LasGAR Basic

Laser gas control valve with Piezo activation and upstream gas valves
LGRB type series analog and digital (EtherCAT/Profinet)
Operating instructions
Version 00

ID no.:
1/20/2022
PS31015A
Version: 00
Date: 2021

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Operating instructions

Table of contents
1 Notes about using the operating instructions .............................................................................. 5
1.1 About these instructions ............................................................................................................ 5
1.2 Warnings used .......................................................................................................................... 5
1.3 Symbols ................................................................................................................................... 6
1.4 Abbreviations............................................................................................................................ 6

2 Basic safety instructions ................................................................................................................ 7

2.1 Intended use ............................................................................................................................ 7
2.2 Personnel qualification .............................................................................................................. 8
2.3 Duties of the machine manufacturer ........................................................................................... 9
2.3.1 Technical requirements ............................................................................................................. 9
2.3.2 Responsibility with regard to the operator .................................................................................... 9
2.4 Responsibility of the operator ................................................................................................... 10
2.5 Duties of the personnel............................................................................................................ 10
2.6 Behavior in case of emergency ................................................................................................. 10
2.7 Personal protective equipment ................................................................................................. 10

3 Product description ...................................................................................................................... 11

3.1 Description............................................................................................................................. 11
3.2 Function ................................................................................................................................ 12
3.2.1 Cutting gas selection ............................................................................................................... 13
3.2.2 Cutting gas control .................................................................................................................. 13
3.2.3 Communication....................................................................................................................... 13
3.2.4 Input filter unit ....................................................................................................................... 14
3.3 Scope of delivery..................................................................................................................... 14
3.4 Technical data ........................................................................................................................ 15
3.5 Type code .............................................................................................................................. 15
3.6 Type plate .............................................................................................................................. 15

4 Transport and storage ................................................................................................................... 16

5 Assembly and installation ............................................................................................................ 17

5.1 Assembly ............................................................................................................................... 17
5.2 Gas installation....................................................................................................................... 22
5.2.1 Gas connections...................................................................................................................... 22
5.2.2 Connecting gases .................................................................................................................... 24
5.3 Electrical installation............................................................................................................... 26
5.3.1 Analog device variant............................................................................................................... 27
5.3.2 Digital device variant ............................................................................................................... 30
5.3.3 Connection of upstream valves (gas selection)............................................................................ 35

6 Start-up .......................................................................................................................................... 39
6.1 Start-up ................................................................................................................................. 39

7 Operation ....................................................................................................................................... 40
7.1 Switching on .......................................................................................................................... 40

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Operating instructions

7.2 Switching off .......................................................................................................................... 40

7.3 Selecting cutting gas input ...................................................................................................... 40
7.4 Querying the target value ......................................................................................................... 41
7.5 Changing cutting gas ............................................................................................................... 42
7.6 Calibration and function check ................................................................................................. 43
7.7 Additional functions ................................................................................................................ 44
7.8 Process data objects................................................................................................................ 45

8 Troubleshooting ............................................................................................................................ 47
8.1 Restoring the power supply ...................................................................................................... 50

9 Service ........................................................................................................................................... 51
9.1 Inspection and maintenance plan ............................................................................................. 51
9.2 Filter change in the input filter unit .......................................................................................... 52
9.2.1 Taking device out of service ..................................................................................................... 53
9.2.2 Changing the gas filter............................................................................................................. 53
9.2.3 Changing the control air filter ................................................................................................... 54

10 Decommissioning and disposal ................................................................................................... 55

10.1 Decommissioning/dismantling .................................................................................................. 55
10.2 Disposal ................................................................................................................................. 55

11 Appendix ........................................................................................................................................ 56
11.1 Product observation................................................................................................................. 56
11.2 Material defects and defects of title .......................................................................................... 56
11.3 Declaration of conformity ......................................................................................................... 57

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Operating instructions
Notes about using the operating instructions

1 Notes about using the operating instructions

1.1 About these instructions
These operating instructions serve to explain how to transport, assemble, and put the
LasGAR into service, prevent personal injury and property damage, guarantee fault-free
operation, and avoid damaging the environment. In addition, the operating instructions
contain information for the operator of the machine in which the LasGAR is installed.
1. The operating instructions are part of the product. Keep the operating instructions
carefully.
2. Transfer the operating instructions to any subsequent owner or user.
For additional information, contact the manufacturer at the following address:
HOERBIGER Flow Control GmbH
Südliche Römerstraße 15
86972 Altenstadt
Germany
Information on the Internet: www.hoerbiger.com

1.2 Warnings used

Warnings warn about dangers that can occur when handling the product. There are four
danger levels with the following signal words:
Signal word Meaning
DANGER Identifies a danger with high risk that can cause death or
severe injury.

WARNING Identifies a danger with a medium risk that can cause death
or severe injury.

CAUTION Identifies a danger with a low risk that can cause slight or
moderate injury.

NOTICE Identifies a danger that can cause property damage.

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Operating instructions
Notes about using the operating instructions

1.3 Symbols

This symbol indicates useful and important information.

ü This symbol stands for a prerequisite that must be fulfilled before performing an
action.
ð This symbol stands for an individual action to be performed.
1. Numbers indicate several steps to be performed in an action instruction: Step 1
2. Step 2
9 This symbol stands for the intermediate result of an action.
9 This symbol stands for the result of an entire action instruction.

1.4 Abbreviations
Term / Abbreviation Explanation
PDO Process data object

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Operating instructions
Basic safety instructions

2 Basic safety instructions

2.1 Intended use
The LasGAR serves to control the cutting gas pressure for switching laser welding gases
on and off when laser cutting. The device may only be used within the specified power
limits. For specification, see technical data sheet.
ü All requirements for the safety of the device are fulfilled, see chapter Technical re-
quirements, page 9.
ü All legal requirements are fulfilled for the machine in which the device is installed.
ü All safety equipment is properly installed and functional.
ü The operating personnel have received initial training from the machine manufac-
turer.
1. Ensure that employees working on the device have the required qualification.
2. Only use the device in connection with laser cutting equipment.
3. Only operate the device with the defined media, see technical data sheet.
4. Only operate the device with dry, dust- and particle-free, pure gases, see technical
data sheet.
5. Do not reconfigure the device or change it in any way.

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Operating instructions
Basic safety instructions

2.2 Personnel qualification

Unqualified personnel cannot detect risks and is therefore subject to greater dangers.
1. Only commission qualified personnel with the activities described in these
instructions.
2. Make sure that the personnel adheres to the locally valid regulations and rules for
safe and danger-conscious work.
The following target groups are addressed in these instructions:
Trained person: A trained person is somebody who has been trained extensively by the
operator in his tasks in connection with the safe operation of the valves.
Training is conducted by specialized personnel.
Electrically-qualified person: An electrically-qualified person is somebody who, based on
his specialized training, knowledge, and experience, as well as knowledge of the
applicable regulations, can judge and perform the work with which he is commissioned
and detect possible hazards independently.
Pneumatically-qualified person: A pneumatically-qualified person is somebody who, based
on his specialized training, knowledge, and experience with respect to pneumatic
components and systems as well as knowledge of the applicable regulations, can judge
and perform the work with which he is commissioned and detect possible hazards –
especially with respect to interactions between pneumatic, mechanical, electrical, and
control-technical components – independently.

Activity Authorization
■ Assembly ■ Trained person
■ Start-up ■ Qualified person

■ Installation incl. electrical connection ■ Electrically-qualified person

■ Work on the pneumatic systems ■ Pneumatically-qualified person

■ Operation ■ Trained person

■ Service ■ Qualified person

■ Troubleshooting
■ Elimination of faults
■ Taking out of service

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Operating instructions
Basic safety instructions

2.3 Duties of the machine manufacturer

2.3.1 Technical requirements

Damage due to carbon dust
Carbon dust from compressed air compressor can damage the valve.
■ Avoid carbon dust.

1. For adherence to the media quality for cutting gases and control air prescribed in the
chapter , suitable filters, compressed air dryers, and oil separators must be provided,
if possible near the valve connections.
2. Use screw connections with O-rings to connect pipes. NOTICE! PTFE seals and liquid
seals may not be used since parts can loosen and contaminate the valve.
3. Flush or pig compressed air and gas lines for the device before installation in order to
remove all particles and deposits in the line completely, see chapter Connecting
gases, page 24.
4. Do not use the device as a safety valve for pressure limitation.
5. Ensure that the construction surrounding the device can safely absorb the static and
dynamic forces arising during operation.
6. After assembly of the device, perform a sound measurement and take suitable sound
protection measures if necessary.
7. Set up the main switch and EMERGENCY STOP switch on the superior controller of
the machine.
8. Provide gas supply, gas lines, and connections according to the device's
requirements; see chapter Gas installation, page 22.
9. Make sure that the media pressures on the device do not cause any hazard, see
technical data sheet.
10. Only use suitable pressure lines.
11. Adhere to the storage and operation duration for the line specified by the
manufacturer of the pressure line.

2.3.2 Responsibility with regard to the operator

1. Complete operating instructions according to the results of the risk assessment and
the safety measures taken.
2. Determine the relevant content of the operating instructions for the operator and
transfer the operating instructions to the operator of the machine.

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Operating instructions
Basic safety instructions

2.4 Responsibility of the operator

The assumed duties of the operator are:
1. Adherence to operational safety regulations.
2. Adherence to the valid national occupational safety regulations.
3. Adherence to the intended use of the valve.

2.5 Duties of the personnel

1. Carefully read and understand operating instructions before assembly and starting up
the device.
2. Heed and follow all safety instructions, notes, requirements, and information.
3. Keep operating instructions in the immediate area during installation and start-up.

2.6 Behavior in case of emergency

1. Switch off main switch of the machine in order to de-energize the machine.
2. Switch off gas supply.
3. Secure machine against unintentional switching on.
4. Command all people to leave the danger zone.
5. Secure the danger zone.
6. Inform responsible supervisor.
7. Rescue injured persons from the danger zone as soon as it is possible to do this
without endangering yourself.

2.7 Personal protective equipment

Flying parts, escaping liquids, and sharp edges can cause severe and life-threatening
injuries.
1. When working on pneumatic systems, wear eye protection according to EN 166.
2. Wear work gloves according to EN 388.

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Operating instructions
Product description

3 Product description
3.1 Description
Devices in the LasGAR type series are used for efficient gas control in laser cutting
machines and are typically composed of the following components:
1. Gas control valve for regulation of the cutting pressure
2. Digital or analog communication interface
3. Upstream valve unit with switching valves for gas selection
4. Input filter unit to protect against coarse dirt particles from the supply line
The structure is modular and can vary depending on the installation situation.
The following are available type series:
■ LasGAR Basic: The entry-level device offers optimized pressure and flow for all
machines with low and medium laser power up to approx. 10 kW.
■ LasGAR Plus: The high-performance device offers increased pressure and flow for all
machines with high laser power up to 30 kW.

1
4

Fig. 1: Example: Gas control valve (for variants, see technical data sheet)

1 Gas control valve basic or plus 3 Upstream valve unit (option)

2 Communication interface 4 Input filter unit (option)

The compact, ready-to-use unit can be installed in laser cutting machines and connected
using gas and electric connections.

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Operating instructions
Product description

3.2 Function
In the following, the general functional principle will be explained using the example of a
LasGAR device with the filter unit, 3-gas upstream valve unit, and gas control valve
components:
1. The input filter unit (option) protects devices against particles from the gas supply
lines.
2. The upstream valve unit (option) switches gases applied to the inlet on or off.
3. The communication interface establishes the connection between the machine
control and the gas control valve.
4. The gas control valve regulates the input pressure of an applied cutting gas and the
required output pressure.

5 6 7

y1
y4

y2
8

y3

3 9

Fig. 2: Example: Pneumatic switching principle

1 Input gas 1 6 3-gas upstream valve unit

2 Input gas 2 7 Gas control valve
3 Input gas 3 8 Gas output
4 Input control pressure 9 Communication interface - analog or
5 Input filter unit digital

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Operating instructions
Product description

3.2.1 Cutting gas selection

The cutting gases applied to the input of the upstream valve unit are fed by switching
one of the integrated 2/2-way valves Y1, Y2, or Y3 to the input of the control valve Y4.
The valves must be electrically locked against one another. Depending on the device
model and options purchased, there are different variants for the valve control and
locking, as shown in the following table:
LasGAR Basic HOERBIGER Activation of the Locking of the
Upstream valve upstream valves upstream valves
analog with provided by provided by
customer customer

without provided by provided by

customer customer

digital with Only with accessory Via accessory

Y-cable, then to Y-cable
connection X2

without provided by provided by

customer customer

3.2.2 Cutting gas control

The control valve Y4 regulates the output pressure according to the target value specified
by the machine control and provides the pressure to the laser cutting head.
The pressure sensor P1 measures the input pressure of the control valve. The current
value is output as an analog signal for processing by the machine control.
The following functions can be implemented by the customer:
■ Check whether the current pressure at the control valve input is higher than the
selected pressure target value.
■ Securing against gas mixing during cutting gas switching. The switching occurs only
when the pressure P1 is lower than the pressure of the newly selected gas.
In addition, for the “digital communication” model, warnings are output if the input
pressure is too low.
The pressure sensor P2 handles the electronic control for recording the actual pressure.
The value is also output as an electric signal.
For quick pressure reduction, the control valve is able to ventilate the pressure at the
output via integrated ventilation holes.

3.2.3 Communication
Depending on the model, the communication with the machine control is handled in
analog (0 – 10 V, 4 – 20 mA) or digital (EtherCAT/Profinet) fashion.

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Operating instructions
Product description

3.2.4 Input filter unit

The optional input filter unit is a particle filter with 2 or 3 filter cartridges (10 µm
apiece) on the cutting gas inputs and a filter screen (100 µm) at the control pressure
input. The filter cartridges protect the upstream valves, the control valve, and
downstream components such as the cutting heads against large dirt particles and can
be changed out.

3.3 Scope of delivery

The scope of delivery includes:
■ Laser gas valve according to model selected; see type key on the transport carton
■ Accompanying card with link to product page (QR code)

Gas lines and connections are not included in the scope of delivery.

The detailed operating instructions can be downloaded from the Internet at

www.hoerbiger.com.

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Operating instructions
Product description

3.4 Technical data

Technical data, see technical data sheet.

3.5 Type code

Type key, see technical data sheet.

3.6 Type plate

1
2
3
4
7
5
6

Fig. 3: Type plate

1 Product name 5 Software version number

2 ID number 6 Type designation
3 Serial number 7 Data matrix code
The data matrix code includes the
content of the type plate.
4 Date of manufacture (ww/yy)

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Operating instructions
Transport and storage

4 Transport and storage

Damage due to missing packaging!
The device can be damaged due to packaging missing during transport and storage.
■ Only transport and store the device in the original packaging.

The LasGAR is packed in a carton. The device can be moved by hand.

1. Transport the device to the installation location and unpack it immediately prior to
installation.
2. Place the packaging materials in the recycling container.
3. The pneumatic connections are secured with a protective film against dirt
penetration. Only remove this protective film immediately before connecting the
pneumatic lines.

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Operating instructions
Assembly and installation

5 Assembly and installation

5.1 Assembly

DANGER
Mortal danger due to flying parts!
Improperly fastened parts can fly around and cause life-threatening injuries.
■ Ensure that the construction surrounding the device can safely absorb the static and
dynamic forces arising during operation.
■ Fasten the device as specified using 2 fastening holes at the rear or 3 fastening holes
on the side.
■ Use screw locking to fasten the device.
■ Adhere to tightening torques.

CAUTION
Personal injury or property damage due to incorrect installation position!
Incorrect installation position can cause disturbances in the valve function. Personal
injury and property damage can result.
■ Be sure to heed the vertical installation position according to the following figures.

CAUTION
Personal injury or property damage due to covered ventilation openings!
Covered ventilation openings can cause severe injuries and damage to the valve.
■ Make sure that the distance between the ventilation openings and the surrounding
parts is at least equal to the opening diameter.

X
Fig. 4: Fastening single controller without connection plate, through bore d 4.2

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Assembly and installation

X X

Fig. 5: Fastening single controller with connection plate, through bore d 4.2

Fig. 6: 2- and 3-gas special model, fastening from above, through bore d 6.5

X X
Fig. 7: 2- and 3-gas special model, fastening from front, through bore d 6.5

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Assembly and installation

X X
Fig. 8: 2- and 3-gas standard model with filter block, fastening from above, through bore d 6.5

X X
Fig. 9: 2- and 3-gas standard model with filter block, fastening from front, through bore d 6.5

X X
Fig. 10: 1-gas model, fastening from above, through bore d 4.2

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X X

Fig. 11: 1-gas model, fastening switching valve (optional), M4 thread

X X
Fig. 12: 2- and 3-gas standard model, fastening from above, through bore d 6.5

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Fig. 13: 2- and 3-gas standard model, fastening from front, through bore d 6.5

y
y

Fig. 14: Ventilation openings

1. Fasten devices via the fastening bores securely and vibration-free.

2. For the single controller with and without connection plate, use M4 screws,
tightening torque 2.8 ± 0.5 Nm.
3. Fasten all other models with M6 screws, tightening torque 9.5 ± 0.5 Nm.
4. Use screw locks.
5. Make sure that the ventilation openings are always free and not partially or
completely covered. Only then is correct operation guaranteed.

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Assembly and installation

5.2 Gas installation

5.2.1 Gas connections

Fig. 15: Gas connection

1 Cutting gas output G¼

Fig. 16: Gas connection single controller

1 Cutting gas input 1 G⅜ 2 Cutting gas output 1 G¼

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Assembly and installation

1 2
Fig. 17: Gas connection 1-gas variant

1 Proportional valve input G⅛ (PST) 3 Cutting gas input G⅜

2 Cutting gas output G¼ 4 Switching valve input M5

5
1
2

Fig. 18: Gas connection 2- and 3-gas variant with or without filter

1 Cutting gas input G⅜ 4 Cutting gas input G⅜

2 Control air input M5 5 Cutting gas output G¼
3 Cutting gas input G⅜

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Operating instructions
Assembly and installation

5.2.2 Connecting gases

DANGER
Mortal danger due to improperly connected pressure lines!
The pressure lines are under high pressure. Improperly connected lines can loosen under
pressure, whip around, and cause life-threatening injuries.
■ Only have the device started up by trained personnel.
■ Only have faults on the device eliminated by trained personnel.
■ Before start-up and troubleshooting, check the connections.
■ Only have compressed air supply and cutting gases connected by trained personnel.
■ Before installation, depressurize all lines and lock them against switching on again.
■ Only operate the device within the prescribed power limits, see technical data sheet.
■ Do not use any grease when mounting the lines (e.g. threaded connections).

DANGER
Mortal danger with use of oxygen as cutting gas!
Using oxygen as a cutting gas can cause life-threatening injuries and damage to the
device.
■ Heed maximum operating pressure; see technical data sheet.
■ When changing filter cartridges in the input filter unit, only use greases that are
suitable for oxygen.

WARNING
Personal injury and property damage due to undefined machine states!
Undefined machine states can cause severe injuries and damage to the valve.
■ Wear prescribed protective equipment.

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Operating instructions
Assembly and installation

CAUTION
Personal injuries and property damage due to contaminated compressed air or
gas lines!
Contaminated compressed air or gas lines can cause injuries and damage to the valve.
■ Only use dry, clean compressed air and gases. Adhere to the media quality; see
technical data sheet.
■ Before each gas connection, place a filter with max. 10 µm mesh size upstream. Do
not use filters based on sintering material.
■ Only supply compressed air and gases through clean lines free of particles and dust.
■ Flush compressed air and gas lines before connection to the valve or clean them with
a brush (cleaning scraper) in order to remove particles and deposits (see Fig. Clean-
ing the gas line with cleaning scraper, page 25 below).
■ Only use O-ring seals for compressed air and gas connections (see Fig. Screwing with
O-ring seal, page 25 below); do not use PTFE sealing tape, pastes, adhesive
threaded seals, or hemp.

Cleaning scraper

Media flow

Line Deposits
Fig. 19: Cleaning the gas line with cleaning scraper

Fig. 20: Screwing with O-ring seal

1. Remove protective films from the connections.

2. Connect gas lines according to drawings in chapter Gas connections.
3. Connect control air supply to the control air connection.
4. Connect argon, compressed air, oxygen, or nitrogen supply to the connections Gas 1,
Gas 2, or Gas 3.
5. Check connections for tight fit and leaks.

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Operating instructions
Assembly and installation

5.3 Electrical installation

For the electrical installation, 2 device variants are distinguished:
■ LasGAR Basic analog (0 – 10 V or 4 – 20 mA)
■ LasGAR Basic digital (EtherCAT or Profinet)

1 2
Fig. 21: Electrical connections

1 Analog input/power supply X1 2 Digital input/communication

interface

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5.3.1 Analog device variant

1
10
9

Fig. 22: Connection of cable screen

1 Screen line to connection X1 2 Connection to machine body

If necessary, the screening clamps can be moved to the opposite housing side.

1. Connect the 24 V power supply to X1.

2. Check plug connection for correct fit.
3. Connect the screen of the connection line to the machine body.
4. To improve the immunity to EMC interference, strip the cable to plug connection X1
approx. 150 mm away from the plug to approx. 20 mm and fasten it in the screen
clamp (1).
5. To improve the immunity to EMC interference, connect the valve via one of the two
grounding connections on the housing to the machine body (2) using a line with as
large a cross section as possible.
Plug connection Connection Pin assignment
X1 Control signals 1: 24 V
M12x1 A-coded 2: Target value
8-pin plug
3: GND
4: Input pressure P1
5: Output pressure P2
6: Ready/pressure reached
7: UART RxD
8: UART TxD

Tab. 1: Analog connection

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Assembly and installation

Power pack

Analog In
Controller

Digital In/Out

Analog Out

Fig. 23: Block switching diagram, single controller, analog

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Operating instructions
Assembly and installation

Power pack Analog In Digital In/Out Analog Out

Controller

Fig. 24: Block switching diagram, 2-gas variant, analog

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Assembly and installation

Power pack Analog In Digital In/Out Analog Out

Controller

Fig. 25: Block switching diagram, 3-gas variant, analog

5.3.2 Digital device variant

1. Connect 24 V power supply to X1. NOTICE! Do not connect pin 2!
2. Connect input cable to X2 EtherCAT or Profinet.
3. Check plug connection for correct fit.
4. Connect the screen of the connection lines X1 and X2 to the machine body.
5. In order to improve the immunity to EMC interference, strip the insulation from the
cable on the plug side and fasten the cable screen to the machine body with a
grounding clip.

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Assembly and installation

Plug connection Connection Pin assignment

X1 Power supply 1: 24 V
M12x1 A-coded 2: Do not connect!
8-pin plug
3: GND
4: Gas output 1
5: Gas output 2
6: Gas output 3
7: UART RxD
8: UART TxD

X2 EtherCAT/Profinet input 1: TD+

M12x1 D-coded 2: RD+
4-pin socket
3: TD-
4: RD-

Tab. 2: EtherCAT and Profinet connections

Power pack

Digital In/Out
Controller

Fig. 26: Block switching diagram, single controller, digital

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Assembly and installation

Power pack Digital In/Out

Controller

Fig. 27: Block switching diagram, 2-gas variant, digital

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Power pack Digital In/Out

Controller

Fig. 28: Block switching diagram, 2-gas variant with double N2 input, digital

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Assembly and installation

Power pack Digital In/Out

Controller

Fig. 29: Block switching diagram, 3-gas variant, digital

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Operating instructions
Assembly and installation

5.3.3 Connection of upstream valves (gas selection)

Fig. 30: 2-Gas upstream valve block

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Operating instructions
Assembly and installation

Fig. 31: 3-Gas upstream valve block

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Operating instructions
Assembly and installation

Fig. 32: 3-Gas upstream valve block with quick ventilation valve

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Operating instructions
Assembly and installation

Fig. 33: Electrical connection schema LasGAR Basic digital with activation of upstream valves via
Y-cable

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Operating instructions
Start-up

6 Start-up
6.1 Start-up

DANGER
Mortal danger due to improperly connected pressure lines!
The pressure lines are under high pressure. Improperly connected lines can loosen under
pressure, whip around, and cause life-threatening injuries.
■ Only have the device started up by trained personnel.
■ Only have faults on the device eliminated by trained personnel.
■ Before start-up and troubleshooting, check the connections.
■ Only have compressed air supply and cutting gases connected by trained personnel.
■ Before installation, depressurize all lines and lock them against switching on again.
■ Only operate the device within the prescribed power limits, see technical data sheet.
■ Do not use any grease when mounting the lines (e.g. threaded connections).

WARNING
Personal injury and property damage due to undefined machine states!
Undefined machine states can cause severe injuries and damage to the valve.
■ Wear prescribed protective equipment.

1. Check whether electrical cables and gas lines are connected correctly as described in
the chapters Gas installation, page 22 and Electrical installation, page 26.
2. Connect compressed air supply, control air, and cutting gases to superior air and gas
supply.
3. Switch on 24 V power supply.

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Operating instructions
Operation

7 Operation
7.1 Switching on
ð Switch on the 24 V power supply for the device.
9 The initialization starts.
9 After a few seconds, the device is ready for operation and goes into the operating
state specified by the input signals:
– Analog variant: Connection X1, digital output “Ready”
– Digital variant: via PDO GAS_STA Bit 1

7.2 Switching off

ð Switch off 24 V power supply of the device.
9 The cutting gas output of the device is ventilated.

7.3 Selecting cutting gas input

Depending on the model, the cutting gases are selected via already-existing external
upstream valves or via the upstream valves provided by HOERBIGER.
For correct functionality and to prevent a mixing of the gases, a special activation logic
must be used. Below is an example for a safe activation of the different cutting gases.

Activation of the cutting gases must be done via the machine control. For the digital
variant, with a Y-cable (option), activation is also possible via the bus communication,
see Fig. Electrical connection schema LasGAR Basic digital with activation of upstream
valves via Y-cable, page 38.

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Operating instructions
Operation

Ethercat
Analog
Gas 1

Gas 2

Gas 3

Control air

Valve output

1 2 3 3
Fig. 34: Example activation logic of upstream valves – valve output

1 Switch-on time cutting gases tON: 3 Electric control inputs

approx. 80 ms1) interlocking 3)
2 Switching time for cutting gases in
case of gas change tCHANGE: approx.
230 ms 1) 2)

1)
The time from switching on the upstream valve until gas is available at the input of
the control valve.
2)
After switching off a gas, all control inputs for the gas selection are locked for
150 ms (tLOCK). As soon as the time has elapsed, the inputs are active again; that
is, with delay-free switching of the gases, the selected gas is available at the output
after 230 ms.
3)
To protect against the simultaneous selection of several gases, the electric control
inputs for gas selection are interlocked.

7.4 Querying the target value

The output pressure is regulated according to the target value specification that comes
from the machine control. Here, the following inputs are used:
■ Analog variants: X1, Pin 2
■ Digital variants: 0 … 20000 digits, process data object (PDO) P_SOLL

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Operation

7.5 Changing cutting gas

The type of installation behind the cutting gas output of the valve is crucial for the
selection of a time-optimal procedure for the cutting gas change.
If necessary, the optimal procedure must be determined via tests.
The use of pressure sensors for input and output pressure allows quick gas change times.

With use of a large cutting nozzle or a small hose and cutting head volume:
Variant 1
From low output pressure to higher output pressure (e.g. gas 1: 0.6 bar to gas 2: 10 bar).
1. Switch off the active upstream valve through the machine's control signals.
2. Set target value to P2max:
Analog variant: 10 V DC or 20 mA (depending on the variant)
Digital variant: 20000
9 The input pressure on the proportional valve is reduced via the still-present target
value.
3. Switch on the upstream valve for the desired cutting gas, see chapter Selecting
cutting gas input, page 40.
Variant 2
From high output pressure to lower output pressure (e.g. gas 1: 10 bar to gas 2: 0.6 bar).
1. Switch off the active upstream valve through the machine's control signals.
2. Set target value to P2max:
Analog variant: 10 V DC or 20 mA (depending on the variant)
Digital variant: 20000
9 The input pressure on the proportional valve is reduced via the still-present target
value
3. Wait until the value of the input pressure sensor on the device is lower than the
bottle pressure of the new desired gas.
4. Switch on the upstream valve for the desired cutting gas, see chapter Selecting
cutting gas input, page 40.
5. Specify the new target value through the machine's control signals.

Changing the cutting gas when using a small cutting nozzle or a large hose/
cutting head volume
Variant 1
From low output pressure to higher output pressure (e.g. gas 1: 0.6 bar to gas 2: 10 bar).
1. Switch off the active upstream valve through the machine's control signals.
2. Set target value to 0 bar:
Analog variant: 10 V DC or 20 mA (depending on the variant)
Digital variant: 00000
9 The input pressure on the proportional valve is reduced via the ventilation
connection of the valve.
3. Switch on the upstream valve for the desired cutting gas, see chapter Selecting cut-
ting gas input, page 40.

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Operation

Variant 2
From high output pressure to lower output pressure (e.g. gas 1: 10 bar to gas 2: 0.6 bar).
1. Switch off the active upstream valve through the machine's control signals.
2. Set target value to 0 bar:
Analog variant: 10 V DC or 20 mA (depending on the variant)
Digital variant: 00000
9 The input pressure on the proportional valve is reduced via the still-present target
value.
3. Wait until the value of the input pressure sensor on the device is lower than the
bottle pressure of the new desired gas.
4. Switch on the upstream valve for the desired cutting gas, see chapter Selecting
cutting gas input, page 40.
5. Specify the new target value through the machine's control signals.

For optimal ventilation times, the option QEV – quick exhaust valve can be ordered, see
type code. If only 2 cutting gases are used with the 3-gas variant, the third, free
switching valve can be used as a quick exhaust valve. If 3 cutting gases are used, the
quick exhaust valve is a separate screw-in valve.

7.6 Calibration and function check

The LasGAR Basic analog initializes automatically with each input process and then
reports the operating state “ready”. If the “ready” signal does not come, there is a fault,
see chapter Troubleshooting, page 47.
The LasGAR Basic digital has a calibration of the sensors, whereby the sensor values are
zeroed. This can be triggered via the digital communication interface without
disconnecting the valve from the power supply.
Calibration procedure for LasGAR Basic digital:
1. Set the input pressure in front of the proportional valve to 0 bar.
2. Trigger calibration process: GAS_SEL bit 3 = 1, see chapter Process data objects,
page 45.
3. Wait for response: GAS_STA bit 4, value = 1 (successful), value = 0 (error)

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Operating instructions
Operation

7.7 Additional functions

For the process logging and monitoring by a superior control, the following responses are
available via the valve outputs. Depending on the variant, this information can be queried
directly or via the digital interface, see chapter Electrical installation, page 26.

LasGAR Basic analog and digital

■ Input pressure p1 of the currently selected cutting gas, measured with pressure
sensor P1
■ Output pressure p2 of the currently selected cutting gas, measured with pressure
sensor P2

LasGAR Basic analog

■ Ready signal (pin 6) includes the following status: Power supply, controller output
and sensors. Error messages, see chapter Troubleshooting, page 47.
Switch conditions for “ON” = pressure reached:
(actual pressure-target pressure) < 4 % of pressure target value + 0.1 bar (stored
fixed in the controller, can only be adjusted via Bluetooth app in level 2/3 > Analyze/
Optimize)
■ Automatic target value compensation: In order to compensate for voltage drops in the
signal line, the target value is set to 0 automatically when the controller is switched
on.
Prerequisite: When switching on the controller, the machine controller must output
the pressure target value 0 bar (0 V DC).

LasGAR Basic digital

■ Pressure reached signal GAS_STA Bit 0 output, value = 1 (pressure reached). Error
messages as for analog variant on GAS_STA Bit 0.
■ Ready signal via GAS-STA Bit 1 output, value = 1 (Ready).
Switching conditions for “ON” = pressure reached:
(actual pressure-target pressure) < 4 % of pressure target value + 0.1 bar, adjustable
via PR_RE in the range ± 17 %

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Operation

7.8 Process data objects

Objects Function Size Value Description
PR_RE: Output 1 Word Target value Measurement window pressure
Pressure reached
reached [%] Format: 0x0000

P_IST: 1 Word Actual value Response actual pressure

actual value 0 to 20000 [mbar]

PV_IST: 1 Word Pre-pressure Response pre-pressure

pre-pressure 0 to 30000 [mbar]

GAS_STA: 1 Word Bit 0: Response pressure reached

gas status Pressure 1 = ready
reached

Bit 1: Response controller ready

Controller 1 = ready
status

Bit 2: Response supply gas

Gas warning <110 %* target Gas warning:
input pressure < set value
*1.1 1 = fault

Bit 3: Response supply gas

Gas warning <105 %* target Gas error:
input pressure < set value
*1.05 1 = fault

Bit 4: Self-calibration (offset output

Calibration pressure) is executed
running 1 = running
0 = calibration ready

REG_ST: 1 Word Controller Set value pressure control circuit

set value output 0 to 10000
D-controller pressure
control circuit

SER_NR 1 Word Serial number Serial number: Device

format decimal 1 to 9999

SW_VER 1 Word Software Software version

version Format hexadecimal

DATA_1 1 Word Reserve No data content

PAR_SEL 1 Word Control Response of selected parameter

parameter

DATA_3 1 Word Reserve No data content

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Operation

Objects Function Size Value Description

PR_RE Input 1 Word Higher byte 0 to 17.0 % of target value
(0xFF00) Pressure reached above
Lower byte 0 to 170 (or 0xAA)
(0x00FF) 0 to 17.0 % of target value
Pressure reached below
0 to 170 (or 0xAA)

P_SOLL 1 Word Target value Selection target value

0 to 20000 [mbar]

GAS_SEL 1 Word Bit 0: Selection upstream valve 1

Gas selection 1 0= OFF, 1 = ON

Bit 1: Selection upstream valve 2

Gas selection 2 0= OFF, 1 = ON

Bit 2: Selection upstream valve 3

Gas selection 3 0= OFF, 1 = ON

Bit 3: Request of the self-calibration

Calibration (offset output pressure)
query 0 = OFF, 1 = START

Bit 8 – 15: Selection controller parameter

Parameter list list

Tab. 3: EtherCAT/Profinet process data objects

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Operating instructions
Troubleshooting

8 Troubleshooting
DANGER
Mortal danger due to improperly connected pressure lines!
The pressure lines are under high pressure. Improperly connected lines can loosen under
pressure, whip around, and cause life-threatening injuries.
■ Only have the device started up by trained personnel.
■ Only have faults on the device eliminated by trained personnel.
■ Before start-up and troubleshooting, check the connections.
■ Only have compressed air supply and cutting gases connected by trained personnel.
■ Before installation, depressurize all lines and lock them against switching on again.
■ Only operate the device within the prescribed power limits, see technical data sheet.
■ Do not use any grease when mounting the lines (e.g. threaded connections).

DANGER
Mortal danger due to improper troubleshooting!
Improper elimination of faults can cause life-threatening injuries.
■ Only eliminate faults that are described in the chapter Troubleshooting, page 47.
■ For all other faults, contact HOERBIGER.

Fault/message Possible cause Remedy

No cutting gas pressure Failure of the electrical or ð See chapter Restoring
pneumatic power supply the power supply,
page 50.

Soiling in the valve 1. Only supply dry and

pure gases in clean,
particle- and dust-free
lines.
2. If necessary, replace
device.

Soiling of the input filter ð Change filter

unit (only LGRPF model) cartridges, see chapter
Filter change in the
input filter unit,
page 52.

Control air supply of 1. Check control air

upstream valve unit drops pressure.
below minimum pressure 2. Increase control air
4.5 bar pressure to 6 – 7 bar if
necessary.

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Operating instructions
Troubleshooting

Fault/message Possible cause Remedy

“Ready” signal Insufficient power supply ð Check power supply.
does not come after Pressure sensor fault ð Replace device.
switching on the 24 V
power supply

“Ready” signal Missing or insufficient ð Check control air

does not come after start of pneumatic control air supply. NOTICE! Self-
self-calibration pressure calibration was not
completed.

Pressure sensor fault ð Replace device.

“Ready” signal goes out Failure of the electrical ð Check power supply,
during operation supply or excessive or see technical data
insufficient supply voltage sheet.

Calibration activated and ð Wait until the

running calibration has ended.

Calibration not completed 1. Start calibration again.

successfully 2. Check control air
pressure.
3. Replace device.

Output pressure lower than Control air pressure or ð See chapter Restoring
selected with target value cutting gas pressure too the power supply,
or low page 50.

No “Pressure reached” Soiling in the valve 1. Only supply dry and

signal pure gases in clean,
particle- and dust-free
lines.
2. If necessary, replace
device.

Tolerance window for ð Check tolerance

“Pressure reached” signal window and set higher
set too low if necessary (only for
"digital" version), see
chapter Process data
objects, page 45.

Soiling of the input filter ð Change filter

unit cartridges, see chapter
(only LGRPF model) Filter change in the
input filter unit,
page 52.

Nozzle diameter too large, ð Select smaller nozzle or

input pressure too low higher input pressure.

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Operating instructions
Troubleshooting

Fault/message Possible cause Remedy

Output pressure higher Soiling in the valve ð If necessary, replace
than selected device.
with target value

Error message “gas Control air pressure or ð See chapter Restoring

warning” or gas error (only cutting gas pressure too the power supply,
with digital version) low page 50.

Soiling in the valve 1. Only supply dry and

pure gases in clean,
particle- and dust-free
lines.
2. If necessary, replace
device.

Soiling of the input filter ð Change filter

unit cartridges, see chapter
(only LGRPF model) Filter change in the
input filter unit,
page 52.

Gas mixture after gas Gas change times too short ð Adjust the gas change
change times, see chapter
Selecting cutting gas
input, page 40.

Gas mixture without gas Upstream valve soiled or ð If necessary, replace

change defective device.

Cutting pressure not stable Target value fluctuations ð Check target value
signal.

Soiling in the valve ð If necessary, replace

device.

Output pressure stops Supply voltage missing, ð Apply supply voltage or

upstream valve not switch off upstream
switched off valve.

Power supply: Output Input voltage outside of ð

signal flashes with 1 Hz 24 V DC ± 10 %

Controller output: Output Input pressure too low or 1. Check input pressure,
signal flashes with 2 Hz lacking control pressure min. 5 bar.
(pilot air) 2. Check control air
pressure, min. 4 bar.

Offset of the sensors: Calibration of sensors not ð Switch valve on and

Output signal flashes with successful off.
3 Hz

Tab. 4: Faults

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Operating instructions
Troubleshooting

8.1 Restoring the power supply

With failure of the electric or pneumatic power supply, the output of the device is
ventilated within 200 ms in order to prevent an escape of the process gases. There is no
pressure on the output and further gas escape on the output is prevented.
1. Switch control signals of the upstream valves and the target value of the gas output
to “OFF”.
9 When the pneumatic control air supply is restored, the device goes into the
operating state specified by the input signals.
2. As soon as the pneumatic control air supply is available again, activate the control
signals of the upstream valves and the target value of the gas output.
9 Once the electric power supply is restored, the device automatically starts an
initialization that takes 5 – 15 s. During this time, there is no pressure on the gas
output. After that, the device goes into the operating state specified by the input
signals.
3. As soon as the ready signal “ON” is indicated, activate control signals of the
upstream valves and the target value of the gas output.

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Operating instructions
Service

9 Service
WARNING
Personal injury and property damage due to improper servicing
Malfunctions can results.
■ In case of fault, do NOT service the device.
■ In case of fault, shut the device down immediately.
■ Remove the complete valve and send it to the manufacturer's local agent for
servicing.

9.1 Inspection and maintenance plan

Work to be performed ir d w ¼y y oh
■ Check compressed air and gas connections for X
leaks.

■ Check electrical cable for cracks, kinks, and X

damage to the cable insulation.
■ Replace damaged cables.

■ Check electrical plug connection and union X

nuts to ensure they are tight.
■ If necessary, tighten union nuts.

■ Check fixed clamping of the screen on the X

screening clamp.
■ If necessary, fix or replace clamp.

■ Check body connection between LGR and X

machine body.
■ If necessary, tighten screws.

■ Check screws to ensure they are tight, tighten X

if necessary.

■ Check type plates to ensure they are present, 1

visible, legible, and complete; replace if
necessary.

■ Check filter cartridges in input filter unit for ir 1

soiling and replace if necessary. (Only for
LGRPF model)

Legend: ir= if required, d = daily, w = weekly , ¼ = quarterly, y = annually,

oh = operating hours

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Service

9.2 Filter change in the input filter unit

DANGER
Mortal danger due to unsuitable components!
The use of unsuitable components can cause life-threatening injuries.
■ Use only the manufacturer’s filter sets since these are suitable for oxygen use.

DANGER
Mortal danger due to incorrect greases!
The O-rings of the filter elements are pre-greased with oxygen-suitable grease. The use of
other greases can cause life-threatening injuries.
■ Never re-grease O-rings.

A filter change can only be done in the models LGRPF (LasGAR Plus),
LGRBF (LasGAR Basic), and for the LASFIL Compact.

The input filter unit is equipped with one filter per gas input and one filter for the control
air connection. Soiled filter elements can be changed out.

1 2 3 4 5

Fig. 35: Filter unit with replacement filters

1 Fastening screws 4 O-ring

2 Filter housing 5 Filter cartridge cutting gases
3 Filter use control air

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Service

Replacement filters can be ordered using the following item numbers:

Filter Item number Scope of delivery
Filter set for cutting gas inputs PS12739A 1 filter cartridge with O-rings
mounted and pre-greased with
oxygen grease

Filter set for control lift input PS12740A 1 filter element

1 O-ring

Tab. 5: Replacement filter

9.2.1 Taking device out of service

DANGER
Mortal danger due to residual energies!
After switching off, there are residual electrical and pneumatic energies on the device
that have to be reduced slowly and can cause life-threatening injuries if the device is
touched.
■ Disconnect the device from electrical and pneumatic power supplies before
dismantling.
■ Wait 10 seconds until residual energies in the system have been reduced completely.

WARNING
Risk of injury due to pressure
■ Do not perform any work on the valve when it is pressurized.

1. De-energize and depressurize the device.

2. Lock and ventilate the gas and compressed air supply.
3. Wait 10 seconds until residual energies in the device have been reduced completely.
4. Check whether the gas and pressure supplies are depressurized.

9.2.2 Changing the gas filter

1. Loosen the 4 fastening screws (1) in order to loosen the filter unit from the LasGAR
or the connection plate.
2. Pull the filter cartridge (5) out of the filter housing (2) using an M8 screw.
3. In the filter housing (2), check the installation space of the filter cartridge (5) for
soiling and clean if necessary.
4. Push the new filter cartridge into the filter housing (2) and press it in by hand up to
the stop. In the process, heed the correct position of the two pre-mounted O-rings.
5. Screw the filter unit with 4 fastening screws (1) to the LasGAR or the connection
plate, tightening torque 6 Nm ± 0.5 Nm.

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Service

9.2.3 Changing the control air filter

1. Loosen the 4 fastening screws (1) in order to loosen the filter unit from the LasGAR
or the connection plate.
2. Remove O-ring (4) from the control air connection.
3. Remove the filter insert (3) from the filter housing (2).
4. In the filter housing (2), check the installation space of the filter insert (3) for soiling
and clean if necessary.
5. Insert the new filter insert (3) into the filter housing (2).
6. Insert the O-ring (4).
7. Screw the filter unit with 4 fastening screws (1) to the LasGAR or the connection
plate, tightening torque 6 Nm ± 0.5 Nm.

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Decommissioning and disposal

10 Decommissioning and disposal

10.1 Decommissioning/dismantling

WARNING
Risk of injury due to pressure
■ Do not perform any work on the valve when it is pressurized.

DANGER
Mortal danger due to residual energies!
After switching off, there are residual electrical and pneumatic energies on the device
that have to be reduced slowly and can cause life-threatening injuries if the device is
touched.
■ Disconnect the device from electrical and pneumatic power supplies before
dismantling.
■ Wait 10 seconds until residual energies in the system have been reduced completely.

1. De-energize and depressurize the device.

2. Lock and ventilate the gas and compressed air supply.
3. Wait 10 seconds until residual energies in the device have been reduced completely.
4. Check whether the gas and pressure supplies are depressurized.
5. Loosen electrical cabling.
6. Loosen gas lines.
7. Take device components apart.
8. Dispose of components, see chapter Disposal, page 55.

10.2 Disposal
The disposal of the packaging and used parts is the customer’s responsibility.
ð Dispose of the product according to the local regulations at approved collection
points or have removed by approved disposal companies.

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Operating instructions
Appendix

11 Appendix
11.1 Product observation
Our goal is continuous enhancement of our products and close cooperation with the
customer. Please tell us about faults or problems with the valve.

11.2 Material defects and defects of title

These operating instructions and technical details with respect to the specifications and
figures in these operating instructions are subject to change without notice.
The company HOERBIGER Flow Control GmbH makes no quality or durability guarantees,
and also no guarantees about suitability for a particular purpose. These must be agreed
upon expressly in writing. Public statements, promotions, and advertising do not
constitute quality specifications for the product.
The operator’s claims relating to material defects and defects of title assume that he
presses this claim in writing immediately, at the latest within two working days.
HOERBIGER Flow Control GmbH is in no case responsible for damage to the product
itself or consequential damages caused by the product that are caused by improper
handling of the product.
Insofar as HOERBIGER Flow Control GmbH is responsible for a defect, HOERBIGER Flow
Control GmbH will, at its option, provide rectification of substitute performance.
Liability of HOERBIGER Flow Control GmbH – regardless of the legal justification – exists
only in case of intention or gross negligence, negligent injury of life, body, health for
defects that were fraudulently concealed or whose absence was guaranteed expressly in
writing. Furthermore, according to the product liability law for personal injury or property
damage to privately used objects.
In case of negligent injury of essential contract duties, HOERBIGER Flow Control GmbH
is also liable, also in case of slight negligence, however limited to the contract-typical,
foreseeable damages. Additional claims are excluded.
In case individual regulations of these operating instructions, the applicable legal
regulations or other instructions of HOERBIGER Flow Control GmbH are disregarded,
material defects and defects of title are terminated.
In particular, HOERBIGER Flow Control GmbH is not responsible for failures or faults
that are caused by modifications by the customer or other persons. In such cases, the
repair costs due will be invoiced. These will also be invoiced for the checking of the
device if no fault could be found on the device.
There are no claims to the availability of previous versions and to the ability to refit
devices delivered to the respective current series state.

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Appendix

11.3 Declaration of conformity

The current declaration of conformity is included in the scope of delivery and it can be
found in the download area on the company's website:
http://www.hoerbiger.com/

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PS31015A