Hyintensity fiber laser инструкция по эксплуатации - RukovodstvoRus.ru - инструкции пользования и руководства

Инструкция по эксплуатации

80709J — 3-я редакция

HyIntensity Fiber Laser

HFL010

HFL015

HFL020

HFL030

HyIntensity Fiber Laser

HFL010

HFL015

HFL020

HFL030

Источник

HyIntensity Fiber Laser TM

	HFL010 TM
	HFL015 TM
	HFL020 TM
Instruction Manual	HFL030	TM

807090 – Revision 3

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HyIntensity Fiber Laser

HFL010, HFL015, HFL020, and HFL030

Instruction Manual

(P/N 807090)

Revision 3 – November, 2012

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

Hypertherm, HyIntensity Fiber Laser, HFL010, HFL015, HFL020 and HFL030 are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.

Hypertherm, Inc.	Hypertherm Europe B.V.
Etna Road, P.O. Box 5010	Vaartveld 9
Hanover, NH 03755 USA	4704 SE
603-643-3441 Tel (Main Office)	Roosendaal, Nederland
603-643-5352 Fax (All Departments)	31 165 596907 Tel
info@hypertherm.com (Main Office Email)	31 165 596901 Fax
800-643-9878 Tel (Technical Service)	31 165 596908 Tel (Marketing)
technical.service@hypertherm.com (Technical Service Email)	31 165 596900 Tel (Technical Service)
800-737-2978 Tel (Customer Service)	00 800 4973 7843 Tel (Technical Service)
customer.service@hypertherm.com (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)	Hypertherm Japan Ltd.
877-371-2876 Fax (Return Materials Authorization)	Level 9, Edobori Center Building
return.materials@hypertherm.com (RMA email)	2-1-1 Edobori, Nishi-ku
	Osaka 550-0002 Japan
Hypertherm Plasmatechnik GmbH	81 6 6225 1183 Tel
Technologiepark Hanau	81 6 6225 1184 Fax
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland	Hypertherm Brasil Ltda.
49 6181 58 2100 Tel	Rua Bras Cubas, 231 – Jardim Maia
49 6181 58 2134 Fax	Guarulhos, SP — Brasil
49 6181 58 2123 (Technical Service)	CEP 07115-030
	55 11 2409 2636 Tel
Hypertherm (S) Pte Ltd.	55 11 2408 0462 Fax
82 Genting Lane
Media Centre	Hypertherm México, S.A. de C.V.
Annexe Block #A01-01	Avenida Toluca No. 444, Anexo 1,
Singapore 349567, Republic of Singapore	Colonia Olivar de los Padres
65 6841 2489 Tel	Delegación Álvaro Obregón
65 6841 2490 Fax	México, D.F. C.P. 01780
65 6841 2489 (Technical Service)	52 55 5681 8109 Tel
	52 55 5683 2127 Fax
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building	Hypertherm Korea Branch
495 ShangZhong Road	#3904 Centum Leaders Mark B/D,
Shanghai, 200231	1514 Woo-dong, Haeundae-gu, Busan
PR China	Korea, 612-889
86-21-60740003 Tel	82 51 747 0358 Tel
86-21-60740393 Fax	82 51 701 0358 Fax

07/18/12

	table of contents
Safety…………………………………………………………………………………………………………………………………….	S-1
Introduction………………………………………………………………………………………………………………………………………………………………………….	S-1
Operating instructions, guidelines, and rules……………………………………………………………………………………………………………………..	S-2
Protection of personnel……………………………………………………………………………………………………………………………………………………….	S-3
Laser safety officer………………………………………………………………………………………………………………………………………………………………	S-3
Condition of laser beam equipment……………………………………………………………………………………………………………………………………	S-3
Laser safety………………………………………………………………………………………………………………………………………………………………………….	S-4
Laser safety warnings………………………………………………………………………………………………………………………………………………………….	S-5
Health concerns…………………………………………………………………………………………………………………………………………………………………..	S-9
Laser safety eyewear (LSE)………………………………………………………………………………………………………………………………………………..	S-9
Acoustical noise…………………………………………………………………………………………………………………………………………………………………..	S-9
Warning signs……………………………………………………………………………………………………………………………………………………………………..	S-9
Gas, fumes and air quality…………………………………………………………………………………………………………………………………………………..	S-9
Confined spaces……………………………………………………………………………………………………………………………………………………………….	S-10
Oxygen gas distribution for laser cutting………………………………………………………………………………………………………………………….	S-11
Public exhibitions and demonstrations……………………………………………………………………………………………………………………………..	S-11
Large area viewing…………………………………………………………………………………………………………………………………………………………….	S-11
Training……………………………………………………………………………………………………………………………………………………………………………….	S-12
Product stewardship………………………………………………………………………………………………………….	PS-1
Introduction……………………………………………………………………………………………………………………………………………………………………….	PS-1
National and local safety regulations……………………………………………………………………………………………………………………………….	PS-1
Certification test marks…………………………………………………………………………………………………………………………………………………….	PS-1
Differences in national standards…………………………………………………………………………………………………………………………………….	PS-1
Safe installation and use of shape cutting equipment…………………………………………………………………………………………………….	PS-1
Procedures for periodic inspection and testing………………………………………………………………………………………………………………	PS-2
Qualification of test personnel………………………………………………………………………………………………………………………………..	PS-2
Residual current devices (RCDs)…………………………………………………………………………………………………………………………………….	PS-2
Higher-level systems………………………………………………………………………………………………………………………………………………………..	PS-3
Environmental stewardship………………………………………………………………………………………………	ES-1
Introduction……………………………………………………………………………………………………………………………………………………………………….	ES-1
National and local environmental regulations………………………………………………………………………………………………………………….	ES-1
The RoHS directive…………………………………………………………………………………………………………………………………………………………..	ES-1
Proper disposal of Hypertherm products………………………………………………………………………………………………………………………..	ES-1
The WEEE directive…………………………………………………………………………………………………………………………………………………………	ES-1
The REACH regulation……………………………………………………………………………………………………………………………………………………..	ES-1
Proper handling and safe use of chemicals…………………………………………………………………………………………………………………….	ES-2
Fumes emission and air quality………………………………………………………………………………………………………………………………………..	ES-2
Electromagnetic Compatibility (EMC) ………………………………………………………………………..	EMC-1
Introduction……………………………………………………………………………………………………………………………………………………………………	EMC-1
Installation and use……………………………………………………………………………………………………………………………………………………….	EMC-1
Assessment of area……………………………………………………………………………………………………………………………………………………….	EMC-1
Methods of reducing emissions……………………………………………………………………………………………………………………………………	EMC-1
Mains supply………………………………………………………………………………………………………………………………………………………..	EMC-1

HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2

table of contents

Maintenance of cutting equipment……………………………………………………………………………………………………………………………….	EMC-2
Cutting cables……………………………………………………………………………………………………………………………………………………………….	EMC-2
Equipotential bonding……………………………………………………………………………………………………………………………………………………	EMC-2
Earthing of the workpiece……………………………………………………………………………………………………………………………………………..	EMC-2
Screening and shielding……………………………………………………………………………………………………………………………………………….	EMC-2

Warranty……………………………………………………………………………………………………………………………….	W-1
Attention……………………………………………………………………………………………………………………………………………………………………………..	W-1
General……………………………………………………………………………………………………………………………………………………………………………….	W-1
Patent indemnity…………………………………………………………………………………………………………………………………………………………………	W-2
Limitation of liability…………………………………………………………………………………………………………………………………………………………….	W-2
National and local codes……………………………………………………………………………………………………………………………………………………	W-2
Liability cap…………………………………………………………………………………………………………………………………………………………………………	W-2
Insurance…………………………………………………………………………………………………………………………………………………………………………….	W-2
Transfer of rights…………………………………………………………………………………………………………………………………………………………………	W-2

Specifications………………………………………………………………………………………………………………………..	1-1
Fiber laser supply…………………………………………………………………………………………………………………………………………………………………	1-1
Overview……………………………………………………………………………………………………………………………………………………………………..	1-1
Requirements………………………………………………………………………………………………………………………………………………………………	1-2
Optical specifications…………………………………………………………………………………………………………………………………………………	1-3
Dimensions – HFL010, HFL015, and HFL020…………………………………………………………………………………………………………	1-4
Dimensions – HFL030……………………………………………………………………………………………………………………………………………….	1-5
LF150 laser head – 051025………………………………………………………………………………………………………………………………………………	1-6
Overview……………………………………………………………………………………………………………………………………………………………………..	1-6
Mounting dimensions………………………………………………………………………………………………………………………………………………….	1-7
Collimator dimensions………………………………………………………………………………………………………………………………………………..	1-8
Collimator dimensions………………………………………………………………………………………………………………………………………………..	1-9
System gas requirements………………………………………………………………………………………………………………………………………………….	1-10
Gas quality and pressure requirements…………………………………………………………………………………………………………………..	1-10
Chiller requirements…………………………………………………………………………………………………………………………………………………………..	1-11
Coolant……………………………………………………………………………………………………………………………………………………………………..	1-11
Flow rates…………………………………………………………………………………………………………………………………………………………………	1-11
Cooling capacity………………………………………………………………………………………………………………………………………………………	1-11
Gas control console – 051024……………………………………………………………………………………………………………………………………….	1-12
Overview…………………………………………………………………………………………………………………………………………………………………..	1-12
Beam delivery optical cable (BDO)………………………………………………………………………………………………………………………………….	1-13
Laser head controller – 051026……………………………………………………………………………………………………………………………………..	1-14
Overview…………………………………………………………………………………………………………………………………………………………………..	1-14
CNC Requirements…………………………………………………………………………………………………………………………………………………………..	1-15
Hypertherm CNC……………………………………………………………………………………………………………………………………………………..	1-15
Generic CNC……………………………………………………………………………………………………………………………………………………………	1-16

Installation…………………………………………………………………………………………………………………………….	2-1
Upon receipt…………………………………………………………………………………………………………………………………………………………………………	2-1
Claims…………………………………………………………………………………………………………………………………………………………………………………..	2-1
Installation requirements………………………………………………………………………………………………………………………………………………………	2-2

ii	HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2

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Noise levels…………………………………………………………………………………………………………………………………………………………………………..	2-2
Placement of system components………………………………………………………………………………………………………………………………………	2-2
Site preparation before startup……………………………………………………………………………………………………………………………………………	2-3
Installation requirements………………………………………………………………………………………………………………………………………………………	2-4
System components……………………………………………………………………………………………………………………………………………………	2-5
Cables and hoses……………………………………………………………………………………………………………………………………………………….	2-5
Power cables (customer-supplied)…………………………………………………………………………………………………………………………….	2-5
Supply gas hoses (customer supplied)……………………………………………………………………………………………………………………..	2-5
Recommended grounding and shielding practices…………………………………………………………………………………………………………….	2-6
Introduction…………………………………………………………………………………………………………………………………………………………………………..	2-6
Types of grounding……………………………………………………………………………………………………………………………………………………..	2-6
Steps to take……………………………………………………………………………………………………………………………………………………………….	2-7
Placement of the fiber laser supply…………………………………………………………………………………………………………………………………..	2-11
Lifting the fiber laser supply……………………………………………………………………………………………………………………………………..	2-12
Fiber laser supply preparation…………………………………………………………………………………………………………………………………………..	2-13
General information………………………………………………………………………………………………………………………………………………….	2-13
Emergency stop (E-Stop) switch installation………………………………………………………………………………………………………….	2-14
Electrical diagram for external safety switches……………………………………………………………………………………………………….	2-15
Stack Light installation……………………………………………………………………………………………………………………………………………..	2-16
Dehumidifier drain installation………………………………………………………………………………………………………………………………….	2-17
Mounting the laser head controller (LHC)………………………………………………………………………………………………………………………..	2-19
Mounting the gas console…………………………………………………………………………………………………………………………………………………	2-20
Chiller considerations………………………………………………………………………………………………………………………………………………………..	2-21
Mounting the laser head……………………………………………………………………………………………………………………………………………………	2-22
Install the laser head mounting bracket…………………………………………………………………………………………………………………..	2-22
Laser head grounding………………………………………………………………………………………………………………………………………………	2-23
Laser head mounting dimensions……………………………………………………………………………………………………………………………	2-23
Beam delivery optical cable connection…………………………………………………………………………………………………………………………..	2-25
General Precautions…………………………………………………………………………………………………………………………………………………	2-26
Unpacking Instructions…………………………………………………………………………………………………………………………………………….	2-26
Beam delivery optical cable installation…………………………………………………………………………………………………………………..	2-27
Collimator installation………………………………………………………………………………………………………………………………………………………..	2-28
General precautions…………………………………………………………………………………………………………………………………………………	2-28
Collimator proximity sensor………………………………………………………………………………………………………………………………………	2-33
Laser head connectors……………………………………………………………………………………………………………………………………………………..	2-35
Coolant hose connections………………………………………………………………………………………………………………………………………………..	2-36
Fiber laser supply to laser head……………………………………………………………………………………………………………………………….	2-37
Beam delivery optical cable and collimator coolant hoses…………………………………………………………………………………….	2-38
Fiber laser supply to chiller………………………………………………………………………………………………………………………………………	2-40
Cable connections…………………………………………………………………………………………………………………………………………………………….	2-41
Hypernet cable: fiber laser supply to a Hypertherm CNC – 223171……………………………………………………………………	2-41
Hypernet cable: fiber laser supply to laser head controller – 223171…………………………………………………………………..	2-42
Gas console control cable – 223138…………………………………………………………………………………………………………………….	2-43
Laser head I/O cable – 223169……………………………………………………………………………………………………………………………	2-44
Gas hoses………………………………………………………………………………………………………………………………………………………………………….	2-45
Gas control console to laser head…………………………………………………………………………………………………………………………..	2-45

HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2

iii

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Laser head controller power cable – (customer supplied)…………………………………………………………………………………………….	2-46
Line disconnect switch…………………………………………………………………………………………………………………………………………….	2-47
Main power cables (fiber laser supply and chiller)…………………………………………………………………………………………………………..	2-47
Connect the power……………………………………………………………………………………………………………………………………………………………	2-48
Gas requirements………………………………………………………………………………………………………………………………………………………………	2-49
Gas regulators……………………………………………………………………………………………………………………………………………………………………	2-50
Supply gas plumbing…………………………………………………………………………………………………………………………………………………………	2-51
Connect the supply gases……………………………………………………………………………………………………………………………………….	2-52
Initial setup………………………………………………………………………………………………………………………………………………………………..	2-53
CNC setups………………………………………………………………………………………………………………………………………………………………………	2-54
Hypertherm CNC setup…………………………………………………………………………………………………………………………………………..	2-54
Lens assembly installation…………………………………………………………………………………………………………………………………………………	2-58
General precautions…………………………………………………………………………………………………………………………………………………	2-58

Set-up and Operation……………………………………………………………………………………………………………	3-1
Safe operation………………………………………………………………………………………………………………………………………………………………………	3-2
Sequence of operation with a Hypertherm CNC………………………………………………………………………………………………………	3-3
Sequence of operation with a generic CNC……………………………………………………………………………………………………………..	3-4
Marking and cutting mild steel with a generic CNC………………………………………………………………………………………………….	3-5
H2O valve…………………………………………………………………………………………………………………………………………………………………….	3-6
Flow meters…………………………………………………………………………………………………………………………………………………………………	3-6
Fiber-to-fiber coupling unit…………………………………………………………………………………………………………………………………………	3-6
Laser power supply operation diagrams……………………………………………………………………………………………………………………………..	3-7
Power ON sequence………………………………………………………………………………………………………………………………………………….	3-7
Laser power supply – faulted state………………………………………………………………………………………………………………………….	3-8
Laser power supply – laser beam OFF state…………………………………………………………………………………………………………..	3-9
Laser power supply – laser beam ON state………………………………………………………………………………………………………….	3-10
Operating the laser head controller………………………………………………………………………………………………………………………………….	3-11
Navigating the Display Screen…………………………………………………………………………………………………………………………………	3-12
Changing the value of a parameter:………………………………………………………………………………………………………………………..	3-12
Laser head controller screen navigation………………………………………………………………………………………………………………….	3-13
Operating parameters………………………………………………………………………………………………………………………………………………	3-13
Calibration screen navigation…………………………………………………………………………………………………………………………………..	3-14
Diagnostics screen navigation…………………………………………………………………………………………………………………………………	3-15
Setup screen navigation…………………………………………………………………………………………………………………………………………..	3-16
Laser head controller faults……………………………………………………………………………………………………………………………………..	3-18
Laser head controller setup………………………………………………………………………………………………………………………………………………	3-19
Calibration………………………………………………………………………………………………………………………………………………………………………….	3-21
Nozzle position calibration……………………………………………………………………………………………………………………………………….	3-21
Capacitive height sensor (CHS) calibration……………………………………………………………………………………………………………	3-23
Laser head operation…………………………………………………………………………………………………………………………………………………………	3-28
Pointing laser……………………………………………………………………………………………………………………………………………………………	3-28
Beam centering………………………………………………………………………………………………………………………………………………………..	3-28
Hypertherm CNC beam centering……………………………………………………………………………………………………………………………………	3-29
Using the “Tape shot” method for beam centering…………………………………………………………………………………………………	3-29
Tape shot procedure………………………………………………………………………………………………………………………………………………..	3-29

iv	HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2

	table of contents
Hypertherm CNC interface………………………………………………………………………………………………………………………………………	3-30
Setting pulse laser time and pulse laser power………………………………………………………………………………………………………	3-31
Generic CNC beam centering………………………………………………………………………………………………………………………………………….	3-32
Pulsing the fiber laser using a generic CNC……………………………………………………………………………………………………………………	3-33
Pulsing the laser with a custom waveform………………………………………………………………………………………………………………	3-34
Gas console operation………………………………………………………………………………………………………………………………………………………	3-35
Test cut gas pressures……………………………………………………………………………………………………………………………………………..	3-35
Adjust side jet pressure……………………………………………………………………………………………………………………………………………	3-36
Focal position……………………………………………………………………………………………………………………………………………………………	3-37
Laser Cutting……………………………………………………………………………………………………………………………………………………………………..	3-38
Mild steel – oxygen assisted……………………………………………………………………………………………………………………………………	3-38
Mild steel – air and nitrogen assisted……………………………………………………………………………………………………………………..	3-39
Stainless steel – nitrogen assisted………………………………………………………………………………………………………………………….	3-39
Aluminum – nitrogen assisted………………………………………………………………………………………………………………………………….	3-39
Optimizing fiber laser cut quality……………………………………………………………………………………………………………………………………….	3-40
Surface of a laser cut……………………………………………………………………………………………………………………………………………….	3-40
General steps for optimizing laser cut quality…………………………………………………………………………………………………………	3-41
Mild steel……………………………………………………………………………………………………………………………………………………………………………	3-42
Optimizing cut quality for 6 mm (0.25 inch) mild steel (oxygen assisted)……………………………………………………………..	3-42
Consumables…………………………………………………………………………………………………………………………………………………………………….	3-50
Cut charts…………………………………………………………………………………………………………………………………………………………………………..	3-51
HFL010 (1.0 kW) Mild Steel* cut chart — Metric………………………………………………………………………………………………………………	3-51
HFL010 (1.0 kW) Mild Steel* cut chart — English…………………………………………………………………………………………………………….	3-52
HFL010 (1.0 kW) Stainless Steel* cut chart — Metric………………………………………………………………………………………………………	3-53
HFL010 (1.0 kW) Stainless Steel* cut chart — English…………………………………………………………………………………………………….	3-54
HFL010 (1.0 kW) Aluminum* cut chart — Metric………………………………………………………………………………………………………………	3-55
HFL010 (1.0 kW) Aluminum* cut chart — English…………………………………………………………………………………………………………….	3-55
HFL015 (1.5 kW) Mild Steel* cut chart — Metric……………………………………………………………………………………………………………..	3-56
HFL015 (1.5 kW) Mild Steel* cut chart — English……………………………………………………………………………………………………………	3-57
HFL015 (1.5 kW) Stainless Steel* cut chart — Metric……………………………………………………………………………………………………..	3-58
HFL015 (1.5 kW) Stainless Steel* cut chart — English……………………………………………………………………………………………………	3-59
HFL015 (1.5 kW) Aluminum* cut chart — Metric………………………………………………………………………………………………………………	3-60
HFL015 (1.5 kW) Aluminum* cut chart — English…………………………………………………………………………………………………………….	3-61
HFL020 (2.0 kW) Mild Steel* cut chart — Metric……………………………………………………………………………………………………………..	3-62
HFL020 (2.0 kW) Mild Steel* cut chart — English……………………………………………………………………………………………………………	3-63
HFL020 (2.0 kW) Stainless Steel* cut chart — Metric……………………………………………………………………………………………………..	3-64
HFL020 (2.0 kW) Stainless Steel* cut chart — English……………………………………………………………………………………………………	3-65
HFL020 (2.0 kW) Aluminum* cut chart — Metric………………………………………………………………………………………………………………	3-66
HFL020 (2.0 kW) Aluminum* cut chart — English…………………………………………………………………………………………………………….	3-67
HFL020 (2.0 kW) Brass* cut chart — Metric…………………………………………………………………………………………………………………….	3-68
HFL020 (2.0 kW) Brass* cut chart — English…………………………………………………………………………………………………………………..	3-69
HFL020 (2.0 kW) Copper* cut chart — Metric………………………………………………………………………………………………………………….	3-70
HFL020 (2.0 kW) Copper* cut chart — English………………………………………………………………………………………………………………..	3-71
HFL030 (3.0 kW) Mild Steel* cut chart — Metric……………………………………………………………………………………………………………..	3-72
HFL030 (3.0 kW) Mild Steel* cut chart — English……………………………………………………………………………………………………………	3-73
HFL030 (3.0 kW) Stainless Steel* cut chart — Metric………………………………………………………………………………………………………	3-74

HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2

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HFL030 (3.0 kW) Stainless Steel* cut chart — English……………………………………………………………………………………………………	3-75
HFL030 (3.0 kW) Aluminum* cut chart — Metric………………………………………………………………………………………………………………	3-76
HFL030 (3.0 kW) Aluminum* cut chart — English…………………………………………………………………………………………………………….	3-77
HFL030 (3.0 kW) Brass* cut chart — Metric…………………………………………………………………………………………………………………….	3-78
HFL030 (3.0 kW) Brass* cut chart — English…………………………………………………………………………………………………………………..	3-79
HFL030 (3.0 kW) Copper* cut chart — Metric…………………………………………………………………………………………………………………	3-80
HFL030 (3.0 kW) Copper* cut chart — English………………………………………………………………………………………………………………..	3-81
Firmware upgrade procedure……………………………………………………………………………………………………………………………………………	3-82
Setting the IP address……………………………………………………………………………………………………………………………………………..	3-82
Upgrading the firmware……………………………………………………………………………………………………………………………………………	3-84

Maintenance………………………………………………………………………………………………………………………….	4-1
Routine Maintenance……………………………………………………………………………………………………………………………………………………………	4-2
Dehumidifier………………………………………………………………………………………………………………………………………………………………..	4-2
Inspection and cleaning of the collimator…………………………………………………………………………………………………………………..	4-2
Cleaning the quartz block…………………………………………………………………………………………………………………………………………..	4-4
Nozzle inspection………………………………………………………………………………………………………………………………………………………..	4-6
Lens inspection…………………………………………………………………………………………………………………………………………………………..	4-6
Lens removal……………………………………………………………………………………………………………………………………………………………….	4-7
Lens cleaning………………………………………………………………………………………………………………………………………………………………	4-8
Lens installation………………………………………………………………………………………………………………………………………………………..	4-10
Air filter element replacement………………………………………………………………………………………………………………………………….	4-15
LHC error messages…………………………………………………………………………………………………………………………………………………………	4-16
Troubleshooting…………………………………………………………………………………………………………………………………………………………………	4-18
Troubleshooting the gas console…………………………………………………………………………………………………………………………….	4-19
Troubleshooting routines…………………………………………………………………………………………………………………………………………………..	4-20
Mild steel O2 cutting…………………………………………………………………………………………………………………………………………………	4-20
Stainless steel and aluminum N2 cutting…………………………………………………………………………………………………………………	4-22
Troubleshoot the nozzle extension calibration………………………………………………………………………………………………………………….	4-24
Troubleshoot CHS calibration errors………………………………………………………………………………………………………………………………..	4-24
LPC service mode parameters………………………………………………………………………………………………………………………………………….	4-25
LHC diagnostics parameters…………………………………………………………………………………………………………………………………………….	4-29
HyIntensity Fiber Laser Machine Interface………………………………………………………………………………………………………………………..	4-31
LPC 1……………………………………………………………………………………………………………………………………………………………………….	4-31
LPC 2……………………………………………………………………………………………………………………………………………………………………….	4-32

Parts List………………………………………………………………………………………………………………………………..	5-1
Fiber laser supply…………………………………………………………………………………………………………………………………………………………………	5-2
Fiber laser components………………………………………………………………………………………………………………………………………………………..	5-3
Starter kit………………………………………………………………………………………………………………………………………………………………………………	5-4
Consumables……………………………………………………………………………………………………………………………………………………………………….	5-5
LF150 cutting head — lower parts………………………………………………………………………………………………………………………………………..	5-6
Lens assembly parts…………………………………………………………………………………………………………………………………………………………….	5-7
Collimator……………………………………………………………………………………………………………………………………………………………………………..	5-8
Beam delivery optical cable…………………………………………………………………………………………………………………………………………………	5-9
Cables and hoses……………………………………………………………………………………………………………………………………………………………..	5-10

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Safety

Introduction

The Hypertherm HFL015 Fiber Laser consists of 4 assemblies. 1. HFL015 Fiber Laser Supply, part number 051023

Note: The HFL015 fiber laser supply, part number 051023, was certified to IEC 61010-1 Safety requirements for electrical equipment for measurement, control, and laboratory use which covers electrical safety.

2.Fiber Laser Gas Console, part number 051024

3.Fiber Laser Head Controller, part number 051026

4.Fiber Laser Head LF150, part number 051025

“Machine builder” in this context is meant to include any person that integrates the Hypertherm HFL015 Fiber Laser into their final laser cutting system.

The Hypertherm HFL015 Fiber Laser is designed as COMPONENTS FOR INCORPORATION into a laser cutting system for industrial and manufacturing environments. The machine builder is responsible for proper adherence to any and all laser and machine safety regulations and certifications for the laser cutting system designed and manufactured by the machine builder. If required by local code, the machine builder or customer shall make arrangements for the final laser cutting system to be inspected and approved for compliance with local codes and standards by an accredited testing laboratory or third party expert acceptable to the regulatory authority having jurisdiction for the final installation.

Laser beam cutting is a thermal cutting process that uses heat from a laser beam with high-pressure assist gas to augment the removal of metal material. There are general hazards associated with metal cutting and specific hazards using lasers for metal cutting that need to be evaluated and mitigated. The following information provided

with the Hypertherm HFL015 fiber laser is intended to inform the machine builder and the body responsible for the implementation of workplace and laser safety at the installed site of their responsibilities for safe design, installation and use. The appropriate local codes and standards for the final installation shall be consulted. Should any information in this document be in contravention to local codes and standards, the local codes and standards shall take precedence.

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HFL015 fiber laser intended for use in laser cutting systems

The Fiber Laser as sold by Hypertherm is a component intended for sale to machine builders designing and installing the final laser cutting systems. The machine builder has to mount the laser head and enclose the beam and fiber laser cable in a manner that satisfies all applicable standards and regulations. The machine builder has responsibility for the safe design, safe installation, safe use and safe maintenance of the final laser cutting system including but not limited to the provisions to prevent access to the fiber laser beam in the final laser cutting system.

All equipment shall be installed in compliance with the local regulations ( electrical safety, laser safety, workplace safety, etc.) and any verification required by local regulatory authorities having jurisdiction for the site(s) where the final laser cutting system with Hypertherm Fiber Laser components are installed and operated. Voltages inside the Hypertherm HFL015 Fiber Laser Supply enclosure are sufficient to cause fatal injury. The equipment shall be installed by competent and qualified personnel in accordance with the final laser cutting system instructions. In addition to these instructions, ANSI Z136.1 and IEC EN 60825-1 are the recommended primary sources for laser safety information.

Operating instructions, guidelines, and rules

Instructions, guidelines, and rules covering operation and maintenance of final laser system, supplied by the machine builder shall be made available to the laser safety officer and operator and shall be strictly followed. This document for the Hypertherm fiber laser components may supplement but does not satisfy this requirement for the final laser cutting system documentation.

Note 1: In addition to the machine builders’s instructions and these instructions, the following references may be of assistance:

•EN 60825-1 — Safety of laser products — Part 1: Equipment classification and requirements

•ANSI Z136.1; American National Standard for Safe Use of Lasers

•The Laser Institute of America’s (LIA) Guide for the Selection of Laser Eye Protection;

•LIA’s Laser Safety Manual is designed to help those responsible for laser safety at their facility.

•US Code of Federal Regulation of 21CFR1040.10 and 21CFR1040.11 for a complete laser product,

•The USA Occupational Safety Health Administration’s (OSHA) Technical Manual, Section III, Chapter 6, “Laser Hazards”

Note 2: The following reference documents provide basic requirements for metal cutting

•In Canada, CAN/CSA-W117.2-06 Safety in welding, cutting, and allied processes

•In the USA, see ANSI Z49.1:2005 Safety in welding, cutting, and allied processes

Note 3: The following reference documents will help determine welding and cutting particulate/fume sampling:

•ANSI/AWS F1.1 for airborne particulates;

•ANSI/AWS F1.2 for fume generation rates and total fume emission

•ANSI/AWS F1.3 for contaminants.

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Protection of personnel

Good housekeeping with areas free from trip and fall hazards shall be maintained in the workplace so that the final laser cutting system, automated and semi-automated material transport machines, fiber laser and electrical cables, and other apparatus do not create a hazard to operators, service and other personnel including visitors. Appropriate safeguards and warning signs shall be provided to prevent slips, falls, electric shock, burns, inhalation of gases and fumes, and exposure to noise, vibration and heat. Refer to the Safety and Compliance Manual published by Hypertherm for Plasma Cutting Systems which covers many of the same hazards for metal cutting and protection of personnel in the workplace except for Laser Safety aspects which are covered in ANSI Z136.1 and IEC EN 60825-al.

Note: The employer should conduct a physical demands analysis to ensure that any personal protective equipment does not create a health hazard (e.g., neck , back and wrist problems associated with prolonged or repetitive use)

Laser safety officer

A Laser Safety Officer (LSO) shall be appointed at each facility using a fiber laser for welding or cutting. The duties and responsibilities of the LSO should be as outlined in ANSI Z136.1, Section 1.3 in the US or other laser safety regulations applicable to the OEM laser cutting systems at the final installation site.

Note: The LSO is responsible for ensuring that all operators are properly trained and fully aware of the safe operation and hazards of operating a laser welding or cutting system. The LSO is also responsible for communicating and enforcing safety procedures to ensure all personnel (operator, service and visitors) understand the theory of operation for the OEM laser cutting end product and site safety instructions before entering a restricted area or room where a laser can be operating.

The Laser Safety Officer (LSO) shall with support from the final laser cutting system manufacturer conduct a hazard evaluation at the site that takes at least the following into consideration:

A.the potential hazards produced by the operation of the laser equipment;

B.the inherent hazards in the environment in which the equipment is to be operated;

C.the hazards that may occur with operation of the equipment in that environment; and

D.the individuals who may be affected by the hazards.

After completion of this hazard evaluation, the Laser Safety Officer (LSO) shall define the specific laser safety personal protective equipment requirements and procedures.

Condition of laser beam equipment

All laser beam equipment shall be maintained in good mechanical and electrical condition by competent or qualified maintenance personnel as specified by the machine builder. The operator shall report any equipment malfunction, defect, or safety hazard to the laser safety officer, and the use of the equipment shall be discontinued until its safeness has been ensured by the laser safety officer. Repairs shall be made only by competent or qualified maintenance personnel.

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Laser safety

This product is a Class 4 laser capable of cutting metal. The Hypertherm HFL015 Fiber Laser is specifically designed for incorporation or integration into other equipment. As such, it DOES NOT MEET the full requirements for a standalone laser system as defined by 21 CFR 1040.10 and IEC/EN 60825-1. Within the EU, the equipment is supplied with a Certificate of Incorporation indicating harmonized standards considered in the design.

“Machine builder” in this context is meant to include any person that integrates the Hypertherm HFL015 Fiber Laser into their final laser cutting system, or any person who uses the Hypertherm HFL015 Fiber Laser in the form as supplied by Hypertherm.

The label shown below has been affixed to the HFL015 Fiber Laser Supply, part number 051023 to satisfy the US Code of Federal Regulations which indicates equipment does not need to comply with the requirements of 21CFR1040.10 and 21CFR1040.11 for a complete laser product, provided the equipment is labeled with a statement that it is designated for use solely as a component.

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Laser safety warnings

It is the responsibility of the machine builder to meet all of the regulatory requirements for the final laser cutting system. Nonetheless, many of the electronic and labeling requirements have been incorporated into the Hypertherm HyIntensity Fiber Laser to facilitate the final laser cutting system compliance with regulatory requirements.

The following laser safety warning labels are located on the Hypertherm HyIntensity Fiber Laser when the Hypertherm HyIntensity Fiber Laser leaves the Hypertherm factory.

Labels on the front door

On the 1.0 kW laser	On the 1.5 kW laser
(HFL010)	(HFL015)

On the 2.0 kW laser	On the 3.0 kW laser
(HFL020)	(HFL030)

Labels on the top cover

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Label on the Beam delivery outlet

Label on the left side

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Label on the right side

Labels on the rear door

On the 1.0 kW laser	On the 1.5 kW laser
(HFL010)	(HFL015)

On the 2.0 kW laser	On the 3.0 kW laser
(HFL020)	(HFL030)

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Label on the laser head

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During installation it is vital that the laser hazard is fully managed. In particular, the machine builder is required to implement the engineering requirements detailed in IEC/EN 60825-1. Based on the evaluation or certification of the final laser cutting system, additional laser safety warnings may be provided by the machine builder or by the laser safety officer at the installed site.

Health concerns

Personnel assigned to operate or maintain laser beam cutting equipment shall have been properly trained by the machine builders representative or by a qualified instructor and shall understand the safety requirements of metal cutting using lasers.

Laser safety eyewear (LSE)

Laser safety eyewear (LSE) is designed to reduce the amount of incident light of specific wavelengths to a safe level, while transmitting sufficient light for good vision. As LSE often looks alike in style and color, it is important to specifically check both the wavelength and optical density imprinted on all LSE prior to laser use, especially in multi-wavelength facilities where more than one laser may be located. In the USA reference to ANSI Z136.1 is recommended for the selection of appropriate eye wear to protect against reflections of laser radiation.

Acoustical noise

The noise generated by laser beam welding, cutting, or gouging may impair hearing. Hearing protection shall be worn where the noise level exceeds limits as specified by the regulatory authority having jurisdiction Since operators and nearby personnel can be exposed to noise levels in excess of 85 dB(A), it is important that their hearing be protected. The most direct way to control excessive noise is to reduce the intensity at the source or install barriers in the final laser cutting system between the source and the operator station(s). When engineering or administrative control methods fail to bring noise exposure within levels established by the appropriate regulatory authority having jurisdiction, personal protective devices such as earmuffs or earplugs shall be used. It is the responsibility of the machine builder and the body responsible for the implementation of workplace / laser safety at the installed site to measure the acoustical noise in application and ensure personnel are protected from noise levels that exceed limits.

Warning signs

Warning signs shall be posted in conspicuous areas to indicate laser and cutting hazards. The signs shall indicate the need for the appropriate types of protective equipment.

Gas, fumes and air quality

Fumes and gases are generated by removal of metal from the workpiece being cut during laser beam cutting. The body responsible for workplace / laser safety at the installed site needs to control the materials being cut. Before cutting any unfamiliar materials or using any unfamiliar cleaning materials, the Material Safety Data Sheet (MSDS) shall be read to determine whether any hazards may exist when the material removed will be converted to a gas by laser cutting.

Personnel shall not be exposed to concentrations of airborne contaminants above acceptable limits as established by the authority having jurisdiction. The most direct way to control fumes and gases is by ventilation. Air Quality permits may be needed to release fumes outside the building. Consult a local expert for information on local air quality permits, ventilation and fume extraction. Where ventilation alone cannot protect personnel, appropriate personal respiratory protection shall be used as required by the authority having jurisdiction. Where respirators are employed, requirements for the selection and use of respirators shall include, as a minimum, the following:

A.Written procedures for the proper care, use, maintenance, and storage of respirators shall be provided, and the employer shall ensure that these procedures are followed. These procedures shall be developed and set down in writing in consultation with the joint health and safety committee or the health and safety representative, as applicable; and made readily accessible, along with related schedules, to the welder and welding personnel.

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B.The OEM laser cutting end product recommended maintenance and cleaning schedules and procedures shall be followed.

C.Adequate and suitable storage facilities for respirators shall be provided.

D.A person with the appropriate skills and knowledge shall be assigned to examine respirators and carry out the tests or procedures necessary to ensure that they serve their intended purpose; and ensure that the respirators fit the individual workers correctly and are appropriate for their intended purpose.

E.The employer shall provide training and instruction for workers and supervisors on the proper use, care, maintenance, and storage of respirators.

For fume and gases air sampling, where concentrations of airborne fume contaminants are to be determined by sampling of the atmosphere, sampling shall be tested using the NIOSH methodology, other recognized methods, or the guidelines of the authority having jurisdiction. When a helmet is worn, the samples shall be collected inside the helmet in the operator’s breathing zone. The occupational exposure limits shall comply with the regulatory authority having jurisdiction. Contaminant and fume analysis in the lab is covered under two areas:

A.Total welding fume particulate (mg/m3).

B.An elemental analysis of each contaminant (mg/m3). The contaminant particulate and fume testing is important to determine the exposure risk to personnel.

Confined spaces

Confined spaces are defined specifically in the codes and regulations that apply to each work project. Confined spaces need to be considered when the access or egress of personnel is restricted and there is a potential for the accumulation of a hazardous gas, fume, vapor, and dust, or the development of an oxygen-deficient or oxygen-enriched atmosphere that is likely to affect the health and safety of a worker.

If needed, the body responsible for the implementation of workplace / laser safety at the installed site shall have written rescue procedures for confined space emergencies. Before the operator or service personnel enters a confined space to undertake any welding, cutting, or allied process, the personnel shall be informed of and understand the hazards of the confined space and receive instruction on safe procedures for entering, working in, and exiting from

the confined space.

Before a person enters a confined space, a leak test should be done on all joints of any hose or pipelines that have the potential to introduce gases into the confined space. This leak test is done in order to eliminate the possibility of gases being introduced into the confined space.

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Oxygen gas distribution for laser cutting

Oxygen distribution system including connections and valves shall be approved by the regulatory authority having jurisdiction.

•Each outlet on the service piping from which oxygen is withdrawn to supply a portable outlet header shall be equipped with a readily accessible shutoff valve.

•Each service outlet on portable outlet headers shall be provided with a check valve, a readily accessible shutoff valve, and a detachable outlet seal cap that is chained or otherwise attached to the body of the valve.

•Master shutoff valves for oxygen shall be provided at the entry end of the portable outlet header.

•Portable outlet headers for fuel gas service shall be provided with an approved hydraulic backpressure valve installed at the inlet and preceding the service outlets, unless an approved pressure-reducing regulator, an approved backflow check valve, or an approved hydraulic backpressure valve is installed at each outlet. Outlets provided on headers for oxygen service may be fitted for use with pressure-reducing regulators or for direct hose connection.

•Hose for oxygen-fuel gas service shall meet the requirements of RMA IP-7 and CGA E-1.

•Cylinder manifolds, shutoff valves, pressure-reducing regulators, backpressure valves, hoses and connections shall be installed under the supervision of someone properly trained in their assembly and use.

In North America, hose diameters of 19 mm (3/4 in) or smaller are color-coded green for oxygen and red for fuel gases (acetylene, liquefied petroleum gases (LPG), natural gas, hydrogen, etc.). Black hose is used for inert gases, compressed air, and water services.

Note: ISO standard colors are blue for oxygen hose and orange for LPG hose.

Public exhibitions and demonstrations

Safety precautions specific to welding and cutting performed at public demonstrations and exhibits shall protect viewers, demonstrators, and the public. Installation and operation of welding, cutting, and related equipment shall be under the supervision of a competent person designated to ensure the safety of the public. The site shall be so constructed, equipped, and operated as to minimize the possibility of injury to viewers at the site. Materials and

equipment on-site shall be located so as not to interfere with evacuation of people during an emergency. Sites shall be provided with an appropriate type of portable fire extinguisher. Combustible materials at the site shall be shielded from flames, sparks, and molten metal or moved to a safe distance, i.e., 15 m (50 ft). The fire department shall be notified in advance of the public exhibition and demonstration. The public shall be shielded from flames, flying sparks, molten metal, harmful laser radiation, inhalation of hazardous concentrations of fumes and gases and contact with live electrical arts.

Large area viewing

For large area viewing, such as training, demonstrations, shows, and certain automatic laser welding and cutting operations, a large filter window or curtain may be used rather than individual helmets, hand shields, or goggles. It is important to specifically check both the wavelength and optical density for a large filter window or curtain. A combination of windows or curtains and laser safety eye wear (LSE) may be used.

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Training

The laser safety and basic safety training shall be in accordance with the requirements of the authority having jurisdiction. The course contents should include, as a minimum, elements covering:

A.laser safety

B.basic safety

C.hazard identification, including:

a.electrical hazards

b.fire protection and prevention

c.burns

d.radiation

e.fumes and gases

f.noise

g.explosions

D.hazard controls

E.personal protective equipment

F.process-specific welding and cutting safety

G.ergonomic issues

H.care and maintenance of OEM laser cutting end product

Additional training shall be provided on the following subjects if applicable to the nature of work being performed:

A.elevated work and fall protection

B.material handling (basic rigging, hoisting, forklift, etc.)

C.confined spaces

D.welding or cutting of drums and containers

E.work permit systems and policies

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Product stewardship

Introduction

Hypertherm maintains a global Regulatory Management System to ensure that products comply with regulatory and environmental requirements.

National and local safety regulations

National and Local safety regulations shall take precedence over any instructions provided with the product. The product shall be imported, installed, operated and disposed of in accordance with national and local regulations applicable to the installed site.

Certification test marks

Certified products are identified by one or more certification test marks from accredited testing laboratories. The certification test marks are located on or near the data plate.

Each certification test mark means that the product and its safety-critical components conform to the relevant national safety standards as reviewed and determined by that testing laboratory. Hypertherm places a certification test mark on its products only after that product is manufactured with safety-critical components that have been authorized by the accredited testing laboratory.

Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of the following occurs:

• The product is modified in a manner that creates a hazard or non conformance with the applicable standards.

• Safety-critical components are replaced with unauthorized spare parts.

• Any unauthorized assembly, or accessory that uses or generates a hazardous voltage is added.

• There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification, or otherwise.

CE marking constitutes a manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of Hypertherm products with a CE Marking located on or near the data plate

have been tested for compliance with the European Low Voltage Directive and the European EMC Directive. EMC filters needed to comply with the European EMC Directive

are incorporated within versions of the power supply with a CE Marking.

Certificates of compliance for Hypertherm products are available from the Downloads Library on the Hypertherm web site at

https://www.hypertherm.com.

Differences in national standards

Nations may apply different performance, safety or other standards. National differences in standards include, but are not limited to:

• Voltages

• Plug and cord ratings • Language requirements

• Electromagnetic compatibility requirements

These differences in national or other standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product. For example, the CSA versions of Hypertherm’s products do not comply with European EMC requirements, and therefore do not have a CE marking on the data plate.

Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate. These include, but are not limited to:

• Australia

• New Zealand

• Countries in the European Union • Russia

It is important that the product and its certification test mark be suitable for the end-use installation site. When Hypertherm products are shipped to one country for export to another country; the product must be configured and certified properly for the end-use site.

Safe installation and use of shape cutting equipment

IEC 60974-9, titled Arc Welding Equipment – Installation and use, provides guidance in the safe installation and use of shape cutting equipment and the safe performance of cutting operations. The requirements of national and local regulations shall be taken into consideration during installation, including, but not limited to, grounding or

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protective earth connections, fuses, supply disconnecting device, and type of supply circuit. Read these instructions before installing the equipment. The first and most important step is the safety assessment of the installation.

The safety assessment must be performed by an expert, and determines what steps are necessary to create a safe environment, and what precautions should be adopted during the actual installation and operation.

Procedures for periodic inspection and testing

Where required by local national regulations,

IEC 60974-4 specifies test procedures for periodic inspection and after repair or maintenance, to ensure electrical safety for plasma cutting power sources built in conformity with IEC 60974-1. Hypertherm performs the continuity of the protective circuit and insulation resistance tests in the factory as non-operating tests. The tests are performed with the power and ground connections removed.

Hypertherm also removes some protective devices that would cause false test results. Where required by local national regulations, a label shall be attached to the equipment to indicate that it has passed the tests prescribed by IEC60974-4. The repair report shall indicate the results of all tests unless an indication is made that a particular test has not been performed.

Qualification of test personnel

Electrical safety tests for shape cutting equipment can be hazardous and shall be carried out by an expert in the field of electrical repair, preferably someone also familiar with welding, cutting, and allied processes. The safety risks to personnel and equipment, when unqualified personnel are performing these tests, may be much greater than the benefit of periodic inspection and testing.

Hypertherm recommends that only visual inspection be performed unless the electrical safety tests are specifically required by local national regulations in the country where the equipment is installed.

Residual current devices (RCDs)

In Australia and some other countries, local codes may require the use of a Residual Current Devices (RCD) when portable electrical equipment is used in the workplace or at construction sites to protect operators from electrical faults in the equipment. RCDs are designed to safely disconnect the mains electrical supply when an imbalance is detected between the supply

and return current (there is a leakage current to earth). RCDs are available with both fixed and adjustable trip currents between 6 to 40 milliamperes and a range of trip times up to 300 milliseconds selected for the equipment installation, application and intended use. Where RCDs are used, the trip current and trip time on RCDs should be selected or adjusted high enough to avoid nuisance tripping during normal operation of the plasma cutting equipment and low enough in the extremely unlikely event of an electrical fault in the equipment to disconnect the supply before the leakage current under a fault condition can pose a life threatening electrical hazard to operators.

To verify that the RCDs continue to function properly over time, both the trip current and the trip time should be tested periodically. Portable electrical equipment and RCDs used in commercial and industrial areas in Australia and New Zealand are tested to the Australian standard AS/‌NZS 3760. When you test the insulation of plasma cutting equipment to AS/‌NZS 3760, measure the insulation resistance according to Appendix B of the standard, at 250 VDC with the power switch in the ON position to verify proper testing and to avoid the false failure of the leakage current test. False failures are possible because the metal oxide varistors (MOVs) and electromagnetic compatibility (EMC) filters, used to

reduce emissions and protect the equipment from power surges, may conduct up to 10 milliamperes leakage current to earth under normal conditions.

If you have any questions regarding the application or interpretation of any IEC standards described here, you are required to consult with an appropriate legal or other advisor familiar with the International Electrotechnical standards, and shall not rely on Hypertherm in any respect regarding the interpretation or application of such standards.

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Higher-level systems

When a system integrator adds additional equipment; such as cutting tables, motor drives, motion controllers or robots; to a Hypertherm plasma cutting system, the combined system may be considered a higher-level system. A higher-level system with hazardous moving parts may constitute industrial machinery or robotic equipment, in which case the OEM or end-use customer may be subject to additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm.

It is the responsibility of the end-use customer and the OEM to perform a risk assessment for the higher-level system, and to provide protection against hazardous moving parts. Unless the higher-level system is certified when the OEM incorporates Hypertherm products into it, the installation also may be subject to approval by local authorities. Seek advice from legal counsel and local regulatory experts if you are uncertain about compliance.

External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end use installation site. When the external interconnecting cables are subject to oil, dust, water, or other contaminants, hard usage ratings may be required.

When external interconnecting cables are subject to continuous movement, constant flexing ratings may be required. It is the responsibility of the end-use customer or the OEM to ensure the cables are suitable for the application. Since there are differences in the ratings and costs that can be required by local regulations for higher level systems, it is necessary to verify that any external interconnecting cables are suitable for the end-use installation site.

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Environmental stewardship

Introduction

The Hypertherm Environmental Specification requires RoHS, WEEE and REACH substance information to be provided by Hypertherm’s suppliers.

Product environmental compliance does not address the indoor air quality or environmental release of fumes by the end user. Any materials that are cut by the end user are not provided by Hypertherm with the product. The end user is responsible for the materials being cut as well as for safety and air quality in the workplace. The end user must be aware of the potential health risks of the fumes released from the materials being cut and comply with all local regulations.

National and local environmental regulations

National and local environmental regulations shall take precedence over any instructions contained in this manual.

The product shall be imported, installed, operated and disposed of in accordance with all national and local environmental regulations applicable to the installed site.

The European Environmental regulations are discussed later in The WEEE Directive.

The RoHS directive

Hypertherm is committed to complying with all applicable laws and regulations, including the European Union Restriction of Hazardous Substances (RoHS) Directive that restricts the use of hazardous materials in electronics products. Hypertherm exceeds RoHS Directive compliance obligations on a global basis.

Hypertherm continues to work toward the reduction of RoHS materials in our products, which are subject to the RoHS Directive, except where it is widely recognized that there is no feasible alternative.

Declarations of RoHS Conformity have been prepared for the current CE versions of Powermax plasma cutting systems manufactured by Hypertherm. There is also

a “RoHS mark” on the Powermax CE versions below the “CE Marking” on the data plate of CE versions of Powermax series units shipped since 2006. Parts

used in CSA versions of Powermax and other products manufactured by Hypertherm that are either out of scope or exempt from RoHS are continuously being converted to RoHS compliance in anticipation of future requirements.

Proper disposal of Hypertherm products

Hypertherm plasma cutting systems, like all electronic products, may contain materials or components, such as printed circuit boards, that cannot be discarded with ordinary waste. It is your responsibility to dispose of any Hypertherm product or component part in an

environmentally acceptable manner according to national and local codes.

• In the United States, check all federal, state, and local laws.

• In the European Union, check the EU directives, national, and local laws. For more information, visit www. hypertherm.com/weee.

• In other countries, check national and local laws.

• Consult with legal or other compliance experts when appropriate.

The WEEE directive

On January 27, 2003, the European Parliament and the Council of the European Union authorized Directive 2002/96/EC or WEEE (Waste Electrical and Electronic Equipment).

As required by the legislation, any Hypertherm product covered by the directive and sold in the EU after August 13, 2005 is marked with the WEEE symbol. This directive encourages and sets specific criteria for the collection, handling, and recycling of EEE waste. Consumer and business-to-business wastes are treated differently

(all Hypertherm products are considered business-to- business). Disposal instructions for the CE versions of Powermax plasma systems can be found at www.hypertherm.com/weee.

The URL is printed on the symbol-only warning label for each of these CE version Powermax series units shipped since 2006. The CSA versions of Powermax and other products manufactured by Hypertherm are either out of scope or exempt from WEEE.

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The REACH regulation

The REACH regulation (1907/2006), in force since

June 1, 2007, has an impact on chemicals available to the European market. The REACH regulation requirements for component manufacturers states that the component shall not contain more than 0.1% by weight of the Substances of Very High Concern (SVHC).

Component manufacturers and other downstream users, such as Hypertherm, are obligated to obtain assurances from its suppliers that all chemicals used in or on Hypertherm products will have a European Chemical Agency (ECHA) registration number. To provide chemical information as required by the REACH regulation, Hypertherm requires suppliers to provide REACH declarations and identify any known use of REACH SVHC. Any use of SVHC in amounts exceeding 0.1% w/w of the parts has been eliminated. The MSDS contains a full disclosure of all substances in the chemical and can be used to verify REACH SVHC compliance.

The lubricants, sealants, coolants, adhesives, solvents, coatings and other preparations or mixtures used by Hypertherm in, on, for, or with its shape cutting equipment are used in very small quantities (except the coolant)

and are commercially available with multiple sources that can and will be replaced in the event of a supplier

problem associated with REACH Registration or REACH Authorization (SVHCs).

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require that Material Safety Data Sheets (MSDS) be made available for all chemicals. The list of chemicals is provided by Hypertherm. The MSDS are for chemicals provided with the product and other chemicals used in

or on the product. MSDS can be downloaded from the Downloads Library on the Hypertherm web site at https:// www.hypertherm.com. On the Search screen, insert MSDS in the document title and click on Search.

In the USA, OSHA does not require Material Safety Data Sheets for articles such as electrodes, swirl rings, retaining caps, nozzles, shields, deflectors and other solid parts of the torch.

Hypertherm does not manufacture or provide the materials that are cut and has no knowledge whether the fumes released from materials that are cut will pose a physical hazard or health risk. Please consult with your supplier or other technical advisor if you need guidance concerning the properties of the material you will cut using a Hypertherm product.

Fumes emission and air quality

Note: The following information on air quality is intended for general information only and should not be used as a substitute for reviewing and implementing applicable government regulations or legal standards in the country where the cutting equipment will be installed and operated.

In the USA, the National Institute for Occupational Safety and Health (NIOSH) Manual of Analytical Methods (NMAM) is a collection of methods for sampling and analyzing contaminants in workplace air. Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO or commercial suppliers of sampling and analytical equipment, may have advantages over NIOSH methods.

For example, ASTM Practice D 4185 is a standard practice for the collection, dissolution, and determination of trace metals in workplace atmospheres. The sensitivity, detection limit, and optimum working concentrations

for 23 metals are listed in ASTM D 4185. An industrial hygienist should be used to determine the optimum sampling protocol, considering analytical accuracy, cost, and optimum sample number. Hypertherm uses a third party industrial hygienist to perform and interpret air quality testing results taken by air sampling equipment positioned at operator stations in Hypertherm buildings where plasma cutting tables are installed and operated.

Where applicable, Hypertherm also uses a third party industrial hygienist to obtain air and water permits.

If you are not fully aware and up to date on all applicable government regulations and legal standards for the installation site, you should consult a local expert prior to purchasing, installing, and operating the equipment.

ES-2	Hypertherm Fiber Laser Instruction Manual – 807090 Revision 3

Electromagnetic Compatibility (EMC)

Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.

The limits required by EN60974-10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be necessary to use other measures to further reduce interference.

This cutting equipment is designed for use only in an industrial environment.

Installation and use

The user is responsible for installing and using the cutting equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of the work piece. In other cases, it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases, electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Assessment of area

Before installing the equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a.Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the cutting equipment.

b.Radio and television transmitters and receivers.

c.Computer and other control equipment.

d.Safety critical equipment, for example guarding of industrial equipment.

e.Health of the people around, for example the use of pacemakers and hearing aids.

f.Equipment used for calibration or measurement.

g.Immunity of other equipment in the environment. User shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures.

h.Time of day that cutting or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other

activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.

Compliance Information

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ELECTROMAGNETIC COMPATIBILITY

Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way, except as set forth in and in accordance with the manufacturer’s written instructions.

Cutting cables

The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting installation and adjacent to it should be considered.

However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode (nozzle for laser heads) at the same time.

The operator should be insulated from all such bonded metallic components.

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steel work,

a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct

connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.

Note: The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will in crease the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is provided in IEC 60974-9, Arc Welding Equipment, Part 9: Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire cutting system may be considered for special applications.

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Compliance Information

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Warranty

Attention

Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty, and will constitute misuse of the Hypertherm Product.

You are solely responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee

or warranty regarding the safe use of the product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship for the specific periods of time set forth herein and as follows: if Hypertherm is notified of a defect (i) with respect to

the plasma power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax brand power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, and with respect to torch lifter assemblies within a period of one

(1)year from its date of delivery to you, and with respect to Automation products one (1) year from its date of delivery to you, with the exception of the EDGE Pro CNC and ArcGlide THC, which shall be within a period of two

(2)years from the date of delivery to you, and (iii) with respect to HyIntensity fiber laser components within a period of two (2) years from the date of its delivery to you, with the exception of laser heads and beam delivery optical cables, which shall be within a period of one (1) year from its date of delivery to you.

This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters. In addition, Hypertherm does not warranty systems that have been damaged as a result of poor power quality, whether from phase converters or incoming line power. This warranty shall not apply to any product which has been incorrectly installed, modified, or otherwise damaged.

Hypertherm provides repair, replacement or adjustment of the Product as the sole and exclusive remedy, if and only if the warranty set forth herein properly is invoked and applies. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherm’s place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight pre paid by the customer. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph and with Hypertherm’s prior written consent.

The warranty set forth above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability

or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty.

Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs are not authorized

to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.

Compliance Information

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WARRANTY

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will have the right to defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement (and in any event no longer than

fourteen (14) days after learning of any action or threat of action), and Hypertherm’s obligation to defend shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential direct, indirect, punitive or exemplary damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranty, failure of essential purpose, or otherwise, and even if advised of the possibility of such damages.

National and local codes

National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.

Liability cap

In no event shall Hypertherm’s liability, if any, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim, action, suit or proceeding (whether in court, arbitration, regulatory proceeding or otherwise) arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

Insurance

At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products.

Transfer of rights

You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty. Within thirty (30) days before any such transfer occurs, you agree to notify in writing Hypertherm, which reserves the right of approval. Should you fail timely to notify Hypertherm and seek its approval as set forth herein, the Warranty set forth herein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise.

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Section 1

Specifications

Fiber laser supply

Overview

The HyIntensity Fiber Laser (HFL) is a laser system based on all solid state components. The fiber laser supply contains two to six laser engines and a beam combiner unit. Incoming electricity is converted to optical power by single emitter based pump laser diodes in each engine, which is converted to a high brightness infrared (non-visible) laser beam. Light from each of the laser engines enters the beam combiner unit which funnels the light into a single output fiber. This configuration has a wall plug electrical to optical output power efficiency greater than 28%. All of the optical components are water cooled to provide stable operation. A dehumidifier in the fiber laser supply maintains the humidity level inside the cabinet enclosure.

Fiber laser supplies

Part number	Description
051041	HFL010 — 1.0 kW fiber laser supply, with the fiber coupling unit, 400-480 VAC, 50/60 Hz
051042	HFL010 — 1.0 kW fiber laser supply, without the fiber coupling unit, 400-480 VAC, 50/60 Hz

051023	HFL015 — 1.5 kW fiber laser supply, with the fiber coupling unit, 400-480 VAC, 50/60 Hz
051043	HFL015 — 1.5 kW fiber laser supply, without the fiber coupling unit, 400-480 VAC, 50/60 Hz

051039	HFL020 — 2.0 kW fiber laser supply, with the fiber coupling unit, 400-480 VAC, 50/60 Hz
051044	HFL020 — 2.0 kW fiber laser supply, without the fiber coupling unit, 400-480 VAC, 50/60 Hz

051048	HFL030 — 3.0 kW fiber laser supply, with the fiber coupling unit, 440-480 VAC 50/60 Hz
051053	HFL030 — 3.0 kW fiber laser supply, without the fiber coupling unit, 440-480 VAC 50/60 Hz
051049	HFL030 — 3.0 kW fiber laser supply, with the fiber coupling unit, 380-400 VAC 50/60 Hz
051052	HFL030 — 3.0 kW fiber laser supply, without the fiber coupling unit, 380-400 VAC 50/60 Hz

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Specifications

Requirements

Electrical
HFL010, 015, 020 Input power………………………………..	400-480 VAC, 50/60 Hz (+/- 10%), 3 phase, 10 KVa
HFL030 (051048 and 051053) Input power…………..	440-480 VAC, 50/60 Hz (+/- 10%), 3 phase, 15 KVa
HFL030 (051049 and 051052) Input power…………..	380-400 VAC, 50/60 Hz (+/- 10%), 3 phase, 15 KVa
Note: The customer should permanently wire the fiber laser supply using a 3 phase, 30 amp disconnect.
Input/output (I/O)
Discrete I/O……………………………………………………………….	Out: permanently wired, +24 VDC relay, 100 mA
	In: optically isolated, +24 VDC
Analog I/O………………………………………………………………….	0-10 VDC
Coolant……………………………………………………………………..	See Chiller requirements later in this section.
Environmental
This equipment is intended for indoor use only
Operating temperature range……………………………………	0° C to 40° C (32° F to 104° F)
Humidity……………………………………………………………………..	95% relative humidity, non-condensing
Altitude……………………………………………………………………….	2000 m (6562 feet) maximum

Safety interlocks

External emergency stop (E-Stop) switch with (2) NO contacts (see the Installation section for details) External door interlock switch with (2) NO contacts

Key switch that is only removable in the OFF position Momentary switch with Indicator and (1) NO contact

Personal protection equipment
Safety glasses……………………………………………………………	OD 7+ @1040 – 1100 nm
Machine guards…………………………………………………………	Proper guards installed to protect against diffuse and specular
	laser reflections

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Specifications

Optical specifications

Cutting laser
Operating mode…………………………………………………………	Continuous wave (CW)
Beam shape……………………………………………………………….	Circular
Wavelength………………………………………………………………..	1070 nm (+/- 10 nm)
Rated output power (CW):
HFL010………………………………………………………………………	1000 watts
HFL015………………………………………………………………………	1500 watts
HFL020……………………………………………………………………..	2000 watts
HFL030……………………………………………………………………..	3000 watts
Beam diameter at the focusing lens………………………….	6-8 mm with the 60 mm collimator
	10-12 mm with the 100 mm collimator
Focusing lens…………………………………………………………….	150 mm effective focal length (EFL)
Laser classification…………………………………………………….	Class 4
Pointing laser
Operating mode…………………………………………………………	Continuous wave (CW)
Beam shape……………………………………………………………….	Circular
Wavelength………………………………………………………………..	630 – 680 nm
Rated output power (CW)
HFL010………………………………………………………………………	<10 mW
HFL015………………………………………………………………………	<15 mW
HFL020……………………………………………………………………..	<20 mW
HFL030……………………………………………………………………..	<30 mW
Beam diameter at the focusing lens………………………….	6
Beam diameter…………………………………………………………..	9 mm
Laser classification…………………………………………………….	Class 3B

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1-3

Specifications

Dimensions – HFL010, HFL015, and HFL020

822.9 mm

32.4 in

171.45 mm

6.75 in

1174.5 mm

46.24 in

HFL010 — 185 kg (410 lbs)

HFL015 — 204 kg (450 lbs)

HFL020 — 226 kg (500 lbs)

Front view

889.0 mm

35.0 in

183.13 mm

Side view

7.21 in

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Specifications

Dimensions – HFL030

825 mm

32.5 in

241 mm

9.5 in

1295 mm

51.0 in

Front view

889 mm

35 in

183.13 mm 7.21 in

Side view

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1-5

Specifications

LF150 laser head – 051025

Overview

The LF150 is designed to process material with the HyIntensity Fiber Laser cutting system. The optical design accommodates one 35 mm diameter lens at 150 mm EFL to cover the intended material type and thickness range. Capacitive height sensing between the nozzle and the work piece allows accurate and responsive height positioning. The laser head is protected by a collision mount for lateral and vertical collisions between the nozzle and work piece. The optical path between the collimator and laser head is sealed to prevent particulate and moisture contamination of the optical surfaces. A single cable connects the laser head to the laser head controller and all process signals are communicated back to the fiber laser supply over the Hypernet communications link.

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Specifications

Mounting dimensions

171.5 mm

6.75 in

152.4 mm

6.00 in

57.2 mm

2.25 in

Diameter 108.0 mm 4.25 in

Top view

31.5mm

1.24in

7.8 kg

17.2 lb

Diameter 6.6 mm (0.26 in) through hole (4 places)		90.0 mm
Diameter 11.0 mm (0.43 in) counterbore
		3.54 in
		32.0 mm
		1.26 in
	Diameter 3.0 mm	36.0 mm
Diameter 6.8 mm (0.27 in) through hole (4 places)	(0.118 in)	1.42 in
(2 places)
Diameter 11.1 mm (0.44 in) counterbore	50.0 mm

		1.97 in
101.6 mm	45.0 mm
1.77 in
4.0 in
		62.7 mm
		2.47 in

269.8 mm

10.62 in Full extension

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Specifications

Collimator dimensions

The collimator is installed onto the laser head in the Installation section of this manual

Top view

Diameter 43.0 mm 1.69 in

	175.5 mm
149.7 mm	6.91 in
5.89 in
	9.1 mm
	0.36 in

60 mm collimator		100 mm collimator

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Specifications

Collimator dimensions

The collimator is installed onto the laser head in the Installation section of this manual

Top view

Diameter 35.0 mm 1.38 in

174 mm

132 mm 6.85 in

5.20 in

9.0mm

0.35in

60 mm collimator		100 mm collimator

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Specifications

System gas requirements

Caution:	5 µm filtration is required on oxygen and nitrogen
	supply lines. Failure to use an acceptable filter can
	cause poor cut quality and damage to the laser system.

Gas quality and pressure requirements

Gas type	Quality	Pressure +/- 10%	Flow rate

O2 oxygen*	99.95% pure	800 kPa / 8 bar	170 slpm 360
	Clean, dry, oil-free	116 psi	scfh

N2 nitrogen*	99.5% pure	2.7 MPa / 27 bar	1600 slpm
	Clean, dry, oil-free	400 psi	3400 scfh

Air*	** Clean, dry, oil-free	900 kPa / 9 bar	***250 slpm
	per ISO 8573-1 Class 1.4.2	130 psi	530 scfh

*Oxygen, nitrogen, and air are required to be connected at all times

**ISO standard 8573-1 Class 1.4.2 requirements are:

•Particulates – no more than 100 particles per cubic meter of air at a size of 0.1 to 0.5 microns in the largest dimension and 1 particle per cubic meter of air at a size of 0.5 to 5.0 microns in the largest dimension.

•Water – the pressure dew point of the humidity must be less than or equal to 3° C (37.4° F).

•Oil – the concentration of oil can be no more than 0.1 mg per cubic meter of air.

***If air will not be used as a cut gas, the required pressure and flow rate of the air supply can be reduced:

•Pressure: 500 kPa / 5 bar / 75 psi

•Flow rate: 25 slpm / 53 scfh

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Specifications

Chiller requirements

Caution:	The cooling system must have a filter that allows the coolant to meet the
	specifications for particles shown below. Failure to use a filter capable
	of meeting the particle requirements can cause damage to expensive
	optical components and could be cause for denial of warranty claims on
	these components.

Coolant

Acceptable types of coolant	Distilled water
	Drinkable tap water
	Water/glycol mixture (see “Usage of inhibitors/additives” below)
	Deionized water is NOT allowed
Particles	< 100 μm in diameter.
Conductivity	50 – 500 microSiemens/cm
pH	5.5 – 9.0
Usage of	Usage of inhibitors or additives is allowed if the mixture meets specifications regarding
inhibitors/additives	particles, conductivity, and pH.
	As an example, Hypertherm torch coolant (028872) in 70/30 proportion is allowed
Maximum pressure	5.4 bar (80 psi)
Fitting connections	3/4 in female NPT
Coolant temperature range	25° C (+/– 5° C)

Flow rates

HFL010 (1.0 kW) laser	20 liters (5 gal) per minute minimum
HFL015 (1.5 kW) laser	40 liters (10 gal) per minute minimum
HFL020 (2.0 kW) laser	40 liters (10 gal) per minute minimum
HFL030 (3.0 kW) laser	40 liters (10 gal) per minute minimum

Cooling capacity

HFL010 (1.0 kW) laser	5 kW (17,100 BTU/hr)
HFL015 (1.5 kW) laser	8 kW (27,300 BTU/hr)
HFL020 (2.0 kW) laser	10 kW (34,125 BTU/hr)
HFL030 (3.0 kW) laser	12 kW (40,946 BTU/hr)

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1-11

Specifications

Gas control console – 051024

Overview

The gas console manages the selection of the cut gas and sets its pressure. It also sets the flow rate/pressure of the air supplied to the purge and side-jet ports of the laser head. It contains proportional valves, solenoid valves, pressure transducers, hoses and fittings necessary to perform these functions.

•The maximum recommended length for supply hoses from the gas supply to the gas console is 50 m (150 ft).

•The minimum recommended inner diameter (ID) of the air and oxygen supply hoses is 10 mm (3/8 in).

•The minimum recommended ID of the nitrogen supply hose is 12 mm (1/2 in).

•The maximum hose length from the gas console to the laser head is 10 m (33 ft).

•The maximum cable length from the gas console to the laser head controller is 10 m (33 ft)

	434.77 mm	Fitting	Size
266.7 mm	17.18 in
10.5 in		Air	1/4 in BSPT (female)
	238.2 mm	Oxygen (O2)
	and	1/4 in NPT (female)
	9.38 in	nitrogen (N2)

		Side jet	1/8 in NPT (female)
		Purge	1/8 in NPT (female)
		Cut gas	1/4 in NPT (female)
	473.3 mm
	18.64 in

63.5 mm

2.5 in

203.2 mm

8.0 in

13.0 kg

29.0 lb

6.731 mm

0.265 in (4 places)

460.375 mm

18.125 in

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Specifications

Beam delivery optical cable (BDO)

The optical power from the fiber laser supply is delivered through the fiber optics in the Beam delivery optical cable. Because of the small face area and the high power levels, cleanliness of the input and output optical surfaces is critical to component lifetime and proper operation. Each surface should be inspected, with the magnifier that was supplied with the system, whenever they are removed from their receptacles. To prevent contamination and chipping, the optical surfaces should not be touched.

Note: If cleaning is necessary, see the Cleaning Procedure on page 4-4.

Caution: The minimum bend radius of the Beam delivery optical cable is 100 mm (4 in). The fiber can be damaged if the radius is any smaller.

Diameter = 2 x radius = 200 mm (8 in)

100 mm (4 in)

200 mm

(8 in)

100 mm (4 in)

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1-13

Specifications

Laser head controller – 051026

Overview

The laser head controller includes a liquid crystal display (LCD), operating switches, and a rotary/push knob selector for laser setup and control.

130.50 mm

5.14 in

117.60 mm

4.63 in

298.40 mm 11.75 in

Diameter 5.0 mm (0.20 in)

4 places

63.5 mm

(2.5 in)

203.2 mm

(8.0 in)

Laser head controller mounting bracket dimensions

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Specifications

CNC Requirements

Hypertherm CNC

AC input power

100-240 VAC 50/60 Hz

CNC

EDGE Pro CNC or MicroEDGE Pro with Integrated Sensor THC interface

Z axis lifter

Hypertherm Sensor THC

CNC I/O Interface

All of the CNC I/O signals are communicated over Hypernet to the fiber laser cable connector through a standard Hypernet port

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1-15

Specifications

Generic CNC

Z axis lifter

•Modified to allow mounting of fiber laser head bracket

•Capable of moving fiber laser head (7.8 kg / 17.2 lbs)

CNC I/O interface

Physical connectors: Phoenix contact part numbers 1772405 and 1772418

CNC digital outputs (0-24 VDC sourcing opto-isolators from CNC to laser controller, 24 VDC = active [on])

Fault acknowledge/reset (rising edge triggered)………………………………………………….	Required
Digital beam……………………………………………………………………………………………………………	Required
Pointing laser enable………………………………………………………………………………………………	Required
Corner power pulsing enable…………………………………………………………………………………	Optional
Side jet……………………………………………………………………………………………………………………	Optional
Air select (off = O2, on = air)…………………………………………………………………………………	Required
N2 select………………………………………………………………………………………………………………….	Required

CNC digital inputs (Normally Open [NO] isolated 24 VDC relay contacts from laser controller to the CNC)

Laser fault……………………………………………………………………………………………………………….	Required
Pointing laser status……………………………………………………………………………………………….	Optional
Laser head fault………………………………………………………………………………………………………	Required
Nozzle contact………………………………………………………………………………………………………..	Required
Over range (>10 mm)…………………………………………………………………………………………….	Optional
Gas control fault……………………………………………………………………………………………………..	Required
CNC analog outputs to laser controller (0 – 10 VDC)
Laser power set point (0 – maximum output power in watts)………………………………	Required
Corner power (duty cycle) set point (1 – 99%)……………………………………………………	Optional
Assist gas pressure set point…………………………………………………………………………………	Required
(Air/O2 = 0 – 130 psi, N2 = 0 – 500 psi)
CNC analog input from laser controller (0 – 10 VDC)
Capacitive height sensor voltage (scaling 1 volt per mm)……………………………………	Required for auto height control

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Section 2

Installation

Upon receipt

•Verify that all system components on your order have been received. Contact your supplier if any items are missing.

•Inspect the system components for any physical damage that may have occurred during shipping. If there is evidence of damage, refer to Claims. All communications regarding claims must include the model number and serial number located on the rear of the power supply.

Claims

Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.

Claims for defective or missing merchandise – If any of the merchandise is defective or missing, contact your supplier. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.

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Installation

Installation requirements

All installation and service of the electrical and plumbing systems must conform to national and local electrical and plumbing codes. This work should be performed only by qualified, licensed personnel.

Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual, or your authorized Hypertherm distributor.

Noise levels

Acceptable noise levels as defined by national and local codes may be exceeded by this laser system. Always wear proper ear protection when cutting. Any noise measurements taken are dependant on the specific environment in which the system is used. See also Noise can damage hearing in the Safety section of this manual. Specific information by product can be found in the Hypertherm downloads library at:

https://www.hypertherm.com/Xnet/library/DocumentLibrary.jsp

Select the product you are looking for from the Product Type drop down menu, choose “Regulatory” from the Category drop down menu, and choose “Acoustical Noise Data Sheets” from the Sub Category drop down menu. Hit Submit.

Placement of system components

•Place all system components in position prior to making electrical, gas, and interface connections. Use the diagram in this section for component-placement guidelines.

•Ground all system components to earth. See Recommended grounding and shielding practices in this section for details.

•To prevent leaks in the system, tighten all gas and water connections as shown below:

Torque specifications