaged. After a collision the nozzle must be replaced.

Replacing the ceramic part

1. Loosen and remove the nozzle (6).

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

Replacing the nozzle

1. Loosen and remove the nozzle (6).

2. Screw the new nozzle into the sensor insert by hand.
When using a tool, tighten the nozzle with a maximum torque of 3 Nm.

For spare part order numbers, please refer to Chapter 7.2 “Parts available”, page 7-51.

42 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

5 Maintenance

5.5 Maintaining the protective window cartridge

You should have a replacement cartridge ready at hand before you start removing the old one.
If no second protective window cartridge is available, we recommend that you order one from Precitec
(see Appendix) or immediately affix a suitable protective film over the aperture to cover it (see MOCAP's
product range for instance).

5.5.1 Removing and installing the cartridge

1 Protective window cartridge 2 Locking elements

1. Loosen the locking elements (2).

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

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 43

5.5 Maintaining the protective window cartridge ProCutter Thunder ECO

5.5.2 Maintaining the protective window

1 Clamping ring 2 Protective window

1. Put the cartridge on a clean pad.

2. Carefully lift off the clamping ring (1) from the protective window frame (cartridge) and remove
the protective window (2).
3. Clean the protective window (2) using a cleaning pad soaked in methanol. Then blow away any
dirt with clean air (pressurised air spray can). Repeat until the surface is clean.
If the protective window can no longer be cleaned or if it is damaged, it must be replaced.
4. Carefully insert the clean (new) protective window into the cartridge.
5. Insert the clamping ring (1) and protective window.
Always keep the cartridge (with protective window installed) in a horizontal position when carrying it.

You will find the order number of the protective window in Chapter 7.2 “Parts available”, page 7-51.

44 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

5 Maintenance

5.5.3 Maintaining the axial gasket

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

1 Sealing ring DF (axial gasket)

1. Check the seal.

Axial gaskets that are damaged or no longer leakproof must be replaced.
2. Remove the old sealing ring if necessary.
3. Click the replacement sealing ring into the cartridge.

Notice – Faulty seal!

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

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 45

5.6 Maintaining the sensor insert ProCutter Thunder ECO

5.6 Maintaining the sensor insert

1 Sensor insert 4 Screws (2 x M4x6, size 7)

2 Screws (4 x M6x65, size 5) 5 Area to be cleaned
3 Spatter protection plate

Removal

1. Remove the screws (4).

2. Remove the spatter protection plate (3).
3. Remove the screws (2).
4. Remove the sensor insert.
Depending on the temperature and condition of the O-rings, the sleeve above the sensor insert may
come off. In this case the O-rings and sleeve must be inserted again.

Cleaning

1. Use a suitable cleaning pad (swab) from the optics service case and soak it with methanol.
2. Clean the sensor insert and the inner groove (5) with the cleaning pad (swab) soaked in
methanol and blow away any dirt with clean air.
If the sensor insert can no longer be cleaned, it must be replaced.

Fitting

1. Attach the sensor insert to the connection head and tighten the four screws with a torque of
10 Nm.
Make sure the sensor insert is positioned correctly – it must not get stuck!
If the O-ring on the sensor insert is positioned wrongly or defective, the laser head may leak. Make
sure that the O-rings are positioned correctly.
2. Fit the spatter protection plate again and screw it on.

When the sensor insert has been replaced, we recommend that you install a new ceramic part (see Chapter
5.4 “Maintaining the ceramic part and nozzle”, page 5-42).

46 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

6 Troubleshooting

6 Troubleshooting

6.1 Safety notes

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

Danger - Safety equipment missing or not active!

Any protective or safety equipment removed during troubleshooting will not longer function.
• Any protective or safety equipment removed during troubleshooting must be fitted again - then checked
to ensure it is working properly.

Caution - Laser beam!

When carrying out any maintenance work, unexpected laser beams may cause eye damage.
• The system must be switched off and protected against being switched on again before carrying out
any maintenance work.

Caution - Machine movement!

Unexpected machine movement can cause crush injuries.
• During all troubleshooting work, no hands or other body parts should be in the proximity of the linear
drive or under the laser head.

Attention- Unsuitable spare parts!

Unsuitable spare parts can damage or destroy components.
• Only use the spare parts supplied by Precitec or original spare parts.

Notice - Contaminated optics!

Dust and firmly adhering dirt can lead to burn marks on the optics or damage them.
• Only touch the non-sensitive parts on the optical components.
• Only carry out any work in a clean workplace.

In addition to these specific instructions the general instructions contained in Chapter 1 “Basic safety
notes”, page 1-1 also apply.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 47

6.2 Malfunctions ProCutter Thunder ECO

6.2 Malfunctions
6.2.1 Electrical malfunctions

Malfunction Cause Action to be taken

Distance display is wrong and Sensor cable damaged or loose plug-in – Replace the sensor cable or fix the
changes depending on the connection plug-in connection.
position of the machine

Minor standoff distance – Sensor temperature drift Repeat reference point/ two point
changes – Worn nozzle calibration, incl. [NozzLost].
– Contamination
Measuring distance of dis- Ceramic part contaminated/ wet – Clean and dry off the ceramic part
tance sensor system too small, – Check the cutting gas (observe the
large laser head distance when gas quality specifications, see Chapter
approaching the workpiece 3.6.1, page 23)

6.2.2 Status LED error messages

LED indicator Cause Action to be taken

LED lights up not operational after a power cut – Check the 24V connection(power supply
RED unit)
– Carry out reference travel
(see Chapter 4.4.1, page 34)
after faulty reference travel – Check the reference travel procedure at
the machine controller
– Carry out reference travel
(see Chapter 4.4.1, page 34)
Servo overload Motor current consumption too – Check the mechanical parts
high, mechanical problems – Carry out reference travel
(doesn't move smoothly) (see Chapter 4.4.1, page 34)
Laser head too Excess temperature – Let the laser head cool down
hot – Carry out reference travel
(see Chapter 4.4.1, page 34)
LED does no power supply broken cable or faulty, loose – Check the 24V connection(power supply
NOT light up connection unit)
linear drive not Switching output ’POS.REACHED’ – Check the signals
within the target not set
value range
Linear drive position beyond lin- – Check the linear drive setpoint position
(position not per-
mitted)
ear drive limit

48 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

6 Troubleshooting

6.2.3 Mechanical malfunctions

Malfunction Cause Action to be taken

Cutting gas pressure does Cutting gas hose not connected – Connect the cutting gas hose
not build up properly properly
(see Chapter 3.6.3, page 27)
Protective window cartridge loose – Replace the protective window
or protective window damaged cartridge or push in until it clicks
into place
(see Chapter 5.5.2, page 44)
Seals (O-ring) between ceramic part – Replace the worn seal (see
and sensor insert leak Chapter 5.5.3, page 45).
Cutting gas escapes somewhere – Send the laser head back for
else repair.
Nozzle gets too hot Laser beam obstructed (bad focus – Check focus centring
centring) (see Chapter 4.4.2, page 34)
Lens centring device difficult Thread on adjusting screws – Send the laser head back for
to turn damaged or dirty repair.
Focal position cannot be Wrong focal length of the focusing – Replace the laser head.
found in the adjustment lens or focusing lens damaged – Send the laser head back for
range of the vertical repair.
adjustment device
Bad cut • Focus diameter too large – Replace the laser head.
• Wrong focusing lens installed in – Send the laser head back for
the laser head repair.
• Focusing lens damaged or
wrong focal length
Bad focal position/ focus centring – Check the focal position/ focus
centring, remove the error if
necessary.
(see Chapter 4.4.2, page 34)
Protective window dirty – Clean the protective window and
replace if necessary
(see Chapter 5.5.2, page 44)
Alloy affects results (workpiece) – Adapt the cutting parameters.

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 49

7.1 Basic technical information ProCutter Thunder ECO

7 Appendix

7.1 Basic technical information

7.1.1 Conversion of Units

1.0 mm = 0.03937"
25.4 mm = 1.0"
1.0 kg =2.20 lb (pounds)
1.0 bar =0.1 MPa
=14.50 psi (pounds/square inch)
=0.99 atm (atmosphere)
1.0 l (litre) = 1.06 qt (quarts US)
= 0.88 qt (quarts Imp)
0.0284 l = 1.0 fl oz (fluid ounce)

7.1.2 Gas quality (ISO 8573-1)

Class Solid particles (residual dust) Water (pressure dew Oil (aerosol liquid,
point) vapour)
Max. concentration Max. size [µm] [°C] [mg/m3]
[mg/m3]

1 0.1 0.1 -70 0.01

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

7.1.3 Cooling water - Dew point temperature

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

50 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

7 Appendix

7.2 Parts available

Replacement interval
Inspection interval
Cleaning interval
Replacement part
name Designation P number
Ceramic part KT B2" CON P0571-1051-00001 8h 24h 1 month
Nut MU HP P0591-1095-00001 8h 24h 1 month
Sensor insert F150 SE Thunder F150 ECO RD P0690-113821 24h 24h -
Sensor insert F200 SE Thunder F200 ECO RD P0690-113653 24h 24h -
Clamping ring ZM ProCutter 2.0 WK OG PR P0595-73925 24h 24h 12
month
Sealing ring ZM LightCutter DF P0580-53353 24h 24h 12
month
Spatter protection plate ZM ProCutter THUNDER PP P0690-114064 - 12 12
month month
Protective window ZM ProCutter THUNDER WK OG P0690-113732 24h 24h 12
cartridge month
Protective window OG Y D30 d5 P0795-1201 24h 24h 72h
Flowbox ZO BOX CLEAN II P0001-000-Q0002 - - -
Additional electronics ZE I/O ProCutter P0595 - 62407 - - -
device

7.3 Nozzles available

Name Designation P number

Nozzles (DE) - (nozzle electrodes) DE HP1.5" 0.8 P 0591 – 569 – 00008

DE HP1.5" 1.0 P 0591 – 561 – 00010
DE HP1.5" 1.2 P 0591 – 562 – 00012
DE HP1.5" 1.5 P 0591 – 563 – 00015
DE HP1.5" 1.8 P 0591 – 564 – 00018
DE HP1.5" 2.0 P 0591 – 565 – 00020
DE HP1.5" 2.5 P 0591 – 566 – 00025
DE HP1.5" 3.0 P 0591 – 568 – 00030
DE HP1.5" 0.8 CON P 0591 – 673 – 00008
DE HP1.5" 1.0 CON P 0591 – 571 – 00010
DE HP1.5" 1.2 CON P 0591 – 572 – 00012
DE HP1.5" 1.5 CON P 0591 – 573 – 00015
DE HP1.5" 1.8 CON P 0591 – 574 – 00018
DE HP1.5" 2.0 CON P 0591 – 575 – 00020
DE HP1.5" 2.5 CON P 0591 – 576 – 00025
DE HP1.5" 3.0 CON P 0591 – 577 – 00030
DE HP1.5" 4.0 CON P 0591 – 578 – 00040
DE HP1.5" 5.0 CON P 0591 – 579 – 00050

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 51

7.3 Nozzles available ProCutter Thunder ECO

Name Designation P number

DE HP1.5" 1.0 CON DD P 0591 – 002 – 00010
DE HP1.5" 1.2 CON DD P 0591 – 002 – 00012
DE HP1.5" 1.5 CON DD P 0591 – 002 – 00015
DE HP1.5" 1.8 CON DD P 0591 – 002 – 00018
DE HP1.5" 2.0 CON DD P 0591 – 002 – 00020
DE HP1.5" 2.3 CON DD P 0591 – 002 – 00023
DE HP1.5" 2.5 CON DD P 0591 – 002 – 00025
DE HP1.5" 3.0 CON DD P 0591 – 002 – 00030
DE HP1.5" 3.5 CON DD P 0591 – 002 – 00035
DE HP1.5" 4.0 CON DD P 0591 – 002 – 00040
DE HP1.5" 5.0 CON DD P 0591 – 002 – 00050
Nozzle kit (Kit DE) - 4 x [25 per kit] Kit DE HP1.5" 0.8 P 0591 – 569 – Q0008
Kit DE HP1.5" 1.0 P 0591 – 561 – Q0010
Kit DE HP1.5" 1.2 P 0591 – 562 – Q0012
Kit DE HP1.5" 3.0 P 0591 – 568 – Q0030
Set DE HP1.5" 3.0 CON P 0591 – 577 – Q0030
Set DE HP1.5" 4.0 CON P 0591 – 578 – Q0040
Set DE HP1.5" 5.0 CON P 0591 – 579 – Q0050

Set DE HP1.5" 1.0 CON DD P 0591 – 002 – Q0010

Set DE HP1.5" 1.2 CON DD P 0591 – 002 – Q0012
Set DE HP1.5" 1.5 CON DD P 0591 – 002 – Q0015
Set DE HP1.5" 1.8 CON DD P 0591 – 002 – Q0018
Set DE HP1.5" 2.0 CON DD P 0591 – 002 – Q0020
Set DE HP1.5" 2.3 CON DD P 0591 – 002 – Q0023
Set DE HP1.5" 2.5 CON DD P 0591 – 002 – Q0025
Set DE HP1.5" 3.0 CON DD P 0591 – 002 – Q0030
Set DE HP1.5" 3.5 CON DD P 0591 – 002 – Q0035
Set DE HP1.5" 4.0 CON DD P 0591 – 002 – Q0040
Set DE HP1.5" 5.0 CON DD P 0591 – 002 – Q0050

52 © Precitec GmbH & Co. KG • EN 10/2022 D 380311

7 Appendix

D 380311 © Precitec GmbH & Co. KG • EN 10/2022 53

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