BS03K-CAT SERIES

3kW Smart Laser Cutting Head - User Manual

 BS03K-CAT SERIES 3kW Smart Laser Cutting Head-User Manual

Document History

Edit date Version Topic, revision, action taken

2024/3/6 V1.0 First edition

Thank you for choosing our product!

This manual describes the installation and commissioning of laser cutting head in details so that you can use this
product quickly. You can consult us directly for more details.

Due to the continuous updating of product functions, the product you receive may differ from the introduction in this
manual in some aspects.

We reserve all rights in this document including the issued patents and other registered commercial ownership related
to this document. It is strictly prohibited to use this document in an improper way especially to copy and disseminate it
to third parties.

If you find any errors in this document, please inform us as soon as possible. The data contained in this manual is only
used to describe the product and shall not be regarded as a statement of security interest.

For the benefit of our customers, we will constantly try to ensure that the products we develop comply with the latest
technology.

Raytools AG

Email: [email protected]
Website: www.raytools.ch

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Disclaimer
▪ We reserve the right to change the design in order to improve the quality or expand the application or
comply to manufacturing workmanship.
▪ We will not bear any responsibility for losses and accidents caused by wrong operation or improper
handling of our products.
▪ Dismantling of product will lose all warranty claims excluding the normal replacement of worn parts
and components required for maintenance or commissioning operations.
▪ Unauthorized modification of products or use of non-original spare parts will directly lead to the
invalidation of warranty and liability exemption.
▪ It is recommended to only use the spare parts provided by us or submit them to us or the designated
professional team for installation.

Use Regulations
▪ Ensure that the product is used in a dry environment.
▪ Ensure that the product is used in the environment required by EMC standards.
▪ The product is only allowed to run within the parameters specified in the technical data.

Personnel Responsibilities
▪ Be familiar with the basic provisions of work safety & accident prevention and have received equipment
operation guidance.
▪ Read and understand basic safety instructions and operations.
▪ You must have studied the relevant regulations and safety instructions and understand the possible
hazards.
▪ Comply with relevant regulations and implement corresponding protective measures.

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Safety Instructions
Prevent Electric Shock

▪ Parts of the laser head such as nozzle, sensor, sensor interface and attached fasteners may not
be fully protected by the ground wire due to function fault. These parts may have low voltage. When
installing electrical equipment, please pay attention to taking anti electric shock measures for relevant
personnel.

▪ Note that the equipment shall be grounded as specified.

Guard against Danger

▪ Never put your hands or other body under the laser head.
▪ Repair and maintenance work can only be carried out after the power is turned off.
▪ Do not exceed the specified maximum pressure.
▪ It must be ensured that the laser head is in normal condition at all times.
▪ All fasteners such as bolts and nuts must be tightened.

Laser Caution
▪ Avoid direct laser radiation or scattering to the skin.
▪ Do not stare at the laser beam even when wearing optical equipment.
▪ Use special laser protective eyeglasses that meet the requirements of safety standards IEC 60825-1.

Prevent Waterway Corrosion

▪ In order to avoid corrosion, use the specified coolant and comply with relevant requirements and
specified maintenance intervals.

Noise Prevention
▪ The corresponding measures shall be specified or explained and observed in order to prevent personnel
from being harmed by noise when the cutting air pressure is high.

Storage and Transportation

▪ Observe the storage temperature range allowed by the technical data.
▪ Take reasonable measures to prevent fire, vibration or impact.
▪ Do not store in or near the magnetic field.

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Contents
1 Product Summary ................................................................................................................... 1
1.1 View (with QBH Interface) .................................................................................................... 1
1.2 Monitoring ............................................................................................................................ 2
1.3 LED ........................................................................................................................................ 2
1.4 Technical Datasheet .............................................................................................................. 3
1.5 Mechanical Size .................................................................................................................... 4
1.6 Physical Interface .................................................................................................................. 5
2 Mechanical Installation ........................................................................................................... 6
2.1 Fiber Insertion ...................................................................................................................... 6
2.2 Mounting of Laser Cutting Head .......................................................................................... 7
2.3 Earthing of Laser Cutting Head ............................................................................................. 8
2.4 Inspection of Top Cover Glass (1st Installation/Replacement of Fiber) ................................ 9
2.5 Connection of Cooling Water and Assist Gas ..................................................................... 10
3 System Installation and Commissioning ............................................................................... 13
4 Beam Alignment.................................................................................................................... 15
5 Maintenance ......................................................................................................................... 16
5.1 Cleaning Lens ...................................................................................................................... 16
5.2 Removal and Installation of Lenses .................................................................................... 17
5.3 Replace Ceramic Body and Nozzle ..................................................................................... 19

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1 Product Summary
1.1 View (with QBH Interface)

1 Fiber Interface 7 Water Cooling Interface (⌀6)

2 LED 8 Control Interface

3 Focus Module/XY Alignment 9 Cutting Gas Interface (⌀10)

4 Bottom Cover Glass Assy

10 Nozzle Cooling Gas Interface (⌀8)
5 Preamplifier Interface
11 Retaining Ring
6 TRA (Nozzle Assy)
12 Ceramic Body & Nozzle

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1.2 Monitoring

1. Bottom cover glass temperature

2. Cutting gas pressure

3. Cutting gas temperature

4. Motor

1.3 LED

LED Status Definition (from top to bottom)

LED1: Green on-running normally

Red on-foucs failed

LED2: Green on-running normally

Red on- The slave is not connected or has not entered the OP state.

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1.4 Technical Datasheet

Model BS03K
Wavelength 1080nm
Fiber Interface QBH
Power Rating 3kW
Collimation Length (fC) 100mm
Focusing Length (fF) 150mm
NA max 0.13
Auto Focus Range -22mm…+22mm
Beam Alignment Range -1.5mm…+1.5mm
Mounting Size of Cutting Head 4xM6
Mounting Size of Preamplifier 4xM3
Cutting Gas ⌀10, max. 25bar
Nozzle Cooling Gas ⌀8, max. 5bar
Water Cooling ⌀6, max. 5bar, min. 1.5L/min
Operating Voltage 24V±10%, max. 4A

I/O Interface (19-Pin) Output current must be less than 30mA

Operating Temperature 5℃～55℃

Humidity 30％～95％, without condensing

Weight About 5kg

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1.5 Mechanical Size

Optical Configuration:100:150

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 BS03K-CAT SERIES 3kW Smart Laser Cutting Head-User Manual

1.6 Physical Interface

No. 1 Cooling water (⌀6) No. 2 Cutting gas (⌀10)

No. 3 Nozzle cooling gas (⌀8) No. 4 Preamplifier (SMA)

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2 Mechanical Installation
2.1 Fiber Insertion

WARNING: The optical components must be dust free and all dusts must be cleaned before use. The
fiber shall be horizontally inserted into fiber interface to prevent dust from entering the interface and
falling on the surface of the lens. Upper limit in the fiber before fixing the laser head.

2.1.1 QBH Fiber Insertion

▪ Align the red point at the end of the QBH interface to the red point of the handwheel.
▪ Remove QBH dustproof cover.
▪ Align the red mark of male fiber end to red mark on female QBH of cutting head when you insert the
fiber end straightly to bottom of QBH interface of cutting head.
▪ Turn the QBH handwheel clockwise. It is in place when you hear the "Da" voice, then pull the
handwheel up and turn clockwise to end.

It is recommended to use textured tape to seal the connection of female and male fiber interface after the
installation is finished in order to prevent from dust as much as possible in critical dusty environment.

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2.2 Mounting of Laser Cutting Head

The mounting of laser cutting head to machine tool is shown as below. Customers are advised to Install the laser head
perpendicular to the bed surface as requested and make sure the laser head is locked, which is one of the premises to
ensure the stable cutting.

thru

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2.3 Earthing of Laser Cutting Head

Earthing

The shaking or vibration of cutting head due to incorrect earthing could cause damage to sensor mechanism
and machine.

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2.4 Inspection of Top Cover Glass (1st Installation/Replacement of Fiber)

Maintenance or Repair shall be implemented at dust free workstation.

▪ Loose bolts (item 1 & 2) and pull out the glass holder until you see the complete cover glass.
▪ Seal the openings of cutting head by textured tape immediately.
▪ Check if the top cover glass is clean. If not, blow the cover glass by clean compressed air until it is clean.

The cover glass shall be replaced if it cannot be cleaned or a damage happens.

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2.5 Connection of Cooling Water and Assist Gas

2.5.1 Connection of Cutting Gas

The impurity in cutting gas such as hydrocarbon and steam will damage the lens and cause cutting power fluctuation as
well as inconsistencies between the sections of the work piece. The table below is the recommended cutting gas
specification. The higher the purity of the gas, the better the quality of the cutting section.

Impurity can be filtered out in gas supply tube, but Oxygen and water vapor can permeate light path through nonmetal
materials, which is the source of the appearance of dust and hydrocarbon. Stainless steel fittings are recommended, at
the same time must use filters which can remove a minimum of 0.01 micron particle to purify.

A pressure gauge with a stainless steel diaphragm is recommended. Industrial pressure gauges suck in air. Rubber
diaphragm produce hydrocarbon by aging or other factors.

Gas Purity Maximum content of water vapor Maximum content of hydrocarbon

Oxygen 99.5% <5 ppm <1 ppm

Nitrogen 99.95% <5 ppm <1 ppm
Diameter of cutting gas
⌀10mm (G)
pipe (Outer diameter)
Gas Pressure Max. 25bar (2.5MPa)

CAUTION: Gas interface cannot be replaced arbitrarily especially do not use PTFE TAPE. Otherwise the gas
path will be blocked and cannot do normal cutting which will damage cutting head at the same time.

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2.5.2 Connection of Nozzle Cooling Gas

Dried N2 or fine filtered air is recommended for nozzle cooling. The O2 is prohibited for nozzle cooling.

Gas type N2 or Air (dried and fine filtered)

Gas pressure Max. 5bar (0.5MPa)

Gas interface ⌀8

CAUTION: Gas interface cannot be replaced arbitrarily especially do not use PTFE TAPE. Otherwise the gas
path will be blocked and cannot do normal cutting which will damage cutting head at the same time.

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2.5.3 Connection of Cooling Water

It is important to note that when the laser power is greater than 500W, it is recommended to use water cooling. The
recommended water flow is suggested below.

▪ W1 & W2: cooling pipe of fiber interface

Outer diameter of water hose ⌀6mm

Minimum flow speed 1.5 l/min

Entry pressure 170-520kPa (30-60 psi)

Entry temperature ≥room temperature /＞dew point

Hardness (relative to CaCO3) ＜250mg/liter

PH range 6 to 8
Particle size allowed Diameter less than 200 microns

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3 System Installation and Commissioning

EPOE24

Mark Item Definition

IN Input interface Input signal

OUT Output interface Output signal

24V 24V Connect to 24V

GND 0V Connect to 0V

PE Earthing Earthing

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⚫ Connect the 24V to the I/O board (EPOE24).

⚫ Connect cables as required.

⚫ Configure and debug system setting according to the manual.

Raytools system setting:

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 BS03K-CAT SERIES 3kW Smart Laser Cutting Head-User Manual

4 Beam Alignment

Cutting quality in a great extent depends on whether the lens is in the middle. If the lens is not in the middle, the laser
beam may contact with nozzle or inner wall to produce high temperature deformation. Lens alignment operation
should be considered when nozzle is replaced or the cutting quality declines.

Lens alignment of laser cutting head can be finished by adjusting focus lens, X-Y direction. The X/Y adjusting knob is
located above bottom cover glass as shown below. Adjusting the 2 knobs until the beam is located in the middle of
nozzle. Make sure the laser beam output from the center of nozzle. A method commonly used is tape dotting method
as below:

▪ Fix the cutting head with a big size nozzle (tip size shall be larger than beam size) or adjust to nearly zero
focus.
▪ Pick a scotch tape, flatten it and stick it to the nozzle tip.
▪ Open the red light of the laser. Find and observe the position of red light in the scotch tape.
▪ Shoot laser at low power to check beam penetration size. Beam penetration shall be circle and located in the
nozzle tip center.
▪ Adjust the 2 X/Y adjusting knobs to get beam aligned. The max X/Y adjusting range is roughly from -1.5mm
to +1.5mm.
▪ Tear off the tape and check the shooting hole position in tape.
▪ Repeat the above steps to find out relatively centered position.

Figure 4.1— Beam Adjustment

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5 Maintenance
5.1 Cleaning Lens

It’s necessary to maintain lenses regularly because of the characteristic of laser cutting process. Cleaning to the cover
glass once a week is recommended. The collimating lenses and focusing lenses are recommended to be cleaned once
every 2~3 months. In order to facilitate the maintenance of the cover glass, the cover glass holder adopts a drawer type
structure.

Tools: Dust-proof gloves or fingertip, polyester swab, absolute ethanol, rubber gas blow (purely compressed air).

Cleaning instruction:
▪ To put fingertip onto left thumb and index finger.
▪ Spray absolute ethanol onto the polyester swab.
▪ Hold the edge of the lens with left thumb and index finger gently. (note: avoid touching the surface of
the lens by fingertip in case of trace)
▪ Hold the lens to face eyes by left hand and hold the polyester swab by right hand. Wipe the lens gently
in single direction, from bottom to top or from left to right (Should not wipe back and forth in case of
secondary pollution to lens) and use rubber blow (purely compressed air) to blow the surface of the lens.
Both surfaces should be cleaned. After cleaning, make sure that there is no residual like detergent,
floating ash, foreign matters and impurities.

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5.2 Removal and Installation of Lenses

The whole process needs to be completed in a dust free room. Wear dust-proof gloves or fingertips when removing or
installing the lenses.

5.2.1 Removal and Installation of Bottom Cover Glass/Protection Glass

The cover glass is wearing part which needs to be replaced once it is damaged.

▪ As shown above, loose the 2 bolts to pull out cover glass holder by pinching 2 edges of drawer type
holder.
▪ Seal the mounting openings by textured tape immediately.
▪ Remove the pressing ring (1) and cover glass (2) after wearing fingertips
▪ Clean the cover glass holder and seal ring (3). The elastic seal ring (3) should be replaced if it is
damaged.
▪ Install the cleaned or new cover glass (regardless of the front or back surface) into the holder of cover
glass.
▪ Install the pressing ring.
▪ Insert the cover glass holder back to the laser head and tighten the bolts.

It is not allowed to pull out the edge of seal ring directly as it is very easy to damage the seal ring.
Please wear the clean gloves or fingertips.

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5.2.2 Removal and Installation of Middle Cover Glass/Protection Glass

The cover glass is wearing part which needs to be replaced once it is damaged.

▪ As shown above, loose the 2 bolts to pull out cover glass holder by pinching 2 edges of drawer type
holder.
▪ Seal the mounting openings by textured tape immediately.
▪ Remove the pressing ring (1) and cover glass (2) after wearing fingertips
▪ Clean the cover glass holder and seal ring (3). The elastic seal ring (3) should be replaced if it is
damaged.
▪ Install the cleaned or new cover glass (regardless of the front or back surface) into the holder of cover
glass.
▪ Install the pressing ring.
▪ Insert the cover glass holder back to the laser head and tighten the bolts.

It is not allowed to pull out the edge of seal ring directly as it is very easy to damage the seal ring.
Please wear the clean gloves or fingertips.

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5.3 Replace Ceramic Body and Nozzle

The nozzle is required to be replaced if it gets crash or damaged by laser beam. The dirt on ceramic body is required to
be cleaned or to replace the ceramic body if it gets crash.

▪ Unscrew the nozzle (1).

▪ Press the ceramic body (3) upward by hand to make it fixed without deflection and then unscrew the
retaining ring (2).
▪ Align the pin hole of the new ceramic body with the locating pin. Press the ceramic body (3) upward by
hand and tighten the retaining ring (2).
▪ Screw the new nozzle (1) and get it properly tightened.
▪ Do the capacitance calibration once again after replacing the nozzle or ceramic body.

Only tighten the nozzle and retaining ring by hand (without tools) otherwise it could damage the ceramic body.

Keep the contact surface of all parts clean.

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