1

Basic Laser Applications Training

BYSTAR/BYSPRINT/BYSPEED

TABLE OF CONTENTS I - V


Section I Daily Start-Up
Laser Machine Start-Up (Resonator Start-Up)
Laser Machine Start-Up (Reference Machine and Setup Job)
Laser Machine Start-Up (Ready to Start Cutting)

Section II Procedures
Focal Point & Cutting Head (Machine Specific)
Focal Point of a New Lens (Bystar/Bysprint)
Cleaning the Cutting Head Lens (Bystar/Bysprint)
Focal Point of a New Lens (Byspeed)
Cleaning the Cutting Head Lens (Byspeed)

Section III

Laser Cutting In Non-Capacitive Mode
Assigning A 0,0 For The Rotary Axis
Assigning A 0,0 For Single Flat Fixture Parts
Setting Your Machine to Run In Automatic Mode
Turning Off the System Automatically

Section IV Charts and Guides
Cutting Fundamentals
Four Basic Elements In Achieving A Cut
Assessing Cut Quality
Breaking down the Numbers (MM, Gage, Decimals, Fractions)
Assist Gas Consumption

Section V Tips and FAQ's
Tips and Tricks from the Applications Department
Frequently Asked Questions about Bysoft

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SECTION - I





DAILY START-UP

3

Laser Machine Start Up / Resonator Turn On

1) Verify Cutting Assist Gases are `ON.
Oxygen Cutting Assist to be regulated @ 15 bar/225 psi max.
Nitrogen Cutting Assist to be regulated @ 24 bar/360 psi max.
Both regulators at Source and at Laser Service Unit should be set to the values
mentioned above.

2) Laser Resonator Gases should always be left in the `ON position.
High Purity Gases for Resonator (Carbon, Nitrogen and Helium).
Regulators for these Laser Resonator Gases should be set @ 70-80 psi.
All bottles should be properly identified e.g. marked (in-use, full, empty, etc.)
Always make sure that there is a full stand-by bottle of each gas on hand in case one
should happen to run out.
Also a good practice might be to change out a spent bottle at 150 psi rather than empty.
This can minimize bottom of bottle impurities, if any getting into laser resonator system.

3) Verify that the Compressor is ON and fully functional.

4) Verify that all chiller filters have no leaks and all lines to and from have no kinks. Turn
chiller ON.

5) At the STL Cabinet. Turn the power lever switch to the ON position.

6) At the Byvision Control panel press the reset button located on the right side once.

7) After several minutes or so on the panel pc you will see a window command prompt with
two of the following choices "Manager and "Operator once this command is
implemented you will wait for the next command prompt window that asks for user name
and password for Byvision. Allow 30 seconds or so for all software to fully load (yellow bar
in lower part of screen with message). If "Operator was chosen no password is necessary,
if "Manager then user name will be "expert and password "expert. After twenty
minutes or so, the orange light on top of laser gas cabinet will go on and the message will
read Laser Ready in the laser vision window.

Reference Machine and Set-up Job

8) To complete the activation of the handling systems (change table and/or loader etc.) press
the light curtain reset button (white) located on the machine frame between the two shuttle
tables along side the other handling control buttons. The door button (right side of
controller) needs to be pushed and the machine safety door needs to be open and closed
once. When the safety door is closed and the door button light is on solid, not blinking, all
conditions are now satisfied and the bridge is ready to be referenced.

9) At first start up the bridge must be referenced. Press the Menu button (located near the
lower left side of the pc) from the menu choices press the Hand button. Once in the hand
screen look at the right side menu and press the Reference button. The command line
choice is Cont or Stop. Press Cont on the hand controller which is attached to the right
side of the panel pc. The bridge and cutting head will move to reference position. You are
now ready to set up a job. Proceed to step 10.

10) Press the Menu button located near the lower left hand side of the screen and from the
menu choices press the Work button.

4

Laser Machine Start Up (Set-Up Job Continued)

11) At Work screen operator will call up cutting plans (.ncp or .lcc extension) and Parameter
(material). Press the Job List button in the lower center of screen. Press Add button
located near upper right.

12) Use Select to choose directory and/or cutting plan and OK to confirm selected choices.

13) To choose a parameter and/or change the amount of times the cutting plan runs stay in the
Job list page. Press the Edit button located near the upper right of the screen (just under
the Add button), at the next window press the Select button to get parameters (or choose
Edit to change runs of programs).

14) At the Parameter selection screen use the Filter criteria (lower part of window) to
isolate parameter choices. Highlight your choice from the Parameter selection list (top
section of window) then press OK until you return to the Job list screen.

15) Press the Back button and you will return to the main work screen. There you will see a
graph of your cutting plan on the screen.

16) Press the Info button, this page gives the operator information such as: focus, nozzle size
and which cutting head to use. Press the Close button and youll return to the Work
screen. For Byspeed skip to step 18.

17) Press the purple Serv button at the top of screen and then press Service position, then
press Cont on the hand controller. This will bring the bridge closer to the operator making
the cutting head easily accessible for set up.

18) Refer back to Info. page if necessary and put correct head, nozzle and focus (if you have
auto focus the cutting parameter will take care of focus) then press the Back button to
return to the Hand screen. Once the correct head and nozzle are installed the operator
must align the nozzle.

Ready to Start Cutting

19) To start a cutting plan Back out of info screen which will bring you to the Work
screen.

20) Press Start and the bridge will return to reference.

21) Press the Stop Part button (it will change to yellow upon activation) at the top of the
screen. Using this function will force the machine to stop at the end of each part so the
operator can inspect parts and also help user until he becomes more familiar with the
machine.

22) With edge detection activated cutting head will lower down to sheet in 3 places to
determine materials X and Y zero start point of job. To use edge detection, microjoints,
and/or nozzle cleaning press the button Special Funct. which is located near the lower
right of your panel p.c. and press the option you want to use.

23) Press Cont 3 times so machine can find X and Y zero start of your job. Once located press
Cont to begin cutting. End.

24) If you have other jobs to cut repeat from step 11.

5

Laser Machine Start Up (Ready To Start Cutting Continued)

LASER SHUT DOWN

1) Go to the PLC (handling) screen. If you do not see the Exit command press the Home
button then press the Exit button. This will open a command window, again choose the Exit
command. After the handling screen closes out press the Menu button then press the Main
button.

2) Once at the Main screen of Byvision turn off the computer and resonator by pressing the
close button. The next command window will offer the choices "shut down Byvision,
"shut down resonator, "shut down all, choose "shut down all for usual shut down.
After about several minutes (about ten minutes) the screen will go black, then you need to
turn off the main power lever on the side of the machine.

3) Turn OFF the chiller.

4) Turn OFF assist gas.


Leave Laser Resonator Gases ON !


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SECTION - II






PROCEDURES
















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BYSTAR/BYSPRINT


FOCAL POINT

CLEANING THE CUTTING HEAD LENS























8


BYSTAR / BYSPRINT FINDING THE ZERO FOCUS POINT OF A NEW LENS

Byvision Controls

Purpose: A new Zero Focal Point needs to be determined when a new lens is being installed or when a new
cutting head is being used. The Zero Focus Point is defined as the focus setting where as the focus is
on the surface of the material.

Type of Systems: Auto Focus / Bypos Mirror

Materials / Conditions: 5 or 7.5 Cutting head with new lens
HK25 or HK30 Nozzle
Scotch Tape
2x4 Manila Cardboard tags
Steel blocks wide enough to sit across 2 grates
(Setup) Pulse width single pulse 50ms
(Setup) Laser Power single pulse 50w
(Setup) Default setting, Focal length 5 2.0
(Setup) Default setting, Focal length 7.5 7.0

Note: In determining a focal position, there are two sets of numbers on the cutting head.
There is a Primary and a Secondary focal number.

The Primary focal numbers are found on the front/upper portion of the cutting head. This number is read in increments of 6 or
6mm. (Example: 0,6,12,18) As the focus is full revolution.

The Secondary focal numbers are found on the focal ring on the right side of the cutting head. The numbers are incremental with
a 0.2mm adjustment. (One line = 0.2mm) (Five lines = 1.0mm)

1. Bring the cutting head forward to the service position.
2. Place steel blocks on the table and tape cardboard tags to the blocks.
3. Adjust the focal ring.
a. Set focal ring to 6/0 for the 5 head.
b. Set focal ring to 6/30 for the 7.5 head.
4. Go into manual mode, load a parameter for the correct cutting head.
5. In Hand_Param, set the Focus to 0mm and nozzle distance to 0.2mm.
6. Install HK 25 or HK 30 nozzle and perform nozzle centering.
7. Turn Tool light off and lower the Z axis until the nozzle makes contact with the cardboard tag. (Ensure the
nozzle is clear of the metal blocks.)
8. Take pulse shots on the card moving the Y axis in Jog mode by revolution of the wheel.
a. For the 5 cutting head, adjust the Setup_Default Setting, Focal Length 5 from 0 to 6 in increments
of 0.5mm.
b. For the 7.5 cutting head, adjust the Setup_Default Setting, Focal Length 7.5 from 5 to 20 in
increments of 0.5mm.
9. Review the cardboard tag and look for the hole pattern big small big again.
10. Choose hole that falls in the approximate middle of the small pattern, not just the smallest hole.
11. Change your focus ring by the amount of difference between your original default focus setting and the chosen
position from step 10. (Example On the 5 head you end up with 3.8, lower the focus from 6/0 to 6/18.)
12. Change the Default Setting, Focal Length 5 or Default Setting, Focal Length 7.5 back to their original
settings.

9

BYSTAR / BYSPRINT FINDING THE ZERO FOCUS POINT OF A NEW LENS
MMC Controls
Purpose: A new Zero Focal Point needs to be determined when a new lens is being
installed or when a new cutting head is being used. The Zero Focus Point is
defined as the focus setting where as the focus is on the surface of the material.

Type of Systems: Fixed Focus/Flat Mirror (Mode 0) or Auto Focus/Bypos Mirror
(Mode 2)

Materials/Conditions required: 5" or 7.5" (Cutting head with a new lens)
HK25 or HK30 Nozzle
Scotch Tape
2" x 4" Manila Cardboard tags (Do not use beam
alignment cards)
(2) Steel blocks wide enough to sit across 2 grates
(SETUP) Pulse width for a single shot:all 50ms
(SETUP) Single pulse power:1.8 - 3.5 kw
2%
(SETUP) Single pulse power: 4.0 kw
5%
*When (Bypos Auto Focus) is applicable, change from
(Mode 2) to (Mode 1) in (SETUP Adaptive Optic)
before finding focus.

Note: In determining a focal position there are (2) sets of numbers on the cutting head.
There is a Primary and a Secondary focal number.

The Primary focal numbers on the cutting head is found on the Front/upper portion of
the cutting head. This number is read in increments of 6 or 6mm. (Example: 0, 6, 12,
18). As the focus is lowered the primary focal number will eventually change when the
focal ring rotates 1 revolution.

The Secondary focal numbers are found on the focal ring on right hand side of cutting
head. The numbers are incremental with a 0.2mm adjustment. Numbered by 2,
(0,2,4,6.58)
(1 line = 0.2mm or 0.008") (5 lines = 1mm or 0.040") (30 lines or 1 revolution
= 6mm or 0.240")
A focus position example: 0/42 0 = primary 42 = secondary

*Both fixed and auto focus use the same technique but differ when the offset is added.
See 3 - Final Focus Position

1. Coarse Focal Procedure will secure approximate focal positions on the 5 or 7.5 cutting
heads. Take approximately 10 pulse shots for a coarse focal.
a. Bring cutting head forward (Hand/Move to Zero).
b. Place steel blocks down on to cutting grates and tape cardboard tag to blocks.
c. Adjust focal ring to 0/40. Put HK25 or HK30 nozzle and perform nozzle centering
(Pulse Shot). Return focal ring to 0/00 after nozzle centering.
d. Turn tool Light off of hand controller before pressing -Z. Place nozzle down onto
cardboard tag using hand controller (Hand/Manual Mode). Move nozzle just onto
cardboard tag and clear of metal on underside.
e. Start by pressing pulse on hand controller, open safety door, and adjust focal ring 5
lines at a time. Close door, move cutting head a small distance using the hand
controller (+/-X, +/-Y) so as not to burn another hole in same location.
f. Repeat the above step and take approximately 10 pulse shots or so
0/00,0/10,0/20,0/30, 6/30 more if needed.
g. Remove cardboard tag from blocks and review it. There should be holes burned into
cardboard tag ranging from big small to big again. Find the smallest hole and mark it.
h. See Figure 1

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2. Fine Focal Procedure will secure an accurate focal position on the 5 or 7.5 cutting
heads.
Take approximately 8 to 10 pulse shots before, and 8 to 10 pulse shots after
smallest hole from Coarse Focal Procedure.
a. Do same as done prior for Coarse Focal Procedure and include note below.
b. Review cardboard tag and denote holes now more similar. Look for pattern big small big
again.
c. Choose hole in the approximate middle of small pattern, not just the smallest hole.

Note: The only difference in the Fine Focal Procedure for 5 and 7.5 cutting heads are the
incremental movement of the focal ring.

A 5 cutting head has a beam divergence of 0.6mm or 3 lines on focal ring. During a
Fine Focal Procedure a 5 cutting head will need to take a pulse shot 1 line at a time
through smallest point found during Coarse Focal Procedure. See Figure 2.

A 7.5 cutting head has beam divergence of 1.4mm or 7 lines on focal ring. During a
Fine Focal Procedure a 7.5 cutting head will need to take a pulse shot 2 lines or every
other line through the smallest hole found during Coarse Focal Procedure. Keep in mind
that the 7.5 cutting head is more difficult to determine its focus. See Figure 3.


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3. Final Focus Position

System Fixed Focus/Flat Mirror (Mode 0). When Fine Focal Procedure number has
been determined the offset of 1mm is to be added to the focal position for both 5 and 7.5
cutting heads. This 1mm represents nozzle distance.

Example: 0/42 + 1.0mm = 0/52 (Mark on cutting head)


System Auto Focus/Bypos Mirror (Mode 2) for 5 Cutting Head a 3mm offset must be
added to Fine Focal Procedure number that was found.

Example: 0/48 + 3.0mm = 6/18 (Mark on cutting head)

System Auto Focus/Bypos Mirror (Mode 2) for 7.5 Cutting Head a 5mm offset must
be added to Fine Focal Procedure number that was found.

Example: 0/28 + 5.0mm = 6/18 (Mark on cutting head)

NOTE: When finished finding Zero Focus Point with an Auto Focus/Bypos Mirror
System, you must change (Mode 1) back to (Mode 2) in (SETUP Adaptic Optics)
for auto focus capabilities.

12

BYSTAR - CLEANING THE CUTTING HEAD LENS

Purpose: To ensure consistent cut quality and to properly maintain the cutting head and
lens.

Materials/Conditions required: Alcohol (water-free as per Bystronic spec)
Kodak lens paper
Cotton swabs
2.5mm Allen-wrench
Spanner wrench (specialty tool kit)
Nylon Support/Bushing tool
Vacuum Grease

1. Disassembly:

Note: Keep the cutting head horizontal as you remove the screws to prevent a screw from
falling into the lens assembly.

a) Remove the cutting head from the (Z-axis) and place it gently on a clean flat area with the
nozzle pointing away from you.
b) Remove the (6) outer hex screws at the rear of the cutting head using a 2.5mm Allen-
wrench (see Figure 1).
Figure-1


c) Grip on top of the cutting head as you twist and pull in the same motion. Make sure this is
done slowly, the tube assembly has tendency to come out quickly once it has been
loosened.

Note: Keep the lens tube assembly horizontal at all times during steps d through f to prevent
any particles falling on the lens. (See Figures 2 and 3 for part description of the
Lens Tube Assembly.)

d) Using the spanner wrench given in the special tool kit, loosen the Clamp Ring inside the
tube.
e) Once the clamp ring is loose, remove it with your fingers.
f) Insert the Nylon Support/Bushing Tool into the Lens Tube Assembly until it is flush
with the Heat Expansion Ring.
g) Maintain contact between the tube assembly and the nylon support/bushing tool as you turn
them into the vertical position until the base of the bushing tool is flush with the table.
h) Gently pull the lens tube assembly off of the bushing tool. The lens and heat expansion ring
will be sitting on the bushing tool as you place the lens tube assembly aside. Be careful not
to drop the lens.
i) Leave the lens on top of the expansion and o-rings. Place them down onto a clean location.



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Figure-2


Figure-3

2. Cleaning:
Conditions

i. Clean hands thoroughly before handling lens.
ii. Always keep alcohol bottle closed after use to prevent contaminates from entering the
bottle.
iii. Clean lens using a clean cotton swab dipped into alcohol. Never reuse a cotton swab.
iv. Handle lens with extreme care.

a) Turn the lens over (concave face up) and set it back on the heat expansion and o-rings.
b) Inspect lens for any large particles. Using an alcohol dipped cotton swab, gently roll the
swab
as you pick up the particles. Break and discard the cotton swab as each large particle is
removed.
c) Starting in the center, gently rub the lens with an alcohol dipped cotton swab. Work your
way to the edge of the lens, using a slow circular motion. Discard the used cotton swab and
repeat if necessary.
d) Place a piece of Kodak lens paper over the lens. Use another clean cotton swab and
saturate
the lens paper with alcohol.
e) Slowly pull the lens paper off, to ensure the lens dries even and clean. Repeat if necessary.
f) Turn the lens over (concave face down) and repeat steps b through e.
g) Cover the lens with a clean piece of lens paper to avoid falling particles.
h) Clean lens seat (inside lens tube assembly), using an alcohol dipped cotton swab.

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3. Assembly:

a) Place the lens, o-ring and the heat expansion ring back on top of the nylon support/bushing
tool.
b) Carefully slide the lens tube down over the lens and bushing tool.
c) Maintain contact between the lens tube, lens and bushing tool and return the lens to its
seat.
d) Keeping your hands where they are, flip and remove the lens tube assembly.
e) Replace the clamp ring by turning the spanner wrench with your fingertips until it is snug.

Note: DO NOT OVER TIGHTEN. Inspect the heat expansion ring for space between its rings.
If there is no space between the rings, you must loosen completely and then retighten
until it looks like the excepted picture below (see Figure-4).

Figure-4

f) Look down into the lens tube and check to see your image as you would in a mirror. If your
image is upside down, the lens is in backwards and must be correctly installed before the
new lens (or newly cleaned lens) is used to cut material.
g) Remove the o-rings on the outside of the lens tube assembly by gently pinching with your
fingers to remove and roll them off the tube assembly. Be careful not to stretch the o-rings
or they will not seal properly. Inspect each for cracks or damage. Replace if necessary.
h) Lightly lube with Vacuum Grease. Enough to make o-rings appear shiny, without residual
grease.
i) Carefully replace o-rings and seat into the grooves on the tube.
j) Slowly push lens tube assembly back into head assembly until the lens is seated properly.
k) Align screws with holes and replace the (6) screws.
l) Hand torque.
m) If you have replaced a lens you must now find the Focal Point of the new lens.







15









BYSPEED


FOCAL POINT
































16




Purpose: A new Zero Focal Point needs to be determined when a new lens is being
installed or when a new cutting head is being used. The Zero Focus Point is
defined as the focus setting where as the focus is on the surface of the material.

Type of System: Auto focus Adaptive Optic (BYPOS Mode 1) only

Materials/Conditions required: (Cutting head with a new lens) 5" or 7.5"
Nozzle either a HK25 or HK30
Scotch Tape
2" x 4" Manila Cardboard tag (Do not use beam
alignment cards)
(2) Steel blocks wide enough to sit across cutting
grates
(SETUP) Pulse width for a single shot: 50ms
(SETUP) Single pulse power: 5%

*NOTE: Focus is adjusted via Adaptive Optics in Setup for this procedure only.
A BYSPEED has no manual focal adjustments.

2. Coarse Focal Procedure will secure an approximate focal position for the 5 or 7.5
cutting heads.

Take approximately 12 pulse shots for this coarse focal procedure.

h. Because the 5 and 7.5 cutting head lens have different focal strokes, it is very
important before starting this procedure to make sure that the control system has the
same parameter as the cutting head that focus is being found on. To ensure the
parameter is correct, load a job, any job/attach any parameter same as the cutting head
that focus is being found on. (STARTWORK) then (ABORT) this will enter the correct
parameter within the control system to have proper focusing properties throughout this
procedure.

i. Set up cutting head put a HK25 or HK30 nozzle and perform nozzle centering. (Pulse
Shot).

j. Set up cardboard tag. Place steel blocks down on to cutting grates and tape cardboard
tag to blocks.

k. Place cutting head over tags. Use (HAND/MANUAL MODE) turn tool light off of hand
controller before pressing -Z. Place nozzle down onto cardboard tag using hand
controller. Move nozzle just onto cardboard tag and clear of metal on underside. To
move cutting head slowly onto cardboard tag, keep (Manual Adjust) depressed touch
X or Y or Z rotate wheel - or + to move slowly in any direction.

l. Go to (HAND/PARAMETER) and enter "0" for focal position and enter "0.2" for
nozzle distance.

m. The FOCUS is changed for this procedure only using the values in (SET-UP). Go to
Set-up Values Adaptive Optic 1. Locate Default Setting, Focal width 5.0 inches for 5
head
Focal width 7.5 inches for 7.5 head. Start with a value-2. By pressing pulse on hand
controller and moving cutting head a small distance using the hand controller (+/-X, +/-
Y) so as not to burn another hole in same location.

g. Repeat the above step and take approximately 12 pulse shots. Start at -2 and finish up
at 10 by changing the value by 1mm each time. Ex: -2-1, 0, 1, 2, 3, 10.
BYSPEED FOCUS PROCEDURE: FINDING THE ZERO FOCUS POINT OF A LENS

17

h. Remove cardboard tag from blocks and review it closely. There should be holes burned
into cardboard tag ranging from big to small to big again. Find the smallest hole and
mark it what focus it was.
See Figure 1 below.

Figure 1

Coarse 5 Head Coarse 7.5 Head
Manila Cardboard Tag Manila Cardboard Tag


















* Note: The values shown in Figure 1 are for reference only, actual values obtained may differ.

2. Fine Focal Procedure will secure an accurate focal position on the 5 or 7.5 cutting
heads.
Take approximately 8 to 10 pulse shots before and 8 to 10 pulse shots after
smallest hole from Coarse Focal Procedure

d. Do same as done prior for Coarse Focal Procedure and see note on next page.
e. Review cardboard tag and denote holes now more similar. Look for pattern big small big
again.
f. Choose hole in the approximate middle of small pattern, not just the smallest hole.

Note: The only difference in the Fine Focal Procedure for 5 and 7.5 cutting heads are the
incremental values used in SETUP.

A 5 cutting head has a beam waist length of 1 mm.
During a Fine Focal Procedure a 5 cutting head will need to take a pulse shot
0.2mm at a time through smallest point found during Coarse Focal Procedure.
See Figure 2

A 7.5 cutting head has beam waist length of 1.6 mm.
During a Fine Focal Procedure a 7.5 cutting head will need to take a pulse shot
0.4 through the smallest hole found during Coarse Focal Procedure. Keep in
mind that the 7.5 cutting head is more difficult to determine its focus due to
holes produced on manila tags are smaller and their size change is less.
See Figure 3


10
9
8
7
6
5
4
3
2
1
0
-1
10
9
8
7
6
5
4
3
2
1
0
-1
5 Heads
Approx. Zero
Focus is 1
7.5 Head
Approx. Zero
Focus is 6

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Figure 2 Figure 3

Fine 5 Head Fine 7.5 Head
Manila Cardboard Tag Manila Cardboard Tag

















* Note: The values shown in Figure 2 and Figure 3 are for reference only actual values
obtained may differ.

Now that the FINE VALUES have been found these values can be placed in SETUP. Go to Set-
up Values Adaptive Optic 1. Locate Default Setting, Focal width 5.0 inches for 5 head Focal
width 7.5 inches for 7.5 head.
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
8.4
8.0
7.6
7.2
6.8
6.4
6.0
5.6
5.2
4.8
4.4
5 Head
Accurate Zero
Focus is 1.2
7.5 Head
Accurate Zero
Focus is 6.4

19























SECTION III


PROCEDURES CONTINUED












20

LASER CUTTING IN NON-CAPACITIVE MODE

Purpose: If capacitive sensing is or needs to be disabled or a fix nozzle distance is
required.

Note: In order to cut metal materials with a fixed nozzle distance (non-capacitive)the
capacitive height sensing (detection) must be disabled (in setup) and the
thickness of the material (in metric(located in the cutting parameter)) entered
properly for each material. Once detection is switched to "OFF, the Z-axis will
be locked at the calculated height derived from the material thickness and nozzle
cutting distance.

*Warning: Bystronic does not endorse or encourage non-metallic laser cutting.

1) In SETUP, change the value for sensor from ON to OFF.
(Under SET-UP MACHINE: Detection 0=off 1=on)
2) Select a job, choosing an appropriate parameter.
3) In the Active Param: go to the first page and for the value labeled (Thickness), enter a
number larger than the number originally given.

Example: If cutting , it may read 6.35mm. Initially, place a number at least double
the thickness just to be safe.

4) Start the job as you would normally, being sure to initiate the STOP PART function on
the controller. (Do not use EDGE DETECTION.)
5) When the cutting head advances to the zero position, go to "HAND, then "MANUAL
MODE. Using the hand control, position the cutting head just off the edge of the
material. Press Z- (minus). The cutting head will stop at the calculated Z-height. Open
the access door and measure the distance between the nozzle tip and the material.
6) In Active Param, change the value of the thickness to lower or raise the point where the
Z-axis will stop. A smaller thickness value will lower the cutting head and a larger
thickness value will raise the cutting head. You should allow at least 2-3mm between
your nozzle and the material to be cut. Nozzle distance and focus positions are not
critical when processing non-metals! Be sure to "SAVE PARAM after changing the
thickness value in ACTIVE PARAM.
7) If the desired nozzle distance has not been achieved, press Z+ (PLUS), to raise the Z-
axis. In Active Param, change the value of the thickness to lower or raise the point
where the Z-axis will stop. Press Z- (minus) in MANUAL MODE in order to activate new
Z height.
8) As an additional check, while the Z-axis is in the final lowered position, move the cutting
head to different areas of the table to make sure the material will not make contact with
the nozzle tip! Adjust material thickness in ACTIVE PARAM if necessary.
9) Start the job as you would normally, being sure to again initiate the "STOP PART. (Do
not use EDGE DETECTION.) Adjust the parameters as needed for quality.
10) Remember to turn detection back ON if you want capacitive sensor to properly track
( consistent nozzle distance)!




21

ASSIGNING A 0,0 FOR THE ROTARY AXIS


Purpose: For the first time use of the rotary axis

1. Set up a 2X2 length of solid square stock (sharp cornered, no radius).

2. Place a level in X, then Y to ensure the stock is straight and level.

3. Advance to the zero point (Menu, HAND, Origin, Cont).

4. Choose Manual operation.

5. Using hand (manual) controller rotate the square tube 45 degrees so the corner is directly
up. Looking from the end of the pipe towards the chuck the pipe should look diamond
shape.

6. Maneuver the head until it is approximately over the tube.

7. Turn the (TOOL) light off on the hand control.

8. Bring down the head and adjust in the X and Y until it is directly on top of the square tube.

9. Begin to fire pulse shots until you see the beam spread equally on both sides of the tube.

10. On the screen, read your Y position and write it down.

11. Go to and press the Menu, Main. At the main screen log out then log in with username: by
and a password: ch3362. Now press Admin., press Config. Hardware. Page down until
you see Y-axis: U-axis-coordinate and put in the Y value you found in step 10 (center of
chuck). Back out to main page and log out then log in with regular password.

12. Proceed with your Cutting Plan.
















22

ASSIGNING A 0,0 FOR SINGLE FLAT FIXTURE PARTS

Purpose: To laser cut already machined parts

1. Program an L Bracket in ByPart according to the position of the X and Y stops.

2. Place newly cut L Bracket flush with the X and Y stops.

3. Clamp the L Bracket to cutting grate frame.

4. Reference the head at 0,0.

5. Switch to (Hand, then Manual Mode) and move the head to the Y position. Allow the
nozzle to come close to the edge of the material and then press (Manual Adjust). Inch the
nozzle over until you hear the gas blow loudly. Check to see what this number is on the
Control panels monitor and write it down. This will be your "Y zero point.

6. Repeat Step 5 to find the "X zero point.

7. Go to the Microsoft "WordPad program. Open a document, requesting to see "all files.
Find the saved L Bracket (.lcc file).

8. Scroll down to line (N2). Copy and paste this line, directly above the original line (N2).
This line should read something close to as follows: N2G52X? Y? Your newly pasted line
should now look as follows: N2G51X (The number you wrote down in Step 5) Y (the
number you wrote down in Step 4).

9. Save and exit.

10. This will be your new 0,0 point as long as you are running this program and the L Bracket is
flush against the stops and clamped.

11. To avoid confusion, you will now have (2) N2 lines, the first reading G51, and the second
G52.

12. Abort the original program and select the job again to refresh the newly saved .lcc file.

13. Place the circle flush against the inner 90-degree angle of the L Bracket. Find the center
point of the circle using your new 0,0 point.







23

SETTING YOUR MACHINE TO RUN IN AUTOMATIC MODE

Purpose: To ease time management

1. Place material on both tables.

2. Open up your handling system and press the button MANUAL (F1). Make sure the graphics
that represent whether your tables have materials or not is accurate.

3. Press the GENERAL (F1) tab and activate the Auto button in the upper right corner. You
can now minimize the handling window.

4. You should now have your Byvision screen in front of you. In the upper left corner press the
button labeled Operating mode, next press Automatic mode and then press Close.

5. Load your job(s) and parameters as you would normally.

Note: If you have not programmed for multiple jobs in ByWork, you must manually insert
multiple runs within Menu, WORK (F7), Job list. In Job list highlight the cutting plan then
press Edit (upper right). In the next window that opens press Edit and add the appropriate
amount of runs needed then confirm by pressing OK. Verify amount in the WORK screen lower
left under Program information and Runs.

6. Press START WORK.

7. When the control panel illuminates press the STOP CYCLE button once so it is no longer
illuminated. This ensures that the machine will continue uninterrupted (barring tip-ups) until it
has fulfilled its predetermined tasks.



TURNING OFF THE SYSTEM AUTOMATICALLY


To ensure the system shuts off (turns off high voltage and goes into sleep mode) after the
Joblist cue has been completed, you must go to the Menu, Hand, Setup values machine
screen and page down while looking for the following:

Setup value, auto shutdown system
Switch off after: (0 = off) and insert the amount of minutes until powering down begins.

The (minute) value indicates how long to wait after the job has been completed until the CNC
initiates the automatic shutdown sequence. This should be set to no less than 5 min.













24











SECTION - IV






CHARTS AND GUIDES


25

CUTTING FUNDAMENTALS


The cutting of material is accomplished with the laser beam and a cutting assist gas. The laser
beam is surrounded by the assist gas and is being emitted from the nozzle (see Figure 1).
The beam melts the material and the gas pushes the molten material away from the cut. The
beam creates a funnel into and coming out of the material. Creating a channel for the molten
material to be pushed out the bottom of the material.

Figure 1









26

Figure-2

Two kinds of assist gas are generally used:

Oxygen: Used for cutting mild steel and plate. It provides more heat to the cut,
vaporizing and expelling the material. Oxygen is reactive and should not be used
in cutting material that might ignite.

a. Oxygen cutting with pressures between 3-6 bar is being used on mild
steel, up to approximately thick. The focus is on or just into the
material. Creating the proper heat and channel for the gas to evacuate
the material. When adjusting the parameters with this type of cutting the
gas pressure has the biggest effect on the cut quality, followed by focus
and power (see Figure 2).
b. Low-pressure oxygen cutting with pressures between .3 and .6bar is used
on plate steel above . The focus is above the material, creating a
proper channel for the gas to evacuate the material. When adjusting the
parameters with this type of cutting the gas pressure has the biggest
effect on the cut. Followed by the focus and feed rate. Power has the
least effect on the cut (see Figure 2).

Nitrogen: Which expels material only, is used for stainless, aluminum and other materials
that might ignite. Nitrogen is non-reactive and cools the cut.

a. High-pressure nitrogen cutting "Clean Cut, uses pressures of 8-20 bar.
The focus is at the bottom or just below the material. The high gas
pressures pushes out the material from the small channel created by this
focus. When adjusting the parameters with this type of cutting, focus has
the biggest effect on the cut. Followed by feed rate, gas pressure, and
power (see Figure 2).

27

FOUR BASIC ELEMENTS IN ACHIEVING A CUT


FOCUS
GAS PRESSURE
FEED RATE
POWER

Note: Before you change any parameter settings, check the cutting head for a
proper nozzle alignment and focus position. Also be sure the nozzle is
not loose or damaged.

All of the following parameter changes are listed in order of their
importance while cutting with their respective assist gases.

Cutting with Oxygen

1) GAS PRESSURE- An increase in oxygen is an increase in heat. Oxygen is an accelerant
used to assist the beam in vaporizing the material. Gas pressure is used
to expel molten material. Adjustments are made in .5 bar for high
pressure. Adjustments are made in .1 bar for low pressure.

2) FOCUS- When HIGH PRESSURE cutting, the focus is utilized to melt the material
at a depth of .2 to .4mm.

When LOW PRESSURE cutting, the focus is used to create a proper
channel or (kerf) above the material at a height of .4 to 1.6mm.

3) POWER- An increase in power increases the heat generated in the kerf. A change
in power is made generally in 5% increments.

4) FEED RATE- An increase in the feed rate reduces heat. Adjustments are made +/-
500-100mm/min. for thin material. Adjustments are made 100-
5mm/min. for thick material. The feed rate is relative to the heat
generated by gas, focus and power.

Cutting with Nitrogen

1) FOCUS- Is the most important factor while cutting with nitrogen. Adjustments are
made .2 to .4mm +/- depending on the size of the burr. A heavy burr
indicates the focus being too high. A fine burr indicates the focus being
too low.

2) FEED RATE- An increase in the feed rate reduces heat. Adjustments are made +/-
500-100mm/min. in thin material. Adjustments are made 100-
10mm/min. for thick material.

3) GAS PRESSURE- An increase in gas pressure helps expel the molten material from the kerf
as well as reducing heat. Adjustments are made +/- 1 bar.

4) POWER- An increase in power increases the heat. A decrease in power decreases
the heat. Adjustments are made +/- 5%.




28
Assessing the Cuts
Structural steel: cutting with O
2

Error Possible causes Solutions
No burr, uniform drag lines

right power
right feed rate

Considerable deviation of drag
lines on bottom part, cutting hole
wider at the bottom

feed rate too high
laser power too low
gas pressure too low
focal position too high
reduce feed rate
increase laser power
increase gas pressure
lower focus
Burrs on bottom surfaces similar
to slag, even drop shaped and
easy to remove

feed rate too high
gas pressure too low
focal position too high
reduce feed rate
increase gas pressure
lower focus
Metal burrs joined together can
be removed as a single piece

focal position too high lower focus
Metal burrs on bottom surfaces,
difficult to remove

feed rate too high
gas pressure too low
impurities in gas
focal position too high
reduce feed rate
increase gas pressure
use purer gas
lower focus
Burrs on one side only

nozzle incorrectly centered
nozzle orifice defective
center nozzle
replace nozzle
28
Structural steel: cutting with O
2

Errors Possible causes Elimination
Material expelled from top side

power too low
feed rate too high
increase power
reduce feed rate
Slanting cuts
2 good sides, 2 bad sides

polarizing mirror not
suitable, mounted not
correctly or defective

polarizing mirror mounted
in the place of the
deflection mirror
check the polarizing
mirror



check the deflection
mirror
Blue plasma, workpiece not cut
off during machining

wrong gas (N
2
)
feed rate too high
power too low
use oxygen as process
gas
reduce feed rate
increase power
Inaccurate cutting surfaces

gas pressure too high
damaged nozzle
nozzle diameter too big
poor material
lower the gas pressure
replace the nozzle
install the right nozzle
material with smooth
and even surface
No burrs, drag lines slanting a
long way back cut narrower at
the bottom

feed rate too high reduce feed rate
29
Structural steel: cutting with O
2

Errors Possible causes Elimination
Formation of craters

gas pressure too high
feed rate too low
focus too high
rust on surface of plate
workpiece under
machining has overheated
impurities in material
reduce gas pressure
increase feed rate
lower focus
use better quality
material
Extremely rough cutting surface

focal position too high
gas pressure too high
feed rate too low
material too hot
lower focus
reduce gas pressure
increase feed rate
cool material
- 30 -

Stainless steel: high-pressure cutting with N
2

Error Possible causes Solutions
Formation of fine, regular burrs in
the form of drops

focus too low
feed rate too high

raise focus
reduce feed rate
Formation of long irregular burrs
on both sides in the form of
filaments, with tarnishing on
large templates

feed rate too low
focal position too high
gas pressure too low
material too hot
increase feed rate
lower focus
increase gas pressure
cool material
Formation of long irregular burrs
on just one side of the cutting
edge

nozzle not centered
focal position too high
gas pressure too low
speed too low

center nozzle
lower focus
increase gas pressure
increase speed

Cutting edge yellowish nitrogen containing oxygen
impurities
use a higher quality of
nitrogen
Formation of plasma on straight
sections

feed rate too high
power too low
focus too low

reduce feed rate
increase power
raise focus
The beam breaks feed rate too high
power too low
focus too low
reduce feed rate
increase power
raise focus
Formation of plasma at corners angular tolerance too high
modulation to high
acceleration to high
reduce angular
tolerance
reduce modulation or
acceleration
- 31 -

Stainless steel: high-pressure cutting with N
2

The beam breaks at the
beginning
acceleration too high
focus too low
The molten material
cannot be expelled
reduce acceleration
raise focus
use circular piercing
Use gas ramp
Rough cut nozzle damaged
lens dirty
change nozzle
clean lens, replace if
necessary
Material expelled from the top

power too low
excessive feed
gas pressure too high
increase power
reduce feed
reduce gas pressure
- 32 -

Aluminum alloys: high-pressure cutting with N
2

Error Possible causes Solutions
Formation of long, irregular burrs
on both sides in the form of
filaments, difficult to remove

focal position too high
gas pressure too low
feed rate too low

lower focus
increase gas pressure
increase feed rate
Formation of long, irregular burrs
on both sides, removable by hand

feed rate too low

increase feed rate

Rough cut

nozzle diameter too large
nozzle damaged
gas pressure too high
assemble right nozzle
replace nozzle
reduce gas pressure
Formation of fine, regular burrs,
difficult to remove

focus too low
feed rate too high
raise focus
reduce feed rate feed
rate
Formation of plasma on straight
sections
feed rate too high
focus to low
reduce feed rate
raise focal point
Beam breaks
feed rate too high reduce feed rate
Formation of plasma on corners
angular tolerance too high
modulation to high
acceleration to high
reduce angular
tolerance
reduce modulation or
acceleration
The beam breaks at the
beginning
approach speed too high
focus too low
reduce approach speed
raise focus
Rough cut nozzle damaged replace nozzle
Material expelled from top

power too low
excessive feed

increase power
reduce feed



- 33 -











SECTION - V





TIPS AND FAQ'S

- 34 -


TIPS AND TRICKS FROM THE APPLICATIONS DEPT.

What does your laser cut edge look like?

In order to maintain a quality laser cut edge, it is important to look at some key points which
greatly affect your overall cut quality:

LASER RESONATOR PERFORMANCE
OPTICAL BEAM DELIVERY
FOCAL POINT
ASSIST GAS QUALITY
MATERIAL QUALITY

Lets start at the point where the beam is actually produced: the optical resonator. It is
important to check, on a regular basis, your overall wattage produced at 100% load. Failing to
achieve the proper wattage for your resonator can signify either your optics need to be serviced
or there is a contamination problem in the cavity. Contaminates can be introduced into the
optical cavity by either a bad laser gas bottle or a vacuum breech of the optical cavity.

TIP: Perform and log daily power checks and vacuum tests.

As the beam exits the resonator, we now enter the optical beam delivery system. This is how
we deliver the beam to the cutting head using a series of mirrors to direct the beam down each
axis. The beam delivery is housed within an enclosed path, which is pressurized with a positive
flow of dry compressed air. This positive flow of air pressurized above 1 atmosphere prohibits
contaminates from entering the beam path thereby keeping your optics clean. All of the optics
in the beam delivery have been aligned at the time of installation in order to achieve proper
alignment of the beam, regardless of the position on the cutting table. An improperly aligned
beam delivery could result in different cut qualities across the table due to the beam not
striking the focus lens on center nor exiting out of the nozzle tip on center. Poor cut qualities
can also be a result of dirty or contaminated optics.

TIP: Check and/or clean external optics at least once a month. Check and/or
replace beam air delivery filters. Check compressed air for moisture and/or oil
contaminates.

As mentioned earlier, the beam delivery optics direct the beam to the cutting head. At this
point that the cutting lens focuses the raw beam and the assist gas which is channeled through
the cutting head assembly. The ability to properly focus the beam is the function of the cutting
lens. Focus position is the most important parameter to observe when laser cutting. Failure to
properly adjust the focal position or the lens capability to maintain that position due to thermal
distortion will result in poor cut quality. Thermal distortion occurs when the lens begins to
absorb laser energy due to spatter or contaminates on the lens.

TIP: Check and/or clean the lens at least once per shift. To determine thermal
distortion, perform a strip cut on .120" thick stainless for a length of at least 2
feet. Stop and allow lens to cool then continue to strip cut for another 2 feet.
If the quality of the strip cut goes from clean to burr then clean to burr again,
you have thermal distortion. Replace the lens if this is your result.

One of the most overlooked points in laser cutting is the quality of the assist gases.

As mentioned earlier, the assist gas is introduced into the cutting head. The types of assist gas
can vary depending on the application and the desired edge finish. In the case of oxygen, a
dark oxidized surface is expected with little or no slag on the underside. In the case of nitrogen
or any other inert assist gas, a clean non-oxidized surface is expected. The appearance of
continual slag on the underside of an oxygen-assisted cut can be the result of improper
oxidation due to poor quality assist gas. The appearance of slag and/or discoloration on the
- 35 -

surface of a nitrogen assisted cut can be the result of contaminates such as oxygen and water
molecules.

TIP: Try to utilize liquid based cylinders or bulk systems, which boil off to produce pure
gases. If using compressed cylinder bottles be sure to specify the purity of the gases to
be above 99.995%.

Last, but not least, is the quality of the material you are cutting. There are two factors, which
determine the quality of the material you are cutting: The quality of the surface and the
contents of the material. Lets examine mild steel as an example. Steels, which have rust and
or loose uneven mill scale, will not cut as well as steels without rust and a tight even mill scale.
Steels with a high silicon and carbon content will be more sensitive to heat and therefore limit
the size of contours, which can be cut in a work piece. Voids and impurities can react like small
explosions while cutting and create inclusions and/or loss of cut.

There is a saying: "You can not make a Cadillac out of pressed 1955 Buicks. This is
synonymous with, "Garbage in.Garbage out!

TIP: When cutting thick plate steel try to use controlled steel such as ASTM 572
grade 50 or 60. Specify your material to be free of rust and with a tight mill
scale application.

Avoid A36 when possible as material quality can vary from sheet to sheet and from one area of
the sheet to another! Use pickled and oiled or cold rolled material in thin gage applications.
When diagnosing a poor cut start with the obvious parameters at hand, continue with the
resonator and your way towards the work piece, keeping in mind the above mentioned points
and tips.

TIP: Etching aluminum is not recommended when using Bystronic "Laser Cutting
Systems." Cutting reflective materials (ex. aluminum, copper, brass, etc.) can
pose problems when being cut by a laser. When laser light does not pass
through the material (ex. etching) it can damage a system due to reflectivity
back into the beam delivery system.

Back reflections can cause damage to lenses and mirrors, and can cause the
bellows system to catch fire.

- 41 -

CNC 96 - MMC CONTROLS

DIN
NAME

IDENTIFICATIO
N
DIN
NUMBE
R
DIN
NAME

IDENTIFICATIO
N
DIN
NUMBE
R
St 1203 Deep drawing
sheet
1.0330 AI 99 Pure aluminum 3.025
St W 22 Steel sheet 1.0332 AI 99.9 3.0305
St W 23 Steel sheet 1.0334 AI 99.98 3.0385
St W 24 Steel sheet 1.0335 AIMn Aluman - 100 3.0515
St 34 - 2 1.0151 AIMgSi1M
n
AC 110 Anticorodal 3.2315
St 37 - 2 Mild steel 1.0161 AIMg 1 Peraluman - 100 3.3315
St 42 - 2 1.0181 AIMg 3 Peraluman - 300 3.3535
St 50 - 2 1.0570
St 52 - 3 Mild steel 1.0570
St 60 - 2 1.0533 Cu Copper 2.0000
ST 70 - 2 1.0543 CuZn40 Brass 2.1000
C18 1.0405 Ti Titanium 3.7000
Ck 15 Case-hardened
steel
1.1141
Ck 45 Heat treatable
steel
1.1191 Holz Novopan 9.1100
Ck 75 Spring Steel 1.1248 Holz Plywood 9.1200
QST 37 - 2 Cold forming 1.0221 Holz Construction
timber
9.1300

X5CrNi 18 9 V2A 1.4301 PVC Polyvinyl chloride 1.16927
X6CrNiMoTi1712
2
V4A 1.4571 PMMA Acrylic glass
(Perspex)
9.500

Key to file names

Example: 10332150.A50
Process gas: O = Oxygen N = Nitrogen
L = Compressed air A = Argon
P = Pulsed cutting

Cutting head: 3 = 3.75 5 = 5
7 = 7.5 0 = 10

Laser system:
A = Bystar, BTL 3000 Size 3015
B = Bystar, BTL 3000 Size 4020
C = Bystar, BTL 3500 Size 3015
D = Bystar, BTL 3500 Size 4020
S = Bysprint, BTL 1800 Size 2512/3015

Sheet thickness: Sheet thickness in 1/10 mm (e.g. 150 = 15 mm)

Surface + For sheets under 10 mm thickness a letter is
used
Type of for specifying the surface treatment and the
processing: machining type
E = anodized
F = hot-dip galvanized
K = plastic coated (foil)
L = painted
R = floating piercing (rapid piercing)
V = electro-galvanized
X = floating piercing with plastic-coated foil
Y = floating piercing with hot-dip galvanized
sheet
Z = floating piercing with electro-galvanized
sheet
Material: DIN Number of Material